Beruflich Dokumente
Kultur Dokumente
F
'::
L?OBENGINE
Group 2/Group
CONT ENT S
.: JB E\GI\E TTINE-UPSPECIFICATIONS......, ..
P.\RTS CONFIGURATION
AND DETAILS OF TUNE.UP
C\'LINDER BLOCK
OIL PAN
CYLINDER HEAD
CYLINDER HEAD
C.{M COVER
PISTON.CONrr-ECTING
CRA\KSHAFT AND FLYWHFF I
CLUTCH
E\G I).1ERE A R P LA TE ,...
ENGINE ]\,IOUNTING
BRACKET
CAMSHAFTDRIVE. VALVE MECHANISM.
FRO NT COV E R A ND OIL S E A L . . . . . . . . .
OIL PUI!'IP
OIL COOLE R
INTA K E S Y S TE ]\{......,
EXHAUST \IA\IF'OLD .. .,
WATER PUMP. WATER OUTLET. FAN BLADE
RAD IA I OR
ENG INE E LE CTR]CA LS Y S T E M
EXH AUS TS Y S II \1 ...
TEST RUN P RE CA UTIONS
SERVICEDAT,.\
BONDINGAND SE.\ L I\'] ACENTS
.. I
.. 3
,. 3
.. 4
.. 5
.. t3
. . t4
. . 14
. . t0
..21
. . ll
. . lt
.. 3t
.. 33
.. 39
..4t
.48
.48
. 5l
.. 5l
56
.. 57
. 58
..
bl
L20B(D.O.H.C.)
G4
--t-*{@m1rccr:-e
l!'ra rl?n'=-rr
# ral :n1
r,952(r19,11)
h rn c r
85.0x 86.0
(3.346x 3.386)
lrElrl
icrryrmrno
1 0 .8to I 1 .0
@oNtrFrt
rpm (A/Horn)
230PS/7,500
@tolque
206N.m(21 ke-m,152frlb)i
5,600rPm
216N m (22ks-m,159ftlb)/
6,000rpm (Ai Horn)
7,500rpm
8,000rpm
NLt:
[:--] s?eed
friu:et
i].ock
(1}rt'e: iead
i s uti l j zed.
L l 8 o p tro n a unrt
l
aluminumunit
Forge-strengthened
is newly developed.
C:-:1ing
c,2.)
Unit usingCM40strengthened
malerialis newiy developed.
rod
a---:{s!ufi
unit is
CM40tulftride'processed
n e w l y ' d e v e l oped.
i'':'::eei
tJ?3i lraln
Disc
Cover
G-2
L20B(S.O.H.C.)
Item
Csmshaft
Valve
mm (in)
Intake manifold
Exhaust manifold
G-4
r20B(D.O.H.C.)
Stainless
steelpipe 4'2-l type is
newly developed.
Carburetor
S O L E X5 0 P H H r l w i n
Air cleaner
Dstributor
CDIoptionalunit is
MITSUBTSHI
utilized.
Alternator
Oil sumpsystern
Wetsump
Radiator
OiI cooler
HS30optionalunit is utilized-
Exhaustsystem
c2.)
Dry sump
-2 -
(r l 022u6700).
OIL PAN
The oil pan is availablefor the L20B G2 and
G4 as an optional part. G2 usesa wet sump system,
and G4 usesa dry sump system.
When installing the oil pan, be sure to check
for oil leakage.and thoroughly clean the inside of
pan, removing casting sand and cutting chip completely.
O I L P A N S P E CI F I CA T I O NS
2. G4 specification(dry sumP)
Install blind plugs in the samemanner as L20B
standard.Listed below are the different points'
(l) Oil jet on the top surfaceof block """ Install
the plug for L-series6-cylinder engine (11047
E3000)
(2) Oil hlter mounting stud (15113 21001) ""'Not'needed
(3) Oil filter rilief valve mounting hole ''"" lnstall
blind plug( I 1022 69800)
(4) Breatherbaffle plate (11038 U6000) """ Not
needed
(5) Breather steel net-(l1037 21001) """ Not
needed
( 6) Breather pipe connector ...... Install optional
part ( l 1830A8720).
. Install with the outlet facing front'
Enginespecification
c2.
G4
Parl number
O G2 specification
Utilize the L20B standard unit' In order to
prevent unbalancedmovement of oil, baffle plates
are welded in two stages-inthe pan.
@ G4 specitication
The oil pan for dry sump is of aluminum
casting, and has a double suction structure' The
baffle-plate should be installedby using both plain
and spring washers
1l l l 2 A 7670 {B affl e P l al el
A 7570 (Oi l pan)
15050H5820 l2 pieces)
strainer
Screen.oil
{2 Piecesl
054122OOOP
Gaskt-B
15421 N 3120 (2 P i eces l
S ucti on connector
. 11128 69200
Dr a in p lu g ( 2 p ie ce s)
. 11026 610 0 0
Wa sh e r{ 2 p iecesl
L2OB E ng in e (G ro u P s 2 a n d 4 )
PARTS CONFIGURATIONAND
DETAILS OF TUNE.UP
CYL I NDE R B L O C K
a s o p tl onal
The c y lir r der b l o c k s a l e l v i l i l a i rfc
re s Ic ct i ves
'
e
n
g
i
n
e
C
4
rrrtd
I
G
LlO
B
u l ri ts l- or t he
l]0r0 476?0
Pa rl l.wunr ber
11010 A7660
Dotailsof nrodificalion
br
of toP surface
Grinding
0.5mm (0.020in).
Enlar.redscrewsizefor front
Por tir)n
\16 - :\'iS(4 Places)
Geai trai n mounrj ngbolt s
EniargedbreatherPiPe
dri vi nshol e di ameter
sLl i l l i aa.
,<
lz'
1'.
*?_
L2OBEngine(drouPs2 and4l
head
@ External view of G4 specificationcylinder
L PAN GASKET
The oil pan gasket is providedas optional Part
ano
ihe Gl and G4 for improved durabilitY
ntion of oil leakage.
L PAN GASKET
INDER HEAD
The cvlinder head assembly is provided as2n
,.,.ratunit for rhe L20B Gl and G4 enginesG2
rres the same S.O.H.C. system as does the
(I)
Key
No.
Remarks
Pan Nane
Q'tv
I 1041N7120
HeadAssemblY-CYlinder
0l
11042N?120
Head-Cylinder
02
AC4A.T6
ai
11098N7120
Int"ke
Insert-Valve,
04
ABF3
11099N7120
Ex-haust
lnsert-Valve,
04
ABF3
13212N3120
Cuide-Valve,lntake
04
tiats
f4)
li.r
13213N3120
Guide-Valve,Exiaust
04
PBC2B
PartNumber
1
-5-
Part Name
PartNumber
Remarks
Q'tv
9-33212
Plug-Taper
02
I i051 73403
(P/T 3/8-19)
Plug-Blind
03
I104873403
Plug-Blind(P/T3/4-14)
Q2
t2205zlocf
(6)
Plug-Taper
0l
82-?4a3s-r
Stud-Manifold
l t)
- 270?0Hs000
Oil GallerY
Connector-Heater
0l
1102220100
Collar.CamshaftBracket
08
13 0 5 1 21m0
Brackt{amshaft, Front
01
1305321000
BIacket-Camshaft,Intake
.02
1305521000
Rear
| Bracket-Camshaft,
0l
trOrt ttoOo
Bracket
I Bolt{amshaft
04
Bolt-CamshaftBracket
ztooo
@ t r:oss
@
13215A8600
Pivot
Bush-Rocker
08
11046A4600
Front
Cover-Head,
0l
I 1049E3000
Front
Gasket-Head,
0l
81-1061462
Bolt-Hex(M6)
03
81-10816-62
(M6)
Bolr-Hex
02
10005N5800
Slinger-Engine,Front
01
81.10816-62
Bolr'Hex$'18)
0l
10006A7660
Rear
Slinger-Engine,
0l
11056P3000
06
L= 12?mm (5.00in.)
110s9P3000
Bolt-CylinderHead,Long
04
L = I 53 mm (6.02in.)
1105821001
Washer-Plah
t0
l1044A'?650
Gasket-CylinderHead
01
:l
ii
T = 1.5mm (0 059in-)PtainTYPe
|ft";
PartNamb
PartNumber
l loal A76?0
HeadAssemblY-CYlinder
rrvz A't6'70
Head-CYlindet -
l1098A?670
Remarks
I Q'tY
01
0l
AC44.T6
Insert-Valve,lnla}(e
08
SuperTarkalloY
I1099A7670
lnsert-Valve
I Exhaust
08 ;';;-
t3212 A'76'10
Guide-Valve
to
11048?3403
(3/4)
Plug-Taper
01
9-31208-l
(1/2)
Plug-Taper
03
6)
9-332061
(6)
Plug-Taper
01
9-33122
(22)
Plug-Welch
03
BracketAssembly'
Camshaft(Exhaust)
0l
Bracket{amshaft
01
H5820
1130s0
130s1 H5820
6r
I ABB.3
(6)
| Plug'TaPer
01
Knock-Tube
l0
fsr-totoot
Stud
05
Hs821
y 130s0
01
13051H5821
Bracket-Camshaft
01
(6)
Plug-Taper
01
11022H5820
Knock-Tube
10
a?
82-24840-l
Stud
05
r 3052H5820
Cap-CamshaftFrcnl
o2
13052H5821
Cap-Camsllaft
08
I1022H5820 I Knock-Tube
l0
^
a9
81-20865-1
Bolr-Hex(M8)
t0
81-20875-1
Bolt-Hex(M8)
o4
C9
11063H5820
Bolt-CylinderHeadCover
06
89-11208-l
Nut-Hex
10
093400010P
Washer-Bent
30
9-33206-5
11022H5820
@
@
- 9-33206-s
-^
-7-
.)
Remarks
Key
No.
Part Number
I l05l H5820
Plug
Tube-SPark
04
82-28618-4
Stud(M6)-
36
L rr-,or,ro
Stud(M8)
04
11065N?170
Plate-Btind
04
I 1062H5820
Gasket-WaterOutlet, A
o4
89-15136-1
Washer-SPring
08
89-11206-l
Nut-Hex(M6)
08
40200
13094
Shaft-Tensioner
0051I 0017P
O-Ring
01
89-15138-1
Washer-SPring
01
A0201
13099
Arm
Bolt-Tensioner
0l
054i2 1400P
Gasket.B
01
1308329900
Nut-Lock
01
13073A0200
Adjust
Screw-Chain
01
1308529900
Wire-ClamP
0l
130842990C
Adjust
Cap-Chain
01
at
11044A7671
Gasket.CYlinderHead
01
11056H5820
Head
Bolt-Cylinder
08
L = 92 mm (3.62in.)
=
9
11056H2301
Head
Bolt-Cylinder
o2
L = 97 rnm(3.82in.)
11058H1000
Washer-HeadBolt
10
Part Name
QIy
0t
-enntoltuc PORTS
oF
@ spcificati on
t) The size of lhis port is larger than the standard
one- Grind off the casting skin of the port,
while removing step at the valve insert.(Grinding for increasingthe port diameter is nol
needed.)
2) Grind the manifold mounting bort together
with the manifoldgasket(14035 N7120).
port.
ln ta ke m a n ifo ld
M a n i f o l d g a ske t
Cy lin d e r h e a d
Grind to rernove
Gr in d th e in sid e su r fa c
Ysa
U n i t: mm { i n}
@ G4 specification
( I ) In this cylinder head, machining of 28 mm
(1.10 in) dia. hoie has been made halfway on
both the intake and exhaust ports. Grind the
valve insert portion, 28 mm (1.10 in) dia.
machinedportion and the portion having casting skin to removesteps.
(2) Unlike the unit for G2, the valve guide pressing
length has certainallowance.Cut off the end of
valve guide protruding into the port, along the
contour of the port.
(3) The nurirber of ports in this G4 specification
engine is geater than for G2. Care should be
taken when grinding the ports not to causeany
significantdifferencesin shapeamong them.
-9-
R ocker gui d e
i
---
-T...
__1"::_-.-...__-
--
i l\
i
e!
=G-
\""_".,*
CHAMB E R
MACHININGOF COMBUSTION
Valveposition
@ G2specification'
Unit: mm (in)
43.8- 44.0
(r.724- |.132)
43.8- 44.O
(r .724- r.732)
7s.0(2.9s3)
'1s.4Q.968)
41.2 - 41.4
(r.622- | .630)
4t .2 - 41.4
(1.622- | .630)
0.8 (0.031)
0.8(0-o3l)
40.4- 40.6
(l.s9l - 1.s98)
40.4- 40.6
(1.591- 1.s98)
37.0-37.2
(1.4s7- 1.46s)
37.O- 3'l .2
(1.4s7- 1.46s)
,_)
- 10 '{
Inlake
><
63-38(2.49s3)
Unit: mm (in)
Exllaust
63.32(2.4929)
42.9- 43.1
(1.689- 1.697)
42.8- 43.t)
(r.68s. l .693)
37.8- 38.0
(1.488- 1.496)
3'1.'7- 31.9
(1.484- 1.492)
1.0(0.039)
l.0 (o.o3e)
0.28- 0.32
(0.0r10- 0.0126)
0.33- 0.37
(0.0130.0-014 6 )
2.2 (0.087)
36.8- 3'7.3
(r.449- r .469)
34.2- 34.7
(1.346- 1.366)
c ap.
thjckness
o
o'
2.2 (0.087)
(1.44s. 1.465)
34.t - 34.6
(1.343- 1.362)
L2OBEngine(Groups2 and 4\
)
it$
i!i
rlt
lli.
ii
i;
.l
@ as the
I.D. is especiallysmall at these points.
@ The portion @ must not protrude from the
bottom surfaceof cylinder head.
@ The portion @ .shouldbe machinedsomewhat
higher.
@ The portion @ mgst be machined by aligning
with the head gasketI.D.
@ Area @ must be machined so that the valve
surface is flush with the combustion chamber
wall surface,or is protruding about 0.3 to 0.5
mm (0.012 to 0.020 in).
Any
stepsand burs must be removed.
@
The surfacequality of this machining should be
v2
vs
(cu in)
No definite value can be recommendedas
compressionratio for rally, as the octane value o
gasolinevaries from place to place in the world. It
is preferablehowever not to use a valueexceeding
I l.
@ The volume of the combustionchamber
RATIO
CALCULATIONOF COMPRESSION
For detailed calculation,use the following
formula.
= \ f + vr+\L +vs-v
pt
V;
+l
Compressionratio
per cylinder cm3 (cu in)
Displacement
-12-
cation.
a. Cylinder head for G2: 39.5to 40.5
(2.410to 2.471cu in)
b. Cyllnder head for G4: 25.0 to 26.0 cm
( I .526to I .587cu in)
*Differenceir volume betweencylindeF must
Dewltnrnu.) cm- (u.uJI cu rn,.
CYLINDERHEAD COVER
The cylinder head cover for G2 specification
utilizes the L20B standardunit (or ttnit for L-series
4-cylinder engine)withotlt chatlge,and description
Key
No.
Part Number
Part Name
Q'tv
Hs82o
13264
CoverAssembly-Cylinder
Head
0l
H5820
1326s
Cover-CylinderHead
01
13266H5820
PIate-Baffle
0l
83-20306-9
Screw-Machine
04
@ L ttsoonrezo
Breather-Gas
0l
13228A0200
Washer-RockerCover
06
13274188i0
Nut-RockerCove!
06
81-1063s-62
Bolt-Hex(M6)--
02
89-15436-1
Washer-Plain
02
132?0H 5820
Gasket-RockerCover,A
01
13271Hs820
Cover,B
Gasket-Rocker
o4
tJ
Remarks
4\
L2OBEngine(GrouPs2 and
CAM COVER
This chaPteraPPliesto
diagram is shown
onlY Tlte p rls contigtrratIor')
t lt c
l)elow
( i' 1 s pc e t l t c u t t o n
,.o",f
i.ooJ
cJ
@@9@
-,""-'"
: A
l Jll
*Llt/
reE4
camshartcover
/
I I
I
1 1 0 4 6H 5 8 2 0{4 P i e c e s }J I I
I
Plainwasher
I
I
I
{16 Pieces}- I
89-19,436-10
I
Sprinslockwashr
. I
i
8 9 - 1 5 1 3 61 0 ( 1 6 P i e c e s ) B o t t l
10 {12 P i ees )
81-10620'
PISTON,CONNECTINGRODS'
f i-nxiCxnFr ANDFLYwHEEL
use different
asrally options'
areavailable
nerlbrmatrce
for exclusive
"'' iit.- rri*l load type main bearings
As to
options'
as
usewith L10B arenewlyavailable
existing^.optional
,jl" .o',r"..,i"g rod bushing,the
Li6 should be utilized' Configuration
;;;,-;t
partsis shownbeiow'
diaeram
";"ii;;; of the moving & Beg multi-discclujch is
t;" of a Bore
part
oeii.eo. tfre flvwhiel provided as special
mustbe used.
PARTS
COMPONENT
rl\
ir
' !\'
'.. \
r,l
Aq
- ( ",^..X*
\ \ kii\\*
\
MNJ/
6P:
-14-
Part Name
Part Number
Remarks
Q'ty
12010A7 660
o4
(l)
12010A7 670
Pistonwith Pin
04
12032 A7600
CIip-Piston
08
@ f t2o33 47660
fung Set-Piston
0l
@ -t2041 A7660
Ring-Piston,Top
04
Ring-Piston,2nd
04
orroo
@ L,roou
Ring-Piston,Oil
04
@ f 12i0047660
Rod Assembly.Connecting
04
Washer-Connecting
Rod Bolr
08
Bolt-ConnectingRod
08
12043 A'7660
-12113H5820
@ Lnrcgtt eao
v-/
@
.ol
12201A7660
Shaft Assembly-Cran}
0l
9-31202-1
Plug.(1/8-28)
Q4
Bush-Pilot
01
Key-Woodruff(5 x 16)
03
L yzoz zoooo
r = l.s (0.0s9)
T = 1.s(0.059)
Endgap0.2- 0.4(0.008- 0.016)
RIK VENT
Endgap0.30- 0.90(0.01l8- 0.0354)
cM40,L= 148.6(s.850)
Commonto G2 andG4
Ll4 (4V) option part
S K 5,T= 0.5(0.020)
AMS6304C.
M 10x 1,L=49.0(1.929)Torque
IBolt
exrends
0.13- 0.14(0.0051- 0.0055)by tighieninel
Commonto G2 andG4,CM40tufftride,
stroke86 (3.39),tightenedl9ith 8 bolts
9-26516
o
o
1 3 0 2 1u0100 Sprocket-Crank
0t
G2 only
13021H5820
Gear-Crank
01
150432r000
Gear-OilPump Drive
0l
Commonto G2 and G
r 2302A3500
Oil Thrower-Crank
01
12303N7120
Pulley-Crank
0l
12303N 7 l 7 l
0l
(r s4sl N 7 1 7 1 )
15451N 7 1 7 0
1230865000
Washer-fulley
Bolt
01
G2 orily
1230921000
Bolt-CrankPulley
OI
12309H5820
0l
G_a-o.nly,
Lt4 (4V) option,righrening
rorque
'
I 77 N.m(J8 kg-m,t:O ft.lUl(Uolycbre)
12310E4621
Flywheel
01
12315U6000
Bolt-Fllr/heel
08
SNCI\43
t2I l t 220tO
Bushing-ConnectingRod
08
t2ltt 2201|
(0i)
(08)
G4 on.ly,manufacturedby TSUBAKTMOTO
C4 only, manufacruredbv UNITTa
L2OBEngine(Groups2 and 4)
Key
No.
Part Number
PartName
i ng R od
Bu s h i n g { o n nect
I Q'tY
(08)
@ |
l2l I I 22012
@ I
l 2r l I 2lol3
1 2 1I I 2 2 0 1 4
t 2?l5 47660
122t5 A',]661
1t215A?662
t2215 41663
t2215 A'1664
t2231 A7660
12231 A7661
1223r A7662
(04)
t2?.31A'7663
(04)
L2231A7664
(04)
1224'7A7660
t224't A'7661
(02)
12247A'.7662
(02)
t224'l A7663
(02)
12247A1664
(02)
Renrarks
Commor lo U-l and u4
r / / m i l t s r r al
(08)
Front
Bushing-Main,
Bushing-Main,lntake
02
Bushing-Main,Cenrer
G4,F77material
G,
C"*.*1"
""d' 0 075(0.0010-0 0030)
0.0?5
oit clearance
t; G2 and G4, F77 material
C"-.""
0.0i5 - 0-085 (0.0014- 0 0033)
oil clearance
Commonto G2 and G4, F77 material
0.045 -0-095 (0 0018 - 0'0037)
oil clearance
Cotnr*tt to G2 and G4, F77 material
0.005- O 055 (0.0002' 0 0022)
oil clearance
Commonto G2 and G4, F77 material
0.015- 0.065 (0.0006- 0 0016)
oil clearance
Commonro G2 and-C4,F7? material
0.025-0.075 (0.0010- 0 0030)
oil
"l.ut"n".
Commonto G2 and G4, F77 material
oli cleuance0.035- 0.085 (O.0ql4-0 0033)
Commonto C2 and G4, F77 material
0.045- 0.095 (0.0018- 0 0037)
oil clearance
prston:
Oil clearance between cylinder wall and
PRECAUTIONS
ASSEMBLTNG
Piston
O Pistonclearance
o Measurethe maximum diameter of the
piston,and check whetherpiston-to-bore
is normal.
clearance
. Pistonsare availablefrom gradesI through
coris lessthan specified,
4. If the clearance
rectionbY honingis needed.
I
I
to -
EG
o N unrl'cr'<l1vrlve recesses
(il cngine......One eachfor intake and
crhrusl valves
G4 engine......Two eachfor intake and
cxllauslvalves
Dif f e re n c e i n w e i g h t a m o n g c yl i nders:
W rth i n 1 g ( 0.04 oz)
@ Measurethe piston ring end gap: Make corrections until the gap meetsspecifications.
Connectingrod
O Grindinso1-co:rnectingrod
(a) Grind the entire forged surface.except for
the machined surface.
The poriion indicated by - in the figure
belorvmust be superfinished.
:Superfinish
piston pin
in assembling
O Precautions
Before installing the pin. use alr oil heater to
heat the pistonto 40 - 50'C (lO4 - 122"F).
@ Check clearanceat the valve recesson the lop
of piston.
Place cla,von the valve recessbelbre installing
the cylinder head. and correctly adjust the
valve timing. then turn the crankshaft one
completeturn. Checkdepressionof the clay,to
determine clearance.If abnormal resistanceis
felt when lurning the crankshaft. it is an
indication of interference between piston and
valve; ceaserotation of crankshaft,and correct
the valverecess.
L2OB E n g in e (G ro u P s 2 a n d 4 )
anci small
(b) Chamfer the bolt hole portion
end Portion.
4 places
l \ol l
C 3) I i gl ttcn' rr' .:ol (\rl l l l r(l l l l !' l l ,ti
()l
i
'
ol l lo determtne
"
,' " ' M* ,,.t," ( l ol l gJl i on
correctly.
ti
gl
ttt'
rrcd
" i w hetl rtr l h( bol t i s
- 0. 14 mm
0'
13
o E l ongrti orr ' -
(0 0 0 5 I - 0 0 0 5 5n r)
M o l y c o t eI o
(b t B * lo i. i' " 1 , ' t rt in 'b: o rt ; ip p l l
oil t o t he
rttrd rttt ir t c
i hc rl trt' d" ti I' orttott
w asher and bol t seati l l g surtace'
I'
O Weight adjustment
through th{
oi boit tlongut]9n'.:h1tc^:
..rrrt...*
o
connectingrod combination'
;;1,";
iii
J',;:
(.)'f$1;:
:lii:lit:ll?::*,::'*
'Jiiri
:lli
r,liili
ral1-v
iiiili
Crankshaftand f lYwheel
i,il,
ilii:
Ili
'
its,surfa
iJi,"o iit"t'stujg" isfoundon oxide'
withchrome
illl"".'i"
ra
radiusportions'
-il"aln;
the
. CtinO*uinty
ii i
)
-18-
.TF
,f
L2OB E ngin e (G ro u P s 2 a n d 4 )
'r
1() :ippl)'
When installing a tilper pltr!r. he sure
"Araldite " to the p l u g .
r::::"
:
t
%,4,^","
,ti
(f7ooo).
@ Correctionof balance
D i ffe re n c e b e tw e e n 1 a n d 2
i s th e a mo u n t o f ta p e r'
..."t
\
D l fe re n c e b e tw e e n A a ^ d
i s th e o u t-o f-ro u n d n e s s
.
:':'
, r ,B o th th e ta P e r a n d
o u t-o f-ro u n d n e s s m u s l b e
w i l h i n o .o o 5 m m (0 0 o 0 2 i n)
@ M easurecrankshaftbend.
Cranksh aft b en d : L ess t han
0.0 2 mm t0 .00 08In )
@ M easuli:rgbearingclearances
C rank oi n orl cl earan c e:
0 05O 0 05s .i ff {O C O2O
O OO 22 Ln)
r-
sb'
'w
,Sbu
-',
Dr iv e in t he piJ o t b u s h i n g .
_ 19 _
Part Number
30411A8601
Part Name
Plate-Engine,Rear
Q'ty
Remarks
0l
0l
30411H5820
i-^1i--;'n^!!n+in^
,rrvqrrr!15.
rrLurws
GINE MOUNTINGBRACKET
. The mounting conditions differ between G2
Part Number
Part Name
Remarls
Qly
11232W5800
BracketEngineMounting
FrontR.H.
0l
11233W5800
0l
11230A7670
01
tt233 A7610
0l
80-l1035-1
Bolt-Hex, Bracket
04
89.15140-1
Washer-Spring
04
I
i
I
Part Number
1300122021
Part Name
Camshaft
COMPONENTPARTS
@ G2 specification
o The configuration d.rawing is omitted. (Refer
to the catalogfor L20B standardversion.)
Q' ty
0l
Remarks
L16 option,intale & exhaust68"
1300122022
(01)
13001,22023
(01)
13001A7660
13001A7661
(01)
(0t)
i303218000
Dowel-Camshaft
0l
I 1024K0100
Plug-Tapir
0l
Part Name
Remarks
Q' ty
130102 r000
Plate-Caml,ocating
0l
81.20616-62
Bolt-Hex(M6)
02
13024E4621
Sprocket-Camshaft
01
l30l s N3120
Washer-Camshaft
0l
LY26 option
89 -1 51 4 6 -I
washer-Spring
OI
I301211002
Bolt-Camshaft
01
13028U6000
Chain-Carnshaft
0l
L20B standard
Ll8 option,with shoeretainer
13070N7120
Tensioner-Chain
0l
81-20635.62
Bolt-Hex (M6)
02
13085U6000
Guide-Chain,Tension
01
13091A3500
Guide-Chain,Slack
0l
81.20616-62
Bolt-Hex(M6)
02
I
L20B slandard
02
8t.20614-62
89-15436-l
Washer-Plain
02
13201A7660
Valrelntake
04
(13201E462r)
t3202 A-7660
Valve-Exhaust
(04)
valveheaddiamete l4
ODtion.tuff tride-processed,
lin),ltgUoltl
rnio (t.rlin), t,t;t di"t9!g J
-t-(0j
head diameter44 nl
Lf4 ."t io" *ht"."-Dlated. valve
( l 73 in), stemdiamdter8 mm (0.31 in). hollowed r
04
valveheaddiameter36 ODrion.tufftride'processed,
(04)
(r32O28462r)
;';'ii.;;i;;,';#
L14
s mm(0.:r in),hollowel
aiarneG
valveheaddiameter36 nl
"Dti"^Jln..e'plated,
8 *-10'1Lin)'I9llot"9in),stemdiam6t.t
al .42
t3203 22010
Outer
Spring-Valve,
08
Ll6 option
1320422010
Spring-Valve,lnner
08
Ll6 option
13205N3120
Seat-ValveSprinS,Outer
08
13206
N7120
Seat-ValYeSPrinS,Inner
08
1320't A'7660
Seal-Oil,Valve
08
Option
13209N7120
Retainer-Valve
08
L18option
13210N7120
collet-Y alve
16
L18 option
13218A7660
Guide-Rocker
08
Option
1323421000
Pivot-ValveRocker
08
U0100
13235
Lock Nut-Pivot
08
I
I
I
I
I
I
t
- -
: rc'+.,$Si.:il{
Part Name
1325s48600
SPring
Retainer-Rocker
08
t32s6 21003
Rocker
Spring-Valve
08
1325121009
Rocker AssemblY'Valve
08
(13257W0300)
Remarks
Q'ty
(08)
For L-series
LPGengine
G4 specification
o The configuration drawing is shown below.
r3020N7170
fn dl ? i nl
*-king
Lt 8 (4V)
"ptiot, i n)
10.5mm (0.413
r3001N7l7l
angle?2'' valvelift
l3 552 H5820
13024Hs820
13015H5820
89-15142-l
-h
Washer-Camshaft
TensionerAssembiY'Chain
1310047670
liiiir
iiti
1Il1
{ {lil
xili
.i tl
tit,
1*t
rtl
i
t,i
Unit: mm (in)
iiii
1323184200
T = l.2s(0.0492)
(0.0s
12)
T = 1.30
T=I.3s(0.0s31)
l)
r = 140(0.0ss
T = 1.45(0.0s71
T = 1.50(0.0591
. )t
L l 4 (4
*Common to intakeand
T = 1.55(0.0610)
T=1.60(0.0530)
T = 1.65(0.06s0)
T = 1.70(0.0669)
T = 1.7s(0.0689)
T = 1.80(0.0709)
13229A02lr
r = r.8s(0.0728)
r = r.90(0.0748)
r = 1.95(0.0768)
13229 A0214
r = 2.00(0.0787)
13229 A0215
T = 2.0s(0.0807)
r = 2.10(0.0827)
13229 A0217
r = 2.ls (0.08a6)
13229 A0218
r = 2.20(0.0866)
13229 AQ219
T = 2.2s(0.0886)
T = 2.30(0.0906)
t3229 H5860
T = 2.3s(0.092s)
i3229H5861
T = 2.a0(0.09as)
13229lls862
T = 2.4s(o.o96s)
T = 2.s0(0.098a)
13229H5864
T = 2.ss(0.1004)
T = 2.60(0.102+)
T = 2.6s(0.10a3)
13229Hs86?
,.
r=2.70(0.1q9.3)
T = 2.?5(0.1083)
T = 2.80(0.1102)
'i
;t{
I
t3229 A1600
Ll4 (4V)
* C ommonto i ntake
T = r c< / n r r r r \
Ll 8.R (4
T = 2.90(0.1la2)
t3229 A7601
t3229 A7602
T = 2.9s(0.1l6l )
t3229 A7603
T = 3.00(0.1181)
r = 3.0s(0.1201)
13229A7605
T = 3-10(0.1220)
l3 229A7606
T = 3.ls (0.1240)
T = 3.20(0.1260)
t3229 A7&'7
T = 3.2s(0.1280)
13229 A7608
T = 3.30(0.1299)
13229 A'7609
13229A1610
T = 3.3s (0.1319)
t3229 A'1611
T = 3.40(0.1339)
T = 3.45(0.13s8)
T = 3.50(0.1378)
13229A7613
13229 A7614
T = 3.ss(0.1398)
\3229 A1615
T = 3.60(o.lal7)
Ll4 (4v) option, common to intake and exhaust
13207 A760Q
13201A7671
V al veheaddi ameter29.5(l .l 6l i n) ,
stemdiameter7 (0.28 in)
Ll4 (4V) option
Gasket-FrontCover,R.H.
Part Number
t3to6 A7670
C a s k et-F ro nt C o v e r.L H
01
@.
8t-30850-62
Bolt-He\ (NI8)
02
,tt
81-30840-62
0l
0-62
8l -3083
0l
/?q)
89-i5438-l
Parl Narne
I
I
i
Remarks
Q'tv
L14 (4V ) opti on
Washer-Plain
fu"'"" .-*",--{ffi\,
--ffi'
#"'
",,"".-{AZi
Gear\
qtt'Se"r=>A\
/\t7
.->l-'z-"
Part Nanre
a'"
r)
Prrt Number
Remarks
Q' t)
1310047670
GearTrain AssemblY-Engine 0l
F ro n t
1310147670
Plat e-Cear
0l
'3102H5820
Cover-Cear
01
t 3104H5820
S p a cre
0l
13103H5820
StopperPIate
04
Ll 4 (4V ) optj on
83,20306-9
Screw-Machine
08
-21 -
.4
Part Number
1_
Remarks
Q'ty
13ll0 47600
0l
Ll4 (4V)option
13112A7600
Ge a r-I st
OI
407
IE
0l
327
13113A7600
15046H5720
Pin
02
13114H5820
Spacer-Gear
02
8294HsSzo
Ball Bearing
02
-1-
13120A7600
0l
t3r22 pJ600
Gear- 2nd
0l
487
0t
307
13t23 A7600
L
f
T.
Pin
13114H5820
Spacer-Gear
Hsszo
'.,2s4
Ball Beaing
Q2
13130A7630
01
13132A7630
Cear-3rd
01
3lT
BZ94 H582O
I
I
02
r5u6Hs72O
I 02
.I
I BallBearing
02
J
liik'
02
Ll4(4v)option
A7600
13140
0l
r3r42tl6o}
Gear - 4th
01
13143A7600
Drive
Sprocket-Chain
0l
Hs720
15046
Pin
02
13114H5820
Spacer-Cear
02
13294H5820
Ball Bearing
02
8t -10625-62
Bolt-GearCover
0l
2sr
0l
81-10650-52
E-
t102332200
Dowel-GearTrain Plate
02
A76?0
13028
ChainAssemblY
0l
will be discussedlater.
)
-28:'|LA
6Slinks
rB.D.C.
Part Number
B"
o"
Cam
Lifr
I G2;68'cam 17.2
Remarks
13001 22021
31
6t
bl
3l
I5
l5
7.50
1300122022
45
15
75
45
l5
15
1300t 22023
35
65
74
34
l5
20
17
82
42
t5
20
70o-exhaust
72.camlgd Jb(
I G?:inrake
8.50 G2:
I - 76' cam3,ircl
78
38
l5
20
d. i )
-r
6_l )
1300147661
47
i3001 47660
43
r3001N7t70
40
60
60
40
l0
l0
10.5
0
r3001 N7l7l
44
64
64
44
t0
l0
r0.50
Valvetiming adjustment
O In cird-erto obta.in the best perlormance
rvilh
'io
the mlly option camshaft, ii is
ne."rrury
adjust valve riming ai specified
in the a6ove
table.
O Value timing_w i vary wilh the elon-eation
of
chain and rhe exlent to which
the bortom
surface of cylinder head was ground.
It is
therefore necessaryto measurethe
actuai value
(center angle) using a dial gauge,
and adjust to .
Mark
--Angle
Differencefrom mark I
72016'
G4;70"cam ? f,D
G4:72"carn 3!i
_ the specifiedtimine.
(!) VaJuetiming.adjusiment
can be don, by ,.tect-'
lng a proper dorvelhole in the
cam ,p.""L.tCam sprocket
O G2 specification
70"46'
690,t6'
670 46'
13" 46'
'r50l6'
760 46'
7 8016,
3o
."
deJayed delayed
120
delayed
4)
L 20B Engine( Gr oups2 and
I30rs
Hs8r0'
I- 3i.",i'J':Tii3l]",
0".,(r3014
ttil;'1t"fi:,::il'ii:
;ito; ioi,oju't*.nt'
-o
measureclearanceon
When newly assernbling'
a,1oit9l1
irl""'ti,t*rlivlinderheadto. late ln this
thickness'
i'jl""li'?," oi'iit"-"'l"t cap otre intake or
.^*.'-i"t,rff ,n" catrishaft aud
exhlttst vulvefor Ine stlrenlelll'
,'J:l"".'
ui,'I*:l;:.'::,.,Jii,l:f
. +l*'o";,
V al ve cl earrnce
U ni t: mm (i n)
l ntake
C ol d
engi ne
For advancesetting
r 3024 H5820
H ot engrne.
Exhausi
0.30
0.25
(0.010) (0.012)
0.35
0.30
(0.012) (0.014)
settmg
For delaY
13025H5820 For advancesetring
VALVE CLEARANCE
I G2 sPecification
''
li"][:
JTi",'il',:']
['i:1*ix*t'i:"1:l':,
engrne.
liE.t.n.. (hot enginel
lntake 0 25 mm
0 3ommr00l I in)
irj.orbi^1.Exhaust
when measunng
Use the dial gauge' as shown
the valve caP thickness'
G4 specification
changingthe llick:
.- Adjust valve clearanceoy
in the figure
shown
cap
the valve
"f
""Jt
below.
I
t
I
o
tt
-30-
Part Name
Part Number
Remarks
Q'ty
togetherwith block,
L20B standard;Machine
and grind the surfaceby 0.5 mm (0.020 in)-
13501U6000
Front
Cover-Engine,
0t
r 3520U6000
Casket-FrontCover,R.H.
01
13521U6000
Gasket-FrontCorer, L.H.
01
13049U0100
lnlet-Water
0r
1305021000
Gasket-Water,
lnlet
01
81.10828-62
lnlet
Bolt-Water,
02
11046'73402
Dowel
02
For mountingwaterpump
81.i0620-62
Bolt-Hex(M6)
02
03
81,I0645-62
1354021001
Bolt-Hex(M8 x 78)
04
81.10845-1
Bolt-Hex(M8)
OI
01
80-10875-1
89-15138-1
Washer-Spri-ng
06
13502A7660
lndicator-Timing
01
8r-10612-62
Bolt-Hex(M6)
0l
Option
@ G4 specification
The G4 specification differs from G2. as it
adopts the dry sump system. The compor'tent
parts drawing shown on the next page is prepared on the basis of the Ll4(4V) optionai
unit. and therefore contains some par{s unnecessaryfor the G4 specification.The contponent parts list given under the drawing provides the correct G4 parts.
L2OBEngine(Groups2 and 4\
Plug9-33135
1350i A7670
Front
Cover AssemblY-Engine
135i0u6000
Gasket-FrontCover,R H'
13521U6000
to G2'
t20B standard,modify according
13049U0100
Bolt-Water,lnlet (M8)
N3120
15045
1506621001
8l -10820-l
89.1513&l
For mountingwaterPumP
For mounting front cover
8l -10655-1
8t -10890-1
)
PartNumber
89-15136-l
Part Name
Washer-Spring
03
r 350221000
lndicator-Timing
0l
8t -10612-62
Bolt-Hex(M6)
0l
12279R46tO
Parl Name
Seal-Oil,Crank Rear
Seal-Oil,Crank Front
Remarks
Q'ty
Man-ufacturedby NDK
0l
NOK
,'
0l
(01)
(13042A3sl0)
122892l 003
(01)
(12279R4600)
13042A8600
05
I
89-15138-
Part Number
Remarks
Q'ty
Sal-Oil,BearingCap
NOK
NDK
02
S Y S T E MDI A G R A M
O I L RE CI RCUL A T I NG
O G2 specification
OIL PUMP
o The G2 specification uses the wet sump system, and the L-seriesengine production unit
should be utilized.
. The G4 specificationusesthe dry sump system,
and the Ll8(4V) optional unit is adopted.
Ereather
\rt./i
-33-
f -
r - _ - _ - >- - _ l - - - - _ - 'l
l!ll
nde, head
n d e rb r o c k
f-.J
i
I
lltankl
oir catch
o Pe n
I
oo"n
--------->
;^---
lrt
T-T_-
tt
:nginqpump
F\
ssurepump
i\
5-----
L--
li
| I
l\l
/G\
-1 n-
tli.
iil
'
T-
Part Name
Q'tv
21001
1s010
PumpAssembly'Oil
0t
150662100t
Gasket-OilPumP To CoYer
01
1503621000
Bolt-OilPump
02
h---l
I
Remarks
li?,fl'1'r
aH:?:!8fi:I,".?lLiTJll;11'
rI
02
89-15438-l
Washer-Pla:in
04
89-15138-1
Washer-Sp!ing
04
1504021001
PumPDrive
Spindld-Oil
0l
l s0s047660
StrainerAssemblY-Oil
0l
15055U8000
Tube-Suction
0l
15051A7660
Screen-Strainer
01
8r-20620-62
Bolt-Hex
0l
1505973400
Gasket-OilStrainer
0l
8l -10825-62
Bolt-Hex(Oil Strainer)
02
1523847660
Filter
BracketAssembly-Oil
01
-34Jn,.{
oir tank
1503721000
i,, t
uaru,
, neourato,
PUMP
G2 specification
Part Number
B reather
----.--
t
light'weightunit
Option,small-sized,
_I
I
L
I
Option; for installation of oil cooler
Q'ty
Part Name
Part Number
t5241A766Q
Connector-Oil
0i
Assembleafter applying"Araldite"
15236N3120
O-Ring
01
LY 26 option
0l
Option
1523'1A7660
l5 21469800
washer-Stud
01
152t3 A766Q
S tu d -O i lF i l te r
0l
Option
1520865011
ElementAssembly'OilFilter
0l
and
The oil-pump incorporatesthe scavenging
pressurizinggear pumps on the sameshaft.
The oil pump is driven by the timing belt from
tlre end of the crankshaft at l/2 the crankshaft
speed.(External driving system)
When assemblingthe oil pump, the oil pump
drive and driven pr-rlley must be carefully
aligned.
O,l puhp
dr i v e s hft
Oil pumpplate
Oi l pump dri ve gear
D ri ve shaft p;n
Oil p u m p co ve r
Oi l pump gasket
Oil p u m p d r ive n sh a ft
-35-
or cL.atc
- - ^- - .
cn
tl l r t
value)
s (Reference
Clearance
the
Clearancemm (in)
(Cl)
Sideclearance
Thickness mm (in)
Tip cleararce(C2)
Lessthan0.12(0.0047)
Part Name
Part Number
1 5 0 1 3N 7 1 7 0
0.085-0.115
(0.0033- 0.004s)
15013N7r7l
0.r05- 0.135
(0.0041- 0.00s3)
15013N7r72
.0.155
0_125
, 0.0061)
(0.0049
wheneverthe pump is
Checkeachclearance
t
I
I
t
I
t
@
<oi l tank
I
I
I
I
g-@
@----Gi
/-
@-
-36-
Part Number
a)
N 7l 7 0
r rsolo
15011N71?0
Part Name
Remarks
Qty
Ll8 (4V) option
PumpAssembly-Oil
0l
Pipe-Suction
0l
@ L , r o, r, u r t t o
Gasket-Suction
0l
15412N7170
Connector-Oil, I
01
l54r 3 N7171
Connector-Oil, L
0t
15413A?670
Connector-Oil, L
01
15414N7170
Washer-Connector
03
15417N7170
Nut-Lock
02
15415N7170
. Bracket-OilPump
01
80.i1035-1
Bolt-Hex(Ml0)
03
89-15140-l
Washer-Spring
03
15020A7670
t!mP, Front
Plate-Oil
01 I Option
15Q21A',76'10
Plate-OilPump,Rear
01
r-l
80-3080
Bolt-Hex (lt{8)
01
89-15438-1
Washer-PIain
02
89-15r 38-l
Washer-spring
89-12608-l
Nut-Self Lock
0t
C9
15416A?600
Oil PumP
Bar-Adjusting,
0l
81-2Q612-62
Bolt-Hex
o4
1542r N3120
Connector-Suction
02
LY 26 option
t5422 A1610
Pipe-Suction
02
Option
!5423 A1670
A
Hose-Suction,
02
Option
15424A'1610
B
Hose-Suction,
0l
Option
| 5425-A'7610
Hose-Suction,
C
0l
Option
15427N3120
Clamp-Hose
08
LY 26 option
Option
I 01
+
ruP
^-/ffi@
W+.:
Key
No.
o
o
Part Name
PartNumber
(01)
(1s451N7171)
(l s4s3Hs82i)
15452N3120
( 1545?N3l2l )
bv TSUBAKIMOTO
T l8 {4V) oDtion.manufactured
I
0l
by LINITiA
Ll4 (4V) option,manufactured
(01)
by TSUBAKIMOI
Ll4 (4V) oprion,manufactured
Belt-OilPump
15453H5820
by UNIfiA
Ll8 (4V) option,manufactured
0l
Pulley-OilPumpDrive
15451N7170
Remarks
Q'ty
0l
by UNITTA
LY26option,manufactured
(01)
by TSUBAKIMOTO
LY26 option,manufactured
Pulley-OilPump
.#
F rom oi l pump
[\--1-,*+**^ m{n
ti /*+r,,_g_\ul
lro_*
To be.mounted to
c y l i nder bl oc k
l* I l rJ
-Jt
Remarks
Q\Y
Part Name
Part Number
15238N3120
Bracket-OilFilter
0l
LY26 option
15413N3120
Connector-Oil,I
0l
15236N3120
O-Ring
0t
LY26 option
1521469800
Washer-Stud
0l
15213N3120
Stud-OilFilter
0l
LY26 option
\9'
1520865011
ElementAssembly-OilFilter
0l
olL cooLER
)lL COOLER
adopttheair cooledtvpe'
o o' coolersareavailable
asoptionsfor bothGl
,i, 3Tlt
and G4 specifications.
'
"""1n'l;",c4
E4220)ror HS30
3|'][:."FjiilZt"o;ib3.ttot
(2) G4 specification
fhe liorizontal type is ayailableas an option.
+-=\------------]6
u_---_l
| |
trF
A
oir rank +
/A
\3/
r.r
\t
|I
|I
/;\
&-/v
-r
T--".-,ar
\4)
l' +irtlfHI
F-- --t__
- ----
--)-
__-,__:7
I
|
v/
l-.
-ll
l- ll
r".t N"'n"
Number I
lfr:1| Part
2gosA'76'70
lOl
| cooler-oil
lt
loiv I
I ot I option
t^ |
l(?)l
|
Washer-Connector
|
|
102
ls4l4N7l70
rr-
1 s4 l?N 7l?o
l@l
Nut-t-ock
rIOI
$413 A76'1t
ls + t : N?t 7t
Connector-oil,l
I C o n n e c to r,OiLl .
tl
ft-..:.;.
ffi;:itr:'1;' ,
|
Ll8 (aV)option
|
lo t
lL l8 (4 v )o p t io n , f o rL t y p e c o n n e c t o t
"Araldite".
ol
Oltion;rightenafterapplving
I
I
I Ot
-39:+L -
Remarks
OIL H OS E
@ G2 specification
213s5 A7660
Hose-OilCooler
[L=1,150run (a5.28in)]
21356A7660
@ G4 specification
ts430 47670
21355.A'7670
21355A767|
(187,0lin)]
IL=4,?s0mm
21355A7672
OIL TANK
o The oil tank is available as an optional part
15260A76'10
r52'.70
A7670
15413N7171
154t3A'167|
15414N7170
15417N7170
I l128 69200
l102661000
152'1tA7670
_40_
11125K0475
? 10 (formerVioiet) oPtionalPart
Tank Assembly-OilCatch
I 1862K04?5
I 1864K04?5
11871K0475
1?32148?00
in the rear trunk room for the oil tank. Connect hoses according to the system diagram.
O G4 specification
lnstall one catchtank in the enginecompartment for dry sumpengine,and one catchtank
Part Number
-f-
Part Name
Q'ty
l1125K0475
Carch
Tank AssemblY-Oil
02
K047s
r 1862
Tank-Oil Catch
02
i 1864KO475
Cap-Oil Catch
02
I326723000
Connector'Breather
03
11871Ko4?5
Bracket-OilCatch Tank
02
1?321A8700
3 way Connector
OI
Remarks
?10 (formerViolet) oPtionalPart
li
I
I NT A K E S Y S T E M
The component
The intake manifold length is availablein
types. In the left-hand drive car, the b
Master-Vacis located close to the intake
tem, so the shorter intake manifold IL=8Omm
(3. l5in)l must be used.
I4002A?660
L= l l Omm(4.33i n)
89-31304-l
Plue(PT 1/4-19)
47475N3300
t4002 A766r
14003A'7661
L = 85mm(3.35in)
Plug@T I /4-19)
To be connectedto Mastei-Vac.Install to #4 Port.
47475N3300
14035N7120
Gasket -Manifol d
r
89.15438.
89-ll108-l
1601022010
t6t'74 t4610
1617514610
1617614610
Gasket-Insulator,Carburetor
89-15138-1
89-l1108-l
ODtion.for 14W3 A'1661manifold.
16174A7660
r6t75 A7660
161't6A't660
89-15138-1
For 14003A7661manifold
8l -10816-l
)
-42_
.J1-
Part Name
-l-
L
T
Remarks
89-l1108-l
Nut-Hex(M8)
08
For 14003A7661monifold
t636O A'7660
Kit-Throttle Unkage
0l
16361A?660
Drum Assembly-Thtottle
01
rc3$ A'16&
Drum.ThrottleShaft
0t
1638018810
Bolt-BallJoint
02
89-r5142.1
Washer-Spring
02
163'10A1660
Rod Assembly-Connecting
01
16371 A0202
Clip-BallJoint
01
16373A'1660
Rod-Connecting
0l
1637540200
Nut-Hex
0l
8 9 - l rl o s .l
l;
0l
16375A7660
Bracket-ThrotlleSluIt
0l
81-10820-62
Bolt-Hex(M8)
03
r63'.76 A'7660
wire
Bracket-Accelerator
0l
83-60514-14
Screw-Machine
01
81-r0612-62
Bolt-Hex(M6)
04
H587s
16360
Kit-Throttle Linkage
0l
16361H5820
DrumThrottle
01
16362H5820
Lever-Throltle
0l
16376H5820
Stopper-Throttle
01
1637814600
Spring-AdjustScrew
01
16:19Hsszo
Screw-Throttle Adjust
01
'l
0l
1637140203
Q' ty
Wire-Accelerator
0l
-43 -
To be ftxedto 1637547660
roup!;2 and 4)
@
a
I
q ra / q
@
D
@6)
/@
.L/9
,-Y effi AqAl *4
*+
\^\5#n
16)
| | o
,*,/^<
W'
'vaH'
>$a^ft
/
@----
6B). AXi,/
\:jjl
-{N
"KW L-o
\ Ff-.
^@'.
)D
Key
No.
PartNumber
u
Front
a,
A__*
Part Name
Remarks
Q'ty
0l
14003N7171
Manifold-lntake
02
89.31304-l
Plug-Btind(PT t i4-19)
03
Connector-PiPe
0l
1-la00l
14035 N7170
Gasket-lntakeManifold
04
89.15436-t
Washer-Plain
l2
89-15136-l
Washer-Sprilg
11
89-t1206-l
Nut-Hex(M8)
tz
t617414610
Insulator-Carburetor
04
i61?514610
Gasketlnsulator, Manifild
04
F
-
Manifold AssemblY'lntake
N7171
L lr'ctseqtot
\@
ht
o /f
4
I
I
Ll6option
Part Number
Part Narne
Q-ty
1617614610
Carburetor
Gasket-lnsulator,
04
89-15138-l
Washer-Spring
l6
89-1I108-1
Nut-Hex
lo
(D
1601022010
AssemblY-Twin 0l
Carburetor
16360H587s
Kit-Throttle, Unkage
0l
16361H58?0
Drum-Throttle
0l
r6362H5820
Lever-Throttle
0l
16376H5820
Stopper-Tfuottle
0l
163?9H5820
Scfew-Tluottle Adjust
0l
Sprihg-AdjustScrew
0l
Remarks
L16 opti on
t- 1637814600
161:625510
Washer
02
Fitted to carburetor
16r2415520
Nut
02
Fitted to carburetor
l6l l4 25520
Screw-Adjust
0l
@,
r 6 r 3 22 5 5 20
Nut
0l
16184li 510
PushRod
r614525s20
Spring-Adjust
t6292 25520
Rhg-Snap
83-60525-65
uvrr
t60'71)5521
Screw
0?
Fitted to carburetor
16360A76?0
Kit-Throttle, Linkage
01
1636147670
Drum Assembly-Tfuottle
0l
t6362.A'1670
Drum-Tfuottle
0l
Lever'Throttle
0l
T
[
L ro:o:eroro
D^ tr lir < - n a \
\F,J
I 0l
v.u,
0l
I 0l
0r
0l
16362H5820
16376H5820
Stopper-Throttle
0l
16379H5820
Screw-Throttle Adjust
0l
1637814600
Spring-Adjust Screw
01
t63?6 A7610
Wire
Bracket-Accelerator
0l
Installto intakemanifold
Part Name
Part Number
83-60514-14
118100
47670
L terotozoto
-r l8 100A7660
r- t8lol 47660
Remarks
Q'tv
Screw-Machine(M5 x 0'8)
0l
Wire Assembly-Accelerator
0l
Wire-Accelerator
0l
T
F
I
-Li H drive car only, oPtion(G2)
Wire Assembly-Accelerator
0l
Wire-Accelerator
0l
T
S O L E Xs O P HHCA RB UR E T O R
FICATIONS
SPECI
Unit'
Specification
G2
Item
s0(1.e7)
43(r.69)
43
s0(1.97)
50
Main Jet
#180
#150
Float Level
24(0.e4)
#EL
22''
run.
SizeNo.
Part Number
SizeNo.
#t20
t6033 25924
#160
1603325528
t6033 25925
#l o)
t6033 25529
t@33 25926
#t70
16034 25523
#130
t6034 25524
t6033 2592'l
#t4t)
16033 25928
#180
16033 25520
#t45
1603425572
#l8s
1603425525
#150
t60342ss2r
#r90
1603325521
#r55
16034 25520
#r9s
t6034 25526
-46-
PartNumber
SizeNo.
PartNumber
t6036HO222
#190
16036 25521
#130
16036H0224
#200
1603625723
#140
16036H0226
#2to
16036 25522
SizeNo.
t6036 25524
16036H0228
#160
t6036 25'720
#230
1603625s23
#170
160362512l
#240
160362s52'.7
#180
1603625722
1603625520
After'warming up the engine,open the throttle
valve fully beginning from approximately
1,000 rpm in any gear position, and raise
engine speed to the level at which the maximrim output can be obtained.In this case;
-47:-
t-
Part Number
Part Name
Q'tv
16500E46tr
CleanerAssembly.Air
02
E46lo
16s46
ElementAssembly-Air
02
16500E4620
CleanerAssembly-Air
02
Remarks
124optionGplittype)
EXHAUST MANIFOLD
il
O G2 specification
14004A7660
14035N7120
@ G4 speciiication
t4004A7670
89-15r36-1
89-l1206-l
t uFtlride-treat
ed to provideadditional
againstbendingduring high speedopera
r he L I 8(4V)optionalunit.
L 2 0 B Engine(Groups2 and 4)
o G2 specilicat ioti
Unit: mm (in
Part Name
Part Number
Remarks
Q'tv
21010E3027
PumpAssemblY-Water
0l
4 2 1000
2101
PumP
Casket-Water
0l
2107821002
Bolt-Hex(M8)
0l
89-l5138-l
Washer-Spring
02
2107921002
Bolt-Hex(M6)
0l
89-15136-1
washer-Spring
0l
8t-2062?'62
Bolt-Hex(M6)
02
21051N7120
Pulley-Fan
0l
L l8-option
21061N7l l0
Front
BIade-Fan.
01
Ll8 option.300(11.81)dia'T
21062N7120
Blade-Fan,Rerr
0l
21064N7170
Spacer-Fan
82-26622-l
-srud
(M6)
0l
l'6 (0'063)
-
T = 3.2(0 126)
Ll8 (4V)option,
I oo
89-ii136-1
washer-Spring
04
89.r1206-l
Nut-Hex(M6)
04
llT l0Nl l l 0
Belt-Far
01
21200H780?
Thermostat AssemblY
01
V ai veopens/o.) L (l /u ry
0l
OPtion
11060.47660 Outlet-Water
l r062N7l 20
Water
Oasket-Outlet
0l
8r .r 0816-62
Bo l I.H e x(M 8 )
03
2508089900
TemPerature
Gauge-Water
0i
2525137700
\ut-Ground, Water
TemperatureCauge
0l
-49-
.::.,.\:,
Unit: mm (in)
Part Name
Part Number
Remarks
Q'tv
6 cytinderengine
Standardfor L-series
2t0to E3027
PumpAssembly-Water
0l
2101421000
PumP
Casket-water
OI
8r.?0800-l
Bolt-Hex(M8)
Q2
89-15138-l
Washer-Spring
02
21079H5820
Bolt-Hex(M6)
01
89-ls I l6-t
Washer-Spring
0l
8t.20622-62
Bolt-Hex(M6)
02
-l
21051N7170
Pulley-Fan
0l
21061N7120
Blade-Fan,Front
0t
21062N7120
Blade-Fan,Rear
0t
21064N7170
Spacer-Fan
82-26622-t
I Stud(M6)
!
r ra /4v\^nri^n T=32(0.126)
0l
04
i36-1
89-15
Washer-Spring
04
89-11206-1
Nut-Hex(M6)
04
I i720N7120
Belt-Fan
0l
L18option,BANFLEX l lM-825
2\200 H7802
ThermostatAssembly
0l
valveopens76.5'c (1?0"F)
11061N7170
Manifold-Water
0l
Ll4(4v)option
-----l
I1062H5821
Outlet,B
Gasket-Water
02
89-15138-l
washer-Spring
04
89-lI108-l
Nut-Hex(M8)
04
l1060u0100
Outlet-Water
01
r 1062s0600
Gasket-WaterOutlet
0l
81.10828-62
Bolt-Hex(M8)
02
27070H5000
Connector-Heater
0l
2s08089900
Gauge-WaterTemPerature
01
252513'l'700
Nut-Ground,Water
Gauge
Temperature
0l
RADIATOR
Option, aluminum
21400A1660
21501w5301
21503K2405
n
@ G4 specificatio
Part Number
Part Name
Remarks
Q'ty
2140Q A'1660
Radiator Assembly
01
Option,aluminum
2r50t A76'10
UPPer
Hose-Radiator,
0l
Option
2t503 A767Q
Hose-Radiator,Lower
01
Option
87-23144
Clamp-Hose
04
ENGINEELECTRICALSYSTEM
IGNITION SYSTEM
. The competition proven MITSUBISHICDI
systemis adoPtedasrally specification.
Part Name
Part Number
Q'tv
Remarks
22100A7601
DistributorAssembly
0l
2211821000
Support-Distributor
OI
Commonto G2 and G4
83-60614-14
Machine-Screw
0l
89-r5436-i
Washer-Plain
0l
81.10628-62
Bolt-Hex(M6)
02
22t79 E3000
Packlng.Support
0l
22t80 '71200
O-Ring
0l
22020M0820
Amplifier-CDl
01
22433M0820
Coil-CDl
0r
-51 -
22401 A4617
22450u6700
YAZAKI, L20Bstandard
CoilTo Distributor
L20Bstandard
SUMITOMO,
(224s0u61tO)
2245l U6000
YAZAKI,L20Bstandard
CableAssemblY-Higlt
TensionNo. I
L20Bstandard
SUMITOMO,
22451B80lI
?2452N6001
YAZAKI. L20Bstandard
CableAssenrblY'High
T e n si onN o.2
L20Bstandard
SUMITOMO,
(224srN60lI )
r1453N6001
CableAssemblY'High
TensionNo. 3
L20Bstandard
SUMtTOMO,
(:2453N601I )
22454? l00l
Cable AssemblY-Hi8h
TensionNo' 4
YAZAKI,L20Bstandard
L20Bstandard
SUMITOMO,
(224542t0r0)
iitiliirl
2t0Lo
224',1?
W1
@ G4 specitication
I t lu !
rI f t i i r l
i tNit:t
(22401N7171)
iifi1
2240rN7177
ilii:r
ll. ! ' l
ti
2?45t A7670
Cable AssemblY-High
Tension Coil To Distributor
Cable Assembly-High
TensionNo. I
22452A76'70
CableAssemblY
TensionNo- 2
22450u6700
:
':l
22453A'1670
22454A76'70
TensionNo. 3
Cable AssemblY-High
TensionNo. 4
224'1221010
ALTERNATOR
. Two types of alternators,60(A) and 80(A). are
available as options. These alternators lrave
increasedcapacity to meet rally requirements'
e When using the optional alternator. the
oDtional fan belt (BAN FLEX belt) must rlso
bi used, as the groove in the pulley isdifterent
-52-
'..-fu!''
Pait Name
Remarks
Q'ty
0l
Option,for G2,80(A)
23100N7170
0l
Option,for C4,80(A)
(23100N7l2l )
(01)
23100N7120
Altemator AssemblY
1r710N7170
Bracket-Alternator
0l
80.11045.1
Bolt.Hex(Ml0 x 1.5)
02
for ul ano u4
540-l
89-15
Washer-Plain
02
89-15140-l
Washer-Sprhg
02
80-30804-l
Bolt-Alternator
0l
89-15438-l
Washer.Plain
02
89-15138-1
Washer-Spring
0l
89.1l?08-l
Nut.Hex(M8)
0l
l l715u0500
Bar-AdjustAlternator
0r
ror ul
0l
0l
0l
01
For G2 and G4
1r715N7170
2107821002
Bolt-Hex(M8)
8l-20895-1
89-1513&1
Washer-Spring
_53-
Circuitdiagramof lC regulatorbuilt-intype
alternator(HITACHI tYPe)
F ie ld co il
-u-
standardunits.
STARTERMOTOR
o The G2 and G4 engines.
usethe sameL-series
PartNumber
23300U0102
Remarks
Part Name
Q'ty
StarterMotor Assembly
0t
by HITACHI
lkw, manufactured
0l
by MITSUBISHI
lkW, manufactured
23300U01ll
EXHAUST SYSTIi M
. Although enginediff :rs betweenG2 and G4,
the exhaustsystem afl:er the exhaustfront tube
is not d ifl'erent.
. Optional rally parts are available for PA l0
?7
"@ 6
@- tr---@ I
-o
|,.e:
o-ffi.^
il"r"l*__ff
_I
ffir-
/-\
l^
a\'
f / r- ',:,Wb
i rGl
,/
6 6 6 y g i- $
./
l+
A\ -
--_LL
i ruok ftoor
/A A
flti
,,4-fl-l-\n-1
Exhaustrear*ffi
I \,,/
@6
steelpipingor bellowstub(
Stainless
mendedtor part @ for higherdurab
Properlyinstallbolt,@ andnut @.
o
o
o
Part Number
Part Name
Remarks
Q'tv
2060r A7660
Plate-FixingTube
0l
Option
20604N6320
Collar-FixingTube
0t
710 opti on
81-30838-l
Bolt-Exlaust Flange
o4
20602S0600
Nut"Exhaust
o4
89-15438-l
Washer-Plain
04
\q/
2003147660
Adapter.Ex-tnust
Center
0l
_56-
ta
F
Option
-Ir
Part Name
Part Number
Remarks
Q'tv
20621 A7660
Clamp-ExhaustCenter, A
0l
20622 A7660
Clamp-ExhaustCenter, B
0l
20622 28501
MountingRubber,Exhaust
0?
20050A7660
Rear
Tube-Exhaust,
0l
206t2 A'1660
Tube
Clamp-Exhaust
0l
10040A7660
Muffler AssemblY
0l
20134A7660
Clamp-Muffler
02
56124H 1001
Bush-Rubber
02
5611373000
Washer
02
Option
Option
@ Valveclearance
G2 specification; '
lntake 0.25mm (0.010in) I
Exhaust0.30mm (0.012in) |
G4 specit'ication:
I
Intake 0.30mm (0.012in) |
Exhaust0.35mm (0.014in) J
Adjust
with
englne
warm.
@ Specifiedengineoil
Use mineral oil of SAE viscosity#30 or above
in the SC, SD, SE, CC, or CD classof A.P.I.
classitlcation.
Presswith a force
o f 4 9 N { 5 kg , I 1 lb ) '
IExample]
.'
2 - 3 m m ( 0. 08. 0. 12 in l
Maker
Ignitiontiming
G2 specification:
B.T,D.C.30"/4.000 rpm
G4 specification;
B.T.D.C.28'/4,000 rpm
This setting. however, may be modified correspondingto the octane value of the gasoline
which differs t'rom place to place provided that
no knocking is clused.
SHELL
x-100(#40),MYRINAOtL(20w40),
RoTELI-ASX
ROTELLAOIL (20W50),
orl- (#30,#40)
MOBIL
(10ws0)
MOBILS.H.C.
IDEMITSU
CASTROL
351(equiv.to
CASTROLPRODUCT
(#40)
GTX
#40),cAsTRoL
TOTAL
CTS(2OW5O)
ALTIGRADES
-57 -
I
L 2 O BE n g in e( G r o u P2s a n d4 \
o The criticaloil pressureis 294 kPa(2.94
kg/cm'?
, 43 psi)/4,000rPm.(While
@ Coolingwatertemperature
a The temperature
shouldbe 80 - 8'5'C
I 85"F) duringactualrunning.
Oil level
G2 specification;
iame as L20B productionengine,Max' 3'8
I (4 US qt. 3-318Imp qt). min. 2.8S(3 US
qt,2-I 12 Imp qt).
Do not poui oil above the Max' line, or it
.uy tpout out during high speedoperation'
G4 specification;
Olt shouldbe at the middle-level position in
the oil tank. When checkingoil level, oil
should exceed50"c (122'F),
temperatr-rre
and enginespeedshould be at 1.100 rpm'
oil pressure
ProDer
'pressuie
should be 588 - 686 kPa (5 88 Oil
6.86 bar. 6 -1 kglcmz,85 - 100 psi) [at I l0'C
(130'F) or lessl/4.000rPm.
.aA'r
Warmingup after starting the engine
a Avoid sudden engine speed increases.
enginespeedto a maximum of 4,000
to the oil pressureimmediately
attention
starting.
Do not race engine when oil and
temperaturesare low.
SERVICEDATA
Maior clearances
-=-----=Item
Unit: iim I
Engine
Bore
Piston-To'Cylinder
O Clearance
of Bearing
(0.008
- 0.016)
oil
0.3 - 0.9
(0.012- 0.03s)
MaLt
- 0.0024)
0-o5s- 0.060(0.0022
Rod
Connecting
- 0.b022)
0.050
- 0.0ss(o.0o2o
2fi4
Intake
0.2s (0.010)
0.30- (0.012)
Exhaust
0.30 (0.012)
o.3s
ValveClearance
SparkPlugGap
- o.0o3s)
0.08-0.09 (o.0o3l
o.2 .0.4
Top
zung
Pisron
EndGap
G4
-----t---------......-
0.7 - 0.8
(0.014)
(0.028- 0.031)
t
:
:----===....-
N.m
Cy[nderHeadBolts
(Tightenin three
steps.)
C4
G2
kg-m
ft-lb
N .m
kg-m
ft-lb
39
4.O
29
39
4.0
29
znd time
59
6.0
43
59
6.0
43
Final
74
t.)
54
74
7.5
54
Elongation
0.13- 0.14mm
(0.005r -0.0055i;)
s e - 6 e 1 6 . 0 - 7 . 01 4 3 - s l s 9 -6 9 | 6 . 0 -7 . 0 I. 4 3- 5 1
lst time "M"
39
4.0
29
39
4.O
29
Final
59
6.0
43
59
6.0
43
59.
6.0
43
s9
6.0
43
Znd time
88
9.0
65
88
9.0
65
Final
118
12.O
87
118
12.O
8',7
CrankPulleyBolt
'M"
118
12.0
87
177
18.0
130
CamSprocketBolt
'M"
78
8.0
58
'78
8.0
58
20
2.0
15
l .)
ClutchCoverBolt
20
2.O
I4
20
2.O
l4
3.5
25
34
3.5
25
3.5
25
3.5
25
Flwheel Bolt
34
3.5
25
oil PumpBracketBolt
34
3.5
25
*"M":
*"O":
Apply "Molycote'].
Apply engineoil to threadedportion.
For the connectingrod bolt, apply engineoil to the washer.
-59-
34
torque
Standardntttsand botts tiglttening
StandardTighteningTorque
StandardValue
AllowableRange
0.33- 0.44
7.8 - 10.8
7.8- 10.8
0.54. 0.74
7.5- r0.5
1.'7- 10.4
on their
having the tbllowing nrarks ernbossed
bolts
the
to
applicable
is
data
The above
mark:
Embossed
-"'- - (MaterialS20C or KMS)
4T4
(MaterialS40C)
7T-7
gT-g
(MaterialCR40)
head'
BONDINGAND S E A L I N G A G E N T S
Bonding and sealingagentsto be usedfor engineasselnbly.
To be appliedto:
BondingAgent or SealingAgent
ThreebondNo.4
Silicon Bond
KE45
Araldite
Front Cover*
2.
RockerCover*
3.
4.
5.
6.
7.
Water TemperatureGauge-
8.
Blind Plug -
CrankRearOil Seal-
2.
SideOil Seal
3.
Front CoverGasker
-
4.
CyLinderHeadGasket-
5.
CylinderHeadGasket-
6.
7.
Air CleanerBody -
Blind Plug -
Crank
2.
Blind PIug-
3.
Biind Plug-
Oil Gallery
4,
Blind Plug -
Cyiinder Head(Oil)
5.
HeaterConnector
6.
PipeConnector
l.
Qenngs161
- Oii Filter Bracket(inciudingBlind Plug)
8.- Guide-
Front CoverGasket
Rocker CoverCa:ket
Cylinder Head
lntake Manifold
Cyiinder Head(Water)
Around CylinderBlock
Cl,llnderBlock
Oil LevelCauge
9.
Connector-
RockerCover(Breather)
10.
Connector-
Vacuum(lntake Manifold)
ll
Pressure
Switch(Oil Filter Bracket)
- 6l -
E n g in e (G ro u P s 2 a n d 4 )
To be appliedto:
BondingAgentor SealingAgent
RetainingCompound
Bolt -
EngineMountingBracket
Bolt -
AlterantorBracket
Nut -
Air Cieaner
Rearsurfaceof Crankshaft
i.
Flywheel*
Alternator Bracket*
-62-
CylinderBlock