Piston: Overview Kia Spectra I рестайлинг

Note. Replacing a piston also requires replacing piston rings.

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1. Check circumference of piston for damage, scoring, or unusual wear patterns. Replace piston as needed.
2. Check outside diameter of each piston at a 90° right angle to piston pin, 0.650 in. (16.5 mm) below oil ring land's lower edge. PISTON DIAMETER: NOTE: If piston is collapsed or bell mouthed, replace piston.
3. Check piston-to-cylinder wall clearance by subtracting piston diameter from the largest cylinder wall diameter, at each cylinder. Clearance: 0.0015~0.0021 in (0.039~0.053 mm) Maximum: 0.006 in (0.15 mm )
4. If clearance exceeds maximum, replace piston or rebore cylinders and fit oversized pistons to all cylinders.

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1. Insert a new piston ring into a piston ring groove and check piston ring-to-side clearance.
2. If clearance exceeds the maximum, replace piston.
3. Inspect piston rings for damage, abnormal wear, or breakage.
4. Replace piston rings if necessary.
5. Insert piston ring into cylinder by hand.
6. Square ring in cylinder by inverting a piston into cylinder and pushing ring to the bottom of its travel in cylinder.
7. Place a feeler gauge in end gap and check end gap clearance. END GAP CLEARANCE
8. Replace piston ring if necessary.

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1. Measure each piston pin hole diameter at X and Y directions in four locations shown in figure. (Scheme 112) Diameter: 0.7872~0.7875 in (19.994~20.002 mm)
2. Measure each piston pin diameter at X and Y direction at four locations shown in illustration. (Scheme 113) Diameter: 0.7869~0.7871 in (19.987~19.993 mm)
3. Subtract piston pin diameter from pin hole diameter to determine piston pin to piston clearance. Clearance: 0.00004~0.00006 in (0.001~0.015 mm)
4. If clearance exceeds specification, replace piston and piston pin. NOTE: Piston and piston pin are a matched set.

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1. Clean all parts before assembly.
2. Apply a coat of clean engine oil to all sliding and rotating parts before assembly.
3. Replace main bearings and rod bearings if they are peeling, burned or otherwise damaged. NOTE: Do not reuse old gaskets or seals.
4. Install one piston pin clip into clip grooves on piston.
5. Insert connecting rod into piston and slide piston pin through piston and through connecting rod until it makes contact with the piston pin clip already installed. NOTE: Verify that piston and rod are assembled in same direction as they were prior to disassembly.
6. Install second piston pin clip into clip grooves on opposite side of piston.
7. Hold piston upright and move connecting rod back and forth. Check that rod moves freely.
8. Install three piece oil ring onto piston. Apply clean engine oil to the oil ring expander and upper and lower oil rings. Install expander onto piston so that expander ends face upward. Install lower oil ring onto piston. Ring may be installed with either face upward. Install upper oil ring onto piston. Ring may be installed with either face upward.
9. Check that oil ring expander separates upper and lower oil rings, and that oil ring assembly spins freely on piston.
10. Use a ring expander and install second ring.
11. Use a ring expander and install top ring. NOTE: Top ring and second ring should be installed with "R" mark facing up.
12. Align piston ring gaps as shown in illustration.
13. Inspect journals and bearings for any foreign material. Clean crankshaft, oil holes and main bearing journals thoroughly, and dry components with compressed air.
14. Install grooved main bearings into saddles on engine block.
15. Install thrust bearings with oil groove facing crankshaft.
16. Set crankshaft on installed bearings.
17. Install remaining main bearings into main bearing caps.
18. Position Plastigage on crankshaft journals.
19. Install main bearing caps along with lower main bearings according to cap number and mark.
20. Tighten main bearing cap bolts according to the following procedure: Tighten bolts in order shown in illustration. (Scheme 123) Tightening torque: 28.9 lb-ft (39.2 N.m, 4kg-m) Loosen bolts in reverse of order shown. Retighten bolts in order shown. Tightening torque: 14.5 lb-ft (19.6 N.m, 2kg-m) Mark bolts for rotational reference. Rotate bolts 90°(1/4 Turn) in order shown. Rotate bolts another 60°(1/6 Turn) in order shown. CAUTION: Do not rotate crankshaft with Plastigage™ on crankshaft journals.
21. Remove main bearing caps and check bearing clearance. NOTE: The widest point of Plastigage™ is the smallest clearance, and the narrowest point of Plastigage is the largest clearance.
22. If oil clearance exceeds specification, grind and polish crankshaft and use undersized main bearings. Oil Clearance: 0.00095-0.00165 in (0.024-0.042 mm)
23. Lift crankshaft out of cylinder block and carefully remove Plastigage from main bearings and crankshaft journals.
24. Apply a light coat of engine oil on main bearings and install crankshaft by gently lowering it onto bearings.
25. Apply a light coat of oil on crankshaft main bearing journals and on main bearings on main bearing caps.
26. Install main bearing caps along with lower main bearings according to cap number and <-- mark.
27. Tighten main bearing cap bolts according to the following procedure: Tighten bolts in order shown in illustration. (Scheme 125) Tightening torque: 28.9 lb-ft (39.2 N.m, 4kg-m) Loosen bolts in reverse of order shown. Retighten bolts in order shown. Tightening torque: 14.5 lb-ft (19.6 N.m, 2kg-m) Mark bolts for rotational reference. Rotate bolts 90°(1/4 Turn) in order shown. Rotate bolts another 60°(1/6 Turn) in order shown.
28. Rotate crankshaft to ensure it does not bind.
29. Place a dial indicator against front of crankshaft and zero gauge.
30. Using a prying tool, move crankshaft forward and zero dial indicator.
31. Move the crankshaft toward the rear of block with prying tool and check the amount of movement on dial indicator. End Play: 0.0032-0.0111 in (0.080-0.282 mm)
32. If end play exceeds specification, grind crankshaft and install oversized thrust bearings, or replace crankshaft and thrust bearings. THRUST BEARING WIDTH
33. Install a bearing into connecting rod.
34. Place rubber sleeves (rubber fuel line works well) on connecting rod bolts to protect crankshaft from damage.
35. Check piston rings for correct end gap stagger.
36. Place piston (cylinder number one) with"F"mark facing front of engine block, then slip piston and connecting rod assembly into a piston ring compressor.
37. Rotate crankshaft so that crank pin journal for specific cylinder is at its lowest point (bottom dead center).
38. Lower piston and connecting rod assembly until piston ring compressor makes contact with deck surface of engine block.
39. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes contact with crankshaft. NOTE: Follow this procedure for remaining piston and connecting rod assemblies.
40. Install a connecting rod bearing in each connecting rod cap.
41. Place a piece of Plastigage™ on crank pin journals.
42. Install connecting rod caps, aligning marks made previous to disassembly and torque to specification. Tightening torque: 34.7-36.9 lb-ft (47-50 N.m, 4.8-5.1 kg-m) NOTE: When installing the connecting rods, match marks made on the connecting rod and cap to reference mark made on cylinder block to prevent oil starvation to the connecting rod bearings.
43. Loosen and remove connecting rod caps.
44. Check the connecting rod bearing clearance. Oil clearance: 0.0008-0.0019 in (0.020-0.05 mm) Maximum: 0.004 in (0.10 mm)
45. If oil clearance exceeds maximum oil clearance specification, grind the crankshaft and use undersized connecting rod bearings.
46. Apply a coat of clean engine oil to connecting rod bearing in connecting rod cap.
47. Install connecting rod cap and torque to specification. Tightening torque: 34.7-36.9 lb-ft (47-50 N.m, 4.8-5.1 kg-m)
48. Insert a thickness gauge between connecting rod and crankshaft and check connecting rod side clearance. NOTE: Do not measure between connecting rod cap and crankshaft. Side clearance: 0.0044-0.0103 in (0.110-0.262 mm) Maximum: 0.012 in (0.30 mm)
49. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap.
50. Apply a light coat of clean engine oil to rear oil seal.
51. Install rear oil seal into rear cover by hand.
52. Press oil seal into rear cover. NOTE: Oil seal must be pressed in until it is nearly flush with surface of rear cover. Protrusion: 0-0.02 in (0~0.5 mm)
53. Apply a coat of silicone sealer to rear cover. Thickness: lash 0.08 in (2 mm)
54. Install the rear cover. Tightening torque: 5.8-8.0 lb-ft (7.8-10.8 N.m, 0.8-1.1 kg-m)
55. Remove any sealant that protrudes from rear cover onto oil pan mounting surface.
56. Apply clean engine oil to new front oil seal and oil pump body.
57. Install front oil seal by hand.
58. Press oil seal into oil pump body. NOTE: Oil seal must be pressed in until it is nearly flush with front surface of oil pump body. Protrusion: 0.02-0.04 in (0.5-1.0 mm)
59. Install a new O-ring seal.
60. Apply a bead of silicone sealant to oil pump body as shown in illustration. Thickness: 0.04-0.08 in (1-2 mm) CAUTION: Oil pump body must be installed within 5 minutes after silicone sealant is applied.
61. Install oil pump with six bolts. Tightening torque: 14-19 lb-ft (19-26 N.m, 1.9-2.6 kg-m)
62. Remove any sealant that protrudes from oil pump onto oil pan mounting surface.
63. Remove all foreign material from water pump mounting surface.
64. Install water pump with a new gasket and torque to specification. Tightening torque: 14-19 lb-ft (19-26 N.m, 1.9-2.6 kg-m)
65. Install oil pressure switch. Tightening torque: 8.7-13.7 lb-ft (11.7-17.6 N.m, 1.2-1.8 kg-m)
66. Apply a small amount of engine oil to rubber seal of oil filter.
67. Install oil filter until rubber seal contacts base and then tighten filter 1 and 1/6 turn using an oil filter wrench.
68. Install oil strainer with a new gasket. Tightening torque: 5.8-8.7 lb-ft (7.8-11.8 N.m, 0.8-1.2 kg-m)
69. Remove all foreign material from gasket surface.
70. Apply a continuous bead of silicone sealant to oil pan contact surfaces. NOTE: Install oil pan within five minutes of applying silicone sealer.
71. Install oil pan and tighten oil pan bolts. Tightening torque: 5.8-8.0 lb-ft (7.8-10.8 N.m, 0.8-1.1 kg-m)
72. Clean thread sealant from flywheel bolts and bolt holes in crankshaft. NOTE: If thread sealant cannot be removed from bolt, replace flywheel bolt. If you are using new flywheel bolts, do not apply sealant: new bolts have sealant already applied to threads.
73. Install separator plate onto cylinder block. Tightening torque: 13.7-22.4 lb-ft (18.6-30.4 N.m, 1.9-3.1 kg-m)
74. Install flywheel (M/T) or drive plate/backing plate/adapter (A/T) assembly onto crankshaft.
75. Install bolts (apply sealant to reused bolts).
76. Install locking tool.
77. Tighten bolts in two or three steps to the specified torque. Tightening torque: 71-75.9 lb-ft (97-103 N.m, 9.8-10.5 kg-m)
78. Install clutch disc and clutch cover (M/T).
79. Center the clutch disc with SST or equivalent and torque clutch cover bolts to specification (M/T). Tightening torque: 16-24 lb-ft (22-32 N.m, 2.2-3.3 kg-m)
80. Remove locking tool.
81. Remove all foreign material from contact surface of cylinder head and cylinder block.
82. Place cylinder head gasket onto cylinder block and lower cylinder head onto cylinder block.
83. For additional cylinder head installation information, see «CYLINDER HEAD REMOVAL & INSTALLATION»(ref-159087-S26531699592005020100000).
84. Install cylinder head bolts.
85. Tighten cylinder head bolts according to following procedure: Tighten cylinder head bolts in order shown in illustration. (Scheme 148) Tightening torque: 36.1 lb-ft (49 N.m, 5 kg-m) Loosen bolts in reverse of order shown. Retighten cylinder head bolts in order shown. Tightening torque: 28.9 lb-ft (39.2 N.m, 4 kg-m) Mark cylinder head bolts for rotational reference. Rotate cylinder head bolts 90°(1/4 Turn) in order shown. Rotate cylinder head bolts another 90°(1/4 Turn) in order shown.
86. Install HLA's. See «HYDRAULIC LASH ADJUSTER (HLA)»(ref-159087-S05928658102005020100000).
87. For camshaft sprocket and timing belt information, see «TIMING SYSTEM»(ref-159087-S07179243332005020100000).
88. Install new intake manifold gasket.
89. Install intake manifold. Tightening torque: 13.7-18.8 lb-ft (18.6-25.5 N.m, 1.9-2.6 kg-m)
90. Install intake manifold bracket. Tightening torque: 27.5-38.3 lb-ft (37.2-51.9 N.m, 3.8-5.3 kg-m)
91. Install generator and generator mounting bolts and adjusting bolt.
92. Install generator belt and adjust it to specification. Generator drive belt deflection New: 0.31-0.35 in (8-9 mm) Used: 0.35-0.39 in (1-90 mm)
93. Tighten all bolts to specified torque. Tightening torque: Mounting bolts: 27-38 lb-ft (37-52 N.m) Adjusting bolt: 14~19 lb-ft (19-52 N.m)
94. Install front and rear engine hangers.
95. Hang engine with baby crane from engine stand.
96. Install exhaust manifold and coolant bypass pipe. Tightening torque: A: 28.2~34 lb-ft (38.2-46.1 N.m, 3.9-4.7 kg-m) B: 15.9~21 lb-ft (21.6-28.4 N.m, 2.2-2.9 kg-m)
97. Install No. 3 engine mount and bracket. Tightening torque: 54.1-75.9 lb-ft (73.5-102.9 N.m, 7.5-10.5 kg-m)
98. Install No. 2 engine mount. Tightening torque: 27.5-38.3 lb-ft (37.2-51.9 N.m, 3.8-5.3 kg-m)
99. Install transaxle and eight transaxle mounting bolts Tightening torque: 4 upper bolts (1,2,3,4): 65.8-86.1 lb-ft (89-116 N.m, 9.1-11.9 kg-m) 4 lower bolts (5,6,7,8): 27.5-38.3 lb-ft (37-52 N.m, 3.8-5.3 kg-m)
100. Install starter. Tightening torque: 27-38 lb-ft (37-52 N.m, 3.7~5.8 kg-m)
101. Fill with specified type and amount of engine oil and check for leaks.

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1. Disconnect negative battery cable.
2. Relieve fuel system pressure. See «FUEL DELIVERY SYSTEM»(ref-170871-S40342409422005011900000) .
3. Drain engine coolant.
4. Drain engine oil.
5. Remove PCV hose and ventilation hose.
6. Remove accelerator cable and auto cruise control cable if equipped.
7. Remove air intake hose and fresh air duct.
8. Disconnect brake vacuum hose and purge control vacuum hose at dynamic chamber.
9. Remove upper radiator hose.
10. Disconnect fuel hose from injector rail. WARNING: Keep open flames and sparks away from open fuel lines or a fire or explosion may result.
11. Remove heater hoses.
12. Disconnect IAC and throttle position sensor connectors.
13. Disconnect injector connectors.
14. Disconnect electrical connectors, remove bracket and reinstall engine hanger. Tightening torque: 27.5~38.3 lb.ft (37.2~51.9 N.m, 3.8~5.3 kg.m)
15. Disconnect ground strap.
16. Remove exhaust manifold heat shield.
17. Remove exhaust manifold pipe.
18. Remove coolant bypass pipe.
19. Remove intake manifold support bracket.
20. For camshaft and HLA removal procedure, see «HYDRAULIC LASH ADJUSTER (HLA)»(ref-159087-S05928658102005020100000) .
21. For timing belt removal procedure, see «TIMING SYSTEM»(ref-159087-S07179243332005020100000) .
22. Loosen cylinder head bolts in two or three steps following order shown in figure.
23. Remove cylinder head.

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1. Install new cylinder head gasket onto cylinder block and lower cylinder head onto engine.
2. Install cylinder head bolts.
3. Tighten cylinder head bolts according to following procedure: Tighten cylinder head bolts in order shown in illustration. (Scheme 173) Tightening torque: 36.1 lb.ft (49 N.m, 5 kg.m) Loosen bolts in reverse of order shown. Retighten cylinder head bolts in order shown. Tightening torque: 28.9 lb.ft (39.2 N.m, 4 kg.m) Mark cylinder head bolts for rotational reference. Rotate cylinder head bolts 90° (1/4 Turn) in order shown. Rotate cylinder head bolts another 90° (1/4 Turn) in order shown.
4. For timing belt installation procedure, see «TIMING SYSTEM»(ref-159087-S07179243332005020100000).
5. For camshaft and HLA installation procedure, see «HYDRAULIC LASH ADJUSTER (HLA)»(ref-159087-S05928658102005020100000).
6. Install intake manifold support bracket. Tightening torque: 27.5~38.3 lb.ft (37.2~51.9 N.m, 3.8~5.3 kg.m)
7. Install coolant bypass pipe Tightening torque: 65.8~86 lb.ft (89.2~116.6 N.m, 9.1~11.9 kg.m)
8. Install exhaust manifold. Tightening torque: A: 28~34 lb.ft (38~46 N.m, 3.9~4.7 kg.m) B: 16~21 lb.ft (22~28 N.m, 2.2~2.9 kg.m)
9. Install exhaust manifold heat shield. Tightening torque: 13.7~22.4 lb.ft (18.6~30.3 N.m, 1.9~3.1 kg.m)
10. Reconnect ground strap.
11. Install connector bracket and reconnect electrical connectors. Tightening torque (engine hanger bolt): 27.5~38.3 lb.ft (37.2~51.9 N.m, 3.8~5.3 kg.m)
12. Connect injector connectors.
13. Connect IAC and throttle position sensor connectors.
14. Install heater hoses.
15. Connect fuel hose to fuel injector rail.
16. Install upper radiator hose.
17. Connect brake vacuum hose and purge control vacuum hose.
18. Install air intake hose and fresh air duct.
19. Install accelerator cable and check cable deflection. If deflection is not correct, adjust by turning nut "A". Deflection: 0.04~0.12 in (1~3 mm)
20. Install cruise control cable if equipped.
21. Install PCV hose and ventilation hose.
22. Fill engine with specified amount and type of engine oil. (Refer to «LUBRICATION SYSTEM»(ref-159087-S23437577582005020100000) ).
23. Fill engine with specified amount and type of coolant. (Refer to «COOLING SYSTEM»(ref-159087-S16219678212005020100000).
24. Connect negative battery cable.
25. Start engine and check for oil and coolant leaks and HLA noise.
26. Operate engine until cooling fans cycle and check ignition timing.

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1. For camshaft and HLA disassembly, see «HYDRAULIC LASH ADJUSTER (HLA)»(ref-159087-S05928658102005020100000) .
2. Protect HLA bore with SST(K95A-1000-E) or equivalent. Compress valve springs with SST or equivalent and allow enough room to remove valve locks.
3. Slowly release pressure and remove valve spring from cylinder head.
4. Remove valve seals with SST or equivalent.
5. Repeat same procedure on all 16 valves.
6. Keep valves in correct order if they are to be reused.
7. Mark cylinder so that valves can be installed to their original positions.
8. Remove valves from cylinder head.
9. Remove lower spring seals from cylinder head.

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1. Inspect cylinder head for damage, cracks, and leakage of oil and water. Replace cylinder head if necessary.
2. Clean cylinder head and cylinder block mounting surfaces of all gasket material. NOTE: Do not allow gasket material to fall into oil passages or oil control plug.
3. Measure cylinder head for straightness in six directions as shown in figure. Distortion: 0.004 in (0.10 mm) Maximum
4. If distortion exceeds specification, resurface or replace cylinder head. Only remove the amount of material required to achieve a flat surface. Maximum material removal: 0.004 in (0.1 mm)
5. Check cylinder head height. Height: 5.272~5.280 in (133.9~134 mm)
6. If cylinder head height is not within specification, replace cylinder head. NOTE: If cylinder head requires machining, remove intake and exhaust manifolds and check their mounting surfaces for straightness.
7. Measure intake and exhaust manifold mating surface distortion at two directions shown in figure. Distortion: 0.008 in (0.20 mm) Maximum
8. If distortion exceeds specification, resurface or replace cylinder head. Maximum material removal: 0.008 in (0.20 mm)
9. Check cylinder block for distortion of cylinder head mating surface (block deck) in six directions shown in figure. Distortion: 0.006 in (0.15 mm) Maximum
10. If distortion exceeds specification, resurface block deck. Maximum material removal: 0.008 in (0.20 mm)

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1. Set front and rear camshaft bearing journals on V-blocks.
2. Position a dial indicator on center bearing journal and zero dial.
3. Rotate camshaft in V-blocks and check runout. Runout: 0.0012 in (0.03 mm) maximum
4. Check camshaft for uneven wear patterns, cracks, or damage.
5. Measure cam lobe heights at two points as shown in illustration. (Scheme 197) Lobe height Intake: 1.6415 in (41.6949 mm) Exhaust: 1.6629 in (42.2369 mm)
6. Check camshaft bearing journal diameter (X and Y directions) on both sides (A and B) of journal as shown in figure. (Scheme 198) Standard diameter: 1.0606~1.0616 in (26.940-26.965 mm) Minimum diameter: 1.0594 in (26.910 mm) Out-of-round: 0.002 in (0.05 mm) maximum
7. Replace camshafts if necessary.
8. Measure camshaft journal oil clearance with HLAs removed.
9. Remove all foreign material and oil from journals and bearing surfaces.
10. Set camshafts onto cylinder head.
11. Position Plastigage™ on journals in axial direction.
12. Do not rotate camshafts.
13. Install camshaft caps according to cap number and arrow mark.
14. Install cap bolts. Tighten them in five or six steps in order shown in illustration. (Scheme 199) Tightening torque: 8.32-10.49 lb-ft (11.28-14.22 N.m, 1.15~1.45 kg-m)
15. Loosen camshaft cap bolts in five or six steps in order shown.
16. Remove camshaft caps.
17. Measure oil clearances. Oil clearance: 0.0014~0.0031 in (0.035~0.081 mm) Maximum: 0.006 in (0.15 mm)
18. If oil clearance exceeds specification, replace cylinder head.
19. Install camshafts.
20. Place a dial indicator against end of camshaft.
21. Using a prying tool, move camshaft as far forward as possible.
22. Zero dial.
23. Using prying tool, move camshaft as far rearward as possible.
24. Check gauge to determine how much end play is present. End play: 0.0003~0.0004 in (0.08~0.10 mm) Maximum: 0.008 in (0.20 mm

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1. Inspect each valve for following: Damaged or bent valve stem Rough or damaged face Damaged or unevenly worn stem tip
2. Resurface or replace valve as needed. Margin thickness Intake: 0.0472 in (1.2 mm) Exhaust: 0.0472 in (1.2 mm)
3. Measure length of each valve. Length Intake: 4.052 in (102.92 mm) Exhaust: 3.993 in (101.42 mm)
4. Measure diameter of each valve stem. Diameter Intake:0.2350~0.2356 in (5.970-5.985 mm) Exhaust: 0.2348-0.2354 in (5.965-5.980 mm)
5. Measure inside diameter of each valve guide at points shown in figure. Diameter intake and exhaust valve guide: 0.2367-0.2374 in (6.01-6.03 mm)
6. Calculate valve stem-to-valve guide clearance. Subtract outer diameter of valve stem from inside diameter of respective valve guide. Clearance> Intake valve: 0.0010-0.0023 in (0.025-0.060 mm) Exhaust valve:0.0012-0.0025 in (0.030-0.065 mm) Max: 0.008 in (0.20 mm)
7. If clearance exceeds specification, replace valve, and/or valve guide.
8. Measure protrusion height of each valve guide. Replace valve guide as needed. A: Intake: 0.539-0.563 in (13.7-14.3 mm) B: Exhaust: 0.658-0.681 in (16.7-17.3 mm) NOTE: Intake and exhaust valve guides are different. Be sure to use correct valve guide.

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1. Inspect contact surface of each valve seat and valve face for following: Roughness Damage Pitting Cracks
2. Resurface valve seats with a 45° valve seat cutter. Resurface valve faces as needed.
3. Apply a coat of Dychem blue to valve face and valve seat and allow to dry.
4. Inspect valve seating by pressing valve against seat and rotating valve 360°. If Dychem blue is not removed 360° around valve face, replace valve. If Dychem blue is not removed 360° around valve seat, resurface valve seat.
5. Measure seat contact width. Width: 0.078-1.059 in (1.98-2.69 mm)
6. Check that valve seat contact area is at center of valve face. If valve seating position is too high, correct valve seat with a 63° valve seat cutter, and a 45° cutter. If seating position is too low, correct valve seat with a 0° and a 45° cutter.
7. Complete seat-cutting process by lapping valve to seat using valve-lapping compound.
8. Inspect valve seat for sinking. NOTE: Clean valves thoroughly before reassembly, and insure that all traces of lapping compound have been removed.
9. Check for valve sink by measuring protruding length (Dimension L) of valve stem to lower valve spring seat.

Scheme 216

1. Inspect each valve spring for cracks and damage.
2. Measure free length and out-of-square. Replace valve springs as needed. Free length: 1.84 in (46.7 mm) Out-of-square: 0.0638 in (1.62 mm) maximum

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1. Install valve, then slide valve seal over seal over valve stem and onto valve guide.
2. Install valves guide seal installer over valve seal. NOTE: Intake and exhaust valve seals are different. Only exhaust valve seals have four teeth. CAUTION: Using a hammer will damage valve seals.
3. Remove the valve guide seal installer.
4. Install lower spring seat on cylinder head.
5. Install HLA protector SST(K95A-1000-E) if available.
6. Install valve spring with narrow spring coils (B) toward cylinder head, and wider coils (A) toward upper spring seat.
7. Install upper spring seat and compress valve spring with SST or equivalent.
8. Install valve locks and release SST or equivalent from valve spring.
9. Tap end of valve stem lightly two or three times with a plastic hammer to verify that valve locks are fully seated.
10. Remove HLA protector (K-95A-1000-E) if used. Repeat procedure for remaining valve assembles.

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1. Disconnect negative battery cable.
2. Remove center cover.
3. Remove ignition coils and high-tension cords.
4. Disconnect PCV hose and ventilation hose.
5. Remove timing belt. See «TIMING SYSTEM»(ref-159087-S07179243332005020100000) .
6. Remove cylinder head cover. NOTE: Align camshaft and crankshaft timing belt alignment marks.
7. Remove phase sensor.
8. Remove camshaft pulleys.
9. Loosen camshaft bearing cap bolts in five or six steps in order shown in figure.
10. Remove camshafts.
11. Mark HLA's to identify their original position if they will be reused. NOTE: Hydraulic Lash Adjusters (HLA) must be installed in location from which they were removed. Failure to install HLA's in their original location will result in premature and uneven wear of HLA's and camshafts.
12. Remove HLA's from cylinder head.
13. Store HLA's upside-down in an oil-filled container.

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Scheme 233

1. Check HLA face for wear or damage, and replace if necessary.
2. With HLA filled with engine oil, hold (A) and press down on (B) by hand. If (B) moves, replace HLA. NOTE: Never attempt to repair or disassemble an HLA.
3. Measure HLA bore diameters (X and Y directions) at two points (A and B) as shown. Distortion: 1.1812~1.1820 in (30.000~30.025 mm)
4. Measure HLA diameters (X and Y directions) at two points (A and B) as shown in illustration. (Scheme 234) Diameter: 1.1795~1.1801 in (29.959~29.975 mm)
5. Calculate clearance between HLA diameter and related HLA bore. Replace HLA and/or cylinder head if necessary. Clearance: 0.00099~0.00259 in (0.025~0.066 mm) Maximum: 0.0071 in (0.180 mm)

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

1. Apply a coat of clean engine oil to friction surfaces of HLA.
2. Install HLA into cylinder head bore. NOTE: If HLA is being reused, install it in its original position.
3. Check that HLA moves smoothly in its bore.
4. Apply clean engine oil to camshaft and camshaft bearing surfaces and install camshaft so that camshaft dowel pins point straight up.
5. Install camshaft bearing caps according to cap number with the directional arrows pointing forward.
6. Install bolts to camshaft bearing caps and tighten in five or six steps in order shown in figure. Tightening torque: 8.32~10.49 lb.ft (11.28~14.22 N.m, 1.15~1.45 kg.m)
7. Apply a coat of clean engine oil to the lip of new camshaft seal.
8. Seat camshaft seal by hand and tap the seal in place until it is flush with the edge of camshaft bearing cap.
9. Install camshaft pulleys onto camshaft, aligning "I" mark with the intake camshaft dowel pin, and "E" mark with exhaust camshaft dowel pin. Tightening torque: 36.2~44.8 lb.ft (49~60.8 N.m, 5.0~6.2 kg.m)
10. Install phase sensor.
11. Install cylinder head cover. Tightening torque: 5.8~8.7 lb.ft (7.8~11.8 N.m, 0.8~1.2 kg.m)
12. Install timing belt. See «TIMING SYSTEM»(ref-159087-S07179243332005020100000) .
13. Connect PCV hose and ventilation hose.
14. Install high tension cords and ignition coils.
15. Install center cover. Tightening torque: 3.6~6.5 lb.ft (4.9~8.8 N.m, 0.5~0.9 kg.m)
16. Connect negative battery cable.

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

1. Disconnect negative battery cable.
2. Drain engine oil.
3. Remove LH and RH side splash shields.
4. Remove front exhaust pipe.
5. Remove oil pan mounting bolts.
6. Remove oil pan with screwdriver or suitable tool as shown in figure. see scheme 249 CAUTION: Do not force tools between cylinder block and oil pan because this may damage sealing surfaces. Do not damage sealing surfaces when removing old sealant.
7. Remove oil strainer.