Mechanical, 2.5L: Removal & Installation Saab 9-2X I

REMOVAL

Set the vehicle on a lift.

Open the front hood fully and support with the front food stay.

Collect the refrigerant from A/C system.

Release the fuel pressure.

Remove the fuel filler cap.

Disconnect the ground cable from battery.

Scheme 37

Remove the air intake duct, air cleaner case and air intake chamber.

Remove the under cover.

Remove the radiator from vehicle.

Disconnect the A/C pressure hoses from A/C compressor.

Remove the air intake chamber stay.

Scheme 38

Disconnect the following connectors and cables.

Front oxygen (A/F) sensor connector

Scheme 39

Rear oxygen sensor connector

Scheme 40

Engine ground cable

Scheme 41

Engine harness connectors

Scheme 42

Generator connector and terminal

Scheme 43

1. Terminal
2. Generator connector

A/C compressor connectors

Scheme 44

Power steering switch connector

Scheme 45

Disconnect the following hoses.

Brake booster vacuum hose

Scheme 46

Heater inlet and outlet hoses

Remove the power steering pump from bracket.

Loosen the lock bolt and slider bolt, and then remove the front side V-belt.

Remove the pipe with bracket.

Scheme 47

Remove the bolts which install the power steering pump to bracket.

Scheme 48

Remove the power steering tank from bracket by pulling it upward.

Scheme 49

Place the power steering pump on right side wheel apron.

Scheme 50

Remove the front and center exhaust pipe.

Remove the nuts which hold lower side of transmission to engine.

Scheme 51

Remove the nuts which install front cushion rubber onto front crossmember.

Scheme 52

Separate the torque converter clutch from drive plate. (AT model)

Lower the vehicle.

Remove the service hole plug.

Remove the bolts which hold torque converter clutch to drive plate.

Remove other bolts while rotating the engine using a socket wrench.

Scheme 53

Remove the pitching stopper.

Scheme 54

Disconnect the fuel delivery hose (A), return hose (B) and evaporation hose (C).

ST 32005086 CONNECTOR REMOVER

Scheme 55

Support the engine with a lifting device and wire ropes.

Scheme 56

Support the transmission with a garage jack.

Scheme 57

Separation of engine and transmission.

Remove the starter.

Remove the bolts which hold upper side of transmission to engine.

Scheme 58

Set the ST to converter case. (AT model)

ST 32005099 STOPPER SET

Scheme 59

Remove the engine from vehicle.

Slightly raise the engine.

Raise the transmission with garage jack.

Move the engine horizontally until main shaft is withdrawn from clutch cover.

Slowly move the engine away from engine compartment.

Note. Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

Remove the front cushion rubbers.

INSTALLATION

Install the front cushion rubbers.

Tightening torque

35 Nm (3.6 kgf-m, 25.8 ft -lb)

Position the engine in engine compartment and align it with transmission.

Note. Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

Scheme 60

Apply a small amount of grease to splines of main shaft. (MT model)

Tighten the bolts which hold upper side of transmission to engine.

Tightening torque

50 Nm (5.1 kgf-m, 36.9 ft -lb)

Scheme 61

Remove the lifting device and wire ropes.

Remove the garage jack.

Install the pitching stopper.

Tightening torque

T1: 50 Nm (5.1 kgf-m, 36.9 ft -lb)

T2: 58 Nm (5.9 kgf-m, 42.8 ft -lb)

Scheme 62

Remove the ST from converter case. (AT model)

Note. Be careful not to drop the ST into the converter case when removing the ST.

ST 32005099 STOPPER SET

Install the starter.

Install the torque converter clutch to drive plate. (AT model)

Tighten the bolts which hold torque converter clutch to drive plate.

Tighten other bolts while rotating the engine using a socket wrench.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft -lb)

Scheme 63

Clog the service hole plug and prevent foreign matters from being mixed.

Install the power steering pump on bracket.

Install the power steering tank to bracket.

Scheme 64

Install the power steering pump on bracket, and tighten the bolts.

Tightening torque

22 Nm (2.2 kgf-m, 16 ft-lb)

Scheme 65

Install the pipe with their bracket.

Scheme 66

Connect the power steering switch connector.

Scheme 67

Install the front side belt and adjust it.

Lift-up the vehicle.

Tighten the nuts which hold lower side of transmission to engine.

Tightening torque

50 Nm (5.1 kgf-m, 36.9 ft -lb)

Scheme 68

Tighten the nuts which install the front cushion rubber onto crossmember.

Tightening torque

85 Nm (8.7 kgf-m, 63 ft-lb)

Note. Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.

Scheme 69

Install the front and center exhaust pipe.

Lower the vehicle.

Connect the following hoses

Fuel delivery hose, return hose and evaporation hose

Heater inlet and outlet hoses

Brake booster vacuum hose

Connect the following connectors

Front oxygen (A/F) sensor connector

Rear oxygen sensor connector

Engine ground cable

Tightening torque

14 Nm (1.4 kgf-m, 10.1 ft -lb)

Engine harness connectors

Generator connector and terminal

A/C compressor connector

Install the air intake chamber stay.

Tightening torque

16 Nm (1.6 kgf-m, 11.6 ft -lb)

Install the A/C pressure hoses.

Install the radiator to vehicle.

Install the air intake duct, air cleaner case and air intake chamber.

Install the under cover.

Install the battery in the vehicle, and connect cables.

Fill engine coolant.

Check the ATF level and replenish it if necessary.

Charge the A/C system with refrigerant.

Remove the front hood stay, and close the front hood.

Take off the vehicle from a lift.

Remove the engine assembly.

Remove the engine mounting from engine assembly.

Install in the reverse order of removal.

Tightening torque

Engine mounting

35 Nm (3.6 kgf-m, 25.8 ft -lb)

Note. Perform the following procedures with the engine installed to the body.

Note. Wipe off any oil or water on the belt and pulley.

Remove the V-belts.

Remove the crank pulley bolt. To lock the crankshaft, use ST.

ST 32005163 CRANK PULLEY WRENCH

Scheme 70

Remove the crank pulley.

Install the crank pulley.

Install the pulley bolt.

To lock the crankshaft, use ST.

ST 32005163 CRANK PULLEY WRENCH

Clean the crankshaft thread using compressed air.

Apply engine oil to the crank pulley bolt seat and thread.

Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 33 ft-lb).

Tighten the crank pulley bolts.

Tightening torque

180 Nm (18.4 kgf-m, 132.8 ft-lb)

Scheme 71

Confirm that the tightening angle of crank pulley bolt is 65 degrees or more. If the tightening angle of crank pulley bolt is less than 65 degrees, conduct the following procedures.

Replace the crank pulley bolts and clean them.

Crank pulley bolt

32005529

Clean the crankshaft thread using compressed air.

Apply engine oil to the crank pulley bolt seal and thread.

Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 33 ft-lb).

Tighten the crank pulley bolts keeping them in an angle between 65 degrees and 75 degrees.

Note. Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover.

Install the A/C belt tensioner.

Scheme 72

Install the V-belt.

Remove the V-belts

Remove the crank pulley.

Remove the timing belt cover (LH).

Remove the front timing belt cover.

Scheme 73

1. Timing belt cover (LH)
2. Front timing belt cover

Install the front timing belt cover.

Tightening torque

5 Nm (0.5 kgf-m, 3.6 ft-lb)

Install the timing belt cover (LH).

Tightening torque

5 Nm (0.5 kgf-m, 3.6 ft-lb)

Scheme 74

1. Timing belt cover (LH)
2. Front timing belt cover

Install the crank pulley.

Install the V-belts.

Remove the V-belts.

Remove the crank pulley.

Remove the timing belt cover.

Remove the timing belt.

Remove the camshaft position sensor.

Remove the cam sprocket No. 2. To lock the camshaft, use ST.

ST 32005019 CAM SPROCKET WRENCH

Scheme 75

Remove the cam sprocket No. 1. To lock the camshaft, use ST.

ST 32005125 CAM SPROCKET WRENCH

Scheme 76

Install the cam sprocket No. 1. To lock the camshaft, use ST.

ST 32005125 CAM SPROCKET WRENCH

Tightening torque

78 Nm (8.0 kgf-m, 57.9 ft -lb)

Note. Do not confuse left and right side cam sprockets during installation. Cam sprocket No. 2 is identified by a protrusion used to monitor the camshaft position sensor.

Scheme 77

Install the cam sprocket No. 2. To lock the camshaft, use ST.

ST 32005019 CAM SPROCKET WRENCH

Tightening torque

78 Nm (8.0 kgf-m, 57.9 ft -lb)

Scheme 78

Install the camshaft position sensor.

Install the timing belt.

Install the timing belt cover.

Install the crank pulley.

Install the V-belts.

Remove the V-belts.

Remove the crank pulley.

Remove the timing belt cover.

Remove the timing belt.

Remove the cam sprocket.

Remove the crank sprocket.

Scheme 79

Install the crank sprocket.

Scheme 80

Install the cam sprocket.

Install the timing belt.

Install the timing belt cover.

Install the crank pulley.

Install the V-belts.

Remove the V-belts.

Remove the crank pulley.

Remove the timing belt cover.

Remove the timing belt.

Remove the cam sprocket.

Disconnect the PCV hose and remove the rocker cover.

Removal of valve rocker assembly

Remove the bolts (a) through (h) in alphabetical sequence.

Note. Leave two or three threads of bolts (g) and (h) engaged in order to retain the valve rocker assembly.

Scheme 81

Remove the valve rocker assembly.

Scheme 82

Install the valve rocker assembly.

Temporarily tighten the bolts (a) through (d) equally in order as shown in the figure.

Note. Do not allow the valve rocker assembly to damage knock pins.

Tighten the bolts (e) through (h) to specified torque.

Tighten the bolts (a) through (d) to specified torque.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft -lb)

Scheme 83

Adjust the valve clearance.

Install the rocker cover, rocker cover gasket and connect PCV hose.

Note. Use new rocker cover gasket.

Install the cam sprocket.

Install the timing belt.

Install the timing belt cover.

Install the crank pulley.

Install the V-belts.

Remove the V-belts.

Remove the crank pulley.

Remove the timing belt cover.

Remove the timing belt.

Remove the cam sprocket.

Remove the crank sprocket.

Remove the timing belt cover No. 2 (LH).

Remove the timing belt cover No. 2 (RH).

Note. Do not damage or lose the seal rubber when removing the timing belt covers.

Scheme 84

Remove the tensioner bracket.

Scheme 85

Remove the camshaft position sensor support. (LH side only)

Remove the oil level gauge guide. (LH side only)

Remove the valve rocker assembly.

Remove the camshaft cap.

Remove the bolts (a) and (b) in alphabetical sequence.

Scheme 86

Equally loosen the bolts (c) through (j) all the way in alphabetical sequence.

Scheme 87

Remove the bolts (k) through (p) in alphabetical sequence using ST.

ST 32005132 TORX(R) PLUS

Scheme 88

Remove the camshaft cap.

Scheme 89

Remove the camshaft.

Remove the oil seal.

Remove the plug from the rear side of camshaft.

Apply a coat of engine oil to camshaft journals and install the camshaft.

Install the camshaft cap.

Apply liquid gasket to the mating surfaces of camshaft cap.

Liquid gasket

THREE BOND 1280B (Part No. 32005003)

Scheme 90

Note. Apply a coat of liquid gasket of 3 mm (0.12 in) in diameter (A) along the edge (B) of camshaft cap (C) mating surface. Assemble them within 20 min. after applying liquid gasket.

Temporarily tighten the bolts (g) through (j) in alphabetical sequence.

Scheme 91

Install the valve rocker assembly.

Scheme 92

Tighten the bolts (a) through (h) in alphabetical sequence.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft-lb)

Scheme 93

Tighten the TORX(R) bolts (i) through (n) in alphabetical sequence using ST.

ST 32005132 TORX(R) PLUS

Tightening torque

18 Nm (1.8 kgf-m, 13.0 ft -lb)

Scheme 94

Tighten the bolts (o) through (v) in alphabetical sequence.

Tightening torque

10 Nm (1.0 kgf-m, 7.2 ft-lb)

Scheme 95

Tighten the bolts (w) and (x) in alphabetical sequence.

Tightening torque

10 Nm (1.0 kgf-m, 7.2 ft-lb)

Scheme 96

Apply a coat of grease to oil seal lips and install the oil seal (A) on camshaft using ST1 and ST2.

Note. Use a new oil seal.

ST1 32005140 OIL SEAL GUIDE

ST2 32005137 OIL SEAL INSTALLER

Scheme 97

Install the plug using ST.

ST 32005139 CAMSHAFT OIL SEAL INSTALLER

Adjust the valve clearance.

Install the rocker cover, rocker cover gasket and connect PCV hose.

Note. Use new rocker cover gasket.

Install the oil level gauge guide. (LH side only)

Install the camshaft position sensor support. (LH side only)

Install the tensioner bracket.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft -lb)

Scheme 98

Install the timing belt cover No. 2 (RH).

Tightening torque

5 Nm (0.5 kgf-m, 3.6 ft-lb)

Install the timing belt cover No. 2 (LH).

Tightening torque

5 Nm (0.5 kgf-m, 3.6 ft-lb)

Scheme 99

Install the crank sprocket.

Install the cam sprocket.

Install the timing belt.

Install the timing belt cover.

Install the crank pulley.

Install the V-belts.

Remove the V-belts.

Remove the crank pulley.

Remove the timing belt cover.

Remove the timing belt.

Remove the cam sprocket.

Remove the intake manifold.

Remove the bolt which installs the A/C compressor bracket on cylinder head.

Remove the valve rocker assembly.

Remove the camshaft.

Remove the cylinder head bolts in alphabetical sequence as shown in the figure.

Note. Leave bolts (a) and (c) engaged by three or four threads to prevent the cylinder head from falling.

Scheme 100

While tapping the cylinder head with a plastic hammer, separate it from cylinder block.

Remove the bolts (a) and (c) to remove the cylinder head.

Scheme 101

Remove the cylinder head gasket.

Similarly, remove the right side cylinder head.

Install the cylinder head and gaskets on cylinder block.

Tighten the cylinder head bolts.

Apply a coat of engine oil to washers and bolt threads.

Tighten all bolts to 29 Nm (3.0 kgf-m, 22 ft-lb) in alphabetical sequence. Then tighten all bolts to 69 Nm (7.0 kgf-m, 51 ft-lb) in alphabetical sequence.

Back off all bolts by 180° in reverse order of installation, and back them off again by 180°.

Tighten all bolts to 42 Nm (3.9 kgf-m, 31 ft-lb) in alphabetical sequence.

Tighten all bolts by 80° - 90° in alphabetical sequence.

Tighten all bolts by 40° - 45° in alphabetical sequence.

Note. Do not tighten the bolts more than 45°.

Further tighten bolts (a) and (b) by 40°- 45°.

Note. Ensure the total "re-tightening angle" in the [former two steps], do not exceed 90°.

Scheme 102

Install the camshaft.

Install the valve rocker assembly.

Install the A/C compressor bracket on cylinder head.

Install the intake manifold.

Install the cam sprocket.

Install the timing belt.

Install the timing belt cover.

Install the crank pulley.

Install the V-belts.

Note. Before conducting this procedure, drain the engine oil completely.

Remove the intake manifold.

Remove the V-belts.

Remove the crank pulley.

Remove the timing belt cover.

Remove the timing belt.

Remove the cam sprocket.

Remove the crank sprocket.

Remove the generator and A/C compressor with their brackets.

Remove the rocker cover.

Remove the cylinder head bolts in alphabetical sequence as shown in the figure.

Note. Leave bolts (a) and (c) engaged by three or four threads to prevent the cylinder head from falling.

Scheme 103

1. Front side

While tapping the cylinder head with a plastic hammer, separate it from cylinder block.

Remove the bolts (a) and (c) to remove the cylinder head.

Scheme 104

1. Front side

Remove the cylinder head gasket.

Note. Do not scratch the mating surface of cylinder head and cylinder block.

Similarly, remove the right side cylinder head.

Remove the clutch housing cover. (MT model)

Remove the flywheel (MT model) or drive plate (AT model).

Lock the crankshaft using ST.

ST 32005107 CRANKSHAFT STOPPER

Scheme 105

Scheme 106

1. MT model
2. AT model

Remove the oil separator cover.

Remove the water by-pass pipe for heater.

Remove the water pump after loosening the bolts in alphabetical sequence as shown in the figure.

Scheme 107

Remove the oil pump from cylinder block.

Use a flat tip screwdriver as shown in the figure when removing the oil pump.

Scheme 108

Remove the oil pan.

Place the cylinder block to face the #2 and #4 piston side upward.

Remove the bolts which secure oil pan to cylinder block.

Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan.

Note. Do not use a screwdriver or similar tools in place of oil pan cutter.

Scheme 109

Remove the oil strainer stay.

Remove the oil strainer.

Remove the baffle plate.

Remove the oil filter using ST.

ST 32005021 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in))

Scheme 110

Remove the water pipe.

Scheme 111

Scheme 112

1. Service hole plug
2. Gasket
3. Snap ring
4. Piston pin
5. Service hole cover
6. O-ring

Remove the service hole cover and service hole plugs using a hexagon wrench (14 mm).

Scheme 113

Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.

Scheme 114

Draw out the piston pin from #1 and #2 pistons using ST.

ST 32005124 PISTON PIN REMOVER

Note. Be careful not to confuse the original combination of piston, piston pin and cylinder.

Scheme 115

Similarly remove the piston pins from #3 and #4 pistons.

Remove the bolts which connect cylinder block on the side of #2 and #4 cylinders.

Back off the bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.

Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts.

Separate the cylinder block (RH) and (LH).

Note. When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.

Scheme 116

1. Cylinder block
2. Rear oil seal
3. Crankshaft
4. Crankshaft bearing
5. Piston

Remove the rear oil seal.

Remove the crankshaft together with connecting rod.

Remove the crankshaft bearings from cylinder block using a hammer handle.

Note. Be careful not to confuse the crankshaft bearing combination. Press the bearing at the end opposite to locking lip.

Draw out each piston from cylinder block using a wooden bar or hammer handle.

Note. Be careful not to confuse the original combination of piston and cylinder.

Scheme 117

1. Crankshaft bearing
2. Crankshaft
3. Cylinder block
4. Rear oil seal

Note. Remove oil on the mating surface of bearing and cylinder block before installation. Apply a coat of engine oil to crankshaft pins.

Position the crankshaft on the #2 and #4 cylinder block.

Apply liquid gasket to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block.

Liquid gasket

THREE BOND 1215 (Part No. 32005013) or equivalent

Note. Do not allow liquid gasket to flow into O-ring grooves, oil passages, bearing grooves, etc.

Scheme 118

Tighten the 10 mm cylinder block connecting bolts on LH side (A - D) in alphabetical sequence.

Tightening torque

10 Nm (1.0 kgf-m, 7.4 ft-lb)

Scheme 119

Tighten the 10 mm cylinder block connecting bolts on RH side (E - J) in alphabetical sequence.

Tightening torque

10 Nm (1.0 kgf-m, 7.4 ft-lb)

Scheme 120

Further tighten the LH side bolts (A - D) in alphabetical sequence.

Tightening torque

(A), (C): 18 Nm (1.8 kgf-m, 13.3 ft -lb)

(B), (D): 18 Nm (1.8 kgf-m, 13.3 ft -lb)

Scheme 121

Further tighten the RH side bolts (E - J) in alphabetical sequence.

Tightening torque

(E), (F), (G), (I): 18 Nm (1.8 kgf-m, 13.3 ft-lb)

(H), (J): 18 Nm (1.8 kgf-m, 13.3 ft-lb)

Scheme 122

Further tighten the LH side bolts (A), (C) to 90°, (B), (D) 40 Nm (4.1 kgf-m, 29.5 ft-lb) in alphabetical sequence.

Scheme 123

Further tighten the RH side bolts (E - J) to 90° in alphabetical sequence.

Scheme 124

Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A - H) in alphabetical sequence.

Tightening torque

(A) - (G): 25 Nm (2.5 kgf-m, 18.1 ft -lb)

(H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)

Scheme 125

Install the rear oil seal using ST1 and ST2.

ST1 32005141 OIL SEAL GUIDE

ST2 32005136 OIL SEAL INSTALLER

Scheme 126

1. Rear oil seal
2. Flywheel attaching bolt

Position the top ring gap at (A) or (B) in the figure.

Position the second ring gap at 180° on the reverse side of the top ring gap.

Scheme 127

Position the upper rail gap at (C) in the figure.

Scheme 128

Align the upper rail spin stopper (E) to the side hole (D) on the piston.

Scheme 129

Position the expander gap at 180° on the reverse side of (C) that shown (F) in the figure.

Scheme 130

Position the lower rail gap at 120° on counterclockwise of (C) that shown (G) in the figure.

Scheme 131

Install the snap ring.

Install snap rings in the piston holes located opposite to the service holes in cylinder block, when positioning all pistons in the corresponding cylinders.

Note. Use new snap rings.

Scheme 132

1. Front side

Scheme 133

Scheme 134

1. Piston
2. Piston pin
3. Snap ring
4. Gasket
5. Service hole plug Tightening torque: Nm (kgf-m, ft-lb) T: 70 (7.1, 50.6)

Install the piston.

Place the cylinder block to face the #1 and #2 cylinder side upward.

Using ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center.

ST1 32005170 CRANKSHAFT SOCKET

Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2.

ST2 32005114 PISTON GUIDE

Scheme 135

Install the piston pin.

Apply a coat of engine oil to ST3.

Insert ST3 into the service hole to align piston pin hole with connecting rod small end.

ST3 32005121 PISTON PIN GUIDE

Scheme 136

Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.

Install the snap ring.

Note. Use new snap rings.

Scheme 137

Apply liquid gasket around the service hole plug.

Liquid gasket

THREE BOND 1215 (Part No. 32005013) or equivalent

Scheme 138

Install the service hole plug and gasket.

Note. Use a new gasket.

Scheme 139

Scheme 140

1. Piston
2. Piston pin
3. Snap ring
4. Gasket
5. Service hole plug
6. Service hole cover
7. O-ring Tightening torque: Nm (kgf-m, ft-lb) T1: 6.4 (0.65, 4.7) T2: 70 (7.1, 50.6)

Place the cylinder block to face the #3 and #4 cylinder side upward. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.

Install the water pipe.

Scheme 141

Install the baffle plate.

Tightening torque

6.4 Nm (0.65 kgf-m, 4.7 ft-lb)

Install the oil strainer and O-ring.

Tightening torque

10 Nm (1.0 kgf-m, 7.2 ft-lb)

Install the oil strainer stay.

Apply liquid gasket to mating surfaces and install the oil pan.

Liquid gasket

THREE BOND 1207C (Part No. 32005015) or equivalent

Scheme 142

Apply liquid gasket to mating surfaces and install the oil separator cover.

Liquid gasket

THREE BOND 1207C (Part No. 32005015) or equivalent

Scheme 143

Install the flywheel. (MT model)

To lock the crankshaft, use the ST.

ST 32005107 CRANKSHAFT STOPPER

Tightening torque

72 Nm (7.3 kgf-m, 52.8 ft -lb)

Scheme 144

Install the drive plate.

To lock the crankshaft, use the ST.

ST 32005107 CRANKSHAFT STOPPER

Tightening torque

72 Nm (7.3 kgf-m, 52.8 ft -lb)

Scheme 145

Install the housing cover.

Installation of oil pump

Discard the front oil seal after removal. Replace with a new one using ST.

ST 32005135 OIL SEAL INSTALLER

Scheme 146

Apply liquid gasket to the matching surface of oil pump.

Liquid gasket

THREE BOND 1215 (Part No. 32005013) or equivalent

Scheme 147

1. O-ring

Apply a coat of engine oil to the inside of oil seal.

Scheme 148

Install the oil pump on cylinder block. Be careful not to damage the oil seal during installation.

Tightening torque

6.4 Nm (0.65 kgf-m, 4.7 ft-lb)

Install the water pump and gasket.

Tightening torque

First: 12 Nm (1.2 kgf-m, 8.7 ft-lb)

Second: 14 Nm (1.4 kgf-m, 10.2 ft -lb)

Scheme 149

Install the water by-pass pipe for heater.

Install the oil filter using ST.

ST 32005021 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in))

Install the oil filter by turning it by hand, being careful not to damage the seal rubber.

Tighten the oil filter 68 mm (2.68 in) in diameter by approx. 1 rotation more after the seal rubber of oil filter comes in contact with cylinder block or oil cooler.

Tighten the cylinder head bolts.

Apply a coat of engine oil to washers and bolt threads.

Tighten all bolts to 29 Nm (3.0 kgf-m, 22 ft-lb) in alphabetical sequence. Then tighten all bolts to 69 Nm (7.0 kgf-m, 51 ft-lb) in alphabetical sequence.

Back off all bolts by 180° first; and back them off again by 180°.

Tighten the bolts (a) and (b) to 34 Nm (3.5 kgf-m, 25 ft-lb).

Tighten the bolts (c), (d), (e) and (f) to 15 Nm (1.5 kgf-m, 11 ft-lb).

Tighten all bolts by 80° - 90° in alphabetical sequence.

Further tighten all bolts by 80° - 90° in alphabetical sequence.

Scheme 150

1. Front side

Install the oil level gauge guide and tighten the bolt (left side only).

Install the rocker cover and rocker cover gasket.

Note. Use new rocker cover gasket.

Install the crank sprocket.

Install the cam sprocket.

Install the timing belt.

Install the timing belt cover.

Install the crank pulley.

Install the generator and A/C compressor brackets on cylinder head.

Install the V-belts.

Install the intake manifold.

Scheme 151

1. Connecting rod cap
2. Connecting rod bearing
3. Top ring
4. Second ring
5. Oil ring
6. Snap ring

Remove the connecting rod cap.

Remove the connecting rod bearing.

Note. Arrange the removed connecting rod, connecting rod cap and bearing in order, to prevent confusion.

Remove the piston rings using the piston ring expander.

Remove the oil ring by hand.

Note. Arrange the removed piston rings in proper order, to prevent confusion.

Remove the snap ring.

Scheme 152

1. Connecting rod bearing
2. Connecting rod
3. Connecting rod cap
4. Oil ring
5. Second ring
6. Top ring
7. Snap ring
8. Side mark Tightening torque: Nm (kgf-m, ft-lb) T: 45 (4.6, 33.3)

Apply oil to the surfaces of the connecting rod bearings.

Install the connecting rod bearings on connecting rods and connecting rod caps.

Position each connecting rod with the marked side facing forward, and install it.

Install the connecting rod cap with connecting rod nut.

Ensure the arrow on connecting rod cap faces toward front during installation.

Install the expander, lower rail and upper rail in this order by hand. Install the second ring and top ring with a piston ring expander.