Daihatsu CB-20 Manuals

Manuals and User Guides for Daihatsu CB-20. We have 1 Daihatsu CB-20 manual available for free PDF download: Workshop Manual

Daihatsu CB-20 Workshop Manual (197 pages)

Brand: Daihatsu | Category: Engine | Size: 48 MB

Index
4
General Information
6
Location of Stamped Engine Type
7
Location of Stamped Engine Serial Number
7
Abbreviation Codes
8
Engine Specification
9
Periodic Maintenance
12
List of Main Specifications
13
Maintenance Service According to Running Distance
14
Periodic Replacement Parts
14
The Engine Proper
16
Engine Sectional Views
17
Engine Components and Tightening Torques
19
Engine Tune-Up
20
Operating Instructions on Engine Tachometer
20
Check and Adjustment of V Belt
20
Check and Adjustment of Spark Plugs
20
Valve Clearance Adjustment
21
Compression Pressure Check
21
Reference Information
21
Check and Adjustment of Contact Points
22
Check and Adjustment of Ignition Timing Check
22
Checking Ignition Timing
22
Adjusting Ignition Timing
22
Checking Ignition Advance
23
Idling Adjustment
23
Initial Check and Adjustment
24
Location of Adjusting Screws
24
Fast Idling Adjustment
25
Function Check of Choke Opener
25
Check and Adjustment of Dash Pot
26
Simple Checking Method of Valve Timing
26
Engine Removal & Installation
27
Special Tools
27
Engine Removal
28
Engine Installation
31
Separating Engine Mounting Brackets
32
Underside View of Engine and Other Related Parts
32
Engine Holder Fabricating Procedure
33
Engine Disassembly
34
Removal of Parts
37
Installing Engine
37
Removing Parts from Front Side
37
Disassembly of Cylinder Head Related Parts Components
39
Removing Valve Rocker Shaft
40
Removing Camshaft
40
Removing Valves and Compression Springs
40
Disassembly of Cylinder Block Related Parts Components
41
Inspection and Repair of Engine Components
45
Cylinder Head Related Parts
45
Checking and Refacing Valve Seats
46
Checking Camshaft Lobe Height
47
Checking Camshaft-To-Cylinder Head Clearance
48
Checking Camshaft for Runout
48
Cylinder Block Related Prats
49
Checking Timing Belt for Damage
54
Checking Timing Belt Tensioner
54
Checking Timing Belt Pulleys for Wear
54
Replacing Camshaft Oil Seal
55
Replacing Crankshaft Front Oil Seal
55
Replacing Crankshaft Rear Oil Seal
55
Assembly of Engine
56
Assembling Piston Pin
57
Installing Piston Rings
57
Installing Crankshaft
57
Installing Piston
58
Installing Connecting Rod Cap
58
Installing Balance Shaft
58
Installing Oil Pump
59
Installing Oil Pump Chain
59
Attaching Balance Shaft Gear Cover
59
Assembly of Cylinder Head Related Parts
60
Attaching Oil Pan
60
Installing Dust Seals
60
Fitting Valve Stem Oil Seal
60
Installing Camshaft Timing Belt Pulley
61
Checking Camshaft End Play
61
Installing Valve Rocker Shaft
61
Attaching Distributor Housing
62
Aligning Mate Marks
62
Cylinder Head Bolt Tightening Sequence
62
Installing Crankshaft Timing Belt Pulley Flanges
62
Installing Timing Belt
63
Timing Belt Tensioner Tightening Sequence
63
Adjusting Valve Clearances
64
Installing Various Components
64
Installing Fuel Pump
64
Installing Clutch Disc
65
Aligning Stamped Mark of Distributor
65
Installing Distributor
65
Engine In-Vehicle Service
67
Timing Belt Related Parts
67
Components
67
Timing Belt Specifications
68
Timing Belt Removal
68
Removing Crankshaft Pulley
68
Removing Timing Belt Cover
69
Removing Timing Belt
69
Crankshaft Front Oil Seal
70
Removing Crankshaft Timing Belt Pulley
70
Removing Crankshaft Oil Seal
70
Camshaft Oil Seal
71
Removing Camshaft Oil Seal
71
Press-Fitting Camshaft Oil Seal
71
Valve Rocker Shaft Related Text
74
Checking Rocker Shaft and Arm
75
Routing Fuel Pump Air Vent Pipe
75
Valve Stem Oil Seal Related Parts
76
How to Find Top Dead Center of each Cylinder
76
Installing Valve Rocker Shaft Only
76
Modification to be Made on Special Tool
76
Valve Springs
77
Valve Stem Oil Seals
77
Free Length
77
Spring Squareness
77
Camshaft Related Parts
78
Removing Camshaft Pulley
78
Cylinder Head Assembly
79
Disconnecting Exhaust Front Pipe
79
Removing Cylinder Head Bolts
79
Removing Cylinder Head
79
Checking Cylinder Bore
80
Checking Cylinder Head for Distortion
80
Checking Cylinder Block Top Surface for Distortion
80
Piston and Oil Pan Related Parts
81
Holding Cylinder Block
82
Removing Engine Rear Mounting Member
82
Removing Connecting Rod
82
Measuring Connecting Rod Bearing Oil Clearance
82
Tightening Connecting Rod Bearing Cap Nuts
83
Installing Oil Pan
83
Installing Clutch Housing Undercover
83
Tightening Cylinder Head Bolts
84
Fuel System
86
Fuel Pump
87
Sectional View of Fuel Pump
87
Fuel Pump Components
87
Removing Fuel Pump
88
Disassembling Fuel Pump
88
Checking Rocker Arm for Damage or Wear
88
Inspecting Function of Check Valves
89
Checking Fuel Pump Push Rod for Wear
89
Measuring Amount of Push Rod Protrusion
89
Checking Fuel Pump
90
Checking Fuel Pump for Fuel Leakage
90
Carburetor Schematic Diagram
91
Carburetor Components
93
Special Service Tools
95
Carburetor Identification
95
Identification of Carburetor
95
Air Horn Section
96
Carburetor Assembly
96
Disassembling Air Horn Section
97
Disassembling Body Section
98
Disassembling Flange Section
99
Checking Air Horn Section
99
Checking Body Section
100
Checking Pump Plunger
100
Checking Body
100
Checking Flange Section
101
Checking Idle Adjusting Screw
101
Checking Diaphragm and Other Items
102
Assembling Flange Section
103
Assembling Body Section
103
Assembling Small Venturi
103
Assembling Steel Ball and Retainer
103
Assembling Power Jet and Valve
104
Assembling Fast Idle Lever
104
Assembling Air Horn Section
105
Solenoid Valve & Gasket
105
Float Level Adjustment
105
Assembling Needle Valve
105
Float Adjusting Points
106
Total Assembly
106
Float Level Adjusting Points
106
Assembling Body on Flange
106
Assembling Air Horn on Body
107
Assembling Air Horn Set Screws
107
Assembling Links and Hoses
108
Adjustments to be Made after Assembly
109
Idle Adjusting Screw
109
Fast Idle Adjusting Screw
109
Secondary Throttle Function - Starting Angle
109
Kick-Up Setting
110
Acceleration Pump Stroke
110
Choke Opener
110
Accelerator Cable
111
Choke Control Cable
111
Vacuum Hose Connecting Diagram
111
Adjustments of Accelerator and Choke Control Cable
111
Intake and Exhaust Systems
112
Air Cleaner
113
Air Cleaner Element
113
Cleaning Filter Element
113
Intake Manifold
114
Intake Manifold Components and Tightening Torques
114
Disconnecting Cooling Water Hoses
114
Disconnecting Distributor Timing Advance Hose
115
Removing Fuel Pipe
115
Removing Intake Manifold
115
Measuring Intake Manifold Distortion
116
Disconnecting Hoses Related with BVSV
116
Removing Carburetor Assembly
116
Removing Intake Manifold Related Parts
117
Exhaust Manifold
118
Removing Exhaust Front Pipe
119
Removing Exhaust Manifold Stay
119
Removing Exhaust Manifold Assembly
119
Exhaust Manifold Tightening Sequence
120
Exhaust Pipe
121
Exhaust Pipe Components and Tightening Torques
121
Exhaust Front Pipe
122
Exhaust Tail Pipe
122
Lubrication System
124
Block Diagram of Lubrication System
125
Oil Pan
125
Oil Pump
126
Oil Pump Components and Tightening Torques
126
Removing Engine Mounting Member
127
Removing Clutch Housing Undercover
127
Removing Oil Pan
127
Checking Oil Pump Chain Deflection
128
Removing Sprocket
128
Removing Oil Pump
128
Disassembling Oil Pump
129
Checking Strainer and Outlet Pipe
129
Checking Oil Pump
129
Checking Oil Pump Shaft to Body Clearance
130
Measuring Tip Clearance
130
Measuring Side Clearance
130
Checking Relief Valve
131
Assembling Relief Valve
131
Assembling Oil Pump Rotor Set
131
Simple Test Checking Oil Pump Operation
132
Attaching Oil Pump
132
Installing Sprocket
132
Scaler Applying Procedure
133
Oil Pan Attaching Bolt Tightening Sequence
133
Attaching Clutch Housing Undercover
134
Cooling System
136
Schematic View of Cooling System
137
Radiator
137
Water Pump
137
Thermostat
138
Fan Motor
138
Radiator Thermo Control Switch
138
Filling Amount of Anti-Freezing Solution
138
Measuring Instrument
139
In-Vehicle-Check
139
Checking Radiator Water Leak
139
Removing Radiator
139
Checking Radiator Cap
140
Special Service Tools and Measuring Instrument
141
Removing Water Pump Pulley
141
Removing Water Pump
142
Removing Bearing and Seal Set
142
Checking Rotor and Seal Set
143
Checking Water Pump Bearing
143
Press-Fitting Water Pump Bearing
143
Removing Thermostat
145
Checking Thermostat
145
Forced Cooling Mechanism
146
In-Vehicle-Check of Circuit
146
Radiator Thermo Control Switch Check
146
Removing Fan Shroud
147
Checking Fan Motor
147
Engine Electrical System
148
Engine Electrical Wiring Diagram
149
Starting System
150
Diagram Showing Operation of Starter
150
Starter Components
151
Handling Instructions on Starter
152
Starter in Vehicle Check
152
Magnetic Switch
153
Holding Coil Retention Test
153
Pinion Return Test
153
Pull-In Coil Drawing Test
153
Armature Shaft Thrust Clearance Check
154
No-Load Test
154
Checking Thrust Clearance
154
Starter no Load Test
154
Charging System
155
Alternator
155
Alternator Components and Tightening Torque
156
Checking of each Part
157
Checking Voltage and Current Regulations
157
No Load Test
157
Checking of each Resistance
158
Load Test
159
Alternator Removal
161
Disconnecting Alternator Wirings
161
Removing Alternator
161
Generator Regulator
162
Checking each Resistance of Generator Regulator
162
Electrical Adjustment
163
Mechanical Adjustment
163
Voltage Relay
163
Voltage Regulator
163
Ignition System
164
Distributor Specifications
164
Distributor Components
165
Checking each Part
166
Checking and Adjusting Distributor
166
Checking Spark
166
Checking Ignition Timing Advance
167
Dwell Angle and Variation Test
167
Breaker Arm Contact Point Pressure
167
Condenser Capacity
167
Ignition Timing
168
Aligning Mate Marks of Distributor
168
Ignition Coil
169
Removing Ignition Coil
169
Measurement of Primary Coil Resistance
169
Measurement of Secondary Coil Resistance
170
Measurement of Resistor Resistance
170
Capacity Test
170
Inspection of Diode
170
Spark Plugs
171
Diode Continuity Test
171
Exhaust Emission Control System
172
List of Exhaust Emission Control System
173
List of Abbreviation of Component Names
173
Instructions to be Followed During Check and Adjustment
175
Instructions on Vacuum Hose Connections
175
Measuring Instruments
176
Engine Tachometer
176
Handling Instructions on Might Bag
176
Dash Pot System
177
Deceleration Control System
177
Checking BVSV
177
DP System Diagram
177
Unit Check
178
Dash Pot
178
Vtv
178
DP Unit Check
178
Choke Opener System
179
C/O System Diagram
179
Schematic View of C/O System
179
Blow-By-Gas Recirculation
180
Checking PCV
180
Engine Wont't Start
181
Rough Idling
182
Lack of Power and Poor Acceleration
183
Excessive Fuel Consumption
184
Service Specifications
187
Valve Guide Bush
187
Valves
187
Valve Spring
188
Valve Rocker Shaft and Rocker Arm
188
Cylinder Block
188
Tightening Torques
191
Table of General Standard Bolt Tightening Torque
191
List of Special Tools
193

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Daihatsu CB-20 Workshop Manual (197 pages)

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