F173-20-01B Laser Overhaul Manual (2001MY)

CONTENTS
Title Section
General Information GI
2001 FS
G15M-R
Engine
Manual transaxle
B3
J2
LASER Technical Data TD
Overhaul Special Tools ST
Manual 2001 Ford Japan Limited.

PRINTED IN AUSTRALIA, FEB. 2001
F173-20-01B
D ENGINE
D MANUAL TRANSAXLE
FOREWORD
This Manual explains the disassembly,

inspection, repair, and reassembly
procedures for the aboveĆindicated engine
and manual transaxle. In order to do these
procedures safely, quickly, and correctly,
you must first read this manual and any
other relevant service materials carefully.
The information in this manual is current
up to FEBRUARY 2001. Any changes that
occur after that time will not be reflected in
this particular manual. Therefore, the
contents of this manual may not exactly
match the mechanism that you are
currently servicing.
Parts & Service

AsiaĆPartner Export Office
Hiroshima, Japan
GENERAL INFORMATION
GI
GI
HOW TO USE THIS MANUAL ............................. GI-2

RANGE OF TOPICS .......................................... GI-2
SERVICING PROCEDURE ............................... GI-2
SYMBOLS.......................................................... GI-4
ADVISORY MESSAGES ................................... GI-4
UNITS ................................................................... GI-5
UNITS TABLE .................................................... GI-5
FUNDAMENTAL PROCEDURES ........................ GI-6
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT................................................... GI-6
SPECIAL SERVICE TOOLS .............................. GI-6
DISASSEMBLY.................................................. GI-6
INSPECTION DURING REMOVAL,
DISASSEMBLY............................................... GI-6
ARRANGEMENT OF PARTS ............................ GI-7
CLEANING OF PARTS...................................... GI-7
REASSEMBLY................................................... GI-7
ADJUSTMENT ................................................... GI-8
RUBBER PARTS AND TUBING ........................ GI-8
HOSE CLAMPS ................................................. GI-8
TORQUE FORMULAS....................................... GI-9
VISE ................................................................... GI-9
ELECTRICAL SYSTEM...................................... GI-10
CONNECTORS................................................ GI-10
NEW STANDARDS ............................................ GI-14
NEW STANDARDS TABLE ............................. GI-14
ABBREVIATIONS .............................................. GI-16
ABBREVIATIONS TABLE................................ GI-16
GI–1
HOW TO USE THIS MANUAL

RANGE OF TOPICS
Z4F201000001101
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
— Removal/Installation
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment
• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts and visual inspection) have been omitted.
End Of Sie
SERVICING PROCEDURE
Z4F201000001102
Inspection, Adjustment
• Inspection and adjustment procedures are divided into steps. Important points regarding the location and
contents of the procedures are explained in detail and shown in the illustrations.
WGIWXX0009E
Repair Procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
GI–2
3. Procedure steps are numbered and the part that is the main point of the procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
GI
WGIWXX0010E
End Of Sie
GI–3
SYMBOLS
Z4F201000001103
• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol Meaning Kind
Apply oil New appropriate engine oil or gear oil
Apply brake fluid New appropriate brake fluid
New appropriate automatic transaxle/transmission

Apply automatic transaxle/transmission fluid
fluid
Apply grease Appropriate grease
Apply sealant Appropriate sealant
Apply petroleum jelly Appropriate petroleum jelly
Replace part O-ring, gasket, etc.
Use SST or equivalent Appropriate tools
End Of Sie MESSAGES

ADVISORY
Z4F201000001104
• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
Specifications
• The values indicate the allowable range when performing inspections or adjustments.
Upper and Lower Limits

• The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
End Of Sie
GI–4
UNITS
UNITS
GI
UNITS TABLE
Z4F201200002101
Electrical current A (ampere)

Electric power W (watt)
Electric resistance Ω (ohm)
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
Number of
rpm (revolutions per minute)
revolutions
kPa (kilo pascal)
Positive pressure kgf/cm2 (kilogram force per square

centimeter)
psi (pounds per square inch)
N·m (Newton meter)
kgf·m (kilogram force meter)
Torque kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
N (Newton)
Weight g (gram)
oz (ounce)
Conversion to SI Units (Système International d'Unités)

• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.
Rounding Off
• Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
Upper and Lower Limits

• When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is
an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI
unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
• The actual converted values for 2.7 kgf/cm2 are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
GI–5
FUNDAMENTAL PROCEDURES
PREPARATION OF TOOLS AND MEASURING EQUIPMENT
Z4F201400004101
• Be sure that all necessary tools and measuring equipment are available before starting any work.
WGIWXX0023E
End Of Sie
SPECIAL SERVICE TOOLS
Z4F201400004102
• Use special service tools or equivalent when they are required.
WGIWXX0024E
End Of Sie
DISASSEMBLY
Z4F201400004103
• If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked
in a place that will not affect their performance or external appearance and identified so that reassembly can be
performed easily and efficiently.
WGIWXX0027E
End Of Sie DURING REMOVAL, DISASSEMBLY

INSPECTION
Z4F201400004104
• When removed, each part should be carefully inspected for malfunction, deformation, damage, and other
problems.
GI–6
GI
WGIWXX0028E
End Of Sie
ARRANGEMENT OF PARTS
Z4F201400004105
• All disassembled parts should be carefully arranged for reassembly.
• Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
WGIWXX0029E
End Of Sie OF PARTS

CLEANING
Z4F201400004106
• All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.
Warning
• Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear
protective eye wear whenever using compressed air.
WGIWXX0030E
End Of Sie
REASSEMBLY
Z4F201400004107
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, these parts should be replaced with
new ones:
— Oil seals
— Gaskets
— O-rings
— Lockwashers
— Cotter pins
— Nylon nuts
WGIWXX0031E
GI–7
• Depending on location:
— Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts
should be installed before sealant hardens to prevent leakage.
— Oil should be applied to the moving components of parts.
— Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.
WGIWXX0032E
End Of Sie
ADJUSTMENT
Z4F201400004108
• Use suitable gauges and/or testers when making adjustments.
WGIWXX0033E
End Of Sie
RUBBER PARTS AND TUBING
Z4F201400004109
• Prevent gasoline or oil from getting on rubber parts or tubing.
WGIWXX0034E
End OfCLAMPS
HOSE Sie
Z4F201400004110
• When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly
with large pliers to ensure a good fit.
WGIWXX0035E
GI–8
End Of Sie
TORQUE FORMULAS
Z4F201400004111
• When using a torque wrench-SST or equivalent combination, the written torque must be recalculated due to the
extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque using the following GI
formulas. Choose the formula that applies to you.
Torque Unit Formula
N·m N·m × [L/(L+A)]
kgf·m kgf·m × [L/(L+A)]
kgf·cm kgf·cm × [L/(L+A)]
ft·lbf ft·lbf × [L/(L+A)]
in·lbf in·lbf × [L/(L+A)]
A : The length of the SST past the torque wrench drive
L : The length of the torque wrench
WGIWXX0036E
End Of Sie
VISE
Z4F201400004112
• When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
WGIWXX0037E
End Of Sie
GI–9
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
CONNECTORS
Z4F201700006101
Data Link Connector
• Insert the probe into the service hole when connecting a jumper wire to the data link connector.
Caution
• Inserting a jumper wire probe into the data link connector terminal may damage the terminal.
WGIWXX0040E
Disconnecting Connectors
• When disconnecting connector, grasp the connectors, not the wires.
• Connectors can be disconnected by pressing or
pulling the lock lever as shown.
WGIWXX0041E
WGIWXX0042E
Locking Connector
• When locking connectors, listen for a click indicating they are securely locked.
GI–10
ELECTRICAL SYSTEM
GI
WGIWXX0043E
Inspection
• When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring
harness side.
• Inspect the terminals of waterproof connectors
from the connector side since they cannot be
accessed from the wiring harness side.
Caution
• To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.
WGIWXX0044E
WGIWXX0045E
Terminals
Inspection
• Pull lightly on individual wires to verify that they are secured in the terminal.
WGIWXX0064E
Replacement
• Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it
locks securely.
• Insert a thin piece of metal from the terminal side of the connector and with the terminal locking tab pressed
down, pull the terminal out from the connector.
GI–11
ELECTRICAL SYSTEM
WGIWXX0046E
Sensors, Switches, and Relays

• Handle sensors, switches, and relays carefully. Do not drop them or strike them against other objects.
WGIWXX0047E
Wiring Harness
Wiring color codes
• Two-color wires are indicated by a two-color code symbol.
• The first letter indicates the base color of the wire and the second the color of the stripe.
CODE COLOR CODE COLOR
B Black O Orange
BR Brown P Pink
G Green R Red
GY Gray V Violet
L Blue W White
LB Light Blue Y Yellow
LG Light Green
WGIWXX0048E
Fuse
Replacement
• When replacing a fuse, be sure to replace it with one of the same capacity. If a fuse fails again, the circuit
probably has a short and the wiring should be inspected.
• Be sure the negative battery cable is disconnected before replacing a main fuse.
GI–12
ELECTRICAL SYSTEM
• When replacing a pullout fuse, use the fuse
puller.
GI
WGIWXX0049E
WGIWXX0050E
End Of Sie
GI–13
NEW STANDARDS
NEW STANDARDS
NEW STANDARDS TABLE
Z4F202800020101
• Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
AP Accelerator Pedal — Accelerator Pedal
ACL Air Cleaner — Air Cleaner
A/C Air Conditioning — Air Conditioning
BARO Barometric Pressure — Atmospheric Pressure
B+ Battery Positive Voltage VB Battery Voltage
— Brake Switch — Stoplight Switch
— Calibration Resistor — Corrected Resistance #6
CMP sensor Camshaft Position Sensor — Crank Angle Sensor
CAC Charge Air Cooler — Intercooler
CLS Closed Loop System — Feedback System
CTP Closed Throttle Position — Fully Closed
CPP Clutch Pedal Position — Idle Switch
CIS Continuous Fuel Injection System — Clutch Position
CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6
CKP sensor Crankshaft Position Sensor — Crank Angle Sensor 2
DLC Data Link Connector — Diagnosis Connector
DTM Diagnostic Test Mode — Test Mode #1
DTC Diagnostic Trouble Code(s) — Service Code(s)
DI Distributor Ignition — Spark Ignition
DLI Distributorless Ignition — Direct Ignition
EI Electronic Ignition — Electronic Spark Ignition #2
ECT Engine Coolant Temperature — Water Thermo
EM Engine Modification — Engine Modification
— Engine Speed Input Signal — Engine RPM Signal
EVAP Evaporative Emission — Evaporative Emission
EGR Exhaust Gas Recirculation — Exhaust Gas Recirculation
FC Fan Control — Fan Control
FF Flexible Fuel — Flexible Fuel
4GR Fourth Gear — Overdrive
— Fuel Pump Relay — Circuit Opening Relay #3
FSO
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
solenoid
GEN Generator — Alternator
GND Ground — Ground/Earth
HO2S Heated Oxygen Sensor — Oxygen Sensor With heater
IAC Idle Air Control — Idle Speed Control
— IDM Relay — Spill Valve Relay #6
— Incorrect Gear Ratio — —
— Injection Pump FIP Fuel Injection Pump #6
— Input/Turbine Speed Sensor — Pulse Generator
IAT Intake Air Temperature — Intake Air Thermo
KS Knock Sensor — Knock Sensor
MIL Malfunction Indicator Lamp — Malfunction Indicator Light
MAP Manifold Absolute Pressure — Intake Air Pressure
MAF sensor Mass Air Flow Sensor — Airflow Sensor
MFL Multiport Fuel Injection — Multiport Fuel Injection
OBD On-Board Diagnostic — Diagnosis/Self Diagnosis
OL Open Loop — Open Loop
GI–14
NEW STANDARDS
New Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
GI
— Output Speed Sensor — Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter — Catalytic Converter
O2S Oxygen Sensor — Oxygen Sensor
PNP Park/Neutral Position — Park/Neutral Range
— PCM Control Relay — Main Relay #6
PSP Power Steering Pressure — Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
— Pressure Control Solenoid — Line Pressure Solenoid Valve
Pulsed
PAIR Pulsed Secondary Air Injection — Secondary Air Injection System
injection
— Pump Speed Sensor — NE Sensor #6
Injection
AIR Secondary Air Injection — Secondary Air Injection System with air
pump
SAPV Secondary Air Pulse Valve — Reed Valve
SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection
— 12 Shift Solenoid Valve
— Shift Solenoid A
— Shift A Solenoid Valve
— 23 Shift Solenoid Valve
— Shift Solenoid B
— Shift B Solenoid Valve
— Shift Solenoid C — 34 Shift Solenoid Valve
3GR Third Gear — 3rd Gear
TWC Three Way Catalytic Converter — Catalytic Converter
TB Throttle Body — Throttle Body
TP sensor Throttle Position Sensor — Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch — Lockup Position
Transmission (Transaxle) Control
TCM — ECAT Control Unit
Module
Transmission (Transaxle) Fluid
— — ATF Thermosensor
Temperature Sensor
TR Transmission (Transaxle) Range — Inhibitor Position
TC Turbocharger — Turbocharger
VSS Vehicle Speed Sensor — Vehicle Speed Sensor
VR Voltage Regulator — IC Regulator
VAF sensor Volume Air Flow Sensor — Air flow Sensor
Warm Up Three Way Catalytic
WUTWC — Catalytic Converter #5
Converter
WOT Wide Open Throttle — Fully Open
#1 : Diagnostic trouble codes depend on the diagnostic test mode
#2 : Controlled by the PCM
#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhaust manifold
#6 : Part name of diesel engine
End Of Sie
GI–15
ABBREVIATIONS
ABBREVIATIONS
ABBREVIATIONS TABLE
Z4F203000011101
EX Exhaust
IN Intake
PCV Positive crankcase ventilation
SST Special service tool
1st GR First gear
2nd GR Second gear
3rd GR Third gear
4th GR Forth gear
5th GR Fifith gear
End Of Sie
GI–16
ENGINE
B3
(FS) B3
ENGINE ................................................................ B3-2

ENGINE OVERHAUL SERVICE WARNING ..... B3-2
ENGINE MOUNTING......................................... B3-2
ENGINE DISMOUNTING................................... B3-3
TIMING BELT DISASSEMBLY .......................... B3-3
CYLINDER HEAD DISASSEMBLY (I) ............... B3-6
CYLINDER HEAD DISASSEMBLY (II) .............. B3-8
CYLINDER BLOCK DISASSEMBLY (I) ............. B3-9
CYLINDER BLOCK DISASSEMBLY (II) .......... B3-12
OIL JET REMOVAL ......................................... B3-14
CYLINDER HEAD INSPECTION/REPAIR....... B3-14
VALVE INSPECTION....................................... B3-15
VALVE GUIDE INSPECTION .......................... B3-15
VALVE GUIDE REPLACEMENT ..................... B3-16
VALVE SEAT INSPECTION/REPAIR.............. B3-16
VALVE SPRING INSPECTION........................ B3-17
CAMSHAFT INSPECTION .............................. B3-18
CAMSHAFT OIL CLEARANCE INSPECTION. B3-18
CAMSHAFT END PLAY INSPECTION............ B3-19
TAPPET INSPECTION .................................... B3-19
CYLINDER BLOCK INSPECTION/REPAIR .... B3-19
PISTON INSPECTION..................................... B3-20
PISTON CLEARANCE INSPECTION/REPAIRB3-20
PISTON RING CLEARANCE INSPECTION.... B3-20
PISTON PIN CLEARANCE INSPECTION....... B3-21
CRANKSHAFT INSPECTION.......................... B3-22
CRANKSHAFT OIL CLEARANCE
INSPECTION/REPAIR.................................. B3-22
CRANKSHAFT END PLAY
CONNECTING ROD INSPECTION ................. B3-23
CONNECTING ROD OIL CLEARANCE
CONNECTING ROD SIDE CLEARANCE
INSPECTION ................................................ B3-24
PISTON AND CONNECTING ROD
INSPECTION ................................................ B3-24
TENSIONER SPRING INSPECTION .............. B3-24
TENSIONER INSPECTION ............................. B3-24
ROTOR CLEARANCE INSPECTION .............. B3-25
PLUNGER SPRING INSPECTION .................. B3-25
BOLT INSPECTION......................................... B3-26
VALVE CLEARANCE INSPECTION................ B3-26
VALVE CLEARANCE ADJUSTMENT ............. B3-27
OIL JET INSTALLATION ................................. B3-29
CYLINDER BLOCK ASSEMBLY (I) ................. B3-30
CYLINDER BLOCK ASSEMBLY (II) ................ B3-34
CYLINDER HEAD ASSEMBLY (I) ................... B3-37
CYLINDER HEAD ASSEMBLY (II) .................. B3-39
TIMING BELT ASSEMBLY .............................. B3-42
B3–1
ENGINE
ENGINE
ENGINE OVERHAUL SERVICE WARNING
Z4F242402000101
Warning
• Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect
your skin by washing with soap and water immediately after this work.
End Of Sie
ENGINE MOUNTING
Z4F242402000102
1. Install the SSTs (arms and attachments) to the
cylinder block holes as indicated in the figure, and
hand tighten the SSTs (bolts).
Z8AE2224E001
2. Assemble the SSTs (bolts, nuts and plate) to the

specified positions.
3. Adjust the SSTs (bolts) so that less than 20 mm
{0.79 in} of thread is exposed.
4. Make the SSTs (arms and plate) parallel by
adjusting the SSTs (bolts and nuts).
Z8AE2224E002
5. Tighten the SSTs (bolts and nuts) to affix the

SSTs firmly.
Warning
• Self-locking brake system of the engine
stand may not be effective when the
engine is held in an unbalanced position.
This could lead to sudden, rapid
movement of the engine and mounting
stand handle and cause serious injury.
Never keep the engine in an unbalanced
position, and always hold the rotating
Z8AE2224E003
handle firmly when turning the engine.
6. Mount the engine on the SST (engine stand).

7. Drain the engine oil into a container.
8. Install the drain plug and a new washer.
Tightening torque
30—41 N·m {3.0—4.2 kgf·m, 22—30 ft·lbf}
Z8AE2224E004
B3–2
ENGINE
End Of Sie
ENGINE DISMOUNTING
Z4F242402000103
• Dismount in the reverse order of mounting.
End Of Sie
TIMING BELT DISASSEMBLY
Z4F242402000104
1. Disassemble in the order indicated in the table.
. B3
Z8AE2224E999
1 Spark plug 7 No.3 engine mount bracket

2 Cylinder head cover 8 Timing belt guide plate
(See B3–4 Cylinder Head Cover Disassembly Note) 9 Timing belt
3 Crankshaft pulley (See B3–4 Timing Belt Disassembly Note)
(See B3–4 Crankshaft Pulley Disassembly Note) 10 Tensioner, tensioner spring
4 Water pump pulley 11 Idler
5 Oil level dipstick 12 Timing belt pulley
6 Timing belt cover
B3–3
ENGINE
Cylinder Head Cover Disassembly Note
1. Loosen the cylinder head cover bolts a few turns
in the order shown.
Z8AE2224E006
Crankshaft Pulley Disassembly Note

1. Hold the crankshaft using the SST.
Z8AE2224E007
Timing Belt Disassembly Note

1. Turn the crankshaft clockwise and align the timing
marks as shown.
Caution
• Forcefully twisting the belt, turning it
inside out, or allowing oil or grease on it
will damage the belt and shorten its life.
Z8AE2224E008
2. Mark the timing belt rotation on the belt for proper

reinstallation.
Z8AE2224E009
B3–4
ENGINE
3. Turn the tensioner clockwise using an Allen
wrench.
4. Disconnect the tensioner spring from the hook
pin.
B3
Z8AE2224E010
End Of Sie
B3–5
ENGINE
CYLINDER HEAD DISASSEMBLY (I)
Z4F242402000105
1. Disassemble in the order indicated in the table. .
Z8AE2224E998
1 Camshaft pulley 3 Cylinder head

(See B3–7 Camshaft Pulley Disassembly Note) (See B3–7 Cylinder Head Disassembly Note)
2 Camshaft 4 Cylinder head gasket
(See B3–7 Camshaft Disassembly Note)
B3–6
ENGINE
Camshaft Pulley Disassembly Note
• Hold the camshaft using a wrench on the cast
hexagon as shown.
B3
Z8AE2224E017
Camshaft Disassembly Note

• Loosen the camshaft cap bolts a few turns in the
order shown.
Z8AE2224E018
Cylinder Head Disassembly Note

• Loosen the cylinder head bolts a few turns in the
order shown.
Z8AE2224E019
End Of Sie
B3–7
ENGINE
CYLINDER HEAD DISASSEMBLY (II)
Z4F242402000106
.
1 Tappet
2 Adjustment shim
3 Valve keeper
(See B3–8 Valve Keeper Disassembly Note)
4 Upper valve seat
5 Valve spring
6 Lower valve spring seat
7 Valve
8 Valve seal
(See B3–8 Valve Seal Disassembly Note)
Z8AE2224E997
Valve Keeper Disassembly Note

1. Remove the valve keeper using the SST.
Z8AE2224E029
Valve Seal Disassembly Note

1. Remove the valve seal using the SST.
Z8AE2224E030
End Of Sie
B3–8
ENGINE
CYLINDER BLOCK DISASSEMBLY (I)
Z4F242402000107
1. Disassemble in the order indicated in the table. .
B3
Z8AE2224E996
1 Water pump 7 Oil strainer

2 Oil pump 8 Oil pan upper block
(See B3–10 Oil Pump Disassembly Note) (See B3–11 Oil Pan Upper Block Disassembly
3 Flywheel (MTX), Drive plate (ATX) Note)
(See B3–10 Flywheel (MTX), Drive Plate (ATX) 9 Oil pump cover
Disassembly Note) 10 Outer rotor
4 End plate 11 Inner rotor
5 Rear cover 12 Plunger
(See B3–10 Rear Cover Disassembly Note)
13 Oil pump body
6 Oil pan
(See B3–10 Oil Pan Disassembly Note)
B3–9
ENGINE
Oil Pump Disassembly Note
1. Remove the front oil seal using a screwdriver
protected with a rag.
Z8AE2224E036
Flywheel (MTX), Drive Plate (ATX) Disassembly Note

1. Hold the crankshaft using SST.
Z8AE2224E037
Rear Cover Disassembly Note

1. Remove the rear oil seal using a screwdriver
protected with a rag.
Z8AE2224E038
Oil Pan Disassembly Note

1. Remove the oil pan mounting bolts.
Caution
• Do not force a prying tool between the oil pan upper block and the oil pan. Doing so may damage
the contact surfaces.
2. Remove the sealant from the bolt threads.

3. Screw an oil pan bolt into the weldnut to make a
small gap between the oil pan upper block and
the oil pan.
Z8AE2224E039
B3–10
ENGINE
4. Remove the oil pan using the separator tool.
B3
Z8AE2224E040
Oil Pan Upper Block Disassembly Note

1. Remove the two bolts at the rear of the cylinder block.
2. Loosen the oil pan upper block bolts a few turns
in the order shown.
Z8AE2224E041
3. Remove the oil pan upper block using the

separator tool.
Z8AE2224E042
End Of Sie
B3–11
ENGINE
CYLINDER BLOCK DISASSEMBLY (II)
Z4F242402000108
.
Z8AE2224E995
1 Connecting rod cap 7 Piston

2 Lower connecting rod bearing 8 Connecting rod
3 Piston and connecting rod 9 Main bearing cap
(See B3–13 Piston and Connecting Rod (See B3–13 Main Bearing Cap Disassembly Note)
Disassembly Note) 10 Lower main bearing
4 Upper connecting rod bearing 11 Crankshaft
5 Piston ring 12 Upper main bearing, thrust bearing
6 Piston pin 13 Cylinder block
B3–12
ENGINE
Piston and Connecting Rod Disassembly Note
1. Assemble the SST as shown.
B3
Z8AE2224E053
2. Insert SST No.2 into the piston pin as shown and

fully screw in SST No.1.
Z8AE2224E054
3. Set the piston and connecting rod on the SST as

shown.
4. Press out the piston pin.
Z8AE2224E055
Main Bearing Cap Disassembly Note

• Loosen the main bearing cap bolts a few turns in
the order shown.
Z8AE2224E056
End Of Sie
B3–13
ENGINE
OIL JET REMOVAL
Z4F242410730101
Removal
1. Drill a hole into the center of the oil jet head with a
7 mm {0.28 in} drill bit.
2. Remove the spring and ball through the hole.
3. Tap the hole with a M8 x 1.25 tap to 8 mm {0.31
in} deep
4. Screw a M8 x 1.25 bolt into the tapped hole.
5. Attach the sliding hammer to the bolt.
Caution
• Twisting or turning the sliding hammer
while removing the oil jet can damage the
cylinder block.
Z8AE2224E091
6. Pull the sliding hammer straight upward and

discard the oil jet.
Z8AE2224E092
End Of Sie HEAD INSPECTION/REPAIR

CYLINDER
Z4F242410100101
1. Carry out color contrast penetrate examination on the cylinder head surface. Replace the cylinder head if
necessary.
2. Inspect for the following and repair or replace if necessary.
(1) Sunken valve seats.
(2) Excessive camshaft oil clearance and end play.
3. Measure the cylinder head for distortion in the six
directions as shown.
Maximum distortion
0.10 mm {0.004 in}
4. If the cylinder head distortion exceeds the

maximum, repair by grinding the height or replace
the cylinder head. If the cylinder head height is
not within the specification, replace it.
Standard height
Z8AE2224E068
124.45—124.55 mm {4.8996—4.9035 in}
Maximum grinding
0.15 mm {0.006 in}
5. Measure the manifold contact surface distortion

as shown.
Maximum distortion
0.10 mm {0.004 in}
6. If the distortion exceeds the specification, grind

the surface or replace the cylinder head.
Maximum grinding
0.15 mm {0.006 in}
Z8AE2224E069
B3–14
ENGINE
End Of INSPECTION
VALVE Sie
Z4F242412111101
1. Measure the valve head margin thickness of each
valve. Replace the valve if necessary.
Margin thickness B3
IN: 1.10 mm {0.043 in}
EX: 1.20 mm {0.047 in}
2. Measure the length of each valve. Replace the

valve if necessary.
Standard length
IN: 89.49—90.09 mm {3.524—3.546 in}
Z8AE2224E070
EX: 89.79—90.39 mm {3.536—3.558 in}
Minimum length
IN: 89.28 mm {3.515 in}
EX: 89.38 mm {3.519 in}
3. Measure the stem diameter of each valve in X

and Y directions at the three points (A, B, and C)
shown. Replace the valve if necessary.
Standard diameter
IN: 5.970—5.985 mm {0.2351—0.2356 in}
EX: 5.965—5.980 mm {0.2349—0.2354 in}
Minimum diameter
IN: 5.940 mm {0.2339 in}
EX: 5.935 mm {0.2337 in}
Z8AE2224E071
End Of GUIDE
VALVE Sie INSPECTION
Z4F242410280101
1. Measure the inner diameter of each valve guide
in X and Y directions at the three points (A, B, and
C) shown. Replace the valve guide if necessary.
Standard inner diameter

6.01—6.03 mm {0.2367—0.2374 in}
Z8AE2224E072
2. Measure the protrusion height (dimension A) of

each valve guide without lower valve spring seat.
Replace the valve guide if necessary.
Standard height
13.5—14.1 mm {0.532—0.555 in}
Z8AE2224E073
End Of Sie
B3–15
ENGINE
VALVE GUIDE REPLACEMENT
Z4F242410280102
Note
• Intake and exhaust valve guides are different.
Valve Guide Removal

• Remove the valve guide from the combustion
chamber side by using the SST.
Z8AE2224E074
Valve Guide Installation

1. Assemble the SSTs so that depth L is as
specified.
Depth L
13.5—14.1 mm {0.532—0.555 in}
Z8AE2224E075
2. Tap the valve guide in from the side opposite the

combustion chamber until the SST contacts the
cylinder head.
3. Verify that the valve guide projection height
(dImension) is within the specification.
Standard height
13.5—14.1 mm {0.532—0.555 in}
Z8AE2224E076
End Of SEAT
VALVE Sie INSPECTION/REPAIR
Z4F242410102101
1. Measure the seat contact width. If necessary,
resurface the valve seat using a 45°° valve seat
cutter and/or resurface the valve face.
Standard width
0.90—1.30 mm {0.036—0.051 in}
2. Verify that the valve seating position is at the

center of the valve face.
Z8AE2224E077
B3–16
ENGINE
(1) If the seating position is too high, correct the
valve seat using a 65°° (IN) or 75°° (EX) cutter,
and a 45°° cutter.
(2) If the seating position is too low, correct the
valve seat using a 35°° cutter, and a 45°°
cutter. B3
Z8AE2224E078
3. Check the sinking of the valve seat. Measure the

protruding length (dimension L) of the valve stem.
Replace the cylinder head if necessary.
Standard dimension L
IN: 39.0 mm {1.535 in}
EX: 39.0 mm {1.535 in}
Maximum dimension L
IN: 39.6 mm {1.559 in}
EX: 39.6 mm {1.559 in}
Z8AE2224E079
End Of SPRING
Z4F242412125101
1. Apply pressing force to the pressure spring and
check the spring height. Replace the valve spring
if necessary.
Pressing force
IN: 177.1—200.3 N {18.05—20.42 kgf, 39.71—
44.92 lbf}
EX: 177.1—200.3 N {18.05—20.42 kgf,
39.71—44.92 lbf}
Standard height
IN: 36.5 mm {1.44 in}
Z8AE2224E080
EX: 36.5 mm {1.44 in}
2. Measure the out-of-square of the valve spring.

Replace the valve spring if necessary.
Maximum valve spring out-of-square

IN: 1.54 mm {0.061 in}
EX: 1.54 mm {0.061 in}
Z8AE2224E281
End Of Sie
B3–17
ENGINE
CAMSHAFT INSPECTION
Z4F242412420101
1. Set the No.1 and No.5 journals on V-blocks.
Measure the camshaft runout. Replace the
camshaft if necessary.
Maximum runout
0.03 mm {0.0012 in}
Z8AE2224E082
2. Measure the cam lobe height at the two points as

shown. Replace the camshaft if necessary.
Standard height
IN: 43.7014 mm {1.7205 in}
EX: 43.2061 mm {1.7010 in}
Minimum height
IN: 43.5914 mm {1.7162 in}
EX: 43.0961 mm {1.6967 in}
Z8AE2224E083
3. Measure the journal diameters in X and Y

directions at the two points (A and B) as shown.
Replace the camshaft if necessary.
Standard diameter
No.1, 5: 25.940—25.965 mm {1.0213—1.0222
in}
No.2, 3, 4: 25.936—25.965 mm {1.0212—
1.0222 in}
Minimum diameter
No.1, 5: 25.890 mm {1.0193 in}
Z8AE2224E084
No.2, 3, 4: 25.886 mm {1.0191 in}
End Of Sie
CAMSHAFT OIL CLEARANCE INSPECTION
Z4F242412420102
1. Position Plastigauge atop the journals in the axial
direction.
2. IInstall the camshaft cap. (SeeB3–40 Camshaft
Assembly Note)
3. Remove the camshaft cap. (See B3–7 Camshaft
Disassembly Note)
4. Measure the oil clearance. Replace the cylinder
head if necessary.
Standard clearance
0.035—0.081 mm {0.0014—0.0031 in}
Z8AE2224E085
Maximum clearance
0.15 mm {0.006 in}
End Of Sie
B3–18
ENGINE
CAMSHAFT END PLAY INSPECTION
Z4F242412420103
1. Install the camshaft cap. (See B3–40 Camshaft Assembly Note)
2. Measure the camshaft end play. Replace the
cylinder head or camshaft if necessary.
Standard end play

B3
0.08—0.20 mm {0.0032—0.0078 in}
Maximum end play

0.21 mm {0.008 in}
3. Remove the camshaft cap. (See B3–7 Camshaft

Disassembly Note)
Z8AE2224E086
End Of Sie
TAPPET INSPECTION
Z4F242412310101
1. Measure the diameter of each tappet bore.
Standard diameter
30.000—30.025 mm {1.1812—1.1820 in}
Z8AE2224E087
2. Measure the diameter of each tappet.
Standard diameter
29.959—29.975 mm {1.1795—1.1801 in}
3. Calculate the clearance between the tappet and

the related tappet bore. Replace the tappet or
cylinder head if necessary.
Standard clearance
0.025—0.066 mm {0.00099—0.00259 in}
Z8AE2224E088
Maximum clearance
0.180 mm {0.0071 in}
End Of Sie
CYLINDER BLOCK INSPECTION/REPAIR
Z4F242410300101
1. Measure the distortion of the cylinder block top
surface in the six directions as shown. Repair by
grinding or replace if necessary.
Maximum cylinder block distortion

0.05 mm {0.002 in}
Standard cylinder block height

261.4—261.6 mm {10.292—10.299 in}
Maximum grinding
0.20 mm {0.008 in}
Z8AE2224E089
B3–19
ENGINE
2. Measure the cylinder bores in X and Y directions
at 67 mm {2.64 in} below the top surface.
3. If the cylinder bore exceeds the wear limit,
replace the cylinder block or rebore the cylinder
and install the oversize pistons so that the
specified piston-to-cylinder clearance is obtained.
Note
• Base the boring diameter on the diameter of
an oversize piston. All cylinders must be the
same diameter.
Z8AE2224E090
Cylinder bore
(mm {in})
Size Diameter
Standard 83.000—83.019 {3.2678—3.2684}
0.25 {0.01} oversize 83.250—83.269 {3.2776—3.2783}
0.50 {0.02} oversize 83.500— 83.519 {3.2874—3.2881}
Wear limit
0.15 mm {0.006 in}
End Of Sie
PISTON INSPECTION
Z4F242411010101
• Measure the outer diameter of each piston at a
right angle (90°°) to the piston pin, 16.5 mm
{0.6450 in} below the oil ring groove lower edge.
Piston diameter
mm {in}
Size Diameter
Standard 82.953—82.975 {3.2659—3.2667}
0.25 {0.01} oversize 83.203—83.225 {3.2758—3.2765}
0.50 {0.02} oversize 83.453—83.475 {3.2856—3.2864}
Z8AE2224E095
End Of Sie
PISTON CLEARANCE INSPECTION/REPAIR
Z4F242411010102
1. Calculate the piston-to-cylinder clearance. Replace the piston or rebore the cylinders to fit oversize piston if
necessary.
Standard clearance
0.039—0.065 mm {0.0016—0.0025 in}
Maximum clearance
0.15 mm {0.006 in}
2. If the piston is replaced, the piston rings must also be replaced.

End Of Sie
PISTON RING CLEARANCE INSPECTION
Z4F242411010103
1. Measure the piston ring-to-ring land clearance
around the entire circumference. Replace the
piston and piston ring if necessary.
Standard clearance
Top: 0.035—0.065 mm {0.0014—0.0025 in}
Second: 0.030—0.065 mm {0.0012—0.0025
in}
Oil: 0.022—0.065 mm {0.0009—0.0025 in}
Maximum clearance
0.20 mm {0.008 in}
Z8AE2224E096
B3–20
ENGINE
2. Insert the piston ring into the cylinder by hand and
use the piston to push it to the bottom of the ring
travel.
3. Measure each piston ring end gap using a feeler
gauge. Replace the piston ring if necessary.
B3
Standard end gap
Top: 0.15—0.25 mm {0.006—0.009 in}
Second: 0.15—0.30 mm {0.006—0.011 in}
Oil rail: 0.20—0.70 mm {0.008—0.027 in}
Maximum end gap

Z8AE2224E097
1.0 mm {0.039 in}
End
PISTONSie
Of PIN CLEARANCE INSPECTION
Z4F242411010104
1. Measure each piston pin hole diameter in X and Y
directions at the four points (A, B, C, and D) as
shown.
Standard diameter
18.988—19.000 mm {0.7476—0.7480 in}
Z8AE2224E098
2. Measure each connecting rod small end inner

diameter in X and Y directions as shown.
Standard diameter
18.943—19.961 mm {0.7458—0.7858 in}
Z8AE2224E099
3. Measure each piston pin diameter in X and Y

directions at the four points (A, B, C, and D) as
shown.
Standard diameter
18.974—18.980 mm {0.7471—0.7472 in}
4. Calculate the piston pin-to-piston pin bore

clearance. Replace the piston and/or piston pin if
necessary.
Standard clearance
Z8AE2224E100
0.008—0.026 mm {0.0004—0.0010 in}
5. Calculate the connecting rod small end-to-piston pin clearance. Replace the connecting rod or piston pin.
Standard clearance
- 0.037— - 0.013 mm {- 0.0014— - 0.0005 in}
End Of Sie
B3–21
ENGINE
CRANKSHAFT INSPECTION
Z4F242411301101
1. Measure the crankshaft runout. Replace the
crankshaft if necessary.
Maximum runout
0.03 mm {0.0012 in}
Z8AE2224E101
2. Measure the journal diameter in X and Y direction

at the two points (A and B) as shown. Replace the
crankshaft or grind the journal and install the
undersize bearing if necessary.
Main Journal
(mm {in})
Bearing size Diameter
55.937—55.955
Standard
{2.2022—2.2029}
55.687—55.705
0.25 {0.01} undersize
{2.1924—2.1931}
Z8AE2224E102
Out-of-round
0.05 mm {0.002 in} max.
Crank pin
(mm {in})
Bearing size Diameter
47.940—47.955
Standard
{1.8874—1.8879}
47.690—47.705
0.25 {0.01} under size
{1.8776—1.8781}
Out-of-round
0.05 mm {0.002 in} max.
End Of Sie
CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR
Z4F242411301102
1. Position a plastigauge atop the journals in the axial direction.
2. Install the main bearing cap. (See B3–31 Main Bearing Cap Assembly Note)
3. Remove the main bearing cap. (See B3–13 Main Bearing Cap Disassembly Note)
4. Measure the main journal oil clearance. If the
clearance exceeds the maximum, replace the
main bearing or grind the main journal and install
the undersize bearings so that the specified oil
clearance is obtained.
Standard clearance
0.024—0.050 mm {0.0010—0.0019 in}
Maximum clearance
0.067 mm {0.0026 in}
Z8AE2224E103
(mm {in})
Bearing size Bearing thickness
2.007—2.028
Standard
{0.0791—0.0798}
2.134—2.138
{0.0841—0.0841}
End Of Sie
B3–22
ENGINE
CRANKSHAFT END PLAY INSPECTION/REPAIR
Z4F242411301103
1. Install the main bearing cap. (See B3–31 Main Bearing Cap Assembly Note)
2. Measure the crankshaft end play. If the end play
exceeds the maximum, replace the thrust bearing
or grind the crankshaft and install an undersize
bearing so that the specified end play is obtained.
B3
Standard end play

0.080—0.282 mm {0.0032—0.0111 in}
Maximum end play

0.30 mm {0.012 in}
(mm {in})
Bearing size Bearing thickness Z8AE2224E104
2.500—2.550
Standard
{0.0985—0.1003}
2.625—2.675
{0.1034—0.1053}
2.750—2.800
{0.1083—0.1102}
2.875—2.925
{0.1132—0.1151}
3. Remove the main bearing cap. (See B3–13 Main Bearing Cap Disassembly Note)
End Of Sie
CONNECTING ROD INSPECTION
Z4F242411211101
• Measure each connecting rod for bending and
distortion. Replace the connecting rod if
necessary.
Bending
0.05 mm {0.0020 in} max. /50 mm {1.97 in}
Distortion
0.05 mm {0.0020 in} max. /50 mm {1.97 in}
Center-to-center distance
129.15—129.25 {5.0847—5.0885 in}
Z8AE2224E105
End Of Sie
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR
Z4F242411211102
1. Position a plastigauge atop the journals in the axial direction.
2. Install the connecting rod cap. (See B3–31 Piston and Connecting Rod Assembly Note)
3. Remove the connecting rod cap.
4. Measure the crankpin oil clearance. If the
clearance exceeds the maximum, replace the
connecting rod bearing or grind the crankpin and
use undersize bearings so that the specified
clearance is obtained.
Standard clearance
0.024—0.061 mm {0.0010—0.0024 in}
Maximum clearance
0.067 mm {0.0026 in}
(mm {in}) Z8AE2224E106
Bearing size Bearing thickness
1.509—1.524
Standard
{0.05941—0.05999}
1.629—1.637
{0.06414—0.06444}
1.754—1.762
{0.06906—0.06936}
B3–23
ENGINE
End Of Sie
CONNECTING ROD SIDE CLEARANCE INSPECTION
Z4F242411211103
1. Install the connecting rod cap. (See B3–31 Piston and Connecting Rod Assembly Note)
2. Measure the connecting rod large end side
clearance. Replace the connecting rod and cap if
necessary.
Standard clearance
0.110—0.262 mm {0.005—0.010 in}
Maximum clearance
0.30 mm {0.012 in}
3. Remove the connecting rod cap.

Z8AE2224E107
End Of Sie
PISTON AND CONNECTING ROD INSPECTION
Z4F242411010105
• Check the oscillation torque as shown. If the large
end does not drop by its own weight, replace the
piston or the piston pin.
Z8AE2224E108
End Of Sie SPRING INSPECTION

TENSIONER
Z4F242412711101
• Measure the free length of the tensioner spring.
Replace the tensioner spring if necessary.
Free length
36.6 mm {1.44 in}
Z8AE2224E109
End Of Sie INSPECTION

TENSIONER
Z4F242412711102
• Rotate the tensioner. If the tensioner rotates with
no resistance or does not rotate, replace it.
Z8AE2224E110
End Of Sie
B3–24
ENGINE
ROTOR CLEARANCE INSPECTION
Z4F242419220101
• Measure the following clearance. Replace the
rotor and/or pump body if necessary.
Standard tip clearance

0.130—0.206 mm {0.0051—0.0081 in}
B3
Maximum tip clearance

0.30 mm {0.012 in}
Z8AE2224E111
Standard body clearance

0.113—0.186 mm {0.0045—0.0073 in}
Maximum body clearance

0.22 mm {0.009 in}
Z8AE2224E112
Standard side clearance

0.035—0.095 mm {0.0014—0.0037 in}
Maximum side clearance

0.14 mm {0.006 in}
Z8AE2224E113
End Of SieSPRING INSPECTION

PLUNGER
Z4F242414116101
• Apply pressing force to the pressure spring and
check the spring height. Replace the plunger
spring if necessary.
Pressing force
97.68—107.48 N {9.96—10.96 kgf, 21.91—
24.11 lbf}
Standard height
33.50 mm {1.319 in}
Z8AE2224E114
End Of Sie
B3–25
ENGINE
BOLT INSPECTION
Z4F242410135101
Connecting Rod Bolt Inspection
• Measure the length of each connecting rod bolt.
Replace as necessary.
Standard length
46.7—47.3 mm {1.839—1.862 in}
Maximum length
48.0 mm {1.890 in}
Z8AE2224E115
Main Bearing Cap Bolt Inspection

• Measure the length of each main bearing cap
bolt, Replace as necessary.
Standard length
67.7—68.3 mm {2.666—2.688 in}
Maximum length
69.0 mm {2.717 in}
Z8AE2224E116
Cylinder Head Bolt Inspection

• Measure the length of each cylinder head bolt.
Replace as necessary.
Standard length
104.2—104.8 mm {4.103—4.125 in}
Maximum length
105.5 mm {4.154 in}
Z8AE2224E117
End Of CLEARANCE
Z4F242412111102
1. Remove the cylinder head cover.
2. Verify that the engine is cold.
3. Measure the valve clearance.
(1) Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
(2) Measure the valve clearance at A in the
figure.
Z8AE2224E118
B3–26
ENGINE
Standard valve clearance [Engine cold]

IN: 0.225—0.295 mm {0.0089—0.0116 in}
±0.035 mm {0.010±
(0.26± ±0.001 in})
EX: 0.225—0.295 mm {0.0089—0.0116 in}
±0.035 mm {0.010±
(0.26± ±0.001 in}) B3
(3) If the valve clearance exceeds the standard,

replace the adjustment shim. (See B3–27
VALVE CLEARANCE ADJUSTMENT)
(4) Turn the crankshaft 360° clockwise so that
the No.4 piston is at TDC of the compression
Z8AE2224E119
stroke.
(5) Measure the valve clearance at B in the
figure.
Standard valve clearance [Engine cold]

±0.035 mm {0.010±
IN: 0.225—0.295 mm {0.0089—0.0116 in} (0.26± ±0.001 in})
EX: 0.225—0.295 mm {0.0089—0.0116 in} (0.26±±0.035 mm {0.010±
±0.001 in})
(6) If the valve clearance exceeds the standard, replace the adjustment shim. (See B3–27 VALVE
CLEARANCE ADJUSTMENT)
4. Install the cylinder head cover.
End Of Sie
VALVE CLEARANCE ADJUSTMENT
Z4F242412111103
Perform this same procedure for all camshafts requiring valve clearance adjustment.
1. Turn the crankshaft clockwise so that the cams on the camshaft requiring valve clearance adjustment are
positioned straight up.
2. Remove the camshaft cap bolts as necessary. Remove only one pair of cap bolts at a time. Reinstall the cap
bolts before removing the next pair.
A: For EX side No.1, 2, 3 cylinder adjustment
shim removal.
B: For IN side No.1, 2, 3 cylinder adjustment shim
removal.
C: For EX side No.2, 3, 4 cylinder adjustment
shim removal.
D: For IN side No.2, 3, 4 cylinder adjustment shim
removal.
Note
• For EX side No.2, 3 cylinder adjustment
shim removal, remove bolts either A or C.
• For IN side No.2, 3 cylinder adjustment shim
Z8AE2224E120
removal, remove bolts either B or D.
3. Install the SSTs on the camshaft using the

camshaft cap bolt holes.
Z8AE2224E121
B3–27
ENGINE
Tightening torque
11.3—14.2 N·m {115—145 kgf·cm, 100—125
in·lbf}
Z8AE2224E122
4. Align the marks on the SSTs (shaft and shaft

clamp).
5. Tighten bolts A to secure the SST (shaft).
Z8AE2224E123
6. Face the SST (body) outside of the cylinder head,

and mount it on the SST (shaft) at the point of the
adjustment shim to be replaced.
Z8AE2224E124
7. Face the notch of the tappet so that a fine

screwdriver can be inserted.
8. Set the SST on the tappet by its notch.
9. Tighten bolt B to secure the SST (body).
Caution
• Cylinder head can be damaged when the
tappet is pressed down.
Z8AE2224E125
10. Tighten bolt C, and press down the tappet.
Z8AE2224E126
B3–28
ENGINE
11. Using a fine screwdriver, pry up the adjustment
shim through the notch on the tappet. Remove
the shim by using a magnet.
12. Select proper adjustment shim.
New adjustment shim B3

= Removed shim thickness + Measured
valve clearance – Standard valve
clearance (IN: 0.26 mm {0.010 in}, EX: 0.26
mm {0.010 in})
13. Push the selected shim into the tappet.

Z8AE2224E127
14. Loosen bolt C to allow the tappet to move up.
15. Loosen bolt B and remove the SST (body).
16. Remove the SSTs and tighten the camshaft cap bolts.
Tightening torque
11.3—14.2 N·m {115—145 kgf·cm, 100—125 in·lbf}
17. Check the valve clearance. (Refer to VALVE CLEARANCE, VALVE CLEARANCE INSPECTION.)
End Of Sie
OIL JET INSTALLATION
Z4F242410730102
Installation
1. Temporarily install the crankshaft, connecting rod, and piston to the cylinder block.
2. Coat the oil jet with engine oil.
3. Fit the oil jet into the hole and align the nozzle
with the piston's notch.
4. Put the cylinder block on the press stand.
5. Verify that the oil jet nozzle is properly aligned.
Caution
• If the oil jet nozzle is not properly aligned
after being pressed in, it can damage the
oil jet, cylinder block and the piston.
Z8AE2224E093
6. Press-fit the oil jet into the cylinder block.
Depth
11.0—10.5 mm {0.44—0.41 in}
Pressure
3.2 kN {330 kgf , 726 lbf} min.
Caution
• Depth over specification can damage the
oil jet nozzle.
• Pressure below specification indicates
Z8AE2224E094
loose fit. Replace the cylinder block and
oil jet.
End Of Sie
B3–29
ENGINE
CYLINDER BLOCK ASSEMBLY (I)
Z4F242402000109
1. Assemble in the order indicated in the table.
.
Z8AE2224E052
1 Upper main bearing, thrust bearing 8 Piston ring

2 Crankshaft 9 Upper connecting rod bearing
3 Lower main bearing 10 Piston and connecting rod
4 Main bearing cap (See B3–31 Piston and Connecting Rod Assembly
(See B3–31 Main Bearing Cap Assembly Note) Note)
5 Connecting rod 11 Lower connecting rod bearing
6 Piston 12 Connecting rod cap
7 Piston pin 13 Cylinder block
B3–30
ENGINE
Main Bearing Cap Assembly Note
1. Tighten the main bearing cap bolts a few turns in
the order shown.
B3
Z8AE2224E057
2. Put a paint mark on each bolt head.

3. Using the mark as a reference, tighten the bolts
by turning each 85°°—95°° in the sequence shown.
Z8AE2224E058
Piston and Connecting Rod Assembly Note

1. Assemble the SST as shown.
Z8AE2224E059
2. Insert SST No.2 into the piston pin as shown and

fully screw in SST No.1.
Z8AE2224E060
B3–31
ENGINE
3. Set the SST (stopper bolt) so that dimension L is
as specified.
Dimension L
59.0 mm {2.32 in}
4. Apply clean engine oil to the piston pin.
Z8AE2224E061
5. Insert the piston pin and the SST assembled in

step 2 into the piston and connecting rod.
Z8AE2224E062
6. Press the piston pin into the piston and

connecting rod until the SST (guide) contacts the
SST (stopper bolt).
7. While inserting the piston pin, check the pressure
force. If it is less than the specification, replace
the piston pin or the connecting rod.
Pressure force
4.91—14.70 kN {500—1500 kgf, 1100—3300
lbf}
8. Verify that the second ring is installed with the

Z8AE2224E063
scraper face downward.
9. Position the end gap of the oil ring as shown.
Z8AE2224E064
10. Make sure the F mark faces the front of the

engine.
Z8AE2224E065
B3–32
ENGINE
11. Install the connecting rod caps with the knock
pins and the alignment marks aligned.
12. Tighten the bolts a few turns.
Tightening torque
22.1—26.9 N·m {2.25—2.75 kgf·m, 16.3—19.8 B3
ft·lbf}
Z8AE2224E066
13. Put a paint mark on each bolt head.

14. Using the mark as a reference, tighten the bolts
by turning each 85°°—95°°.
Z8AE2224E067
End Of Sie
B3–33
ENGINE
CYLINDER BLOCK ASSEMBLY (II)
Z4F242402000110
.
Z8AE2224E035
1 Oil pump body 8 Oil pan

2 Plunger (See B3–35 Oil Pan Assembly Note)
3 Inner rotor 9 Rear cover
(See B3–36 Rear Cover Assembly Note)
4 Outer rotor
10 End plate
5 Oil pump cover
11 Flywheel (MTX), Drive plate (ATX)
6 Oil pan upper block (See B3–36 Flywheel (MTX), Drive Plate (ATX)
(See B3–35 Oil Pan Upper Block Assembly Note) Assembly Note)
7 Oil strainer 12 Oil pump
(See B3–35 Oil Strainer Assembly Note) (See B3–36 Oil Pump Assembly Note)
13 Water pump
B3–34
ENGINE
Oil Pan Upper Block Assembly Note
1. Apply silicone sealant to the oil pan upper block
as shown.
Thickness
2.0—3.0 mm {0.08—0.11 in} B3
2. Tighten the two bolts.
Z8AE2224E043
3. Tighten the oil pan upper block bolts a few turns

in the order shown.
Z8AE2224E044
Oil Strainer Assembly Note

• Install the oil strainer gasket as shown.
Z8AE2224E045
Oil Pan Assembly Note

• Apply silicone sealant to the oil pan as shown.
Thickness
2.0—3.0 mm {0.08—0.11 in}
Z8AE2224E046
B3–35
ENGINE
Rear Cover Assembly Note
1. Apply clean engine oil to the oil seal.
2. Push the oil seal slightly in by hand.
3. Press the oil seal in evenly using the SST.
Z8AE2224E047
4. Apply silicone sealant to the rear cover as shown.
Thickness
2.0—3.0 mm {0.08—0.11 in}
Z8AE2224E048
Flywheel (MTX), Drive Plate (ATX) Assembly Note

• Hold the crankshaft using the SST.
Z8AE2224E049
Oil Pump Assembly Note

1. Apply clean engine oil to the oil seal.
2. Push the oil seal slightly in by hand.
3. Press the oil seal in evenly using the SST.
Z8AE2224E050
B3–36
ENGINE
4. Apply silicone sealant to the oil pump as shown.
Thickness
1.0—2.0 mm {0.04—0.07 in}
B3
Z8AE2224E051
End Of Sie HEAD ASSEMBLY (I)

CYLINDER
Z4F242402000111
1. Assemble in the order indicated in the table. .
1 Valve seal
(See B3–37 Valve Seal Assembly Note)
2 Valve
3 Lower valve spring seat
4 Valve spring
(See B3–38 Valve Spring Assembly Note)
5 Upper valve seat
6 Valve keeper
(See B3–38 Valve Keeper Assembly Note)
7 Adjustment shim
8 Tappet
Z8AE2224E028
Valve Seal Assembly Note

1. Assemble the SST so that depth L is as specified.
Depth L
14.8—15.4 mm {0.59—0.60 in}
2. Press the valve seal onto the valve guide by

hand.
Z8AE2224E031
B3–37
ENGINE
3. Tap the SST using a plastic hammer until its
lower end touches the cylinder head.
Z8AE2224E032
Valve Spring Assembly Note

• Install the valve spring with the closer pitch
toward the cylinder head.
Z8AE2224E033
Valve Keeper Assembly Note

• Install the valve keeper using the SST.
Z8AE2224E034
End Of Sie
B3–38
ENGINE
CYLINDER HEAD ASSEMBLY (II)
Z4F242402000112
1. Assemble in the order indicated in the table. .
B3
Z8AE2224E016
1 Cylinder head gasket 3 Camshaft

2 Cylinder head (See B3–40 Camshaft Assembly Note)
(See B3–40 Cylinder Head Assembly Note) 4 Camshaft pulley
(See B3–40 Camshaft Assembly Note)
B3–39
ENGINE
Cylinder Head Assembly Note
1. Tighten the cylinder head bolts a few turns in the
order shown.
Tightening torque
17.2—22.0 N·m {1.75—2.25 kgf·m 12.7—16.2
ft·lbf}
Z8AE2224E020
2. Make point marks on the bolt head, as shown.

3. With the paint marks as a reference point, tighten
the cylinder head bolts another 85°°—95°° in the
tightening order.
4. Then tighten them once again 85°—95° in the
tightening order.
Z8AE2224E021
Camshaft Assembly Note
Caution
• Because there is little camshaft thrust clearance, the camshaft must be held horizontally while it is
installed. Otherwise, excessive force will be applied to the thrust area, causing burr on the thrust
receiving area of the cylinder head journal. To avoid this, the following procedure must be
observed.
1. Assemble camshaft onto the cylinder head, facing

the cam noses at No.1 and No.3 cylinders as
shown.
Z8AE2224E022
2. Apply silicone sealant to the shaded areas as

shown.
Z8AE2224E023
B3–40
ENGINE
3. Hand tighten the camshaft cap bolts marked 5, 7,
2, and 4.
4. Install the camshaft cap bolts and tighten them a
few turns in the order shown.
5. Apply clean engine oil to the new oil seal.
6. Push the oil seal slightly in by hand. B3
Z8AE2224E024
7. Tap the oil seal into the cylinder head using the
SST and a hammer.
Z8AE2224E025
Camshaft Pulley Assembly Note

1. Install the camshaft pulleys, positioning the dowel
pins as shown.
Z8AE2224E026
2. Hold the camshaft using a suitable wrench on the

cast hexagon as shown.
Z8AE2224E027
End Of Sie
B3–41
ENGINE
TIMING BELT ASSEMBLY
Z4F242402000113
.
Z8AE2224E005
1 Timing belt pulley 7 Timing belt cover

2 Idler 8 Oil level dipstick
3 Tensioner, tensioner spring 9 Water pump pulley
4 Timing belt 10 Crankshaft pulley
(See B3–43 Timing Belt Assembly Note) (See B3–43 Crankshaft Pulley Assembly Note)
5 Timing belt guide plate 11 Cylinder head cover
6 No.3 engine mount bracket (See B3–43 Cylinder Head Cover Assembly Note)
12 Spark plug
B3–42
ENGINE
Timing Belt Assembly Note
1. Turn the crankshaft clockwise and align the timing
marks as shown.
B3
Z8AE2224E011
2. Turn the tensioner clockwise using an Allen

wrench.
3. Install the timing belt.
4. Connect the tensioner spring to the hook pin.
5. Turn the crankshaft clockwise twice, and align the
timing marks. If they are not aligned, remove the
timing belt and repeat from Timing Belt Assembly
Note step 1.
Z8AE2224E012
Crankshaft Pulley Assembly Note

• Hold the crankshaft using the SST.
Z8AE2224E993
Cylinder Head Cover Assembly Note

1. Apply silicone sealant to the shaded areas of the
cylinder head as shown.
2. Verify that the grooves on the cylinder head cover
are free of oil, water and other foreign material.
Z8AE2224E014
B3–43
ENGINE
3. Install the cylinder head cover bolts and tighten
them a few turns in the order shown.
Z8AE2224E015
End Of Sie
B3–44
MANUAL TRANSAXLE
J2
(G15M-R)
J2
MANUAL TRANSAXLE........................................ J2-2
PRECAUTION.................................................... J2-2
5TH GEAR THRUST CLEARANCE
PREINSPECTION........................................... J2-2
5TH/REVERSE GEAR AND HOUSING PARTS
DISASSEMBLY............................................... J2-2
5TH/REVERSE GEAR AND HOUSING PARTS
INSPECTION .................................................. J2-6
CLUTCH HOUSING AND TRANSAXLE CASE
COMPONENTS DISASSEMBLY .................... J2-8
PRIMARY SHAFT COMPONENTS
PREINSPECTION......................................... J2-11
DISASSEMBLY............................................. J2-12
INSPECTION ................................................ J2-13
ASSEMBLY................................................... J2-16
SECONDARY SHAFT COMPONENTS
PREINSPECTION......................................... J2-18
DISASSEMBLY............................................. J2-20
INSPECTION ................................................ J2-22
ASSEMBLY................................................... J2-24
DIFFERENTIAL PREINSPECTION ................. J2-27
DIFFERENTIAL DISASSEMBLY ..................... J2-28
DIFFERENTIAL ASSEMBLY ........................... J2-29
BEARING PRELOAD ADJUSTMENT.............. J2-31
CLUTCH HOUSING AND TRANSAXLE
CASE COMPONENTS ASSEMBLY ............. J2-36
5TH/REVERSE GEAR AND HOUSING
PARTS ASSEMBLY...................................... J2-40
J2–1
MANUAL TRANSAXLE
MANUAL TRANSAXLE
PRECAUTION
Z4F511201029101
1. Clean the transaxle exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.
Warning
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.
Caution
• Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the
bearing.
2. Clean the removed parts using cleaning solvent, and dry them using compressed air.
3. Clean out all holes and passages using compressed air, and check that there are no obstructions.
4. Use a plastic hammer when disassembling the transaxle case and other light alloy metal parts.
5. Make sure each part is cleaned before assembling.
6. Coat all movable parts with the specified oil.
7. Replace parts whenever required.
8. Remove old sealant from contact surfaces before applying new sealant.
9. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after
assembly before filling the transaxle with transaxle oil.
Warning
• Although the stand has a self-locking brake system, there is a possibility that the brake may not
hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle
to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold
the rotating handle firmly when turning the transaxle.
End Of SieTHRUST CLEARANCE PREINSPECTION

5TH GEAR
Z4F511201029102
1. Remove the rear cover.
2. Measure the 5th gear thrust clearance using a
dial indicator.
• If the clearance exceeds the maximum, check
the contact surfaces of 5th gear and the
clutch hub. Replace worn or damaged parts.
Clearance
0.100—0.220 mm {0.0040—0.0086 in}
Maximum
0.270 mm {0.0106 in}
Z4F5112M001
End Of Sie
5TH/REVERSE GEAR AND HOUSING PARTS DISASSEMBLY
Z4F511201029103
1. Disassemble in the order shown in the figure.
Caution
• If any old sealant gets into the transaxle during installation of the transaxle case, trouble may
occur in the transaxle. Remove any old sealant from the transaxle case and clutch housing, and
with cleaning fluids.
J2–2
MANUAL TRANSAXLE
J2
J2–3
MANUAL TRANSAXLE
Z4F5112M002
.
1 Rear cover 8 5th/reverse shift fork
Locknut (primary shaft) 9 5th/reverse clutch hub component
2
(See J2–5 Locknut Disassembly Note) 10 5th synchronizer ring
Locknut (secondary shaft) 11 5th gear
3
(See J2–5 Locknut Disassembly Note)
12 Gear sleeve
4 Spacer
13 Secondary 5th gear
5 Reverse synchronizer gear sleeve
14 Lock bolt
6 Primary reverse synchronizer cone
15 Guide bolt
7 Reverse synchronizer ring
16 Lock bolt, ball, and spring
J2–4
MANUAL TRANSAXLE
17 Back-up light switch 31 Primary shaft gear component
18 Neutral switch 32 Secondary shaft gear component
19 Transaxle case component 33 Differential component
20 Magnet 34 Clutch housing
21 Reverse idler shaft 35 Synchronizer key springs
22 Reverse idler gear 36 Clutch hub sleeve
23 5th/reverse shift rod 37 Synchronizer keys J2
24 5th/reverse shift rod end 38 Clutch hub
25 Pin 39 3rd/4th shift fork
26 Crank lever shaft 40 Interlock sleeve
27 Crank lever component 41 Control lever
Shift fork and shift rod component 42 1st/2nd shift fork
28 (See J2–5 Shift Fork and Shift Rod Component 43 Control end
Disassembly Note)
44 Control rod
29 Steel ball
30 Spring
Locknut Disassembly Note

1. Assemble the SST.
2. Lift the transaxle and mount it on the SST.
Z4F5112M003
3. Lock the primary shaft with the SST.

4. Shift to 1st gear to lock the rotation of the primary
shaft.
5. Bend back the caulking of locknuts using a chisel.
6. Remove the locknuts from the primary and
secondary shafts.
Z4F5112M004
Shift Fork and Shift Rod Component Disassembly Note

1. Aligh the ends of the interlock sleeve and of the
control lever (arrow). Turn the shift rod
counterclockwise.
2. While holding the 1st/2nd shift fork with one hand
and the 3rd/4th shift fork with the other, raise
them both at the same time and shift each of the
clutch hub sleeves.
Z4F5112M005
J2–5
MANUAL TRANSAXLE
3. Lift the control end and remove the steel, and at
the same time, remove the control rod from the
clutch housing.
4. Separate the shift rod and shift fork component
from each of the clutch hub sleeves.
Z4F5112M006
End Of Sie
5TH/REVERSE GEAR AND HOUSING PARTS INSPECTION
Z4F511201029104
5th and Reverse Gear Inspection
1. Inspect the synchronizer cones for wear.
• If there is malfunction, replace parts as necessary.
2. Inspect the gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer ring matching teeth for damage and wear.
• If there is malfunction, replace the synchronizer ring.
Synchronizer Ring Inspection

1. Inspect the synchronizer ring teeth for damage, wear, and cracks.
2. Inspect the tapered surface for wear and cracks.
3. Measure the clearance between the synchronizer
ring and the flank surface of the gear.
• If not as specified, replace the synchronizer
ring.
Note
• Set the synchronizer ring squarely in the
gear; then measure around the
circumference.
Standard clearance
1.50 mm {0.059 in}
Z4F5112M007
Minimum
0.80 mm {0.031 in}
Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve and hub operation.
3. Inspect the synchronizer keys for damage, wear, and cracks.
4. Measure the clearance between the hub sleeve
and shift fork.
• If the clearance exceeds the maximum,
replace the hub sleeve and shift fork as a set.
Standard clearance
0.10—0.36 mm {0.004—0.014 in}
Maximum clearance
0.86 mm {0.034 in}
Z4F5112M008
J2–6
MANUAL TRANSAXLE
Reverse Idle Gear and Reverse Lever Inspection
• If there is malfunction, replace the reverse idle gear.
2. Measure the clearance between the reverse idle
gear bushing and the reverse lever.
• If not as specified, replace as necessary.
Standard clearance J2
0.10—0.35 mm {0.004—0.013 in}
Maximum Clearance
0.85 mm {0.033 in}
Z4F5112M009
5th Gear and Sleeve Inspection

1. Measure the clearance between the 5th gear and
the Sleeve.
• If not as specified, replace parts as
necessary.
5th gear inner diameter

34.000—34.025 mm {1.3386—1.3395 in}
Sleeve outer diameter
33.945—33.970 mm {1.3365—1.3373 in}
Clearance
0.030—0.080 mm {0.0012—0.0031 in}
Z4F5112M010
End Of Sie
J2–7
MANUAL TRANSAXLE
CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS DISASSEMBLY
Z4F511217010101
1. Disassemble in the order shown in the figure. .
Z4F5112M011
1 Bearing race (primary shaft) 15 Oil seal (differential)

2 Oil seal (primary shaft) (See J2–10 Oil Seal (Differential) Disassembly
(See J2–9 Oil Seal (Primary Shaft) Disassembly Note)
Note) 16 Bearing race (differential)
3 Bearing race (secondary shaft) (See J2–10 Bearing Race (Differential) Disassembly
(See J2–9 Bearing Race (Secondary Shaft) Note)
Disassembly Note) 17 Reverse lever shaft
4 Funnel (See J2–10 Reverse Lever Shaft Disassembly Note)
5 Guide plate component 18 Reverse lever
6 Change arm 19 Drain plug and washer
7 Roll pin 20 Bearing race (transaxle case)
(See J2–9 Roll Pin Disassembly Note) (See J2–11 Bearing Race (Transaxle Case)
Disassembly Note)
8 Change rod
21 Adjustment shim(s)
9 Boot
22 Bearing race (differential)
10 Selector (See J2–10 Bearing Race (Differential) Disassembly
11 Oil seal (change rod component) Note)
(See J2–9 Oil Seal (Change Rod Component) 23 Adjustment shim(s)
Disassembly Note)
24 Oil seal (differential)
12 Bleeder cover component (See J2–10 Oil Seal (Differential) Disassembly
13 Bleeder Note)
14 Hole cover 25 Oil passage
J2–8
MANUAL TRANSAXLE
Oil Seal (Primary Shaft) Disassembly Note
1. Remove the oil seal using screwdriver.
J2
Z4F5112M012
Bearing Race (Secondary Shaft) Disassembly Note

1. Remove the bearing race by lifting it and the
funnel out together.
Z4F5112M013
Roll Pin Disassembly Note

1. Align the groove for removal of the clutch housing
pin with the position of the roll pin, then tap the pin
out using a pin punch.
Z4F5112M014
Oil Seal (Change Rod Component) Disassembly Note

1. Remove the oil seal using the screwdriver.
Z4F5112M015
J2–9
MANUAL TRANSAXLE
Oil Seal (Differential) Disassembly Note
1. Remove the oil seal using the screwdriver.
Z4F5112M016
Bearing Race (Differential) Disassembly Note

1. Remove the bearing outer race using the SST.
Z4F5112M017
Reverse Lever Shaft Disassembly Note

1. Remove the roll pin using pliers.
Z4F5112M018
2. Protect the reverse lever shaft with a rag and use

pliers to remove the shaft.
Z4F5112M019
J2–10
MANUAL TRANSAXLE
Bearing Race (Transaxle Case) Disassembly Note
1. Remove the bearing race using the SST.
J2
Z4F5112M020
End Of SieSHAFT COMPONENTS PREINSPECTION

PRIMARY
Z4F511217201101
3rd Gear Thrust Clearance
1. Measure the clearance between 3rd gear and 2nd
gear.
the contact surfaces of the 3rd gear, 2nd gear
and 3rd/4th clutch hub. Replace worn and
damaged parts.
Clearance
0.05—0.20 mm {0.002—0.007 in}
Maximum
0.25 mm {0.010 in}
Z4F5112M021
4th Gear Thrust Clearance

1. Measure the clearance between 4th gear and the
bearing.
the contact surfaces of the 4th gear, bearing,
and 3rd/4th clutch hub. Replace worn and
damaged parts.
Clearance
0.17—0.37 mm {0.007—0.014 in}
Maximum
0.42 mm {0.017 in}
Z4F5112M022
End Of Sie
J2–11
MANUAL TRANSAXLE
PRIMARY SHAFT COMPONENTS DISASSEMBLY
Z4F511217201102
Z4F5112M023
1 Bearing (4th gear end) 7 3rd gear

(See J2–13 Bearing (4th Gear End) Disassembly (See J2–13 3rd/4th Clutch Hub Component, 3rd
Note) Synchronizer Ring and 3rd Gear Disassembly Note)
2 4th gear 8 Bearing (primary shaft end)
3 4th synchronizer ring (See J2–13 Bearing (Primary Shaft End)
Disassembly Note)
4 Retaining ring
9 Primary shaft gear
5 3rd/4th clutch hub component
(See J2–13 3rd/4th Clutch Hub Component, 3rd 10 Synchronizer key springs
Synchronizer Ring and 3rd Gear Disassembly Note) 11 3rd/4th clutch hub sleeve
6 3rd synchronizer ring 12 Synchronizer keys
(See J2–13 3rd/4th Clutch Hub Component, 3rd 13 3rd/4th clutch hub
Synchronizer Ring and 3rd Gear Disassembly Note)
J2–12
MANUAL TRANSAXLE
Bearing (4th Gear End) Disassembly Note
1. Remove the bearing using the SST.
J2
Z4F5112M024
3rd/4th Clutch Hub Component, 3rd Synchronizer Ring and 3rd Gear Disassembly Note
1. Remove the retaining ring.
2. Remove the 3rd/4th clutch hub component, 3rd
synchronizer ring, and 3rd gear using the SST.
Z4F5112M025
Bearing (Primary Shaft End) Disassembly Note

Caution
• Use protective plates in the vise to
prevent damage to the primary shaft
gear.
Z4F5112M026
End Of SieSHAFT COMPONENTS INSPECTION

PRIMARY
Z4F511217201103
4th Gear, 3rd Gear Inspection
4th Synchronizer Ring, 3rd Synchronizer Ring Inspection

J2–13
MANUAL TRANSAXLE
ring and the flank surface of the gear.
• If not as specified, replace the synchronizer
ring.
Note
• Set the synchronizer ring squarely in the
gear; then measure around the
circumference.
Standard clearance
1.50 mm {0.059 in}
Z4F5112M027
Minimum
0.80 mm {0.031 in}
3rd/4th Clutch Hub Component Inspection

and shift forks.
Standard
0.10—0.40 mm {0.004—0.015 in}
Maximum
0.90 mm {0.035 in}
Z4F5112M028
Primary Shaft Gear Inspection

1. Inspect the gear contact surface for damage and wear.
• If there is malfunction, replace the primary shaft.
2. Inspect the splines for damage and wear.
4. Inspect the oil passage for clogging.
5. Measure the shaft gear runout.
• If not as specified, replace the primary shaft.
Primary shaft runout

0.050 mm {0.0020 in} max.
Z4F5112M029
J2–14
MANUAL TRANSAXLE
6. Measure the clearance between the shaft gears
and the gears.
necessary.
Shaft Gear
Gear Clearance
(Outer dia.) (Inner dia.)
35.945—35.970 36.000—36.025
3rd
{1.415—1.416} {1.417—1.418} J2
0.030—0.080
30.945—30.970 31.000—31.025 {0.001—0.003}
4th
{1.218—1.219} {1.220—1.221}
Z4F5112M030
End Of Sie
J2–15
MANUAL TRANSAXLE
PRIMARY SHAFT COMPONENTS ASSEMBLY
Z4F511217201104
1. Assemble in the order shown in the figure. .
Z4F5112M031
1 3rd/4th clutch hub 9 3rd/4th clutch hub component

(See J2–17 3rd/4th Clutch Hub Assembly Note) (See J2–17 3rd Gear, 3rd Synchronizer Ring, and
2 Synchronizer keys 3rd/4th Clutch Hub Component Assembly Note)
3 3rd/4th clutch hub sleeve 10 Retaining ring
4 Synchronizer key springs 11 4th synchronizer ring
(See J2–18 4th Synchronizer Ring, 4th Gear, and
5 Primary shaft gear Bearing (4th Gear End) Assembly Note)
6 Bearing (primary shaft end) 12 4th gear
(See J2–17 Bearing (Primary Shaft End) Assembly (See J2–18 4th Synchronizer Ring, 4th Gear, and
Note) Bearing (4th Gear End) Assembly Note)
7 3rd gear 13 Bearing (4th gear end)
(See J2–17 3rd Gear, 3rd Synchronizer Ring, and (See J2–18 4th Synchronizer Ring, 4th Gear, and
3rd/4th Clutch Hub Component Assembly Note) Bearing (4th Gear End) Assembly Note)
8 3rd synchronizer ring
(See J2–17 3rd Gear, 3rd Synchronizer Ring, and
3rd/4th Clutch Hub Component Assembly Note)
J2–16
MANUAL TRANSAXLE
3rd/4th Clutch Hub Assembly Note
1. Install the synchronizer key springs in the clutch
hub with the hooks in the grooves to hold the
three synchronizer key in place.
Synchronizer key size

A: 17.0 mm {0.669 in}
B: 4.3 mm {0.17 in} J2
C: 5.0 mm {0.20 in}
YTA5110M131
2. Align the synchronizer ring grooves with the

synchronizer key during assembly.
Z4F5112M032
Bearing (Primary Shaft End) Assembly Note

1. Install the new bearing using the SST.
Z4F5112M033
3rd Gear, 3rd Synchronizer Ring, and 3rd/4th Clutch Hub Component Assembly Note
1. Install the 3rd gear, 3rd synchronizer ring, and
3rd/4th clutch hub component using a press.
Z4F5112M034
J2–17
MANUAL TRANSAXLE
4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note
1. Install the 4th synchronizer ring, 4th gear, and a
new bearing using the SST.
Z4F5112M035
2. Measure the clearance between the 3rd gear and

2nd gear.
• If not as specified, reassemble the primary
shaft component.
Clearance
0.05—0.20 mm {0.002—0.007 in}
Maximum
0.25 mm {0.010 in}
Z4F5112M036
3. Measure the clearance between the 4th gear and

bearing.
• If not as specified, reassemble the primary
shaft component.
Clearance
0.17—0.37 mm {0.007—0.014 in}
Maximum
0.42 mm {0.017 in}
Z4F5112M037
End Of Sie SHAFT COMPONENTS PREINSPECTION

SECONDARY
Z4F511217301101
1st Gear Thrust Clearance Inspection
1. Measure the clearance between 1st gear and the
differential drive gear.
the contact surfaces of the 1st gear,
differential drive gear of the secondary shaft
gear, and 1st/2nd clutch hub component.
Replace worn and damaged parts.
Clearance
0.05—0.28 mm {0.002—0.011 in}
Maximum
0.33 mm {0.013 in}
Z4F5112M038
J2–18
MANUAL TRANSAXLE
2nd Gear Thrust Clearance Inspection
1. Measure the clearance between 2nd gear and
secondary 3rd gear.
the contact surfaces of the 2nd gear,
secondary 3rd gear, and 1st/2nd clutch hub
component. Replace worn and damaged
parts. J2
Clearance
0.18—0.46 mm {0.007—0.018 in}
Maximum
0.51 mm {0.020 in}
Z4F5112M039
End Of Sie
J2–19
MANUAL TRANSAXLE
SECONDARY SHAFT COMPONENTS DISASSEMBLY
Z4F511217301102
Z4F5112M040
1 Bearing 8 1st/2nd clutch hub component

(See J2–21 Bearing and Secondary 4th Gear (See J2–21 1st/2nd Clutch Hub Component, 1st
Disassembly Note) Synchronizer Ring, and 1st Gear Disassembly Note)
2 Secondary 4th gear 9 1st synchronizer ring
3 Retaining ring 10 1st gear
4 Secondary 3rd gear 11 Bearing (secondary shaft end)
(See J2–21 Secondary 3rd Gear and 2nd Gear (See J2–21 Bearing (Secondary Shaft End)
Disassembly Note) Disassembly Note)
5 2nd gear 12 Secondary shaft gear
6 2nd synchronizer ring 13 Synchronizer key springs
7 Retaining ring 14 Clutch hub sleeve (reverse gear)
15 Synchronizer keys
16 1st/2nd clutch hub
J2–20
MANUAL TRANSAXLE
Bearing and Secondary 4th Gear Disassembly Note
1. Remove the bearing and secondary 4th gear
using the SST.
J2
Z4F5112M041
Secondary 3rd Gear and 2nd Gear Disassembly Note

2. Shift the gears to 1st gear.
3. Remove the secondary 3rd gear and 2nd gear
using the SST.
Z4F5112M042
1st/2nd Clutch Hub Component, 1st Synchronizer Ring, and 1st Gear Disassembly Note
2. Remove the 1st/2nd clutch hub component, 1st
synchronizer ring, and 1st gear using a press.
Z4F5112M043
Bearing (Secondary Shaft End) Disassembly Note

Z4F5112M044
End Of Sie
J2–21
MANUAL TRANSAXLE
SECONDARY SHAFT COMPONENTS INSPECTION
Z4F511217301103
Gears Inspection
Synchronizer Ring Inspection

ring and the side of gear circumferentially using a
feeler gauge.
• If the clearance is exceed the minimum,
replace the synchronizer ring.
Standard clearance
1.50 mm {0.059 in}
Minimum
0.80 mm {0.031 in}
Z4F5112M047
Clutch Hub Component Inspection

and shift fork.
Standard clearance
0.10—0.45 mm {0.004—0.017 in}
Maximum clearance
0.95 mm {0.037 in}
Z4F5112M049
J2–22
MANUAL TRANSAXLE
Secondary Shaft Gear Inspection
1. Inspect the gear contact surface for damage and wear.
• If there is malfunction, replace the secondary shaft.
2. Inspect the splines for damage and wear.
4. Inspect the oil passage for clogging. J2
5. Measure the shaft gear runout.
• If not as specified, replace the secondary
shaft.
Secondary shaft gear runout

0.015 mm {0.0006 in} max.
Z4F5112M050
6. Measure the clearance between the shaft gears

and the gears.
necessary.
mm{in}
Shaft Gear
Gear Clearance
(outer dia.) (inner dia.)
39.445—39.470 39.500—39.525 0.030—0.080
1st
{1.553—1.554} {1.555—1.556} {0.002—0.003}
34.945—34.905 35.015—35.035 0.05—0.09
2nd
{1.376—1.374} {1.378—1.379} {0.002—0.003} Z4F5112M102
End Of Sie
J2–23
MANUAL TRANSAXLE
SECONDARY SHAFT COMPONENTS ASSEMBLY
Z4F511217301104
Z4F5112M051
1 1st/2nd clutch hub 9 1st/2nd clutch hub component

(See J2–25 1st/2nd Clutch Hub Assembly Note) 10 Retaining ring
2 Synchronizer keys 11 2nd synchronizer ring
3 Clutch hub sleeve (reverse gear) (See J2–26 2nd Synchronizer Ring, 2nd Gear, and
4 Synchronizer key spring Secondary 3rd Gear Assembly Note)
5 Secondary shaft gear 12 2nd gear
6 Bearing (secondary shaft end) 13 Secondary 3rd gear
(See J2–25 Bearing (Secondary Shaft End) 14 Retaining ring
Assembly Note) 15 Secondary 4th gear
7 1st gear (See J2–26 Secondary 4th Gear and Bearing
(See J2–25 1st Gear, 1st Synchronizer Ring, and Assembly Note)
1st/2nd Clutch Hub Component Assembly Note) 16 Bearing
8 1st synchronizer ring
J2–24
MANUAL TRANSAXLE
1st/2nd Clutch Hub Assembly Note
1. Install the synchronizer key springs in the clutch
hub with the hooks in the grooves to hold the
three synchronizer keys in place.
Synchronizer key
A: 19.0 mm {0.748 in}
B: 4.3 mm {0.17 in} J2
C: 5.0 mm {0.20 in}
YTA5110M131
Bearing (Secondary Shaft End) Assembly Note

Z4F5112M052
1st Gear, 1st Synchronizer Ring, and 1st/2nd Clutch Hub Component Assembly Note
Note
• The size of the 1st, 2nd, 3rd, and 4th synchronizer rings are the same.
Be careful when installing them. The 2nd ring has the cut-out as shown in the illustration.
• Aligh the synchronizer ring groove and clutch housing hub key when installing.
Z4F5112M053
1. Assemble the 1st gear, 1st synchronizer ring, and

1st/2nd clutch hub component, as shown in the
figure.
Z4F5112M054
J2–25
MANUAL TRANSAXLE
2. Press the 1st/2nd clutch hub component on using
the SST.
Z4F5112M055
2nd Synchronizer Ring, 2nd Gear, and Secondary 3rd Gear Assembly Note
1. Install the 2nd synchronizer ring and 2nd gear.
2. Install the secondary 3rd gear using the SST.
Z4F5112M056
Secondary 4th Gear and Bearing Assembly Note

1. Install the secondary 4th gear and the bearing
using the SST.
Z4F5112M057
2. Measure the clearance between the 1st gear and

the differential drive gear.
Clearance
0.05—0.28 mm {0.002—0.011 in}
Maximum
0.33 mm {0.013 in}
Z4F5112M058
J2–26
MANUAL TRANSAXLE
3. Measure the clearance between the 2nd gear and
the secondary 3rd gear.
• If not as specified, reassemble the secondary
shaft component.
Clearance
0.18—0.46 mm {0.007—0.018 in}
Maximum J2
0.51 mm {0.020 in}
Z4F5112M059
End Of Sie
DIFFERENTIAL PREINSPECTION
Z4F511227100101
Backlash Inspection
1. Measure the backlash of the side gear.
necessary.
Standard
0.050—0.150 mm {0.0020—0.059 in}
Z4F5112M060
End Of Sie
J2–27
MANUAL TRANSAXLE
DIFFERENTIAL DISASSEMBLY
Z4F511227100102
Z4F5112M061
1 Roll pin 7 Bearing (side opposite ring gear)

2 Pinion shaft (See J2–28 Bearing (Side Opposite Ring Gear)
Disassembly Note)
3 Pinion gear
8 Speedometer drive gear
4 Thrust washer
9 Bearing (ring gear side)
5 Side gear (See J2–29 Bearing (Ring Gear Side) Disassembly
6 Thrust washer Note)
10 Ring gear and gear case component
Bearing (Side Opposite Ring Gear) Disassembly Note

1. Remove the bearing using the SSTs.
Z4F5112M062
J2–28
MANUAL TRANSAXLE
Bearing (Ring Gear Side) Disassembly Note
J2
Z4F5112M063
End Of Sie
DIFFERENTIAL ASSEMBLY
Z4F511227100103
1. Assemble in the order shown in the figure..
Z4F5112M064
1 Ring gear and gear case component 6 Side gear

2 Bearing (ring gear side) 7 Thrust washer
(See J2–30 Bearing (Ring Gear Side) Assembly 8 Pinion gear
Note)
9 Pinion shaft
3 Speedometer drive gear
10 Roll pin
4 Bearing (side opposite ring gear) (See J2–30 Roll Pin Assembly Note)
(See J2–30 Bearing (Side Opposite Ring Gear)
Assembly Note)
5 Thrust washer
J2–29
MANUAL TRANSAXLE
Bearing (Ring Gear Side) Assembly Note
Z4F5112M065
Bearing (Side Opposite Ring Gear) Assembly Note

1. Install the speedometer drive gear.
Z4F5112M066
Roll Pin Assembly Note

1. Install the new roll pin as shown in the figure to
hold the pinion shaft.
Z4F5112M067
2. Measure the backlash by the following procedure.

(1) Install the left and right drive shafts in the
differential component.
(2) Support the drive shaft on V-blocks as shown
in the figure.
(3) Measure the backlash of both pinion gears.
• If not as specified, replace worn and
damage parts.
Backlash
0.050—0.150 mm {0.0020—0.059 in}
Z4F5112M068
End Of Sie
J2–30
MANUAL TRANSAXLE
BEARING PRELOAD ADJUSTMENT
Z4F511201029105
1. Install the primary and secondary shaft bearing races into the transaxle case (shims removed).
2. Mount the clutch housing onto the transaxle hanger, and set the differential bearing race into the clutch
housing. Position a piece of pipe against the bearing race and tap it in until it contacts the clutch housing.
3. Set the bearing races into the SSTs (selector) as
shown in the figure.
Note J2
• Turn the selector to eliminate the gap
indicated by the arrow in the figure.
4. Set the differential component into the clutch

housing, and set the bearing race and the SST
(selector) on the differential. Set the SSTs
(selector) for the primary and secondary shaft in
the clutch housing.
Z4F5112M069
Mount the shaft gear assemblies as shown in the

figure.
Z4F5112M070
5. Set the SST (collars) in the positions shown in

the figure.
Z4F5112M071
6. Install the transaxle case and tighten the SST

(bolts) to the specified torque.
Tightening torque
37.3—52.0 N·m {3.9—5.3 kgf·m, 28.2—38.3
ft·lbf}
7. To seat the bearings, mount the SST (bars) on

parts A and B of the selectors, and turn the
selectors so the gaps are widened.
Z4F5112M072
J2–31
MANUAL TRANSAXLE
Then turn the SST in the reverse direction until
the gaps are eliminated.
Z4F5112M073
8. Manually expand the selector until it no longer

turns by hand.
Z4F5112M074
9. Use a feeler gauge to measure the gap in the

SST (selector).
Caution
• Measure the gap around the entire
circumference of the selector.
10. Take the maximum reading and determine the

shim to used as follows.
Primary shaft adjustment shim
• Select the thinnest allowable shim from the
table to obtain standard clearance.
Z4F5112M075
Standard clearance
0—0.05 mm {0—0.002 in}
Example
Reading from step 9: 0.57 mm {0.022 in}
Shim selecting range
(0.57 mm {0.022 in}–0.05 mm {0.002 in})—(0.57 mm {0.022 in}–0 mm {0 in}) = 0.52 mm {0.020 in}—0.57
mm {0.022 in}
Shim
0.55 mm {0.022 in}
Secondary shaft adjustment shim

• Select the thinnest allowable shim from the table to obtain standard clearance.
Tightening amount
0.03—0.08 mm {0.001—0.003 in}
Example
Reading from step 9: 0.57 mm {0.022 in}
Shim selecting range
(0.57 mm {0.022 in}+0.03 mm {0.001 in})—(0.57 mm {0.022 in}+0.08 mm {0.003 in})=0.60 mm {0.024
in}—0.65 mm {0.026 in}
Shim
0.60 mm {0.024 in}
J2–32
MANUAL TRANSAXLE
Thickness of shim
mm{in}
0.20 {0.008} 0.25 {0.010} 0.30 {0.012} 0.35 {0.014}
0.40 {0.016} 0.45 {0.018} 0.50 {0.020} 0.55 {0.022}
0.60 {0.024} 0.65 {0.026} 0.70 {0.028} –
11. Install the SST and a pull scale or torque wrench.

J2
Z4F5112M076
12. Adjust the clearance of the SST (selector) to

obtain the specified preload/pull scale reading.
Note
• Read the preload when the differential starts
to turn.
• Measure several times and calculate the
average value.
Preload
0.5 N·m {5.0 kgf·cm, 4.3 in·lbf}
Reading on pull scale
Z4F5112M077
5 N {0.5 kgf, 1.1 lbf}
13. Use a feeler gauge to measure the gap in the

selector for the differential.
14. Add 0.15 mm {0.006 in} to the measured
clearance and select the combination of shims
closest in value to that measurement.
Example
0.32 mm {0.013 in}
0.32 mm {0.013 in}+0.15 mm {0.006
in}=0.47 mm {0.019 in}
Nearest shim (on thick side) to 0.47 mm
{0.019 in} is 0.50 mm {0.020 in}
Z4F5112M078
Thickness of shim
mm{in}
0.1 {0.004} 0.20 {0.008} 0.25 {0.010} 0.30 {0.012}
0.35 {0.014} 0.40 {0.016} 0.45 {0.018} 0.50 {0.020}
0.55 {0.022} 0.60 {0.024} 0.65 {0.026} 0.70 {0.028}
0.75 {0.030} 0.80 {0.031} 0.85 {0.033} 0.90 {0.035}
0.95 {0.037} 1.0 {0.039} 1.05 {0.041} 1.10 {0.043}
1.15 {0.045} 1.20 {0.047} – –
15. Remove the transaxle case and the SST.

16. Remove the selectors, the primary shaft component, and the differential.
17. Remove the bearing races.
J2–33
MANUAL TRANSAXLE
18. Install the adjustment shim(s) and install the
bearing race using a suitable pipe.
Caution
• Use the adjustment shim(s) selected
during bearing preload adjustment.
Z4F5112M079

Caution
• Use the adjustment shim(s) selected
during bearing preload adjustment.
Z4F5112M103
20. Set the primary shaft gear component and the

differential into the clutch housing.
21. Install the transaxle case, and tighten to the
specified torque.
Tightening torque
37.3—52.0 N·m {3.8—5.3 kgf·m, 27.5—38.3
ft·lbf}
Z4F5112M080

23. Verify that the preload is within the specification.
• If not as specified, return to Step 1.
Preload
1.4—1.9 Nm {14—20 kgf·cm, 13—17 in·lbf}
14—19 N {1.4—2.0 kgf, 3.1—4.4 lbf}
24. Remove the SST.
Z4F5112M081
25. With the transaxle facing in the direction shown in

the figure, install the SST to the primary shaft
gear component.
26. Verify that the preload is within the specification.
• If not as specified, return to Step 1.
Preload
0.12—0.39 N·m {1.2—4.0 kgf·cm, 1.05—3.47
in·lbf}
1.2—3.9 N {0.12—0.40 kgf, 0.27—0.88 lbf}
Z4F5112M082
J2–34
MANUAL TRANSAXLE
27. Remove the SST, transaxle case, primary shaft gear component and differential.
28. Install the secondary shaft gear component and transaxle case, then tighten to the specified torque.
Tightening torque
37.3—52.0 N·m {3.8—5.3 kgf·m, 27.5—38.3 ft·lbf}

30. Verify that the preload is within the specification. J2
• If not as specification, return to Step 1.
Preload
0.2—0.3 N·m {2.0—4.0 kgf·cm, 1.8—3.4
in·lbf}
2—3 N {0.2—0.4 kgf, 0.5—0.8 lbf}
31. Remove the SST and transaxle case.

Z4F5112M083
End Of Sie
J2–35
MANUAL TRANSAXLE
CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS ASSEMBLY
Z4F511217010102
Z4F5112M084
1 Oil passage 12 Hole cover

2 Oil seal (differential) 13 Bleeder
(See J2–37 Oil Seal (Differential) Assembly Note) 14 Bleeder cover component
3 Adjustment shim(s) 15 Oil seal (change rod component)
4 Bearing race (differential) (See J2–38 Oil Seal (Change Rod Component)
(See J2–37 Bearing Race (Differential) Assembly Assembly Note)
Note) 16 Selector
5 Adjustment shim(s) 17 Boot
6 Bearing race (transaxle case) (See J2–38 Boot Assembly Note)
(See J2–37 Bearing Race (Transaxle Case) 18 Change rod
Assembly Note)
19 Roll pin
7 Drain plug and washer
20 Change arm
8 Reverse lever
21 Guide plate component
9 Reverse lever shaft
22 Funnel
10 Bearing race (differential)
(See J2–37 Bearing Race (Differential) Assembly 23 Bearing race (secondary shaft)
Note) 24 Oil seal (primary shaft)
11 Oil seal (differential) (See J2–38 Oil Seal (Primary Shaft) Assembly
(See J2–37 Oil Seal (Differential) Assembly Note) Note)
25 Bearing race (primary shaft)
J2–36
MANUAL TRANSAXLE
Oil Seal (Differential) Assembly Note
1. Apply transaxle oil to the new oil seal lip.
2. Install the oil seal using the SST.
J2
Z4F5112M085
Bearing Race (Differential) Assembly Note

Z4F5112M079
Bearing Race (Transaxle Case) Assembly Note

Z4F5112M103
J2–37
MANUAL TRANSAXLE
Oil Seal (Change Rod Component) Assembly Note
1. Apply transaxle oil to the new oil seal lip.
2. Install the oil seal using a suitable pipe.
Outer diameter of pipe

26.0 mm {1.02 in}
Z4F5112M086
Boot Assembly Note

1. Install the boot with the drain hole facing
downward when mounted on the vehicle.
Z4F5112M087
Oil Seal (Primary Shaft) Assembly Note

1. Apply transaxle oil to outer circumference of the oil seal.
2. Install the new oil seal using a suitable pipe.
Z4F5112M088
J2–38
MANUAL TRANSAXLE
End Of Sie
J2
J2–39
MANUAL TRANSAXLE
5TH/REVERSE GEAR AND HOUSING PARTS ASSEMBLY
Z4F511201029106
Z4F5112M089
1 Clutch housing 3 Control end

(See J2–41 Clutch Housing Assembly Note) 4 1st/2nd shift fork
2 Control rod
J2–40
MANUAL TRANSAXLE
5 Control lever 24 Reverse idle shaft
6 Interlock lever (See J2–43 Reverse Idle Gear and Reverse Idle
Shaft Assembly Note)
7 3rd/4th shift fork
25 Magnet
8 Clutch hub
26 Transaxle case component
9 Synchronizer keys (See J2–43 Transaxle Case Component Assembly
10 Clutch hub sleeve Note)
11 Synchronizer key springs 27 Neutral switch J2
12 Differential differential component 28 Back-up light switch
13 Secondary shaft gear component 29 Lock bolt, ball and spring
(See J2–42 Primary Shaft Gear Component and 30 Guide bolt
Secondary Shaft Gear Component Assembly Note)
31 Lock bolt
14 Primary shaft gear component
(See J2–42 Primary Shaft Gear Component and 32 Secondary 5th gear
Secondary Shaft Gear Component Assembly Note) (See J2–44 Secondary 5th Gear Assembly Note)
15 Spring 33 Gear sleeve
16 Steel ball 34 5th gear
17 Shift fork and shift rod component 35 5th synchronizer ring
(See J2–42 Shift Fork and Shift Rod Component 36 5th/reverse clutch hub component
Assembly Note) (See J2–44 5th/Reverse Clutch Hub Component
18 Crank lever component and 5th/Reverse Shift Fork Assembly Note)
(See J2–43 Crank Lever Component and Crank 37 5th/reverse shift fork
Lever Shaft Assembly Note) (See J2–44 5th/Reverse Clutch Hub Component
19 Crank lever shaft and 5th/Reverse Shift Fork Assembly Note)
(See J2–43 Crank Lever Component and Crank 38 Reverse synchronizer ring
Lever Shaft Assembly Note) 39 Primary reverse synchronizer cone
20 Pin 40 Reverse synchronizer gear sleeve
21 5th/reverse shift rod end 41 Spacer
(See J2–43 5th/Reverse Shift Rod End and 5th/
Reverse Shift Rod Assembly Note) 42 Locknut (secondary shaft)
(See J2–44 Locknut Assembly Note)
22 5th/reverse shift rod
(See J2–43 5th/Reverse Shift Rod End and 5th/ 43 Locknut (primary shaft)
Reverse Shift Rod Assembly Note) (See J2–44 Locknut Assembly Note)
23 Reverse idle gear 44 Rear cover
(See J2–43 Reverse Idle Gear and Reverse Idle
Shaft Assembly Note)
Clutch Housing Assembly Note

1. Assemble the SST.
2. Assembly clutch housing on the SST.
Z4F5112M003
J2–41
MANUAL TRANSAXLE
Primary Shaft Gear Component and Secondary Shaft Gear Component Assembly Note
1. Install the primary shaft gear component and the
secondary shaft gear component together.
Z4F5112M090
Shift Fork and Shift Rod Component Assembly Note

1. Shift to 2nd gear and position the shift fork and
shift rod component as shown.
Z4F5112M091
2. Insert the spring seat and spring into the reverse

lever shaft, install the steel ball, and place a
scraper so that it contacts the steel ball.
3. With the edge of the control end against the
scraper, when the control end is pushed in the
direction of the arrow in the figure so that the ball
goes into the shaft, the rod will at the same time
line up with the shift rod coupling hole in the
clutch housing.
Z4F5112M092
4. Set each clutch hub sleeve to the neutral position,

and tap the shift rod from above so that the steel
ball goes into the center groove (of the three
grooves in the control end).
5. Pull the ball part of the control end forward so that
the steel ball goes into the detent in the groove.
Z4F5112M093
J2–42
MANUAL TRANSAXLE
Crank Lever Component and Crank Lever Shaft Assembly Note
1. Fit the crank lever between the change arm and the control end, and connect the crank lever shaft to the crank
lever.
2. Aligh the pin holes of the crank lever shaft and the
clutch housing, and insert a new pin.
J2
Z4F5112M094
5th/Reverse Shift Rod End and 5th/Reverse Shift Rod Assembly Note
Note
• The mark (indicated by the arrow in the figure) and the shift rod end mounting bolt hole must be aligned.
1. Install shift rod end 1 and the shift rod 2, and

tighten the gate mounting bolt.
Tightening torque
11.8—13.7 N·m {120—140 kgf·cm, 105—121
in·lbf}
Z4F5112M095
Reverse Idle Gear and Reverse Idle Shaft Assembly Note

1. Install the reverse idle gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.
3. Aligh the end of the interlock sleeve with the
control lever (arrow), and at the same time, face
the reverse idle shaft screw hole in the direction
shown in the figure.
Z4F5112M096
Transaxle Case Component Assembly Note

1. Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case, and tighten the
transaxle case installation bolts to the specified torque.
Tightening torque
37.3—52.0 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf}
J2–43
MANUAL TRANSAXLE
2. Install the SSTs through the drive shaft and joint
shaft hole.
Z4F5112M097
Secondary 5th Gear Assembly Note

1. Install the secondary 5th gear as shown.
Z4F5112M098
5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note
1. Install the 5th/reverse clutch hub component and
the 5th/reverse shift fork together.
Z4F5112M099
Locknut Assembly Note

1. Shift to 1st gear.
2. Lock the primary shaft using the SST.
3. Tighten new lock nuts onto the primary and
secondary shafts.
Tightening torque
127.5—205.8 N·m {13.0—20.0 kgf·m, 95—144
ft·lbf}
4. Stake the locknuts.
Z4F5112M100
J2–44
MANUAL TRANSAXLE
5. Measure the 5th gear thrust clearance using a
dial indicator.
• If not as specified, reassemble the transaxle.
Clearance
0.100—0.220 mm {0.0039—0.0087 in}
Maximum
0.270 mm {0.0106 in} J2
Z4F5112M101
End Of Sie
J2–45
TECHNICAL DATA
TD
TECHNICAL DATA ............................................. TD-2

ENGINE ............................................................ TD-2
MANUAL TRANSAXLE..................................... TD-5 TD
TD–1
TECHNICAL DATA
TECHNICAL DATA
ENGINE
Z4F931001001101
Item Specification
Engine type FS
Cylinder head
Height (mm {in}) Standard 124.45—124.55 {4.8996—4.9035}
Distortion (mm {in}) Maximum 0.10 {0.004}
Grinding (mm {in}) Maximum 0.15 {0.006}
Valve and valve guide
IN 1.10 {0.0433}
Margin thickness (mm {in})
EX 1.20 {0.0472}
Standard 89.49—90.09 {3.524—3.546}
IN
Minimum 89.28 {3.515}
Valve length (mm {in})
Standard 89.79—90.39 {3.536—3.558}
EX
Minimum 89.38 {3.519}
Standard 5.970—5.985 {0.2351—0.2356}
IN
Minimum 5.940 {0.2339}
Valve stem diameter (mm {in})
Standard 5.965—5.980 {0.2349—0.2354}
EX
Minimum 5.935 {0.2337}
Valve guide inner diameter (mm {in}) 6.01—6.03 {0.2367—0.2374}
Valve guide protection height (mm {in}) Standard 13.5—14.1 {0.532—0.555}
Valve seat
Seat contact width (mm {in}) Standard 0.90—1.30 {0.036—0.051}
IN 45°
Seat angle
EX 45°
Standard 39.0 {1.535}
IN
Seat sinking Maximum 39.6 {1.559}
(mm {in})
(Valve protection height) Standard 39.0 {1.535}
EX
Maximum 39.6 {1.559}
Valve spring
Pressing force at valve H:36.5 mm
(N {kgf, lbf}) Standard 177.1—200.0 {18.05—20.40, 39.71—44.88}
spring height H {1.44 in}
IN 1.54 {0.061}
Out-of-square (mm {in})
EX 1.54 {0.061}
Camshaft
Camshaft runout (mm {in}) Maximum 0.03 {0.012}
Standard 43.7014 {1.7205}
IN
Minimum 43.5914 {1.7162}
Lobe height (mm {in})
Standard 43.2061 {1.7010}
EX
Minimum 43.0961 {1.6967}
Standard 25.940—25.965 {1.2013—1.0222}
No.1,5
Minimum 25.890 {1.0193}
Journal diameter (mm {in})
Standard 25.936—25.965 {1.0212—1.0222}
No.2,3,4
Minimum 25.886 {1.0191}
Camshaft bearing oil Standard 0.035—0.081 {0.0014—0.0031}
(mm {in})
clearance Maximum 0.15 {0.006}
Standard 0.08—0.20 {0.0032—0.0078}
Camshaft end play (mm {in})
Maximum 0.21 {0.008}
Tappet
Tappet bore diameter (mm {in}) Standard 30.000—30.025 {1.1812—1.1820}
Tappet diameter (mm {in}) Standard 29.959—29.975 {1.1795—1.1801}
Tappet-to-tappet bore Standard 0.025—0.066 {0.00099—0.00259}
(mm {in})
TD–2
TECHNICAL DATA
Item Specification
Cylinder block
Height (mm {in}) Standard 261.4—261.6 {10.292—10.299}
Distortion (mm {in}) Maximum 0.05 {0.002}
Grinding (mm {in}) Maximum 0.20 {0.008}
Standard 83.000—83.019 {3.2678—3.2684}
Cylinder bore diameter (mm {in}) 0.25 {0.01} oversize 83.250—83.269 {3.2776—3.2783}
0.50 {0.02} oversize 83.500—83.519 {3.2874—3.2881}
TD
Wear limit (mm {in}) 0.15 {0.006}
Piston
Piston diameter Measure Standard 82.953—82.975 {3.2659—3.2667}
at 90° to pin bore axis
(mm {in}) 0.25 {0.01} oversize 83.203—83.225 {3.2758—3.2765}
and 16.5 mm {0.650 in}
below oil ring groove 0.50 {0.02} oversize 83.453—83.475 {3.2856—3.2864}
Piston-to-cylinder Standard 0.039—0.065 {0.0016—0.0025}
(mm {in})
Piston ring
Top 0.035—0.065 {0.0014—0.0025}
Piston ring-to-ring groove Second 0.030—0.065 {0.0012—0.0025}
(mm {in})
clearance Oil 0.022—0.065 {0.0009—0.0025}
Maximum 0.20 {0.008}
Top 0.15—0.25 {0.006—0.009}
End gap (Measured in Second 0.15—0.30 {0.006—0.011}
(mm {in})
cylinder) Oil 0.20—0.70 {0.008—0.027}
Maximum 1.0 {0.039}
Piston pin
Diameter (mm {in}) 18.988—19.000 {0.7476—0.7480}
Connecting rod-to-piston
(mm {in}) 18.943—19.961 {0.7458—0.7858}
pin clearance
Piston-to-piston pin
(mm {in}) 18.974—18.980 {0.7471—0.7472}
clearance
Crankshaft
Crankshaft runout (mm {in}) Maximum 0.03 {0.0012}
Standard 55.937—55.955 {2.2022—2.2029}
Main journal diameter (mm {in})
0.25 {0.01} under size 55.687—55.705 {2.1924—2.1931}
Main journal out-of-round (mm {in}) 0.05 {0.002}
Standard 47.940—47.955 {1.8874—1.8879}
Crankpin diameter (mm {in})
0.25 {0.01} under size 47.690—47.705 {1.8776—1.8781}
Crankpin out-of-round (mm {in}) Maximum 0.05 {0.002}
Standard 0.024—0.050 {0.0010—0.0019}
Main journal oil clearance (mm {in})
Maximum 0.067 {0.0026}
Standard 0.080—0.282 {0.0032—0.0111}
Crankshaft end play (mm {in})
Maximum 0.30 {0.012}
Connecting rod and connecting rod bearing
Length (Center to center) (mm {in}) 129.15—129.25 {5.0847—5.0885}
Bending (mm {in}) 0.05 {0.020} max./50 {1.97}
Distortion (mm {in}) 0.05 {0.020} max./50 {1.97}
Standard 0.024—0.061 {0.0010—0.0024}
Connecting rod bearing oil clearance (mm {in})
Maximum 0.067 {0.0026}
Standard 1.509—1.524 {0.05941—0.05999}
0.25 {0.01}
1.629—1.637 {0.06414—0.06444}
Connecting rod bearing thickness (mm {in}) under size
0.50 {0.02}
1.754—1.762 {0.06906—0.06936}
under size
Standard 0.110—0.262 {0.005—0.010}
Connecting rod side clearance (mm {in})
Maximum 0.30 {0.012}
TD–3
TECHNICAL DATA
Item Specification
Tensioner spring
Free length (mm {in}) 36.6 {1.44}
Oil pump
Inner rotor tooth tip to outer rotor Standard 0.130—0.206 {0.0051—0.0081}
(mm {in})
Standard 0.113—0.186 {0.0045—0.0073}
Outer rotor body clearance (mm {in})
Maximum 0.22 {0.009}
Standard 0.035—0.095 {0.0014—0.0037}
Side clearance (mm {in})
Maximum 0.14 {0.006}
Bolt
Standard 46.7—47.3 {1.839—1.862}
Connecting rod bolt length (mm {in})
Maximum 48.0 {1.890}
Standard 67.7—68.3 {2.666—2.688}
Main bearing cap bolt length (mm {in})
Maximum 69.0 {2.717}
Standard 104.2—104.8 {4.103—4.125}
Cylinder head bolt length (mm {in})
Maximum 105.5 {4.154}
Plunger spring
H: 33.50 mm
Pressing force at plunger spring height H (N {kgf, lbf}) 97.68—107.48 {9.96—10.96, 21.91—24.11}
{1.319 in}
End Of Sie
TD–4
TECHNICAL DATA
MANUAL TRANSAXLE
Z4F931001029101
Item Specification
Transaxle type G15M-R
Clearance (mm {in}) 0.05—0.28 {0.002—0.011}
1st gear
Maximum (mm {in}) 0.33 {0.013}
Clearance (mm {in}) 0.18—0.46 {0.007—0.018}
2nd gear
Maximum (mm {in}) 0.51 {0.020}
Clearance (mm {in}) 0.05—0.20 {0.002—0.007} TD
Thrust clearance 3rd gear
Maximum (mm {in}) 0.25 {0.010}
Clearance (mm {in}) 0.17—0.37 {0.007—0.014}
4th gear
Maximum (mm {in}) 0.42 {0.017}
Clearance (mm {in}) 0.100—0.220 {0.0040—0.0086}
5th gear
Maximum (mm {in}) 0.270 {0.0106}
1st gear inner
(mm {in}) 39.500—39.525 {1.555—1.556}
diameter
Secondary
1st gear
shaft outer (mm {in}) 39.445—39.470 {1.553—1.554}
diameter
Clearance (mm {in}) 0.030—0.080 {0.002—0.003}
2nd gear inner
(mm {in}) 35.015—35.035 {1.378—1.379}
diameter
Secondary
2nd gear
shaft outer (mm {in}) 34.945—34.905 {1.376—1.374}
diameter
Clearance (mm {in}) 0.05—0.09 {0.002—0.003}
3rd gear inner
(mm {in}) 36.000—36.025 {1.417—1.418}
diameter
Oil clearance Primary shaft
3rd gear
outer (mm {in}) 35.945—35.970 {1.415—1.416}
diameter
Clearance (mm {in}) 0.030—0.080 {0.001—0.003}
4th gear inner
(mm {in}) 31.000—31.025 {1.220—1.221}
diameter
Primary shaft
4th gear
outer (mm {in}) 30.945—30.970 {1.218—1.219}
diameter
Clearance (mm {in}) 0.030—0.080 {0.001—0.003}
5th gear inner
(mm {in}) 34.000—34.025 {1.3386—1.3395}
diameter
5th gear Sleeve outer
(mm {in}) 33.945—33.970 {1.3365—1.3373}
diameter
Clearance (mm {in}) 0.030—0.080 {0.0012—0.0031}
Clearance between Standard (mm {in}) 0.10—0.45 {0.004—0.017}
1st/2nd shift fork and
hub sleeve Maximum (mm {in}) 0.95 {0.037}
Shift fork and hub
3rd/4th shift fork and
sleeve Maximum (mm {in}) 0.90 {0.035}
hub sleeve
5th shift fork and hub
sleeve Maximum (mm {in}) 0.86 {0.034}
Clearance between Standard (mm {in}) 1.50 {0.059}
Synchronizer ring synchronizer ring and
flank surface of gear Maximum (mm {in}) 0.80 {0.031}
Reverse idle gear and reverse idle gear
reverse lever bushing and reverse maximum (mm {in}) 0.85 {0.033}
lever
TD–5
TECHNICAL DATA
Item Specification
Runout (mm {in}) 0.050 {0.0020}max.
Bearing preload (N·m {kgf·cm, in·lbf}) 0.12—0.39 {1.2—4.0, 1.05—3.47}
Primary shaft gear 0.20 {0.008}, 0.25 {0.010}, 0.30 {0.012},
0.35 {0.014}, 0.40 {0.016}, 0.45 {0.018},
Preload adjust shims (mm {in})
0.50 {0.020}, 0.55 {0.022}, 0.60 {0.024},
0.65 {0.026}, 0.70 {0.028}
Runout (mm {in}) 0.015 {0.0006}max.
Bearing preload (N·m {kgf·cm, in·lbf}) 0.2—0.3 {2.0—4.0, 1.8—3.4}
Secondary shaft gear 0.20 {0.008}, 0.25 {0.010}, 0.30 {0.012},
0.35 {0.014}, 0.40 {0.016}, 0.45 {0.018},
0.50 {0.020}, 0.55 {0.022}, 0.60 {0.024},
0.65 {0.026}, 0.70 {0.028}
Differential bearing preload (N·m {kgf·cm, in·lbf}) 1.4—1.9 {14—20, 13—17}
0.1 {0.004}, 0.20 {0.008}, 0.25 {0.010},
0.30 {0.012}, 0.35 {0.014}, 0.40 {0.016},
0.45 {0.018}, 0.50 {0.020}, 0.55 {0.022},
0.60 {0.024}, 0.65 {0.026}, 0.70 {0.028},
Differential 0.75 {0.030}, 0.80 {0.031}, 0.85 {0.033},
0.90 {0.035}, 0.95 {0.037}, 1.0 {0.039},
1.05 {0.041}, 1.10 {0.043}, 1.15 {0.045},
1.20 {0.047}
Backlash of side gear
Standard (mm {in}) 0.050—0.150 {0.0020—0.059}
and pinion gear
End Of Sie
TD–6
SPECIAL TOOLS
ST
SPECIAL TOOLS .................................................ST-2

ENGINE .............................................................ST-2
MANUAL TRANSAXLE......................................ST-3
ST
ST–1
SPECIAL TOOLS
SPECIAL TOOLS
ENGINE
Z4F941001001101
49 0107 680A 49 L010 1A0 49 E011 1A0
Engine stand Engine hanger Ring gear brake

set set
49 0636 100B 49 B012 0A2 49 S120 170
Valve spring Pivot Valve seat

lifter arm remover
49 B012 005 49 L012 0A0A 49 L011 0A0B
Valve guide Valve seal & Piston pin

remover & valve guide setting set
installer installer set
49 E011 001 49 E011 002 49 T012 0A0A
Piston pin guide Screw Tapper holder

set
49 B014 001 49 H010 401 49 G033 107A
Oil seal installer Oil seal installer Dust cover

installer
49 E301 144
Removing plate
— —
End Of Sie
ST–2
SPECIAL TOOLS
MANUAL TRANSAXLE
Z4F941001029101
49 0107 680A 49 G019 0A0 49 0839 425C
Engine stand Transaxle Bearing puller

hanger set set
49 FT01 361 46 0636 145 498 G030 370
Bearing Fan pulley boss Removing plate ST

remover puller
49 F401 366A 49 G030 795 49 G030 440
Plate Oil seal installer Primary shaft

holder
49 B017 207 49 B017 208 49 B017 209
Attachment G Attachment H Attachment J
49 F401 331 49 F401 335A 49 F401 336B
Body Attachment A Attachment B
49 G030 338 49 G030 380D 49 G017 202
Attachment E Shim selector Preload adapter

set
49 B017 102 49 G030 455
Preload adapter Diff. side gear

holder
—
End Of Sie
ST–3

F173-20-01B Laser Overhaul Manual (2001MY)

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F173-20-01B Laser Overhaul Manual (2001MY)

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CONTENTS

LASER Technical Data TD

Overhaul Special Tools ST

Manual 2001 Ford Japan Limited.

This Manual explains the disassembly,

Parts & Service

HOW TO USE THIS MANUAL ............................. GI-2

HOW TO USE THIS MANUAL

Apply oil New appropriate engine oil or gear oil

Apply brake fluid New appropriate brake fluid

New appropriate automatic transaxle/transmission

Apply grease Appropriate grease

Apply sealant Appropriate sealant

Apply petroleum jelly Appropriate petroleum jelly

Replace part O-ring, gasket, etc.

Use SST or equivalent Appropriate tools

End Of Sie MESSAGES

Upper and Lower Limits

Electrical current A (ampere)

Positive pressure kgf/cm2 (kilogram force per square

Conversion to SI Units (Système International d'Unités)

Upper and Lower Limits

210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

End Of Sie DURING REMOVAL, DISASSEMBLY

End Of Sie OF PARTS

Sensors, Switches, and Relays

ENGINE ................................................................ B3-2

2. Assemble the SSTs (bolts, nuts and plate) to the

5. Tighten the SSTs (bolts and nuts) to affix the

6. Mount the engine on the SST (engine stand).

1 Spark plug 7 No.3 engine mount bracket

Crankshaft Pulley Disassembly Note

Timing Belt Disassembly Note

2. Mark the timing belt rotation on the belt for proper

1 Camshaft pulley 3 Cylinder head

Camshaft Disassembly Note

Cylinder Head Disassembly Note

Valve Keeper Disassembly Note

Valve Seal Disassembly Note

1 Water pump 7 Oil strainer

Flywheel (MTX), Drive Plate (ATX) Disassembly Note

Rear Cover Disassembly Note

Oil Pan Disassembly Note

2. Remove the sealant from the bolt threads.

Oil Pan Upper Block Disassembly Note

3. Remove the oil pan upper block using the

1 Connecting rod cap 7 Piston

2. Insert SST No.2 into the piston pin as shown and

3. Set the piston and connecting rod on the SST as

Main Bearing Cap Disassembly Note

6. Pull the sliding hammer straight upward and

End Of Sie HEAD INSPECTION/REPAIR

4. If the cylinder head distortion exceeds the

5. Measure the manifold contact surface distortion

6. If the distortion exceeds the specification, grind

2. Measure the length of each valve. Replace the

3. Measure the stem diameter of each valve in X

Standard inner diameter

2. Measure the protrusion height (dimension A) of