Workshop Manual - Daihatsu 3 Cyl 993cc EFI

SERVICE SPECIFICATIONS CB-42

CB-41 Coolant capacity

Oil capacity

Valve clearances (HOT)

Pickup

4.4 i

Van

4.6 I

Without oil filter

2.9 I

With oil filter

3.1 I

Intake

0.2 ± 0.05 mm/0.0078 ± 0.002 inch

Exhaust

0.2 ± 0.05 mm/0.0078 ± 0.002 inch

Spark plug gap

CHAMPION

NGK

NIPPONDENSO

RN9YC

BPR5EY

W16EXR-U

0.8 - 0.9 mm

0.7 - 0.8 mm (0.028-0.031 inch)

0.7 - 0.8 mm

(0.031-0.035 inch)

(0.028 - 0.031 inch)

BTDC°/rpm

5 ± 2/950

5±2/900

rpm

950 ±50

900 ±50

CO concentration

1.5 %

Not to exceed 0.2 %

HC concentration

Not to exceed 1000 ppm

Not to exceed 100 ppm

Ignition timing Idle speed CO/HC concentrations

350 rpm Compression pressure

Timing belt pulley

Camshaft

2

LISMPa^kgf/cm ) 2

Minimum

1.03 MPa (10.5 kgf/cm )

Difference between cylinders

0.098 MPa(1.0kgf/cm )

Wear limit (Minimum limit-)

Camshaft

119.9 mm (4.270 inch)

Crankshaft

59.2 mm (2.331 inch)

Oil clearance

Front STD

0.04 - 0.14 mm (0.0016 - 0.0055 inch)

Center STD

0.09 - 0.19 mm (0.0035 - 0.0075 inch)

Rear STD

0.06 - 0.16 mm (0.0024 - 0.0063 inch)

Reference Journal diameter

Cam lobe height

Cylinder head

STD

2

Front

31.960 - 31.980 mm (1.2583 - 1.2591 inch)

Center

47.385 - 47.410 mm (1.8656 - 1.8665 inch)

Rear

48.415 - 48.440 mm (1.9061 - 1.9071 inch)

Intake Minimum limit

39.8 mm (1.5669 inch)

Exhaust Minimum limit

39.8 mm (1.5669 inch)

Runout [Bend]

0.03 mm (0.0012 inch)

Uneven wear of camshaft journal Maximum limit

0.02 mm (0.0008 inch)

Flatness

Cylinder block side

0.1 mm

Intake manifold side Exhaust manifold side Valve seat angel

Intake

45°

Exhaust Valve guide bushes

Oil clearance

Intake

0.040 - 0.075 mm (0.0016 - 0.0030 inch)

Exhaust

0.045 - 0.080 mm (0.0018 - 0.0031 inch)

CB-41 Valves

Contact width with valve seat Valve face angle

Valve stem outer diameter Overall length

Valve rocker arm and valve rocker shaft

Intake

0.9 -1.5 mm (0.035 - 0.059 inch)

Exhaust

1.2 -1.8 mm (0.047 - 0.071 inch)

Intake

6.945 - 6.960 mm (0.2734 - 0.2740 inch)

Exhaust

6.940 - 6.955 mm (0.2732 - 0.2738 inch)

Intake

101.65 mm (4.002 inch)

Exhaust

101.65 mm (4.002 inch)

Free length Installed tension at 34.9 mm

43.3 mm (1.7047 inch) STD

29.9 kg

Minimum limit

25.7 kg

Oil clearance between rocker arm and rocker shaft

16.000 -16.018 mm (0.6299 - 0.6306 inch)

Vaive rocker shaft outer diameter

15.958 -15.984 mm (0.6283 - 0.6293 inch)

Minimum free length

Cylinder block

Flatness cylinder head gasket attaching surface

STD

Oil clearance between piston-tc-cylinder

STD

Piston, piston pin and piston rings

Connecting rod

Crankshaft

33 mm (1.299 inch) 0.1 mm (0.0039 inch)

Maximum limit

Maximum limit

0.03 - 0.12 mm (0.0012 - 0.0047 inch) 0.12 mm (0.0047 inch)

Cylinder bore diameter STD (When over size piston is O/S 0.25 used)

76.00 - 76.03 mm (2.9921 - 2.9933 inch)

O/S 0.50

76.50 - 76.53 mm (3.0118 - 3.0130 inch)

76.25 - 76.28 mm (3.0020 - 3.0031 inch)

Piston ring groove-to-piston ring side clearance

No. 1

0.03 - 0.07 mm (0.0012 - 0.0028 inch)

No. 2

0.02 - 0.06 mm (0.0008 - 0.0024 inch)

Piston ring thickness

No. 1

1.47 -1.49 mm (0.0579 - 0.0587 inch)

No. 2

1.47 -1.49 mm (0.0579 - 0.0587 inch)

No. 1

0.20 - 0.70 mm (0.008 - 0.028 inch)

No. 2

0.20 - 0.70 mm (0.008 - 0.028 inch)

Oil

0.20 -1.10 mm (0.008 - 0.043 inch)

Piston ring end gap

Piston, piston pin and piston rings

0.016 - 0.09 mm (0.0006 - 0.0035 inch)

Valve rocker arm inner diameter

Valve rocker arm spring

Cylinder

1.0 - 1.8 mm (0.0394 - 0.0709 inch) 45.5°

Valve stock thickness

Vaive spring

CB-42

Piston-to-piston pin oil clearance Maximum limit

0.03 mm (0.0012 inch)

Piston pin-to-connecting rod interference fit

0.012 - 0.019 mm (0.0005 - 0.0019 inch)

Big end thrust clearance

0.150 - 0.30 mm (0.0059 - 0.0118 inch)

Maximum bend

0.05 mm (0.0020 inch)

Maximum twist

0.05 mm (0.0020 inch)

Crankshaft bend

0.06 mm (0.0024 inch)

Uneven wear of main journal and crankpin journal

0.01 mm (0.0004 inch)

Main and crankpin journal oil clearance

0.020 - 0.070 mm (0.0008 - 0.0027 inch)

Crankshaft thrust clearance

0.02 - 0.30 mm (0.0008 - 0.0118 inch)

CB-41 Balance shaft

Timing belt pulley

Fly wheel

CB-42

Balance shaft thrust clearance

0.03 - 0.20 mm (0.0012 - 0.0078 inch)

Balance shaft bearing oil clearance

0.025 - 0.1 mm (0.0010 - 0.0039 inch)

Camshaft timing belt pulley outer diameter Minimum limit

119.9 mm (4.270 inch)

Crankshaft timing belt pulley outer diameter Minimum limit

59.2 mm (2.331 inch)

Run out

0.10 mm (0.0039 inch)

Maximum limit

Crankshaft main journal Bearing center thickness Replacement bearing STD bearing Undersize 0.25 bearing Undersize 0.50 bearing

1.986 - 2.006 mm (0.0782 - 0.0790 inch) 2.111 -2.131 mm (0.0831 - 0.0839 inch) 2.236 - 2.256 mm (0.0880 - 0.0888 inch)

Crankpin journal bearing (Connecting rod bearing)

Bearing center thickness Replacement STD bearing Undersize 0.25 bearing Undersize 0.50 bearing

1.486 -1.506 mm (0.0585 - 0.0593 inch) 1.611 -1.631 mm (0.0634 - 0.0642 inch) 1.736 -1.756 mm (0.0683 - 0.0691 inch)

Crankshaft thrust bearing

Bearing center thickness STD Oversize 0.25 bearing Oversize 0.50 bearing

1.940 - 1.990 mm (0.0764 - 0.0783 inch) 2.065 - 2.115 mm (0.0813 - 0.0833 inch) 2.190 - 2.240 mm (0.0862 - 0.0882 inch) PEM00079O0000

TIGHTENING TORQUE Tightening components

Tightening torque N-m

kgf-m

ft-lb

Cylinder head x Spark plug

14.7 - 21.6

1.5-2.2

10.8 - 15.9

Cylinder head x Cylinder block

53.9 - 63.7

5.5 - 6.5

39.8 - 42.0

7.8 -11.8

0.8- 1.2

5.8 - 8.7

2.9 - 4.9

0.3 - 0.5

2.2 - 3.6

2.0 - 3.9

0.2 - 0.4

1.4-2.9

53.0 - 64.7

5.4 - 6.6

39.1 - 47.7

Cylinder block x Oil pan

3.9 - 6.9

0.4 - 0.7

2.9 - 5.1

Cylinder block x Balance shaft thrust plate

9.8 -14.7

1.0-1.5

7.2 -10.8

Connecting rod x Connecting rod cap

23.5 - 30.4

2.4 - 3.1

17.4-22.4

Flywheel x Crank shaft

39.2 - 49.0

4.0 - 5.0

28.9 - 36.2

Crankshaft pulley x Crankshaft

88.3 - 98.0

9.0 - 10.0

65.1 - 72.0

Camshaft timing belt pulley x Camshaft

29.4-44.1

3.0 - 4.5

21.7-32.5

Timing belt tensioner x Balance gear cover

33.3-44.1

3.0 - 4.5

21.7-32.5

Cylinder block x Oil pump

14.7 - 21.6

1.5 - 2.2

10.8 -15.9

5.9 - 8.8

0.6 - 0.9

4.3 - 6.5

Cylinder head x Intake manifold

14.7 - 21.6

1.5-2.2

10.8 - 15.9

Cylinder head x Exhaust manifold

14.7-21.6

1.5 - 2.2

10.8 - 15.9

Balance shaft gear cover x Cylinder block

9.8 - 15.7

1.0-1.6

7.2-11.6

Balance shaft weight x Balance shaft

29.4-44.1

3.0 - 4.5

21.7-32.5

Oxygen sensor x Exhaust manifold

29.4 - 39.2

3.0 - 4.0

21.7-28.9

Coolant temperature sensor x Cylinder head

24.5 - 34.3

2.5 - 3.5

18.1 -25.3

Intake air temperature sensor x Intake manifold

29.4 - 39.2

3.0 - 4.0

21.7-28.9

Coolant temperature sender x Intake manifold

9.8- 17.6

1.0-1.8

7.2 - 13.0

Delivery pipe x Intake manifold

14.7-21.6

1.5-2.2

10.8 - 15.9

Cylinder head cover x Cylinder head

M8 M6

Timing belt cover Crankshaft bearing cap x Cylinder block

Water pump x Water pump pulley

HW-15 WIRE HARNESS CONNECTING TABLE ENGINE Item

Circuit

Dim-Dip relay (2) Headlight LH (Lo) Headlight RH (Lo)

A25 A3 A4

| A35 | A37 i A38

Meter (charge) Back-up lamp SW

D1 G1

Oil pressure SW Meter (temp.)

Item

Wire size & color

Dim-Dip resister (-) Dim-Dip resister (LH) Dim-Dip resister (RH)

0.5 0.5 0.5

L R-G R-B

D2 G2

IC alternator (L) Back-up lamp (+)

0.5 0.5

LW RY

H1 H3

H2 H4

Meter (oil) Water temp, sensor

0.5 0.5

YW YL

J/B (Fuse, heater)

K1

K2

Back-up lamp SW

0.85

LB

J/B (Fuse, engine)

L1

L2

Fuel cut solenoide

0.85

WR

Connect to L1-L2 Connect to L1-L2

L1

L3 L6

IC alternator (IG) Carburetor (outer vent V/V)

0.85 0.85

WR WR

Connect to L1-L2 PYC heater

L1 L22

L21 L23

Water temp. SW (PXC) Water temp. SW(PXC)

0.85 0.85

WR LR

Main fuse J/B (Ignition ST)

Ml M3

M2 M4

Starter (B) Starter (ST)

3 2

WR BY

Main fuse

N1

N2

IC alternator (B)

3

W

J/B (Ignition SW (IG))

N3

N4

Ignition coil (B)

Z

BL

Distributor (-) Connect to N5-N6 Connect to N3-N4 Ignition coil (+) Ignition coil (-) Connect to N5-N6

N5 N5 N3 N22 N6 N5

N6 N11 N20 N23 N24 N25

Ignition coil (-) F/C amp. Distributor (+) Condenser Resister (+) Resister (-)

0.85 0.5 1.25 Z 0.5 0.5

BR BR BL BW BR BR

Choke SW (-)

06

010

Water temp. SW (choke)

0.5

Y-B

HWO0033-OO0OO

HW-17 Item

Circuit

Oil pressure SW (+) Meter combination, (coolant temp.)

H4

H5

H6

Connect to H6-H7

H6

J/B (Fuse: wiper)

I1

| I2

Front wiper SW (+1) Front washer motor (-)

I3

I4

I5

I6

Front wiper SW (+2) Connect to I1-I2 Rear wiper SW (washer) Rear wiper SW (+) Connect to I1-I9

I7

I8

I1

I9

I10

I11

I12

I13

I1

Connect to I1-I9

I1

J/B (Intermittent wiper relay: S) Connect to K5-K6

Item

Wire size & color

H7

Meter combination (oil pressure) (Coolant temp, sensor (+))

0.5 0.5

W-Y Y-L

H8

A/C amp. (9)

0.5

Y-L

Front wiper motor (+)

1.5

L-R

Front wiper motor (+1) Front wiper SW (washer)

0.5 0.5

V-Y L

0.5

I14

Front wiper motor (+2) Front washer motor (+) Rear washer motor (-) Rear wiper motor (-) Rear wiper motor (+)

0.5 0.5 1.0

L-B L-R L-W V-Y L-R

I15

Rear washer motor (+)

1.0

L-R

I16 J

I17 J

Front wiper motor (S) Connect to K36-K14

0.5

L-W L-B

J/B (Fuse: Deffoger (L)) Deffoger SW (-)

K1 K3

K2

Deffoger SW (+) Deffoger (+)

1.5

J/B (Fuse: Heater (L)) Heater blower SW (Hi) Heater blower motor (-)

K5 K7 K8

K6 K8

Heater blower SW (Me) Heater blower SW (Lo)

K10 K12

K11

J/B (Fuse: Heater (L)) A/C SW (-)

K36 K15

K14

Connect to K5-K6 Connect to K5-K6 A/C amp. (4) A/C amp. (5) A/Camp. (10) Idle up VSV (+)

K5 K5

K17

K54

K21

K55 K60 K32

K25

Connect to K12-K13 Condenser fan relay (M-)

K4

1.0

1.0 1.0 1.0

B-R L

Heater blower motor (+) Heater blower motor (-) Heater resister (Hi)

0.5 0.5

L-B L-W L-W

Heater resister (Me) Heater resister (Lo)

0.5 0.5

V-B L

A/C SW (B) Dual pressure SW (+)

1.0 1.0

L-B V-Y

K30 K33

Back lamp SW (+) Meter combination (+B) Idle up VSV (-) Compressor magnet clutch (+) Water temp, gauge (7V) A/C amp. (3)

0.5 0.5 0.5 0.5 0.5 1.0

L-B L-B R L-R Y L-B

K12 K65

K58 K69

A/C amp. (8) Condenser cooling fan motor (-)

0.5 2.5

L B

A/C amp. (6) J/B (Fuse: Engine (L)) Connect to L1-L2

K56

Fuse, A/C (L) Radiator cooling fan motor (+) Fuel pump relay (+B)

0.5

L1

K83 L2 L7

O W-R W-R

J/B (Fuse: Engine No. 2) Connect to L1-L2 Main fuse (B)

N34

L11

L1

L12 M2

Alternator (IG) Dim-Dip relay (7) Starter (B)

0.5 0.5 4.0

W-R W-R W-L

IG SW (ST) Connect to M3-M4

M3 M3

M4

Starter (ST) Fuel pump relay (ST)

2.5 2.5

B-Y B-Y

Main fuse (L)

N1

| N2

J/B (IG SW (B))

4.0

jW

Connect to N1-N2

N1

N3

IG SW (B)

4.0

W

Connect to N11-N5

N11

N4

Fuel pump relay (IG pulse)

0.5

B-R

Connect to N1-N2 J/B (IG coil B) A/C amp. (14) IG SW (IG)

N1

N6

W

N17

N8

4.0

N11

N15

B B-R

N7

N15

Alternator (B) IG coil (B) Ignition coil (-) J/B (IG SW (IG))

4.0

Connect to N7-N45 IG SW (IG2) Meter combination (charge)

N7

N16

N30 03

N31

Engine coolant temp. SW (B) Meter combination (choke)

L1

M1

K9

K13 K16 K18

M5

1.5

0.5

0.5

B B

04

J/B (IG SW (IG)) Fuse holder (Fuse: Engine No. 2) Alternator (L)

4.0

4.0 0.5

W-L W-G

O10

06

Choke SW (-)

0.5

Y-B

07

08

Choke SW (+)

0.5

Y-R

4.0

HW-20 item

Circuit

Item

Wire size & coior

Fuel level sender (+)

H2

H3

Meter combination (Fuel)

0.5

Y-G

Oil pressure SW (+)

H4

H5

Meter combination (oil pressure)

0.5

W-Y

Meter combination (coolant temp.)

H6

H7

Coolant temp, sender (+)

0.5

Y-L

Connect to H6-H7 J/B (Fuse: wiper) Front wiper SW (+1)

H6 11 13

H8 12 14

Thermistor (A/C) Front wiper motor (+) Front wiper motor (+1)

0.5 1.5 0.5

Y-L L-R V-Y

Front washer motor (-) Front wiper SW (+2) Connect to 11-12

15 17 11

16 18 19

Front wiper SW (Washer) Front wiper motor (+2) Front washer motor (+)

0.5 0.5 1.0

L L-B L-R

J/B (Intermittent wiper relay: S)

116

117

Front wiper motor (S)

0.5

L-W

Connect to K5-K6

J

J

K36-K14

1.0

L-B

J/B (Fuse: Heater (L)) Heater blower SW (Hi)

K5 K7

K6 K8

Heater blower motor (+) Heater blower motor (-)

1.0 0.5

L-B L-W

Heater blower motor (-) Heater blower SW (Me)

K8 K10

K9 K11

Heater resister (Hi) Heater resister (Me)

0.5 0.5

L-W V-B

Heater blower SW (Lo) J/B (Fuse: Heater (L)) A/C SW (-)

K12 K36 K15

K13 K14 K16

Heater resister (Lo) A/C SW (B) Dual pressure SW (+)

0.5 1.0 1.0

L L-B V-Y

Connect to K5-K6 Connect to K5-K6

K5 K5

K17 K18

Back lamp SW (+) Meter combination (+B)

0.5 0.5

L-B L-B

Connect to K12-K13 Connect to Z1-Z2 A/C amp. J/B (Fuse: Engine (L)) Connect to L1-L2 J/B (Fuse: Engine No. 2)

K12 Z1 K60 L1 L1 N34

K58 K61 K70 L2 !_7 L11

A/C amp. A/C amp. Water temp gauge (7V) Radiator cooling fan motor (+) Fuel pump relay (+B) Alternator (IG)

0.5 0.5 0.5 1.5 0.5 0.5

L W-B Y W-R W-R W-R

Connect to L1-L2 Main fuse (B)

L1 M1

| L12 M2

Dim-Dip relay (®) Starter (B)

0.5 4.0

W-R W-L

IG SW (ST) Connect to M3-M4

M3 M3

M4 M5

Starter (ST) Fuel Dump relay (ST)

2.5 2.5

B-Y B-Y

Main fuse (L) Connect to N1-N2 Connect to B5-N20

N1 N1 N5

N2 N3 N4

J/B (IG SW (B)) IG SW (B) Fuel pump relay (IG pulse)

4.0 4.0 0.5

W W B-R

Connect to N1-N2

N1

N6

Alternator (B)

4.0

W

J/B (IG coil (B)) IGSW(IG)

N17 l N7

LJM8 N15

IG coil (B) J/B (IG SW (IG))

4.0 4.0

B B

Connect to N7-N15 IG coil (-)

N7 N5

N16 N20

J/B (IG SW (IG)) A/C amp.

4.0 0.5

B

IG SW (IG2)

N30

N31

Fuse holder (Fuse: Engine No. 2)

4.0

W-L

Meter combination (charge) Engine coolant temp. SW (B) Meter combination (choke) J/B (Fuse: ACC (L)) Connect to R1-R2

03 010 07 R1 R1

04 06 O8 R2 R4

Alternator (L) Choke SW (-) Choke SW (+) Cigarette lighter (+) Radio (+)

0.5 0.5 0.5

W-G Y-B Y-R

0.5

■

IG SW (ACC) Radio (speaker (+))

R6 R13

R7 R15

J/B (IG SW (ACC)) Speaker (+)

2.5 0.5

B-W R-Y

Radio (speaker (-)) Fuel pump relay (L)

R14 U7

R16 U12

Speaker (-) Fuel pump motor (+)

0.5 2.5

B-Y L

Body earth (Front RH) Connect to 21-Z2 Connect to Z1-Z2

Z1 Z1 Z1

Z2 Z3 Z4

Body earth (Front LH) Meter combination (Earth) Courtesy SW (-)

1.5 0.5 0.5

W-B W-B W-B

B-R

L 1-°