Engine Mechanical (H4DOTC): Other Subaru Forester SJ

CAUTION

1. Prior to starting work, pay special attention to the following: Always wear work clothes, a safety cap, protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary. Protect the vehicle using a seat cover, fender cover, etc. Prepare the service tools, clean cloth, containers to catch grease and oil, etc.
2. Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.
3. When performing a repair, identify the cause of trouble and avoid unnecessary removal, disassembly and replacement.
4. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.
5. Always use the jack-up point when the shop jacks or rigid racks are used to support the vehicle.
6. Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use.
7. When lifting up the vehicle, make sure to support the vehicle at the jack-up points.
8. Remove contamination including dirt and corrosion before removal, installation, disassembly or assembly.
9. Keep the removed parts in order and protect them from dust and dirt.
10. All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.
11. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil when being assembled.
12. Bolts, nuts and washers should be replaced with new parts as required.
13. Be sure to tighten the fasteners including bolts and nuts to the specified torque.

GENERAL TOOL

V-BELT

Install in the reverse order of removal.

Scheme 618

V-BELT TENSIONER ASSY

Install in the reverse order of removal.

Note. When installing the V-belt tensioner assembly, insert the protrusion of V-belt tensioner assembly into the hole for preventing rotation at the generator bracket.

Scheme 619

Tightening torque

25 N.m (2.5 kgf-m, 18.4 ft-lb)

IDLER PULLEY

Install in the reverse order of removal.

Note. When installing the idler pulley, be careful of the idler pulley cover direction.

Scheme 620

Tightening torque

36 N.m (3.7 kgf-m, 26.6 ft-lb)

Scheme 621

Scheme 622

1. Check the V-belt for cracks, tear or wear.
2. Check the V-belt tensioner assembly and idler pulley for deformation, cracks or other damages.
3. Check that the V-belt ribs are securely placed on the rib grooves for each pulleys.
4. Check that the V-belt tensioner assembly (C) moves in the direction of arrow (D), when the V-belt (A) is pushed and released by the area indicated by the arrow (B).

TIMING CHAIN RH

Note. When replacing a single part, perform the work with the engine assembly installed to body.

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1. Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. >
2. Using ST and by turning the crankshaft, align the alignment marks of crank sprocket, intake cam sprocket RH and exhaust cam sprocket RH to the positions as shown in the figure. NOTE: If the alignment marks are aligned to the positions as shown in the figure, the crankshaft key is located at six o'clock position. ST 18252AA000 CRANKSHAFT SOCKET
3. Push down the chain lever tensioner RH, and with a 2.5 mm (0.98 in) dia. stopper pin or a 2.5 mm (0.98 in) dia. hex wrench inserted into the stopper pin hole in the chain tensioner RH, secure the plunger (A).
4. Remove the chain tensioner RH, and remove the chain tensioner lever RH (A).
5. Remove the chain guide RH, and remove the timing chain RH (A). CAUTION: If the timing chain RH is not installed, the intake camshaft RH and exhaust camshaft RH are kept at zero-lift position. All cams on the camshaft are not pressing down the roller rocker arm (intake valve and exhaust valve). (Under this condition, all valves remain unlifted.) Intake camshaft RH and exhaust camshaft RH can be independently rotated with the timing chain RH removed. When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn it to the outside of range of zero-lift (in range where it can be turned lightly by hand). NOTE: To avoid mixing with LH side, keep the removed part in order.
6. Remove the chain guide RH from the front camshaft cap RH.

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1. Remove the timing chain RH. < Ref. to «TIMING CHAIN RH»(ref-662117-S23766873962014101300000) , REMOVAL, Timing Chain Assembly. >
2. Using ST and by turning the crankshaft, align the alignment marks of crankshaft key, intake cam sprocket LH and exhaust cam sprocket LH to the positions as shown in the figure. ST 18252AA000 CRANKSHAFT SOCKET
3. Push up the chain tensioner lever LH as shown in the figure, and with a stopper pin measuring 1.3 mm (0.05 in) dia. or less (clips, etc.), or with a hex wrench measuring 1.3 mm (0.05 in) dia. inserted into the stopper pin hole in the chain tensioner LH, secure the plunger (A).
4. Remove the chain tensioner LH, and remove the chain tensioner lever LH (A).
5. Remove the O-ring from the cylinder block LH.
6. Remove the chain guide LH, and remove the timing chain LH (A). CAUTION: If the timing chain LH is not installed, the exhaust camshaft LH is kept at zero-lift position. All cams on the exhaust camshaft LH are not pressing down the roller rocker arm (exhaust valve). (Under this condition, exhaust valves remain unlifted.) Intake camshaft LH is kept at lift position. All cams on the intake camshaft LH are pressing down the roller rocker arm (intake valve). (Under this condition, intake valves remain lifted.) Intake camshaft LH and exhaust camshaft RH can be independently rotated with the timing chain LH removed. When the exhaust camshaft LH is turned, the valve heads contact each other and valve stem may bend as described in above. Do not turn the exhaust camshaft LH to the outside of range of zero-lift (in range where it can be turned lightly by hand). #1 piston and #4 piston are located near TDC. If the intake camshaft LH is turned, the valve and the piston may contact and valve stem may bend. Do not turn the intake camshaft LH at this time. NOTE: To avoid mixing with RH side, keep the removed part in order.
7. Using ST and by turning the crankshaft approximately 200° clockwise, align the alignment marks of crank sprocket to the positions as shown in the figure. CAUTION: This procedure is required to prevent the valve and piston contacting with each other, by moving the all pistons to the middle of the cylinders. Never turn counterclockwise because the valve and piston may contact. Counterclockwise turn is allowed only when adjusting precisely the alignment marks, after turning the crank sprocket alignment mark clockwise near the position as shown in the figure. ST 18252AA000 CRANKSHAFT SOCKET
8. Using ST and by turning the intake cam sprocket LH approximately 130°, align the alignment marks of intake cam sprocket LH to the positions (zero-lift position) as shown in the figure. CAUTION: After this work, when the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn the intake camshaft LH and exhaust camshaft LH to the outside of range of zero-lift (in range where it can be turned lightly by hand). NOTE: Intake camshaft LH has three peaks of drive sections for the high-pressure fuel pump. Therefore, there is little range where it can be turned lightly by hand in zero-lift position. ST1 18355AA000 PULLEY WRENCH ST2 18334AA030 PULLEY WRENCH PIN SET
9. Remove the chain guide LH from the front camshaft cap LH.

TIMING CHAIN LH

Note. Be careful that the foreign matter is not into or onto the assembled component during installation. Apply engine oil to all component parts of the timing chain.

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1. Install the chain guide LH to the front camshaft cap LH. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
2. Prepare to attach the chain tensioner LH. Move the link plate (A) in the direction of arrow to press in the plunger (B). With a stopper pin measuring 1.3 mm (0.05 in) dia. or less (clips, etc.) or a hex wrench measuring 1.3 mm (0.05 in) dia. inserted into the stopper pin hole, secure the plunger. NOTE: If the stopper pin hole on the link plate and the stopper pin hole on the chain tensioner are not aligned, check that the first notch of plunger rack (A) is engaged with the stopper tooth (B). If not engaged, retract the plunger a little so that the first notch of plunger rack (A) is engaged with the stopper tooth (B).
3. Check that the crank sprocket is located at the position sown in the figure. If not aligned, using ST turn the crankshaft to align the crank sprocket alignment mark to the position shown in the figure. NOTE: This procedure is required to prevent the valve and piston contacting with each other in the next step. ST 18252AA000 CRANKSHAFT SOCKET
4. Using ST and by turning the intake cam sprocket LH, align the alignment marks to the positions as shown in the figure. CAUTION: When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn the exhaust camshaft LH. ST1 18355AA000 PULLEY WRENCH ST2 18334AA030 PULLEY WRENCH PIN SET
5. Using ST and by turning the crankshaft approximately 130° counterclockwise, align the alignment marks of crankshaft key to the positions as shown in the figure. CAUTION: Never turn clockwise because the valve and piston may contact. Clockwise turn is allowed only when adjusting the key position precisely, after turning the crankshaft counterclockwise to bring the key near the position as shown in the figure. ST 18252AA000 CRANKSHAFT SOCKET
6. Align the alignment mark of exhaust cam sprocket LH to the position shown in the figure. CAUTION: To prevent valve damage, turn the exhaust cam sprocket LH only within the range of zero-lift (in range where it can be turned lightly by hand).
7. Install the timing chain LH and the timing chain guide LH. Match the timing chain mark (blue) to the alignment mark of the crank sprocket. Match the timing chain mark (pink) to the timing mark position of the intake cam sprocket LH. Match the timing chain mark (pink) to the timing mark position of the exhaust cam sprocket LH. Install timing chain guide LH. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
8. Install O-rings to the cylinder block LH. NOTE: Use new O-rings.
9. Install the chain tensioner lever LH (A) and chain tensioner LH. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
10. Pull out the stopper pin from the chain tensioner LH. CAUTION: Confirm the following before pulling out the stopper pin. Matching of the timing chain mark (blue) to the alignment mark of the crank sprocket. Matching of the timing chain mark (pink) to the timing mark position of the intake cam sprocket LH. Matching of the timing chain mark (pink) to the timing mark position of the exhaust cam sprocket LH. NOTE: If the stopper pin cannot be removed, lift the chain tension lever LH to remove as shown in the figure.
11. Using the ST, turn the crankshaft clockwise, and make sure that there are no abnormal conditions. CAUTION: Always make sure to perform this confirmation. ST 18252AA000 CRANKSHAFT SOCKET
12. Using ST and by turning the crankshaft, align the alignment marks of crank sprocket, intake cam sprocket LH and exhaust cam sprocket LH to the positions as shown in the figure. NOTE: If the alignment marks are aligned to the positions as shown in the figure, the crankshaft key is located at six o'clock position. ST 18252AA000 CRANKSHAFT SOCKET
13. Install the timing chain RH. < Ref. to «TIMING CHAIN RH»(ref-662117-S20732787172014101300000) , INSTALLATION, Timing Chain Assembly. >

Note. Be careful that the foreign matter is not into or onto the assembled component during installation. Apply engine oil to all component parts of the timing chain.

Scheme 647

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Scheme 654

1. Install timing chain LH. < Ref. to «TIMING CHAIN LH»(ref-662117-S29719316172014101300000) , INSTALLATION, Timing Chain Assembly. >
2. Install the chain guide RH to the front camshaft cap RH. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
3. Prepare to attach the chain tensioner RH. Move the link plate (A) in the direction of arrow to press in the plunger (B). With a 2.5 mm (0.98 in) dia. stopper pin or a 2.5 mm (0.98 in) (nominal) dia. hex wrench inserted into the stopper pin hole, secure the plunger. NOTE: If the stopper pin hole on the link plate and the stopper pin hole on the chain tensioner are not aligned, check that the first notch of plunger rack (A) is engaged with the stopper tooth (B). If not engaged, retract the plunger a little so that the first notch of plunger rack (A) is engaged with the stopper tooth (B).
4. Make sure that the alignment marks of the crank sprocket, intake cam sprocket LH and exhaust cam sprocket LH are aligned to the positions as shown in the figure.
5. Align the alignment marks of intake cam sprocket RH and exhaust cam sprocket RH to the positions as shown in the figure. CAUTION: To prevent valve damage, turn the intake cam sprocket RH and exhaust cam sprocket RH only within the range of zero-lift (in range where it can be turned lightly by hand).
6. Install the timing chain RH and the timing chain guide RH. Match the timing chain mark (blue) to the alignment mark of the crank sprocket. Match the timing chain mark (pink) to the timing mark position of the intake cam sprocket RH. Match the timing chain mark (pink) to the timing mark position of the exhaust cam sprocket RH. Install the timing chain guide RH. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
7. Install the chain tensioner lever RH (A) and chain tensioner RH. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
8. Pull out the stopper pin from the chain tensioner RH. CAUTION: Confirm the following before pulling out the stopper pin. Matching of the timing chain mark (blue) to the alignment mark of the crank sprocket. Matching of the timing chain mark (pink) to the timing mark position of the intake cam sprocket RH. Matching of the timing chain mark (pink) to the timing mark position of the exhaust cam sprocket RH.
9. Make sure that the alignment marks of the cam sprocket and crank sprocket are aligned to the positions as shown in the figure.
10. Using the ST, turn the crankshaft clockwise, and make sure that there are no abnormal conditions. CAUTION: Always make sure to perform this confirmation. ST 18252AA000 CRANKSHAFT SOCKET
11. Install the chain cover. < Ref. to «INSTALLATION»(ref-662117-S40394697302014101300000) , Chain Cover. >

CAM SPROCKET RH

Note. When replacing a single part, perform the work with the engine assembly installed to body.

Scheme 655

Scheme 656

1. Intake cam sprocket RH Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. > Remove the timing chain RH. < Ref. to «TIMING CHAIN RH»(ref-662117-S23766873962014101300000) , REMOVAL, Timing Chain Assembly. > Hold the intake cam sprocket RH using the ST1 and ST2, and remove the bolts using the ST3. ST1 18355AA000 PULLEY WRENCH ST2 18334AA030 PULLEY WRENCH PIN SET ST3 18270KA010 SOCKET Remove the intake cam sprocket RH.
2. Exhaust cam sprocket RH Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. > Remove the timing chain RH. < Ref. to «TIMING CHAIN RH»(ref-662117-S23766873962014101300000) , REMOVAL, Timing Chain Assembly. > Hold the exhaust cam sprocket RH using the ST1 and ST2, and remove the bolts using the ST3. ST1 18355AA000 PULLEY WRENCH ST2 18334AA030 PULLEY WRENCH PIN SET ST3 18270KA010 SOCKET Remove the exhaust cam sprocket RH.

CAM SPROCKET LH

Note. When replacing a single part, perform the work with the engine assembly installed to body.

Scheme 657

Scheme 658

1. Intake cam sprocket LH Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. > Remove the timing chain LH. < Ref. to «TIMING CHAIN LH»(ref-662117-S18193102732014101300000) , REMOVAL, Timing Chain Assembly. > Hold the intake cam sprocket LH using the ST1 and ST2, and remove the bolts using the ST3. ST1 18355AA000 PULLEY WRENCH ST2 18334AA030 PULLEY WRENCH PIN SET ST3 18270KA010 SOCKET Remove the intake cam sprocket LH.
2. Exhaust cam sprocket LH Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. > Remove the timing chain LH. < Ref. to «TIMING CHAIN LH»(ref-662117-S18193102732014101300000) , REMOVAL, Timing Chain Assembly. > Hold the exhaust cam sprocket LH using the ST1 and ST2, and remove the bolts using the ST3. ST1 18355AA000 PULLEY WRENCH ST2 18334AA030 PULLEY WRENCH PIN SET ST3 18270KA010 SOCKET Remove the exhaust cam sprocket LH.

Scheme 659

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1. Intake cam sprocket RH Install the intake cam sprocket RH by aligning the knock hole (A) of intake cam sprocket RH and the knock pin (B) of intake camshaft RH. NOTE: Before installation, check that there is no foreign matter on the intake cam sprocket RH and intake camshaft RH. Hold the intake cam sprocket RH using the ST1 and ST2, and install the bolts using the ST3. ST1 18355AA000 PULLEY WRENCH ST2 18334AA030 PULLEY WRENCH PIN SET ST3 18270KA010 SOCKET Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Install the timing chain RH. < Ref. to «TIMING CHAIN RH»(ref-662117-S20732787172014101300000) , INSTALLATION, Timing Chain Assembly. > Install the chain cover. < Ref. to «INSTALLATION»(ref-662117-S40394697302014101300000) , Chain Cover. >
2. Exhaust cam sprocket RH Install the exhaust cam sprocket RH by aligning the knock hole (A) of exhaust cam sprocket RH and the knock pin (B) of exhaust camshaft RH. NOTE: Before installation, check that there is no foreign matter on the exhaust cam sprocket RH and exhaust camshaft RH. Hold the exhaust cam sprocket RH using ST1 and ST2, and install the bolts using ST3. ST1 18355AA000 PULLEY WRENCH ST2 18334AA030 PULLEY WRENCH PIN SET ST3 18270KA010 SOCKET Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Install the timing chain RH. < Ref. to «TIMING CHAIN RH»(ref-662117-S20732787172014101300000) , INSTALLATION, Timing Chain Assembly. > Install the chain cover. < Ref. to «INSTALLATION»(ref-662117-S40394697302014101300000) , Chain Cover. >

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1. Intake cam sprocket LH Install the intake cam sprocket LH by aligning the knock hole (A) of intake cam sprocket LH and the knock pin (B) of intake camshaft LH. NOTE: Before installation, check that there is no foreign matter on the intake cam sprocket LH and intake camshaft LH. Hold the intake cam sprocket LH using the ST1 and ST2, and install the bolts using the ST3. ST1 18355AA000 PULLEY WRENCH ST2 18334AA030 PULLEY WRENCH PIN SET ST3 18270KA010 SOCKET Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Install timing chain LH. < Ref. to «TIMING CHAIN LH»(ref-662117-S29719316172014101300000) , INSTALLATION, Timing Chain Assembly. > Install the chain cover. < Ref. to «INSTALLATION»(ref-662117-S40394697302014101300000) , Chain Cover. >
2. Exhaust cam sprocket LH Install the exhaust cam sprocket LH by aligning the knock hole (A) of exhaust cam sprocket LH and the knock pin (B) of exhaust camshaft LH. NOTE: Before installation, check that there is no foreign matter on the exhaust cam sprocket LH and exhaust camshaft LH. Hold the exhaust cam sprocket LH using the ST1 and ST2, and install the bolts using the ST3. ST1 18355AA000 PULLEY WRENCH ST2 18334AA030 PULLEY WRENCH PIN SET ST3 18270KA010 SOCKET Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Install timing chain LH. < Ref. to «TIMING CHAIN LH»(ref-662117-S29719316172014101300000) , INSTALLATION, Timing Chain Assembly. > Install the chain cover. < Ref. to «INSTALLATION»(ref-662117-S40394697302014101300000) , Chain Cover. >

ROCKER COVER RH

Note. When replacing a single part, perform the work with the engine assembly installed to body.

Scheme 667

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1. When working on the vehicle NOTE: When working on the vehicle, perform the following steps also. Remove the air cleaner case. < Ref. to «REMOVAL»(ref-662121-S18634593152014101300000) , Air Cleaner Case. >
2. Remove the #1 ignition coil and the #3 ignition coil. < Ref. to «REMOVAL»(ref-662115-S39420678992014101300000) , Ignition Coil. >
3. Remove the rocker cover RH.
4. Remove the rocker cover gasket RH, #1 spark plug pipe gasket and #3 spark plug pipe gasket, and remove the liquid gasket. CAUTION: When removing the liquid gasket from engine unit using scraper, use special care not to damage the cam lobe of camshaft RH. If the cam lobe of camshaft RH interferes, turn the crankshaft to the position where the scraper does not touch.

ROCKER COVER LH

Note. When replacing a single part, perform the work with the engine assembly installed to body.

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1. When working on the vehicle NOTE: When working on the vehicle, perform the following steps also. Open the front hood, and remove the upper grille bracket from the front hood. Using a marker pen, make alignment marks (A) on both the front hood and the front hood striker. Remove the front hood striker from the front hood. Remove the front center grille assembly from the front hood. Change the front hood damper mounting position from (A) to (B), and completely open the front hood. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb) Remove the clip (A), lift the front of the collector cover in the direction of arrow, and then remove the collector cover. Remove the battery. < Ref. to «REMOVAL»(ref-662144-S03551831502014101300000) , Battery. > Remove the air intake duct (rear). < Ref. to «REMOVAL»(ref-662121-S38398809152014101300000) , Air Intake Duct. > Remove the front exhaust pipe. < Ref. to «REMOVAL»(ref-662147-S11833000002014101300000) , Front Exhaust Pipe. > Remove the nuts which secure the engine mounting to the front crossmember. Lower the vehicle. Remove the intercooler. < Ref. to «REMOVAL»(ref-662121-S20295609002014101300000) , Intercooler. > Disconnect the connector (A) from the brake vacuum pump. Disconnect connector (B) and terminal (C) from the generator, and remove the clip (D) securing the generator cord to the intake manifold. Disconnect connector (A) from A/C compressor, and remove the generator cord from clip (B). Remove the clip (C) securing the generator cord to the fuel pipe protector, and move the generator cord to the left side wheel apron. Disconnect the connector from pressure switch (triple pressure switch). Remove the fuel pipe protector from the high-pressure fuel pump case and intake manifold. Remove the pitching stopper. Remove the bolt securing the transmission harness stay to the CVT. NOTE: This procedure is required to prevent the transmission connector from touching the A/C pressure hose during engine removal/installation. Support the engine with a lifting device and wire ropes. Lift the engine high enough until the stud bolt of the engine mount is drawn out of the crossmember. CAUTION: When lifting up the engine, pay attention to the clearance of each part and be careful not to lift the engine too much, in order to prevent damaging the vehicle. Set the ST between the engine mount and crossmember, and slowly lower the engine. CAUTION: After lowering the engine, check that the ST does not come off even if the engine is bounced. ST 18632AA020 STAND ASSY Remove the lifting device and wire ropes.
2. Remove the side engine oil cooler pipe assembly. < Ref. to «SIDE ENGINE OIL COOLER PIPE»(ref-662113-S33078556482014101300000) , REMOVAL, Engine Oil Cooler Pipe. >
3. Remove the #2 ignition coil and the #4 ignition coil. < Ref. to «REMOVAL»(ref-662115-S39420678992014101300000) , Ignition Coil. >
4. Remove the connector from the water pipe LH.
5. Remove the rocker cover LH.
6. Remove the rocker cover gasket LH, #2 spark plug pipe gasket and #4 spark plug pipe gasket, and remove the liquid gasket. CAUTION: When removing the liquid gasket from engine unit using scraper, use special care not to damage the cam lobe of camshaft LH. If the cam lobe of camshaft LH interferes, turn the crankshaft to the position where the scraper does not touch.

Scheme 679

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1. Install the #1 spark plug pipe gasket and #3 spark plug pipe gasket to the #1 spark plug pipe and #3 spark plug pipe. NOTE: Use a new #1 spark plug pipe gasket and #3 spark plug pipe gasket. Apply a light coat of engine oil to the #1 spark plug pipe gasket and #3 spark plug pipe gasket, and insert them onto the spark plug pipe edge (A).
2. Install the rocker cover gasket RH to the rocker cover RH. NOTE: Use a new rocker cover gasket RH.
3. Apply liquid gasket to the mating surface of rocker cover RH as shown in the figure. NOTE: Before applying liquid gasket, degrease the old liquid gasket seal surface of the engine. Be careful not to allow liquid gasket to be squeezed out from rocker cover RH. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 3±1 mm (0.1181±0.0394 in)
4. Set the rocker cover RH, and tighten the bolts in numerical order as shown in the figure. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
5. Install the #1 ignition coil and the #3 ignition coil. < Ref. to «INSTALLATION»(ref-662115-S28146449132014101300000) , Ignition Coil. >
6. When working on the vehicle Install the air cleaner case. < Ref. to «INSTALLATION»(ref-662121-S38797742302014101300000) , Air Cleaner Case. >

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1. Install the #2 spark plug pipe gasket and #4 spark plug pipe gasket to the #2 spark plug pipe and #4 spark plug pipe. NOTE: Use a new #2 spark plug pipe gasket and #4 spark plug pipe gasket. Apply a light coat of engine oil to the #2 spark plug pipe gasket and #4 spark plug pipe gasket, and insert them onto the spark plug pipe edge (A).
2. Install the rocker cover gasket LH to the rocker cover LH. NOTE: Use a new rocker cover gasket LH.
3. Apply liquid gasket to the mating surface of rocker cover LH as shown in the figure. NOTE: Before applying liquid gasket, degrease the old liquid gasket seal surface of the engine. Be careful not to allow liquid gasket to be squeezed out from rocker cover LH. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 3±1 mm (0.1181±0.0394 in)
4. Set the rocker cover LH, and tighten the bolts in numerical order as shown in the figure. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
5. Connect the connector to the water pipe LH.
6. Install the #2 ignition coil and the #4 ignition coil. < Ref. to «INSTALLATION»(ref-662115-S28146449132014101300000) , Ignition Coil. >
7. Install the side engine oil cooler pipe assembly. < Ref. to «SIDE ENGINE OIL COOLER PIPE»(ref-662113-S23148570782014101300000) , INSTALLATION, Engine Oil Cooler Pipe. >
8. When working on the vehicle Support the engine with a lifting device and wire ropes. Lift the engine, and remove the ST. CAUTION: When lifting up the engine, pay attention to the clearance of each part and be careful not to lift the engine too much, in order to prevent damaging the vehicle. ST 18632AA020 STAND ASSY Lower the engine and remove the lifting device and wire ropes. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb) T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb) Install the bolt which secures the transmission harness stay to the CVT. Tightening torque: 15 N.m (1.6 kgf-m, 11.8 ft-lb) Install the fuel pipe protector to the high-pressure fuel pump case and intake manifold. Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb) Connect the connector to the pressure switch (triple pressure switch). Set the generator cord, and fix the generator cord to the fuel pipe protector using clip (C). Install the generator cord to clip (B), and connect the connector (A) to A/C compressor. Using clip (D), fix the generator cord to the generator cord stay, and connect the connector (B) and the terminal (C) to the generator. Tightening torque: 15 N.m (1.5 kgf-m, 11.1 ft-lb) Connect the connector (A) to the brake vacuum pump. Install the intercooler. < Ref. to «INSTALLATION»(ref-662121-S02050373282014101300000) , Intercooler. > Lift up the vehicle. Install the nuts which hold the engine mounting to the crossmember. NOTE: Make sure that locators (A) of the engine mounting are securely inserted. Tightening torque: 45 N.m (4.6 kgf-m, 33.2 ft-lb) Install the front exhaust pipe. < Ref. to «INSTALLATION»(ref-662147-S39175225412014101300000) , Front Exhaust Pipe. > Install the air intake duct (rear). < Ref. to «INSTALLATION»(ref-662121-S35607443062014101300000) , Air Intake Duct. > Install the battery. < Ref. to «INSTALLATION»(ref-662144-S27539781662014101300000) , Battery. > Fill engine coolant. < Ref. to «FILLING OF ENGINE COOLANT»(ref-662123-S39370784392014101300000) , REPLACEMENT, Engine Coolant. > Install the collector cover. Change the installation position of the front hood damper from (B) to (A). Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb) Install the front center grille assembly to the front hood. Tightening torque: 4.5 N.m (0.5 kgf-m, 3.3 ft-lb) Align the alignment marks (A), and install the front hood striker to the front hood. Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb) Install the upper grille bracket to the front hood, and close the front hood. Tightening torque: 4.5 N.m (0.5 kgf-m, 3.3 ft-lb)

CAMSHAFT RH

The camshaft RH and cam carrier are designed as removing as a unit. Refer to "Cam Carrier" for removal procedures of camshaft RH. < Ref. to CAM CARRIER RH , REMOVAL, Cam Carrier. > < Ref. to CAM CARRIER RH , DISASSEMBLY, Cam Carrier. >

CAMSHAFT LH

The camshaft LH and cam carrier are designed as removing as a unit. Refer to "Cam Carrier" for removal procedures of camshaft LH. < Ref. to CAM CARRIER LH , REMOVAL, Cam Carrier. > < Ref. to CAM CARRIER LH , DISASSEMBLY, Cam Carrier. >

The camshaft RH and cam carrier are designed as installing as a unit. Refer to "Cam Carrier" for installation procedures of camshaft RH. < Ref. to CAM CARRIER RH , ASSEMBLY, Cam Carrier. > < Ref. to CAM CARRIER RH , INSTALLATION, Cam Carrier. >

The camshaft LH and cam carrier are designed as installing as a unit. Refer to "Cam Carrier" for installation procedures of camshaft LH. < Ref. to CAM CARRIER LH , ASSEMBLY, Cam Carrier. > < Ref. to CAM CARRIER LH , INSTALLATION, Cam Carrier. >

Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

Scheme 691

1. Remove the engine from the vehicle. < Ref. to «REMOVAL»(ref-662117-S21453755162014101300000) , Engine Assembly. >
2. Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. >
3. Remove the timing chain RH. < Ref. to «TIMING CHAIN RH»(ref-662117-S23766873962014101300000) , REMOVAL, Timing Chain Assembly. >
4. Remove the rocker cover RH. < Ref. to «ROCKER COVER RH»(ref-662117-S21007045862014101300000) , REMOVAL, Rocker Cover. >
5. Remove the clip holding the engine harness from cam carrier RH.
6. Remove the oil pipe assembly from the scavenge pump and cam carrier RH.
7. Disconnect the water pipe hose from oil pan upper and EGR cooler, and remove the water pipe assembly.
8. When disassembling the cam carrier RH NOTE: When disassembling the cam carrier RH, perform the following steps also. Remove the scavenge pump. < Ref. to «REMOVAL»(ref-662113-S30737546732014101300000) , Scavenge Pump. > Remove the cam sprocket RH. < Ref. to «CAM SPROCKET RH»(ref-662117-S21921788932014101300000) , REMOVAL, Cam Sprocket. >
9. Set the part so that the cam carrier RH is on the upper side.
10. Loosen the bolts holding the cam carrier RH equally, a little at a time in numerical sequence as shown in the figure and remove the cam carrier RH.
11. Remove the O-ring and the roller rocker arm from cylinder head RH. NOTE: Be careful not to confuse the roller rocker arms.
12. Remove the valve shim and the roller rocker arm pivot from cylinder head RH. NOTE: Be careful not to confuse the valve shim and the roller rocker arm pivot.
13. Remove the liquid gasket from cam carrier RH and cylinder head RH.

Scheme 692

Scheme 693

Scheme 694

Scheme 695

Scheme 696

Scheme 697

Scheme 698

Scheme 699

Scheme 700

Scheme 701

1. Remove the engine from the vehicle. < Ref. to «REMOVAL»(ref-662117-S21453755162014101300000) , Engine Assembly. >
2. Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. >
3. Remove the timing chain LH. < Ref. to «TIMING CHAIN LH»(ref-662117-S18193102732014101300000) , REMOVAL, Timing Chain Assembly. >
4. Remove the intake manifold. < Ref. to «REMOVAL»(ref-662119-S34762705842014101300000) , Intake Manifold. >
5. Remove the rocker cover LH. < Ref. to «ROCKER COVER LH»(ref-662117-S07706327262014101300000) , REMOVAL, Rocker Cover. >
6. Remove the clip holding the engine harness from cam carrier LH.
7. Remove the fuel pipe protector from the high-pressure fuel pump case.
8. Remove the fuel pump insulator (A) from the high-pressure fuel pump, and then remove the fuel pipe insulator No. 1 (B) from the high-pressure fuel delivery pipe.
9. Disconnect the connector (A) from the high-pressure fuel pump, and remove the fuel delivery pipe from the high-pressure fuel pump. NOTE: Disconnect the quick connector as shown in the figure.
10. Remove the high-pressure fuel delivery pipe from the high-pressure fuel pump and fuel injector pipe.
11. Disconnect the water pipe hose from oil pan upper, and remove the water pipe assembly.
12. When disassembling the cam carrier LH NOTE: When disassembling the cam carrier LH, perform the following steps also. Remove the high-pressure fuel pump. < Ref. to «REMOVAL»(ref-662119-S02254621002014101300000) , High Pressure Fuel Pump. > Remove the cam sprocket LH. < Ref. to «CAM SPROCKET LH»(ref-662117-S22268930602014101300000) , REMOVAL, Cam Sprocket. >
13. Set the part so that the cam carrier LH is on the upper side.
14. Loosen the bolts holding the cam carrier LH equally, a little at a time in numerical sequence as shown in the figure and remove the cam carrier LH.
15. Remove the O-ring and the roller rocker arm from cylinder head LH. NOTE: Be careful not to confuse the roller rocker arms.
16. Remove the valve shim and the roller rocker arm pivot from cylinder head LH. NOTE: Be careful not to confuse the valve shim and the roller rocker arm pivot.
17. Remove the liquid gasket from cam carrier LH and cylinder head LH.

Scheme 702

Scheme 703

Scheme 704

Scheme 705

Scheme 706

Scheme 707

Scheme 708

Scheme 709

Scheme 710

Scheme 711

1. Set the part so that the cylinder head RH is on the upper side.
2. Apply engine oil to the valve shim and the roller rocker arm pivot, and install the valve shim and the roller rocker arm pivot to the cylinder head RH.
3. Apply engine oil to the O-ring and the roller rocker arm, and install the O-ring and the roller rocker arm to the cylinder head RH. NOTE: Use new O-rings.
4. Apply liquid gasket to the mating surface of cam carrier RH as shown in the figure. NOTE: Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder head RH and cam carrier RH. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. 0877Y0100) or equivalent Liquid gasket applying diameter: 3±0.5 mm (0.1181±0.0197 in)
5. Install the cam carrier RH to the cylinder head RH. Mount the cam carrier RH, then tighten all bolts with a torque of 18 N.m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure. NOTE: Set the intake camshaft RH and the exhaust camshaft RH to the zero-lift position as shown in the figure. Loosen the bolts (3 places) by 180° in numerical order as shown in the figure. Tighten the bolts (3 places) with a torque of 18 N.m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure. Loosen the bolts (3 places) by 180° in numerical order as shown in the figure. Tighten the bolts (3 places) with a torque of 18 N.m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure. Loosen the bolts (3 places) by 180° in numerical order as shown in the figure. Tighten the bolts (3 places) with a torque of 18 N.m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure. NOTE: After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket.
6. Set the part so that the intake manifold is on the upper side.
7. When the cam carrier RH has been disassembled NOTE: When the cam carrier RH has been disassembled, perform the following steps also. Install the cam sprocket RH. < Ref. to «CAM SPROCKET RH»(ref-662117-S02883503752014101300000) , INSTALLATION, Cam Sprocket. > Install the scavenge pump. < Ref. to «INSTALLATION»(ref-662113-S38363502212014101300000) , Scavenge Pump. > NOTE: When installing the scavenge pump, do not turn the intake camshaft RH to the outside of range of zero-lift (in range where it can be turned lightly by hand).
8. Check the cam clearance. < Ref. to «WHEN TIMING CHAIN ASSEMBLY IS REMOVED»(ref-662117-S31430679392014101300000) , INSPECTION, Cam Clearance. >
9. Connect the water pipe hose to oil pan upper and EGR cooler, and install the water pipe assembly. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
10. Install the oil pipe assembly to the scavenge pump and cam carrier RH. Set the oil pipe assembly to the scavenge pump and cam carrier RH, and temporarily tighten the bolts which secure the oil pipe assembly to the scavenge pump and cam carrier RH. NOTE: Use a new gasket. Tighten the bolts which secure the oil pipe assembly to the scavenge pump and cam carrier RH in numerical order as shown in the figure. Tightening torque: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 29 N.m (3.0 kgf-m, 21.4 ft-lb)
11. Secure the engine harness to the cam carrier RH with a clip.
12. Install the rocker cover RH. < Ref. to «ROCKER COVER RH»(ref-662117-S06297646842014101300000) , INSTALLATION, Rocker Cover. >
13. Install the timing chain RH. < Ref. to «TIMING CHAIN RH»(ref-662117-S20732787172014101300000) , INSTALLATION, Timing Chain Assembly. >
14. Install the chain cover. < Ref. to «INSTALLATION»(ref-662117-S40394697302014101300000) , Chain Cover. >
15. Install the engine to the vehicle. < Ref. to «INSTALLATION»(ref-662117-S38088321012014101300000) , Engine Assembly. >

Scheme 712

Scheme 713

Scheme 714

Scheme 715

Scheme 716

Scheme 717

Scheme 718

Scheme 719

Scheme 720

Scheme 721

Scheme 722

Scheme 723

1. Set the part so that the cylinder head LH is on the upper side.
2. Apply engine oil to the valve shim and the roller rocker arm pivot, and install the valve shim and the roller rocker arm pivot to the cylinder head LH.
3. Apply engine oil to the O-ring and the roller rocker arm, and install the O-ring and the roller rocker arm to the cylinder head LH. NOTE: Use new O-rings.
4. Apply liquid gasket to the mating surface of cam carrier LH as shown in the figure. NOTE: Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder head LH and cam carrier LH. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. 0877Y0100) or equivalent Liquid gasket applying diameter: 3±0.5 mm (0.1181±0.0197 in)
5. Install the cam carrier LH to the cylinder head LH. Mount the cam carrier LH, then tighten all bolts with a torque of 18 N.m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure. NOTE: Set the intake camshaft LH and the exhaust camshaft LH to the zero-lift position as shown in the figure. Loosen the bolts (3 places) by 180° in numerical order as shown in the figure. Tighten the bolts (3 places) with a torque of 18 N.m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure. Loosen the bolts (3 places) by 180° in numerical order as shown in the figure. Tighten the bolts (3 places) with a torque of 18 N.m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure. Loosen the bolts (3 places) by 180° in numerical order as shown in the figure. Tighten the bolts (3 places) with a torque of 18 N.m (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure. NOTE: After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket.
6. Set the part so that the installation surface of the intake manifold is on the upper side.
7. When the cam carrier LH has been disassembled NOTE: When the cam carrier LH has been disassembled, perform the following steps also. Install the cam sprocket LH. < Ref. to «CAM SPROCKET LH»(ref-662117-S36376930472014101300000) , INSTALLATION, Cam Sprocket. > Install the high-pressure fuel pump. < Ref. to «INSTALLATION»(ref-662119-S33507547222014101300000) , High Pressure Fuel Pump. > NOTE: Install the high-pressure fuel pump so that the cam lobes on the intake camshaft LH are positioned as shown in the figure. Perform adjustment within the range of zero-lift (in range where it can be turned lightly by hand).
8. Check the cam clearance. < Ref. to «WHEN TIMING CHAIN ASSEMBLY IS REMOVED»(ref-662117-S31430679392014101300000) , INSPECTION, Cam Clearance. >
9. Connect the water pipe hose to oil pan upper, and install the water pipe assembly. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
10. Install the high-pressure fuel delivery pipe to the high-pressure fuel pump and fuel injector pipe. NOTE: Use a new fuel delivery pipe. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
11. Install the fuel delivery pipe to the high-pressure fuel pump, and connect the connector (A) to the high-pressure fuel pump. CAUTION: Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe. When connecting the quick connector, make sure to insert the pipe all the way in before locking the slider. When it is difficult to lock the slider, check that the pipe is fully inserted. Make sure that the quick connector is securely connected. NOTE: Connect the quick connector as shown in the figure.
12. Install the fuel pump insulator (A) to the high-pressure fuel pump, and then install the fuel pipe insulator No. 1 (B) to the high-pressure fuel delivery pipe. NOTE: By pushing the sections (a) shown in the figure, fix the fuel pipe insulator No. 1 (B) to the high-pressure fuel delivery pipe.
13. Install the fuel pipe protector to the high-pressure fuel pump case. Tightening torque: 19 N.m (1.9 kgf-m, 14.0 ft-lb)
14. Secure the engine harness to the cam carrier LH with a clip.
15. Install the rocker cover LH. < Ref. to «ROCKER COVER LH»(ref-662117-S18755219772014101300000) , INSTALLATION, Rocker Cover. >
16. Install timing chain LH. < Ref. to «TIMING CHAIN LH»(ref-662117-S29719316172014101300000) , INSTALLATION, Timing Chain Assembly. >
17. Install the chain cover. < Ref. to «INSTALLATION»(ref-662117-S40394697302014101300000) , Chain Cover. >
18. Install the engine to the vehicle. < Ref. to «INSTALLATION»(ref-662117-S38088321012014101300000) , Engine Assembly. >

Scheme 724

Scheme 725

Scheme 726

Scheme 727

1. Remove the oil pipe from cam carrier RH.
2. Loosen the bolts (front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH, and exhaust rear camshaft cap RH) equally, a little at a time in numerical sequence as shown in the figure, and remove each camshaft cap. NOTE: Arrange camshaft caps in order so that they can be installed in their original positions.
3. Remove the intake camshaft RH and the exhaust camshaft RH from cam carrier RH.
4. Remove the filter from cam carrier RH.
5. Remove the liquid gasket from cam carrier RH and front camshaft cap RH, intake rear camshaft cap RH and exhaust rear camshaft cap RH.

Scheme 728

Scheme 729

Scheme 730

1. Loosen the bolts (front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH) equally, a little at a time in numerical sequence as shown in the figure, and remove each camshaft cap. NOTE: Arrange camshaft caps in order so that they can be installed in their original positions.
2. Remove the intake camshaft LH and the exhaust camshaft LH from cam carrier LH.
3. Remove the filter from cam carrier LH.
4. Remove the liquid gasket from cam carrier LH and front camshaft cap LH, intake rear camshaft cap LH and exhaust rear camshaft cap LH.

Scheme 731

Scheme 732

Scheme 733

Scheme 734

1. Install the filter to the cam carrier RH. NOTE: Use a new filter. Filter insert position: Cam carrier RH end face 0 +0 -0.5 mm ( +0 -0.0197 in) position
2. Set the intake camshaft RH and the exhaust camshaft RH to the cam carrier RH. NOTE: Apply engine oil to the journals of cam carrier RH before setting the intake camshaft RH and exhaust camshaft RH.
3. Install the front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH. Apply liquid gasket to the mating surface of front camshaft cap RH, intake rear camshaft cap RH and exhaust rear camshaft cap RH as shown in the figure. CAUTION: Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward camshaft journal, resulting in engine seizure. Do not apply liquid gasket excessively to the intake center camshaft cap RH and exhaust center camshaft cap RH. NOTE: Before applying liquid gasket, degrease the old liquid gasket seal surface of the front camshaft cap RH, intake rear camshaft cap RH, exhaust rear camshaft cap RH, and cam carrier RH. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. 0877Y0100) or equivalent Liquid gasket applying diameter: Mating surfaces other than ranges A and B 2±0.5 mm (0.0787±0.0197 in) Mating surfaces of range A 3 +1 -0.5 mm (0.1181 +0.0394 -0.0197 in) Mating surfaces of range B 3.5±0.5 mm (0.1378±0.0197 in) Apply engine oil to the journals of each camshaft cap before setting the camshaft cap. Tighten the bolts which secure front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH in numerical order as shown in the figure. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
4. Install the oil pipe to the cam carrier RH. Set the oil pipe to the cam carrier RH, and temporarily tighten the bolts which secure the oil pipe to the cam carrier RH. NOTE: Use a new gasket. Tighten the bolts which secures the oil pipe to the cam carrier RH in numerical order as shown in the figure. Tightening torque: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 31 N.m (3.2 kgf-m, 22.9 ft-lb)

Scheme 735

Scheme 736

Scheme 737

1. Install the filter to the cam carrier LH. NOTE: Use a new filter. Filter insert position: Cam carrier LH end face 0 +0 -0.5 mm ( +0 -0.0197 in) position
2. Set the intake camshaft LH and the exhaust camshaft LH to the cam carrier LH. NOTE: Apply engine oil to the journals of cam carrier LH before setting the intake camshaft LH and exhaust camshaft LH.
3. Install the front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH. Apply liquid gasket to the mating surface of front camshaft cap LH, intake rear camshaft cap LH and exhaust rear camshaft cap LH as shown in the figure. CAUTION: Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward camshaft journal, resulting in engine seizure. Do not apply liquid gasket excessively to the intake center camshaft cap LH and exhaust center camshaft cap LH. NOTE: Before applying liquid gasket, degrease the old liquid gasket seal surface of the front camshaft cap LH, intake rear camshaft cap LH, exhaust rear camshaft cap LH, and cam carrier LH. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. 0877Y0100) or equivalent Liquid gasket applying diameter: Mating surfaces other than ranges A, B and C 2±0.5 mm (0.0787±0.0197 in) Mating surfaces of range A 3.5±0.5 mm (0.1378±0.0197 in) Mating surfaces of range B 3±0.5 mm (0.1181±0.0197 in) Mating surfaces of range C 3 +1 -0.5 mm (0.1181 +0.0394 -0.0197 in) Apply engine oil to the journals of each camshaft cap before setting the camshaft cap. Tighten the bolts which secure front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH in numerical order as shown in the figure. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)

Scheme 738

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

Scheme 744

Scheme 745

1. Visually check the cam carrier filter, and if clogging is found, replace with a new part.
2. Check the camshaft journals for damage and wear. Replace the camshaft if faulty.
3. Check the cam face condition of camshaft, and remove the minor faults by grinding with oil stone. Replace the camshaft if uneven wear is found.
4. Using a dial gauge, check the camshaft bend. If it exceeds the limit, replace the camshaft. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Camshaft bend: Limit 0.020 mm (0.00079 in)
5. Check the cam lobe height "H" and cam base circle diameter "A" of camshaft as shown in the figure, using micrometer. If it is not within the standard, replace the camshaft. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Perform measurement of cam lobe height for fuel pump drive section at three points. Camshaft cam lobe overall height H: Intake Valve drive section Standard 40.77 - 40.87 mm (1.605 - 1.609 in) Fuel pump drive section Standard 41.97 - 42.03 mm (1.652 - 1.655 in) Exhaust Standard 40.72 - 40.82 mm (1.603 - 1.607 in) Camshaft cam base circle diameter A: Standard 34.0 mm (1.339 in)
6. Check the camshaft journal outer diameter using micrometer. If it is not within the standard, replace the camshaft. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Measure outer diameter of each journal at several points, and read the value of most worn location. Camshaft journal outer diameter: Standard 25.946 - 25.963 mm (1.0215 - 1.0222 in)
7. Using a dial gauge, check the thrust clearance of the camshaft. If it is not within the standard or if uneven wear is found, replace each camshaft cap and cam carrier as a set. If necessary replace the camshaft. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Set the dial gauge at end surface of camshaft. Camshaft thrust clearance: Standard 0.068 - 0.116 mm (0.0027 - 0.0047 in)
8. Check the oil clearance on the camshaft using a plastigauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Remove the liquid gasket from cam carrier and front camshaft cap, intake rear camshaft cap and exhaust rear camshaft cap. Clean each camshaft cap and cam carrier journals. Set the camshaft to the cam carrier. Place a plastigauge across the camshaft journals of each camshaft and set the camshaft caps. Tighten the bolts which secure front camshaft cap, intake center camshaft cap, intake rear camshaft cap, exhaust center camshaft cap and exhaust rear camshaft cap in numerical order as shown in the figure. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Loosen the bolts (front camshaft cap, intake center camshaft cap, intake rear camshaft cap, exhaust center camshaft cap and exhaust rear camshaft cap) equally, a little at a time in numerical sequence as shown in the figure, and remove each camshaft cap. Determine camshaft oil clearance by matching the widest point of plastigauge on each journal against scale printed on a package of plastigauge. If it is not within the standard, replace each camshaft cap and cam carrier as a set. If necessary replace the camshaft. Camshaft oil clearance: Standard 0.037 - 0.072 mm (0.0015 - 0.0028 in) Completely remove the plastigauge.

Scheme 746

Scheme 747

Scheme 748

Scheme 749

1. Remove the engine from the vehicle. < Ref. to «REMOVAL»(ref-662117-S21453755162014101300000) , Engine Assembly. >
2. Remove the intake manifold. < Ref. to «REMOVAL»(ref-662119-S34762705842014101300000) , Intake Manifold. >
3. Remove the engine wiring harness. < Ref. to «REMOVAL»(ref-662119-S28105827872014101300000) , Engine Wiring Harness. >
4. Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. >
5. Remove the rocker cover RH. < Ref. to «ROCKER COVER RH»(ref-662117-S21007045862014101300000) , REMOVAL, Rocker Cover. >
6. Remove the cam carrier RH. < Ref. to «CAM CARRIER RH»(ref-662117-S08845425352014101300000) , REMOVAL, Cam Carrier. >
7. Remove the high-pressure fuel delivery pipe assembly from the water pipe assembly and fuel injector pipe.
8. Disassemble the cylinder head RH. NOTE: When disassembling the cylinder head RH, perform the following steps also. Remove the tumble generator valve assembly RH. < Ref. to «REMOVAL»(ref-662119-S40949586682014101300000) , Tumble Generator Valve Assembly. > Remove the fuel injector RH. < Ref. to «FUEL INJECTOR RH»(ref-662119-S09610807622014101300000) , REMOVAL, Fuel Injector. > Remove the EGR cooler from the cylinder head RH. Remove the stud bolt from the cylinder head RH.
9. Set the part so that the cylinder head RH is on the upper side.
10. Loosen the bolts securing the cylinder head RH equally, a little at a time in numerical sequence as shown in the figure and remove the cylinder head bolt.
11. While tapping the cylinder head RH with a plastic hammer, separate to remove it from the cylinder block RH.
12. Remove the cylinder head gasket RH. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.
13. Remove the liquid gasket from the cylinder head RH and cylinder block RH.

Scheme 750

1. Remove the engine from the vehicle. < Ref. to «REMOVAL»(ref-662117-S21453755162014101300000) , Engine Assembly. >
2. Remove the intake manifold. < Ref. to «REMOVAL»(ref-662119-S34762705842014101300000) , Intake Manifold. >
3. Remove the engine wiring harness. < Ref. to «REMOVAL»(ref-662119-S28105827872014101300000) , Engine Wiring Harness. >
4. Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. >
5. Remove the rocker cover LH. < Ref. to «ROCKER COVER LH»(ref-662117-S07706327262014101300000) , REMOVAL, Rocker Cover. >
6. Remove the cam carrier LH. < Ref. to «CAM CARRIER LH»(ref-662117-S14538972082014101300000) , REMOVAL, Cam Carrier. >
7. Remove the high-pressure fuel delivery pipe assembly from the water pipe assembly and fuel injector pipe.
8. Remove the A/C compressor. < Ref. to «REMOVAL»(ref-662134-S25346296512014101300000) , Compressor. >
9. When disassembling the cylinder head LH NOTE: When disassembling the cylinder head LH, perform the following steps also. Remove the tumble generator valve assembly LH. < Ref. to «REMOVAL»(ref-662119-S40949586682014101300000) , Tumble Generator Valve Assembly. > Remove the fuel injector LH. < Ref. to «FUEL INJECTOR LH»(ref-662119-S07288236932014101300000) , REMOVAL, Fuel Injector. >
10. Set the part so that the cylinder head LH is on the upper side.
11. Loosen the bolts securing the cylinder head LH equally, a little at a time in numerical sequence as shown in the figure and remove the cylinder head bolt.
12. While tapping the cylinder head LH with a plastic hammer, separate to remove it from the cylinder block LH.
13. Remove the cylinder head gasket LH. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.
14. Remove the liquid gasket from cylinder head LH and cylinder block LH.

Scheme 751

Scheme 752

Scheme 753

Scheme 754

Scheme 755

Scheme 756

Scheme 757

Scheme 758

Scheme 759

1. Set the part so that the cylinder block RH is on the upper side.
2. Clean the bolt holes in the cylinder block RH. CAUTION: To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc.
3. Apply liquid gasket to both sides of the cylinder head gasket RH as shown in the figure. NOTE: Use a new cylinder head gasket RH. Before applying liquid gasket, degrease the mating surface of cylinder blocks RH and cylinder head RH. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. 0877Y0100) or equivalent Liquid gasket applying diameter: 3±1 mm (0.1181±0.0394 in)
4. Attach the cylinder head gasket RH. NOTE: Check that liquid gasket RH is squeezed out from the cylinder head gasket.
5. Install the cylinder head RH to the cylinder block RH. CAUTION: Be careful not to scratch the mating surface of cylinder head RH and cylinder block RH. Clean the cylinder head bolt threads and apply sufficient engine oil to the washer and cylinder head bolts threads. Mount the cylinder head RH onto the cylinder block RH, and tighten all bolts with a torque of 20 N.m (2.0 kgf-m, 14.8 ft-lb) in numerical order as shown in the figure. Tighten all cylinder head bolts further with a torque of 100 N.m (10.2 kgf-m, 73.8 ft-lb) in numerical order as shown in the figure. CAUTION: If the bolt makes stick-slip sound during tightening, repeat the procedure from step 1 ). In that case, the cylinder head gasket RH can be reused. But it is necessary to remove liquid gasket completely from cylinder block RH, cylinder head RH and cylinder head gasket RH and re-apply to them. Loosen all cylinder head bolts by 360° in the numerical order as shown in the figure. Tighten all bolts with torque of 20 N.m (2.0 kgf-m, 14.8 ft-lb) in numerical sequence as shown in the figure. Tighten all cylinder head bolts with a torque of 42 N.m (4.3 kgf-m, 31.0 ft-lb) in numerical order as shown in the figure. Using angle gauge, tighten all cylinder head bolts with specified angle in numerical order as shown in the figure. Tightening angle: 100°±2° Using angle gauge, tighten the cylinder head bolts (2 places) with specified angle in numerical order as shown in the figure. Tightening angle: 100°±2° Using angle gauge, tighten the cylinder head bolts (4 places) with specified angle in numerical order as shown in the figure. NOTE: After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket. Tightening angle: 50°±2°
6. Set the part so that the installation surface of the intake manifold is on the upper side.
7. When the cylinder head RH has been disassembled NOTE: When the cylinder head RH has been disassembled, perform the following steps also. Install the stud bolts to the cylinder head RH. NOTE: Use a new stud bolt. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) Install the EGR cooler to the cylinder head RH. Set the EGR cooler to the cylinder head RH, and temporarily tighten the bolt and nut which secures the EGR cooler to the cylinder head RH. NOTE: Use a new gasket. Tighten the bolts and nuts which secure the EGR cooler to the cylinder head RH in numerical order as shown in the figure. Tightening torque: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 9 N.m (0.9 kgf-m, 6.6 ft-lb) Retighten the nut shown in the figure. Tightening torque: 9 N.m (0.9 kgf-m, 6.6 ft-lb) Install the fuel injector RH. < Ref. to «FUEL INJECTOR RH»(ref-662119-S25171846352014101300000) , INSTALLATION, Fuel Injector. > Install the tumble generator valve assembly RH. < Ref. to «INSTALLATION»(ref-662119-S18760198172014101300000) , Tumble Generator Valve Assembly. >
8. Install the high-pressure fuel delivery pipe assembly to the water pipe assembly and fuel injector pipe. Set the high-pressure fuel delivery pipe assembly to the water pipe assembly and fuel injector pipe, and temporarily tighten the bolt and flare nut which secure the high-pressure fuel delivery pipe assembly to the water pipe assembly and fuel injector pipe. NOTE: Use a new high-pressure fuel delivery pipe assembly. Tighten the bolts and flare nuts which secure the high-pressure fuel delivery pipe assembly to the water pipe assembly and fuel injector pipe in numerical order as shown in the figure. Tightening torque: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
9. Install the cam carrier RH. < Ref. to «CAM CARRIER RH»(ref-662117-S18154004902014101300000) , INSTALLATION, Cam Carrier. >
10. Install the rocker cover RH. < Ref. to «ROCKER COVER RH»(ref-662117-S06297646842014101300000) , INSTALLATION, Rocker Cover. >
11. Install the chain cover. < Ref. to «INSTALLATION»(ref-662117-S40394697302014101300000) , Chain Cover. >
12. Install the engine wiring harness. < Ref. to «INSTALLATION»(ref-662119-S33507060682014101300000) , Engine Wiring Harness. >
13. Install the intake manifold. < Ref. to «INSTALLATION»(ref-662119-S20346051572014101300000) , Intake Manifold. >
14. Install the engine to the vehicle. < Ref. to «INSTALLATION»(ref-662117-S38088321012014101300000) , Engine Assembly. >

Scheme 760

Scheme 761

Scheme 762

Scheme 763

Scheme 764

Scheme 765

1. Set the part so that the cylinder block LH is on the upper side.
2. Clean the bolt holes in the cylinder block LH. CAUTION: To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc.
3. Apply liquid gasket to both sides of the cylinder head gasket LH as shown in the figure. NOTE: Use a new cylinder head gasket LH. Before applying liquid gasket, degrease the mating surface of cylinder blocks LH and cylinder head LH. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. 0877Y0100) or equivalent Liquid gasket applying diameter: 3±1 mm (0.1181±0.0394 in)
4. Attach the cylinder head gasket LH. NOTE: Check that liquid gasket is squeezed out from the cylinder head gasket LH.
5. Install the cylinder head LH to the cylinder block LH. CAUTION: Be careful not to scratch the mating surface of cylinder head LH and cylinder block LH. Clean the cylinder head bolt threads and apply sufficient engine oil to the washer and cylinder head bolts threads. Set the cylinder head LH to the cylinder block LH, then tighten all bolts with a torque of 20 N.m (2.0 kgf-m, 14.8 ft-lb) in numerical order as shown in the figure. Tighten all cylinder head bolts further with a torque of 100 N.m (10.2 kgf-m, 73.8 ft-lb) in numerical order as shown in the figure. CAUTION: If the bolt makes stick-slip sound during tightening, repeat the procedure from step 1 ). In that case, the cylinder head gasket LH can be reused. But it is necessary to remove liquid gasket completely from cylinder block LH, cylinder head LH and cylinder head gasket LH and re-apply to them. Loosen all cylinder head bolts by 360° in the numerical order as shown in the figure. Tighten all bolts with torque of 20 N.m (2.0 kgf-m, 14.8 ft-lb) in numerical sequence as shown in the figure. Tighten all cylinder head bolts with a torque of 42 N.m (4.3 kgf-m, 31.0 ft-lb) in numerical order as shown in the figure. Using angle gauge, tighten all cylinder head bolts with specified angle in numerical order as shown in the figure. Tightening angle: 100°±2° Using angle gauge, tighten the cylinder head bolts (2 places) with specified angle in numerical order as shown in the figure. Tightening angle: 100°±2° Using angle gauge, tighten the cylinder head bolts (4 places) with specified angle in numerical order as shown in the figure. NOTE: After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket. Tightening angle: 50°±2°
6. Set the part so that the installation surface of the intake manifold is on the upper side.
7. When the cylinder head LH has been disassembled NOTE: When the cylinder head LH has been disassembled, perform the following steps also. Install the fuel injector LH. < Ref. to «FUEL INJECTOR LH»(ref-662119-S09124964782014101300000) , INSTALLATION, Fuel Injector. > Install the tumble generator valve assembly LH. < Ref. to «INSTALLATION»(ref-662119-S18760198172014101300000) , Tumble Generator Valve Assembly. >
8. Install the A/C compressor. < Ref. to «CAM CARRIER LH»(ref-662117-S39311653762014101300000) , INSTALLATION, Cam Carrier. >
9. Install the high-pressure fuel delivery pipe assembly to the water pipe assembly and fuel injector pipe. Set the high-pressure fuel delivery pipe assembly to the water pipe assembly and fuel injector pipe, and temporarily tighten the bolt and flare nut which secure the high-pressure fuel delivery pipe assembly to the water pipe assembly and fuel injector pipe. NOTE: Use a new high-pressure fuel delivery pipe assembly. Tighten the bolts and flare nuts which secure the high-pressure fuel delivery pipe assembly to the water pipe assembly and fuel injector pipe in numerical order as shown in the figure. Tightening torque: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
10. Install the cam carrier LH. < Ref. to «CAM CARRIER LH»(ref-662117-S39311653762014101300000) , INSTALLATION, Cam Carrier. >
11. Install the rocker cover LH. < Ref. to «ROCKER COVER LH»(ref-662117-S18755219772014101300000) , INSTALLATION, Rocker Cover. >
12. Install the chain cover. < Ref. to «INSTALLATION»(ref-662117-S40394697302014101300000) , Chain Cover. >
13. Install the engine wiring harness. < Ref. to «INSTALLATION»(ref-662119-S33507060682014101300000) , Engine Wiring Harness. >
14. Install the intake manifold. < Ref. to «INSTALLATION»(ref-662119-S20346051572014101300000) , Intake Manifold. >
15. Install the engine to the vehicle. < Ref. to «INSTALLATION»(ref-662117-S38088321012014101300000) , Engine Assembly. >

Scheme 766

Scheme 767

Scheme 768

Scheme 769

1. Remove the chain cover securing bolt from the cylinder head LH.
2. Remove the stud bolts from the cylinder head.
3. Remove the valve collet, valve, valve spring retainer, valve spring and valve spring seat from the cylinder head RH. WARNING: Metallic sodium is encapsulated in the exhaust valve. Metallic sodium is a strong alkaline material and thus prone to serious chemical reaction. When handling or disposing of the valve, be sure to confirm "DISPOSAL". < Ref. to «DISPOSAL»(ref-662117-S37746295802014101300000) , Cylinder Head. > CAUTION: During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH. NOTE: Mark each part to prevent confusion. Keep all the removed parts in order for re-installing in their original positions. Compress the valve spring and remove the valve collet using ST. ST 0920287002000 REMOVER AND REPLACER Remove valve, valve spring retainer, valve spring and valve spring seat.
4. Remove the valve collet, valve, valve spring retainer, valve spring and valve spring seat from the cylinder head LH.
5. Remove the valve oil seals from valve guides of cylinder head RH. CAUTION: During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH. Use special care not to damage the cylinder head RH and guide during work. NOTE: For removal of valve guide, refer to INSPECTION. < Ref. to «VALVE & VALVE GUIDE»(ref-662117-S02507383582014101300000) , INSPECTION, Cylinder Head. >
6. For cylinder head LH, remove the valve oil seal in the same manner.

Scheme 770

Scheme 771

1. Using the ST, install the valve oil seals to valve guides of cylinder head RH. CAUTION: During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH. Use special care not to damage the cylinder head RH and guide during work. When installing the valve oil seal, press the ST with hands to install it and never drive the ST with a plastic hammer, otherwise the valve oil seal can be damaged. NOTE: Use a new valve oil seal. Apply engine oil to valve oil seal before installing. The intake valve oil seals and exhaust valve oil seals are distinguished by their colors. Identification colors: Intake [Gray] Exhaust [Green] For installation of valve guide, refer to INSPECTION. < Ref. to «VALVE & VALVE GUIDE»(ref-662117-S02507383582014101300000) , INSPECTION, Cylinder Head. > ST 18261AA010 VALVE OIL SEAL GUIDE
2. For cylinder head LH, install the valve oil seal in the same manner.
3. Install the valve spring seat, valve spring, valve spring retainer, valve and valve collet to the cylinder head RH. CAUTION: During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH. Set the valve spring seat, valve spring and valve spring retainer onto the cylinder head RH. NOTE: Be sure to install the valve spring with its close-coiled end facing the cylinder head side. Coat the valve stem of each valve with engine oil and insert the valve into valve guide. NOTE: When inserting the valve into valve guide, use special care not to damage the oil seal lip. Compress the valve spring and install the valve collet using ST. ST 0920287002000 REMOVER AND REPLACER
4. Install the valve spring seat, valve spring, valve spring retainer, valve and valve collet to the cylinder head LH.
5. Lightly tap the valve spring retainer with a plastic hammer, and make sure that the valve collet is securely attached.
6. Install the stud bolts onto cylinder heads. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
7. Install the chain cover securing bolt to the cylinder head LH. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Scheme 772

1. Visually inspect to make sure that there are no cracks, scratches or other damage.
2. Use liquid penetrant tester on the important sections to check for fissures.
3. Check that there are no marks of gas leaking or water leaking on gasket attachment surface.
4. Check the warping of the cylinder head mating surface that mates with cylinder block at the locations shown in the figure using a straight edge (A) and thickness gauge (B). If it exceeds the limit, correct the surface by grinding it with a surface grinder or replace the cylinder head. NOTE: Measurement should be performed at a temperature of 20°C (68°F). If there is warpage on the cylinder head mating surface, the cylinder head bolt tightening torque and angle tightening may be improper. When installing the cylinder head, make sure that tightening torque and angle tightening work is performed precisely according to the operation procedures. When the cylinder head is replaced, lap each valve. Refer to "VALVE SEAT" for lapping. < Ref. to «VALVE SEAT»(ref-662117-S07145062482014101300000) , INSPECTION, Cylinder Head. > Cylinder head warpage: Limit 0.035 mm (0.0014 in) Cylinder head grinding limit: To 98.4 mm (3.874 in) Cylinder head height: Standard 98.5 mm (3.878 in)

VALVE & VALVE GUIDE

Scheme 773

Scheme 774

Scheme 775

Scheme 776

Scheme 777

Scheme 778

Scheme 779

Scheme 780

Scheme 781

1. Check the valve flange and stem for damage, wear or deformation.
2. Measure the thickness "H" of valve head edge as shown in the figure using a caliper gauge. If it is not within the standard, replace the valve. NOTE: It is possible to differentiate between the intake valve and the exhaust valve by their overall length. Valve overall length: Intake 103.3 mm (4.067 in) Exhaust 95.45 mm (3.758 in) When the valve is replaced, lap the valve. Refer to "VALVE SEAT" for lapping. < Ref. to «VALVE SEAT»(ref-662117-S07145062482014101300000) , INSPECTION, Cylinder Head. > Valve head edge thickness H: Intake (A) Standard 0.8 - 1.2 mm (0.031 - 0.047 in) Exhaust (B) Standard 1.0 - 1.4 mm (0.039 - 0.055 in)
3. Check the clearance between valve and valve guide. Check the clearance between valve and valve guide by measuring the outer diameter of valve stem and the inner diameter of valve guide respectively. Measure the outer diameter of valve stem with a micrometer. If it is not within the standard, replace the valve. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Measure the outer diameter of the valve stem at the six locations as shown in the figure, and read the value of most worn location. When the valve is replaced, lap the valve. Refer to "VALVE SEAT" for lapping. < Ref. to «VALVE SEAT»(ref-662117-S07145062482014101300000) , INSPECTION, Cylinder Head. > Valve stem outer diameter: Intake Standard 5.455 - 5.470 mm (0.2148 - 0.2154 in) Exhaust Standard 5.445 - 5.460 mm (0.2144 - 0.2150 in) Using a caliper gauge, measure the inner diameter of valve guide. If it is not within the standard, replace the valve guide. For replacement procedure, refer to step 4 . NOTE: Measurement should be performed at a temperature of 20°C (68°F). Measure the inner diameter of the valve guide at the six locations as shown in the figure, and read the value of most worn location. Valve guide inner diameter: Standard 5.500 - 5.512 mm (0.2165 - 0.2170 in) Calculate the clearance between valve and valve guide. Clearance between valve and valve guide: Intake Standard 0.030 - 0.057 mm (0.0012 - 0.0022 in) Exhaust Standard 0.040 - 0.067 mm (0.0016 - 0.0026 in)
4. If the clearance between valve and valve guide exceeds the standard, replace the valve or valve guide, whichever shows the greater amount of wear or damage. For replacement procedure of valve guide, refer to the following. NOTE: When the valve is replaced, lap the valve. Refer to "VALVE SEAT" for lapping. < Ref. to «VALVE SEAT»(ref-662117-S07145062482014101300000) , INSPECTION, Cylinder Head. > Insert ST into the valve guide with the combustion chamber upward and remove the valve guide using plastic hammer. CAUTION: Place a wood board wrapped with a waste cloth to stabilize the cylinder head before work. Use special care not to damage the cylinder head during work. Always strike the ST vertically with a plastic hammer. Otherwise, the ST can be damaged. ST 499765700 VALVE GUIDE REMOVER AND INSTALLER Before installing the valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide installation holes of cylinder head. Draw a reference line (A) for insert on the valve guide using a marker as shown in the figure. NOTE: Use a new valve guide. A reference line for insert is used as a guide when tapping-in the valve guide. Valve guide inserting reference line position L: 15 mm (0.5906 in) Apply a enough coat of engine oil to the valve guide, and set the valve guide on the cylinder head with the combustion chamber downward. Insert the ST into the valve guide, and tap-in the valve guide to the reference line (A) for insert using plastic hammer. CAUTION: During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head. Use special care not to damage the cylinder head during work. Always strike the ST vertically with a plastic hammer. Otherwise, the ST can be damaged. ST 499765700 VALVE GUIDE REMOVER AND INSTALLER Measure the valve guide protrusion amount "L" as shown in the figure using a caliper gauge. Insert the ST into the valve guide again, and tap-in the valve guide so that it is positioned within standard by referring to the measured value using plastic hammer. CAUTION: During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head. Use special care not to damage the cylinder head during work. Always strike the ST vertically with a plastic hammer. Otherwise, the ST can be damaged. NOTE: Be careful not to tap-in excessively by repeating the steps of Tapping-in --> Measurement --> Tapping-in --> Measurement, when installing the valve guide. ST 499765700 VALVE GUIDE REMOVER AND INSTALLER Valve guide protrusion amount L: Standard 11.4 - 11.8 mm (0.449 - 0.465 in) Ream the inside of valve guide with the combustion chamber upward using the ST. Put the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise. CAUTION: Place a wood board wrapped with a waste cloth to stabilize the cylinder head before work. Use special care not to damage the cylinder head during work. NOTE: Apply engine oil to the ST. If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone. If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST. ST 499765900 VALVE GUIDE REAMER After reaming, clean the valve guide to remove chips. Check the seating width between valve and valve seat. < Ref. to «VALVE SEAT»(ref-662117-S07145062482014101300000) , INSPECTION, Cylinder Head. >

VALVE & VALVE SHIM

Scheme 782

Scheme 783

1. Visually check the valve shim for damage.
2. Check the clearance between valve and valve shim. Check the clearance between valve and valve shim by measuring the outer diameter of valve stem end and the inner diameter of valve shim respectively. Measure the outer diameter of valve stem end with a micrometer. If it is not within the standard, replace the valve. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Measure the outer diameter of the valve stem end at the two locations as shown in the figure, and read the value of most worn location. When the valve is replaced, lap the valve. Refer to "VALVE SEAT" for lapping. < Ref. to «VALVE SEAT»(ref-662117-S07145062482014101300000) , INSPECTION, Cylinder Head. > Valve stem end outer diameter: Intake Standard 5.455 - 5.470 mm (0.2148 - 0.2154 in) Exhaust Standard 5.445 - 5.460 mm (0.2144 - 0.2150 in) Using a caliper gauge, measure the inner diameter of valve shim. If it is not within the standard, replace the valve shim. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Measure the inner diameter of the valve shim at the two locations as shown in the figure, and read the value of most worn location. If the valve shim has to be replaced, check the cam clearance and replace with the suitable valve shim. < Ref. to «WHEN TIMING CHAIN ASSEMBLY IS REMOVED»(ref-662117-S31430679392014101300000) , INSPECTION, Cam Clearance. > Valve shim inner diameter: Standard 5.500 - 5.560 mm (0.2165 - 0.2189 in) Calculate the clearance between valve and valve shim. If the clearance exceeds the standard, replace the valve or valve shim, whichever shows the greater amount of wear or damage. NOTE: When the valve is replaced, lap the valve. Refer to "VALVE SEAT" for lapping. < Ref. to «VALVE SEAT»(ref-662117-S07145062482014101300000) , INSPECTION, Cylinder Head. > If the valve shim has to be replaced, check the cam clearance and replace with the suitable valve shim. < Ref. to «WHEN TIMING CHAIN ASSEMBLY IS REMOVED»(ref-662117-S31430679392014101300000) , INSPECTION, Cam Clearance. > Clearance between valve and valve shim: Intake Standard 0.030 - 0.105 mm (0.0012 - 0.0041 in) Exhaust Standard 0.040 - 0.115 mm (0.0016 - 0.0045 in)

Scheme 784

Scheme 785

Scheme 786

Scheme 787

Scheme 788

Scheme 789

1. Check the valve seat for damage and deformation.
2. Check the seating width and seating position between valve and valve seat for the intake valve seat and exhaust valve seat. Clean the valve and valve seat. Coat the stem (A) of the valve lightly with engine oil and apply red dye evenly on the valve face (B). Using the valve lapper, slowly insert the valve with red dye applied into the valve guide. Lightly press the valve against the valve seat without turning the valve, and then slowly pull out the valve. Check the seating width "W" of valve seat as shown in the figure, using a caliper gauge. Check the seating width "W" between valve and valve seat by measuring the width of red dye on the seating surface of valve seat. If the seating width "W" between valve and valve seat is out of the standard, correct the seating surface of valve seat using the valve seat cutter. For correcting procedures of the valve seat seating surface, refer to step 3 ). NOTE: When the red dye does not appear seamlessly on the valve seat seating surface, lap the valve. For lapping procedure, refer to step 4 ). When the red dye does not appear seamlessly on the valve seat seating surface even after lapping the valve, correct the valve seat seating surface using the valve seat cutter. For correcting procedures of the valve seat seating surface, refer to step 3 ). Seating width W between valve and valve seat: Intake Standard 0.8 - 1.6 mm (0.031 - 0.063 in) Exhaust Standard 1.1 - 1.7 mm (0.043 - 0.067 in) Wipe off the red dye on the valve and valve seat completely. Coat the stem (A) of the valve lightly with engine oil and apply red dye evenly on the seating surface (B) between valve and valve seat. Using the valve lapper, slowly insert the valve into the valve guide. Lightly press the valve against the valve seat without turning the valve, and then slowly pull out the valve. Check the seating position between valve and valve seat. Check the seating position between valve and valve seat by checking the position of red dye on the valve face. If the seating position between valve and valve seat is not at the center of valve face, correct the seating surface of valve seat using the valve seat cutter. For correcting procedures of the valve seat seating surface, refer to step 3 . Seating position between valve and valve seat: Valve face center After inspection, wipe off the red dye completely.
3. When correcting the seating surfaces of valve seat Correct the seating angle between valve and valve seat using the 45° valve seat cuter. NOTE: Select the size of the valve seat cutter by referring to the outer diameters of the intake valve and exhaust valve. Valve outer diameter: Intake Standard 33.9 - 34.1 mm (1.335 - 1.343 in) Exhaust Standard 28.9 - 29.1 mm (1.138 - 1.146 in) Grind the seating surface so that the seating width between valve and valve seat becomes slightly larger than the standard value. Gradually reduce pressure at the end of grinding process in order to avoid creating a gap on the valve seat correcting surface. Seating angle between valve and valve seat: 45° Lap the valve. For lapping procedure of the valve, refer to step 4 . Check the seating position between valve and valve seat. For inspection of the seating position between valve and valve seat, refer to step 2 ). NOTE: This procedure is necessary to select a seat cutter to be used in step (4). Using the 30°, 75° (IN) or 62° (EX) seat cutter, correct the valve seat so that the seating width between valve and valve seat becomes the standard value. NOTE: Select a proper valve seat cutter according to the following table. Seating position between valve and valve seat Seat cutter selection When the seating position of valve face is high, grind the surface using the 30° seat cutter until seating width between valve and valve seat becomes the standard value. When the seating position of valve face is low, grind the surface using the 75° (IN) or 62° (EX) seat cutter until seating width between valve and valve seat becomes the standard value. When the seating position of valve face is at center, grind the surface evenly using the 30° and 75° (IN) or 62° (EX) seat cutters until seating width between valve and valve seat becomes the standard value. Gradually reduce pressure at the end of grinding process in order to avoid creating a gap on the valve seat correcting surface. Lap the valve. For lapping procedure of the valve, refer to step 4 .
4. When lapping the valve Coat the stem (A) of the valve lightly with engine oil and put a small amount of valve compound evenly on the valve face (B). NOTE: Be careful not to put the valve compound more than necessary. To avoid damaging the valve guide and valve stem, be careful not to let the valve compound contact the valve stem. Using the valve lapper, slowly insert the valve with the valve compound applied into the valve guide, and lap the seating surface between valve and valve seat. First, lift the valve and strike it against the valve seat twice, and then slightly turn the valve once. Repeat these steps as one set. NOTE: To prevent the seating width between valve and valve seat from exceeding the standard value, be careful not to keep turning the valve while pressing it against the valve seat during lapping. Be careful not to lift the valve too far during lapping in order to prevent the valve from coming off the valve guide. Wipe off the valve compound on the valve and valve seat completely after lapping. NOTE: Be careful not to leave any valve compound in order to avoid malfunction. Check the seating width and seating position between valve and valve seat.

Scheme 790

1. Check the valve spring for damage and deformation.
2. Using a caliper gauge, valve spring tester, surface plate and try square, check the valve spring free length, tension/spring height and squareness. If it is not within the standard, replace the valve spring. NOTE: Measurement should be performed at a temperature of 20°C (68°F). To check the squareness of the valve spring, stand the valve spring on a surface plate and check its deflection at the top of the valve spring using a try square. Valve spring free length: Standard 44.03 mm (1.733 in) Valve spring tension/spring height: Set Standard 182 - 210 N (18.56 - 21.41 kgf, 40.92 - 47.22 lbf)/33.0 mm (1.299 in) Lift Standard 440 - 486 N (44.87 - 49.56 kgf, 98.93 - 109.27 lbf)/22.0 mm (0.866 in) Valve spring squareness: Standard 2.5°, 1.9 mm (0.075 in) or less

DISPOSAL

Scheme 791

Scheme 792

1. Wear rubber gloves and remove the broken exhaust valve from the cylinder head.
2. Prepare large container (bucket or oil can) in well-ventilated place, and fill the container with water (10 L or more).
3. Using a pair of large tweezers or pliers, immerse the broken exhaust valve in the water vertically. CAUTION: Completely immerse the broken exhaust valve in the water. Hydrogen gas is produced by the chemical reaction. Therefore, always keep the container away from open flames such as sparks. Because the severe chemical reaction is developed, keep at least 2 to 3 m away from the container.
4. After completion of chemical reaction (after the elapse of 4 to 5 hours), carefully take out the exhaust valve using a pair of large tweezers or pliers, and dispose of the exhaust valve according to the same disposal procedure as other parts. CAUTION: Concerning the liquid waste disposal of the liquid (sodium hydrate) produced in a chemical reaction, follow all governmental regulations and local regulations related to the liquid waste disposal. If the liquid produced in a chemical reaction (sodium hydrate) should touch the skin, immediately wash it away with plenty water.

Scheme 793

Scheme 794

Scheme 795

Scheme 796

Scheme 797

Scheme 798

Scheme 799

Scheme 800

Scheme 801

Scheme 802

Scheme 803

Scheme 804

Scheme 805

Scheme 806

Scheme 807

Scheme 808

Scheme 809

Scheme 810

Scheme 811

Scheme 812

Scheme 813

Scheme 814

1. Remove the engine from the vehicle. < Ref. to «REMOVAL»(ref-662117-S21453755162014101300000) , Engine Assembly. >
2. Remove the crankshaft position sensor plate with drive plate. < Ref. to «REMOVAL»(ref-662126-S07134706032014101300000) , Drive Plate. >
3. Remove the intake manifold. < Ref. to «REMOVAL»(ref-662119-S34762705842014101300000) , Intake Manifold. >
4. Remove the tumble generator valve assembly. < Ref. to «REMOVAL»(ref-662119-S40949586682014101300000) , Tumble Generator Valve Assembly. >
5. Remove the engine wiring harness. < Ref. to «REMOVAL»(ref-662119-S28105827872014101300000) , Engine Wiring Harness. >
6. Remove the chain cover. < Ref. to «REMOVAL»(ref-662117-S16868627142014101300000) , Chain Cover. >
7. Remove the rocker cover. < Ref. to «REMOVAL»(ref-662117-S12059092362014101300000) , Rocker Cover. >
8. Remove the cam carrier. < Ref. to «REMOVAL»(ref-662117-S15905480812014101300000) , Cam Carrier. >
9. Remove the cylinder head. < Ref. to «REMOVAL»(ref-662117-S18972492342014101300000) , Cylinder Head. >
10. Remove the crank sprocket. < Ref. to «REMOVAL»(ref-662117-S03633465042014101300000) , Crank Sprocket. >
11. Remove the engine rear hanger from cylinder block RH.
12. Remove the bolts securing the water pipe assembly and PCV connector to the cylinder block, and remove the water pipe assembly and PCV connector as a set from cylinder block.
13. Remove the O-ring from the cylinder block and PCV connector.
14. Remove the knock sensor from cylinder block LH.
15. Remove the PCV valve from the cylinder block RH.
16. Remove the bolts securing the crankshaft position sensor holder from the cylinder block LH, and remove the crankshaft position sensor with crankshaft position sensor holder.
17. Set the part so that the oil pan is on the upper side.
18. Remove the oil pan upper with oil pan from cylinder block. NOTE: Pry the points shown in the figure with a crowbar wrapped by protective tape, and then remove the oil pan upper.
19. Remove the O-ring from the cylinder block.
20. Set the part so that the cylinder block RH is on the upper side.
21. Remove the #1 and #3 connecting rod caps and pistons from the cylinder block. NOTE: Mark each connecting rod cap and piston with a cylinder number. Turn the crankshaft so that the #1 connecting rod cap (A) is located at the position shown in the figure using ST. ST 18252AA000 CRANKSHAFT SOCKET Using ST, loosen the #1 connecting rod cap bolt, and remove the #1 connecting rod cap bolt and #1 connecting rod cap. ST 18270AA020 SOCKET Using the ST, turn the crankshaft counterclockwise and separate the positions of the #1 pin (A) of crankshaft and the large end (B) of #1 connecting rod. ST 18252AA000 CRANKSHAFT SOCKET Push the #1 connecting rod in the direction of the arrow, and remove the #1 piston with #1 connecting rod from the cylinder block. Turn the crankshaft so that the #3 connecting rod cap (A) is located at the position shown in the figure using ST. ST 18252AA000 CRANKSHAFT SOCKET Using ST, loosen the #3 connecting rod cap bolt, and remove the #3 connecting rod cap bolt and #3 connecting rod cap. ST 18270AA020 SOCKET Using the ST, turn the crankshaft counterclockwise and separate the positions of the #3 pin (A) of crankshaft and the large end (B) of #3 connecting rod. ST 18252AA000 CRANKSHAFT SOCKET Push the #3 connecting rod in the direction of the arrow, and remove the #3 piston with #3 connecting rod from the cylinder block.
22. Set the part so that the cylinder block LH is on the upper side.
23. Remove #2 and #4 connecting rod caps and pistons in the same removal procedure as #1 and 3# connecting rod caps and pistons.
24. Set the part so that the cylinder block RH is on the upper side, and separate the cylinder block. Remove the engine stand from the cylinder block RH. Remove the bolt shown in the figure. Loosen the cylinder block mounting bolts in numerical order as shown in the figure. While tapping the cylinder block RH with a plastic hammer, separate the cylinder block RH from the cylinder block LH. NOTE: Lift the cylinder block RH gradually, and confirm that the crankshaft is remaining in the cylinder block LH. If the cylinder block RH is lifted carelessly when separating, the crankshaft may stick to cylinder block RH, then fall off.
25. Remove the crankshaft from cylinder block LH, and remove the rear oil seal.
26. Remove the O-ring from the cylinder block LH.
27. Remove the crankshaft bearings from the cylinder block. NOTE: Be careful not to confuse the crankshaft bearing combination. Press the bearing at the end opposite to locking lip (A).
28. Remove the liquid gasket from cylinder block.
29. Remove the cylinder block LH from the engine stand.

Scheme 815

Scheme 816

Scheme 817

Scheme 818

Scheme 819

Scheme 820

Scheme 821

Scheme 822

Scheme 823

Scheme 824

Scheme 825

Scheme 826

Scheme 827

Scheme 828

Scheme 829

Scheme 830

Scheme 831

Scheme 832

Scheme 833

Scheme 834

Scheme 835

Scheme 836

Scheme 837

Scheme 838

Scheme 839

Scheme 840

Scheme 841

1. Install the cylinder block LH to the engine stand.
2. Apply engine oil to the crankshaft bearing, and install the crankshaft bearing to the cylinder block. CAUTION: When performing the operation of the cylinder block RH, be careful of the following. Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work. Be careful not to scratch the mating surface of cylinder block during work.
3. Install O-rings to the cylinder block LH. NOTE: Use new O-rings.
4. Apply engine oil to the crankshaft journal, and set the crankshaft to cylinder block LH.
5. Apply liquid gasket to the mating surface of cylinder block RH as shown in the figure. CAUTION: Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work. Be careful not to scratch the mating surface of cylinder block during work. Do not let the liquid gasket overflow to the oil passage and crankshaft bearing portions, because the engine seizure may result. NOTE: Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder block RH and cylinder block LH. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: Mating surfaces other than ranges A, B and C 1±0.5 mm (0.0394±0.0197 in) Mating surfaces of ranges A and C 4±0.5 mm (0.1575±0.0197 in) Mating surfaces of range B 3.2±0.5 mm (0.1260±0.0197 in)
6. Install the cylinder block RH to the cylinder block LH.
7. Join the cylinder blocks. Apply a coat of engine oil to the washers and cylinder block mounting bolt threads. NOTE: To prevent mixture of engine oil into the water jacket, do not apply a large amount. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Loosen all mounting bolts by 180° in numerical order as shown in the figure. CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Loosen the mounting bolts (4 places) by 180° in numerical order as shown in the figure. CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Tighten the mounting bolts (4 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Using angle gauge, tighten the mounting bolts (4 places) with specified angle in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Tightening angle: 60°±2° Loosen the mounting bolts (6 places) by 180° in numerical order as shown in the figure. CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Tighten the mounting bolts (6 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Using angle gauge, tighten the mounting bolts (6 places) with specified angle in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Tightening angle: 60°±2° Install the bolt shown in the figure. NOTE: After tightening, if the liquid gasket is squeezed out in the seal surface area of the chain cover and oil pan upper, completely remove any liquid gasket that is squeezed out. Any liquid gasket on the chamfer area, however, should not be removed. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
8. Set the part so that the installation surface of the oil pan upper is on the upper side.
9. Check that the piston ring gap for each piston is positioned correctly. < Ref. to «PISTON AND CONNECTING ROD»(ref-662117-S31714145272014101300000) , ASSEMBLY, Cylinder Block. >
10. Install the piston and connecting rod to the cylinder block. Apply engine oil to the outer circumference of each piston, crankshaft pin, and in the cylinder block. Turn the crankshaft so that the #1 pin (A) of crankshaft is positioned at TDC using ST. ST 18252AA000 CRANKSHAFT SOCKET Compress the piston ring using piston ring compressor, and insert the #1 connecting rod with #1 piston into cylinder block. CAUTION: Be careful not to damage the cylinder liner and #1 pin of crankshaft by the #1 connecting rod large end. Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off. NOTE: Face the piston front mark (round mark) towards the front of the engine. Insert while lightly tapping the crown of the piston with the handle of a plastic hammer. Turn the crankshaft counterclockwise so that the #1 pin of crankshaft and the large end (A) of #1 connecting rod are positioned as shown in the figure using ST, while pressing the #1 piston crown, and then set the #1 connecting rod cap and #1 connecting rod cap bolt. NOTE: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol. Use a new connecting rod cap bolt. Apply a coat of engine oil to the #1 connecting rod cap seat and the connecting rod cap bolt threads. ST 18252AA000 CRANKSHAFT SOCKET Using ST, tighten the #1 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 25 N.m (2.5 kgf-m, 18.4 ft-lb) in numerical order as shown in the figure. ST 18270AA020 SOCKET Turn the crankshaft clockwise so that the #2 pin (A) of crankshaft is positioned at TDC using ST. ST 18252AA000 CRANKSHAFT SOCKET Compress the piston ring using piston ring compressor, and insert the #2 connecting rod with #2 piston into cylinder block. CAUTION: Be careful not to damage the cylinder liner and #2 pin of crankshaft by the #2 connecting rod large end. Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off. NOTE: Face the piston front mark (round mark) towards the front of the engine. Insert while lightly tapping the crown of the piston with the handle of a plastic hammer. Turn the crankshaft clockwise so that the #2 pin of crankshaft and the large end (A) of #2 connecting rod are positioned as shown in the figure using ST, while pressing the #2 piston crown, and then set the #2 connecting rod cap and #2 connecting rod cap bolt. NOTE: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol. Use a new connecting rod cap bolt. Apply a coat of engine oil to the #2 connecting rod cap seat and the connecting rod cap bolt threads. ST 18252AA000 CRANKSHAFT SOCKET Using ST, tighten the #2 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 25 N.m (2.5 kgf-m, 18.4 ft-lb) in numerical order as shown in the figure. ST 18270AA020 SOCKET Install #3 and #4 pistons and connecting rod caps in the same installation procedure as #1 and 2# pistons and connecting rod caps. Using ST and angle gauge, tighten the #1 connecting rod cap bolts and #4 connecting rod cap bolts with specified angle in numerical order as shown in the figure. ST 18270AA020 SOCKET Tightening angle: 90°+5° -0° Turn the crankshaft so that the #2 connecting rod cap (A) and #3 connecting rod cap (B) is located at the position shown in the figure using ST. ST 18252AA000 CRANKSHAFT SOCKET Using ST and angle gauge, tighten the #2 connecting rod cap bolts and #3 connecting rod cap bolts with specified angle in numerical order as shown in the figure. ST 18270AA020 SOCKET Tightening angle: 90°+5° -0°
11. Install the oil pan upper with oil pan to the cylinder block. Apply liquid gasket to the mating surface of oil pan upper as shown in the figure. NOTE: Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder block and the oil pan upper. Install within 5 min. after applying liquid gasket. Apply liquid gasket 1.5 mm (0.0591 in) outside from the chamfer surface. However, application of liquid gasket on the chamfer surface around the bolt hole is allowed. Liquid gasket: THREE BOND 1217G (Part No. 0877Y0100) or equivalent Liquid gasket applying diameter: 5±1 mm (0.1969±0.0394 in) Install the O-ring to the cylinder block. NOTE: Use new O-rings. Set the oil pan with oil pan upper to the cylinder block, and tighten the bolts in numerical order as shown in the figure. NOTE: After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
12. Set the part so that the installation surface of the intake manifold is on the upper side.
13. Install the crankshaft position sensor with crankshaft position sensor holder to the cylinder block LH. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
14. Install the PCV valve onto the cylinder block RH. NOTE: Apply liquid gasket to the bolt threads of PCV valve. Liquid gasket: THREE BOND 1141G or equivalent Tightening torque: 23 N.m (2.3 kgf-m, 17.0 ft-lb)
15. Install the knock sensor to the cylinder block LH. NOTE: Knock sensor must be positioned toward engine front so that the connector center position is within the range of shaded area shown in the figure. Tightening torque: 24 N.m (2.4 kgf-m, 17.7 ft-lb)
16. Install the O-ring to the cylinder block and PCV connector. NOTE: Use new O-rings.
17. Install the water pipe assembly and PCV connector to the cylinder block. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
18. Install the engine rear hanger to the cylinder block RH. Tightening torque: 21 N.m (2.1 kgf-m, 15.5 ft-lb)
19. Install the crank sprocket. < Ref. to «INSTALLATION»(ref-662117-S03997126022014101300000) , Crank Sprocket. >
20. Install the cylinder head. < Ref. to «INSTALLATION»(ref-662117-S16827527622014101300000) , Cylinder Head. >
21. Install the cam carrier. < Ref. to «INSTALLATION»(ref-662117-S37517107192014101300000) , Cam Carrier. >
22. Install the rocker cover. < Ref. to «INSTALLATION»(ref-662117-S29296595742014101300000) , Rocker Cover. >
23. Install the chain cover. < Ref. to «INSTALLATION»(ref-662117-S40394697302014101300000) , Chain Cover. >
24. Install the engine wiring harness. < Ref. to «INSTALLATION»(ref-662119-S33507060682014101300000) , Engine Wiring Harness. >
25. Install the tumble generator valve assembly. < Ref. to «INSTALLATION»(ref-662118-S19219123542014101300000) , Tumble Generator Valve Assembly. >
26. Install the intake manifold. < Ref. to «INSTALLATION»(ref-662118-S08177319372014101300000) , Intake Manifold. >
27. Apply a coat of engine oil to the oil seal inner periphery and outer periphery, and install the rear oil seal using ST1 and ST2. NOTE: Use a new rear oil seal. ST1 18671AA020 OIL SEAL GUIDE ST2 18657AA030 OIL SEAL INSTALLER
28. Install the crankshaft position sensor plate with drive plate. < Ref. to «INSTALLATION»(ref-662126-S16442961772014101300000) , Drive Plate. >
29. Install the engine to the vehicle. < Ref. to «INSTALLATION»(ref-662117-S38088321012014101300000) , Engine Assembly. >

Scheme 842

Scheme 843

Scheme 844

Scheme 845

1. Remove the oil separator cover from cylinder block RH.
2. Remove the liquid gasket from cylinder block RH.
3. Remove the cylinder block plug (A) and the main gallery plug (B) from cylinder block RH.
4. Remove the liquid gasket from the thread holes of the cylinder block RH, and from the threaded portions of cylinder block plug and main gallery plug.
5. Remove the cylinder block plate from cylinder block LH.
6. Remove the main gallery plug from cylinder block LH.
7. Remove the liquid gasket from the thread holes of the cylinder block LH and main gallery plug.

Scheme 846

Note. To prevent confusion of various parts, mark each part.

1. Remove the connecting rod bearing from connecting rod and connecting rod cap.
2. Remove the piston rings from the piston. NOTE: Arrange the piston rings in order so that they can be installed in their original positions without confusion. Remove the compression rings in the order of top ring and second ring, using piston ring expander. Remove the oil rings in the order of upper rail, lower rail and expander by hand.
3. Remove the circlip on one end from the piston using a flat tip screwdriver. NOTE: Be careful not damage the piston and piston pin, by wrapping the tip of flat tip screwdriver with tape.
4. Remove the piston pin from piston, and remove the connecting rod from piston.
5. Remove the circlip on other end from the piston using a flat tip screwdriver. NOTE: Be careful not damage the piston and piston pin, by wrapping the tip of flat tip screwdriver with tape.

Scheme 847

Scheme 848

Scheme 849

Scheme 850

1. Apply liquid gasket to the threaded portion of the main gallery plug, and install the main gallery plug to the cylinder block LH. NOTE: Before applying liquid gasket, degrease the thread holes of the cylinder block LH and main gallery plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Tightening torque: 37 N.m (3.8 kgf-m, 27.3 ft-lb)
2. Install the cylinder block plate onto cylinder block LH. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
3. Apply liquid gasket to the threaded portions of cylinder block plug and main gallery plug, and install the cylinder block plug (A) and main gallery plug (B) to cylinder block RH. NOTE: Before applying liquid gasket, degrease the thread holes of the cylinder block RH, and the threaded portions of cylinder block plug and main gallery plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Tightening torque: T1: 16 N.m (1.6 kgf-m, 11.8 ft-lb) T2: 37 N.m (3.8 kgf-m, 27.3 ft-lb)
4. Install the oil separator cover to the cylinder block RH. Apply liquid gasket to the mating surfaces of oil separator cover. NOTE: Use new oil separator cover. Before applying liquid gasket, degrease the old liquid gasket seal surface of cylinder block RH. Install within 5 min. after applying liquid gasket. Liquid gasket: Mating surface THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 4±1 mm (0.1772±0.0394 in) Install the oil separator cover to the cylinder block RH, and tighten the oil separator cover bolts in numerical order as shown in the figure. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Scheme 851

Scheme 852

Scheme 853

Scheme 854

Scheme 855

Scheme 856

Scheme 857

Scheme 858

Scheme 859

Scheme 860

1. Install the connecting rod bearing to the connecting rod and connecting rod cap.
2. Install the circlip on one end of the piston using a flat tip screwdriver. NOTE: Be careful not damage the piston, by wrapping the tip of flat tip screwdriver with tape. Make sure the circlip is firmly inserted into the circlip groove. After installing the circlip, rotate the circlip so that its end part (a) and the cutout portion of circlip groove (b) do not match.
3. Set the piston to the connecting rod. NOTE: Align the front mark of piston and the connecting rod direction correctly as shown in the figure.
4. Apply engine oil to the piston pin, and attach the piston pin.
5. Install the circlip on the piston using a flat tip screwdriver. NOTE: Be careful not damage the piston and piston pin, by wrapping the tip of flat tip screwdriver with tape. Make sure the circlip is firmly inserted into the circlip groove. After installing the circlip, rotate the circlip so that its end part (a) and the cutout portion of circlip groove (b) do not match.
6. Install the oil rings to the piston in the order of expander, lower rail and upper rail by hand. NOTE: Oil ring consists of the upper rail, expander and lower rail. Set the ring gap of the expander to the position (A). Set the lower rail spin stopper (D) to the oil groove (C) located above the cutout portion (B) of the piston skirt coating, and hook the lower rail spin stopper (F) to the expander (E). Set the upper rail gap to the position (G), and hook the upper rail spin stopper (H) to the expander (E).
7. Install the compression rings to the piston in the order of second ring and top ring, using piston ring expander. Set the ring gap of the second ring to the position (A) in the figure. NOTE: Install the second ring so that the ring mark (2N) faces the piston crown. Set the ring gap of top ring at (B) in the figure on the 180° opposite direction of (A). NOTE: Install the top ring so that the ring mark (TN) faces the piston crown.
8. Check that the piston ring is installed correctly.

Scheme 861

Scheme 862

Scheme 863

1. Visually inspect to make sure that there are no cracks, scratches or other damage.
2. Use liquid penetrant tester on the important sections to check for fissures.
3. Check that there are no traces of gas leaking or water leaking on the gasket attachment surface.
4. Check the oil passages for clogging.
5. Check for warpage of mating surfaces of the cylinder block that contacts cylinder head using a straight edge and thickness gauge. If it exceeds the limit, correct the surface by grinding it with a surface grinder or replace the cylinder block. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Cylinder block warpage: Limit 0.025 mm (0.00098 in) Grinding limit of cylinder block: To 204.9 mm (8.067 in) Height of cylinder block: Standard 205.0 mm (8.071 in)
6. Using a cylinder bore gauge, check the inner diameter of cylinder liner, cylindricality, out-of-roundness. If it is not within the standard, perform boring and honing, or replace the cylinder block and piston as a set. For boring and honing procedure, refer to step 8 ). NOTE: Measurement should be performed at a temperature of 20°C (68°F). Measure the inner diameter of each cylinder liner in both the thrust and piston pin directions at the heights as shown in the figure. The cylinder bore size mark is stamped on the upper face of the cylinder block. Inner diameter of cylinder liner: Cylinder bore size mark A Standard 86.005 - 86.015 mm (3.3860 - 3.3864 in) Cylinder bore size mark B Standard 85.995 - 86.005 mm (3.3856 - 3.3860 in) Cylindricality of cylinder liner: Limit 0.03 mm (0.0012 in) Out-of-roundness of cylinder liner: Limit 0.010 mm (0.0004 in)
7. Check the clearance between cylinder liner and piston. Check the clearance between cylinder liner and piston by measuring the inner diameter of cylinder liner and the outer diameter of piston respectively. NOTE: For the measurement of the inner diameter of cylinder liner, refer to step 6 ). Check the outer diameter of piston with a micrometer. If it is not within the standard, replace the piston. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Measure the outer diameter of each piston in thrust direction at the height as shown in the figure. Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as guide lines in selecting a standard piston. If the piston is replaced, check the clearance between cylinder liner and piston in the step (2), and select a suitable sized piston. Piston grade point H: 40.0 mm (1.57 in) Piston outer diameter: Standard size (grade A) Standard 85.985 - 85.995 mm (3.3852 - 3.3856 in) Standard size (grade B) Standard 85.975 - 85.985 mm (3.3848 - 3.3852 in) 0.25 mm (0.0098 in) oversize Standard 86.225 - 86.245 mm (3.3947 - 3.3955 in) 0.50 mm (0.0197 in) oversize Standard 86.475 - 86.495 mm (3.4045 - 3.4053 in) Calculate the clearance between cylinder liner and piston. If it is not within the standard, perform boring and honing, or replace the cylinder block and piston as a set. For boring and honing procedure, refer to step 8 . Clearance between cylinder liner and piston: Standard 0.010 - 0.030 mm (0.00039 - 0.00118 in)
8. Boring and honing If any of the inner diameter, cylindricality, out-of-roundness or clearance between cylinder liner and piston is out of standard or if there is any damage on the cylinder liner, rebore it to replace with an oversize piston. CAUTION: When any of the cylinder liner needs reboring, all other cylinder liners must be bored at the same time, and replaced with oversize pistons. (2) If the inner diameter of cylinder liner exceeds the limit after boring and honing, replace the cylinder block and piston as a set. NOTE: Immediately after reboring, the inner diameter of cylinder liner may differ from its real diameter due to temperature rise. Thus, when measuring the inner diameter of cylinder liner, wait until the temperature has cooled to 20°C (68°F). For the measurement of the inner diameter of cylinder liner, refer to step 6 ). Inner diameter of cylinder liner boring limit (diameter): To 86.505 mm (3.4057 in)

Scheme 864

Scheme 865

Scheme 866

1. Check the piston and piston pin for wear or crack.
2. Check the snap ring for distortion or wear.
3. Check the piston ring groove for damage.
4. Check the circlip groove (A) for burr. NOTE: If the burr is found, remove the burr from groove.
5. Check that the piston pin can be inserted into the piston with a thumb at 20°C (68°F).
6. Check the clearance between piston and piston pin. Check the clearance between piston and piston pin by measuring the inner diameter of piston pin hole and the outer diameter of piston pin respectively. Using a caliper gauge, measure the inner diameter of piston pin hole. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Measure the inner diameter of the piston pin hole at the four locations as shown in the figure, and read the value of most worn location. Record the measured value. Measure the outer diameter of piston pin with a micrometer. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Measure the outer diameter of the piston pin at the four locations as shown in the figure, and read the value of most worn location. Record the measured value. Calculate the clearance between piston and piston pin. If it is not within the standard, replace the piston and piston pin as a set. Clearance between piston and piston pin: Standard 0.004 - 0.008 mm (0.0002 - 0.0003 in)

Scheme 867

Scheme 868

1. Make sure the piston ring is not broken or damaged.
2. Using a cylindrical guide, insert the piston ring into the cylinder liner so that they are perpendicular to the cylinder wall, and check the piston ring gap using a thickness gauge. If it is not within the standard, replace the piston ring. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Use piston ring with same size as piston when replacing piston ring. Piston ring gap: Compression ring (top ring) Standard 0.20 - 0.25 mm (0.0079 - 0.0098 in) Compression ring (second ring) Standard 0.40 - 0.50 mm (0.0157 - 0.0197 in) Oil ring (upper rail and lower rail) Standard 0.10 - 0.35 mm (0.0039 - 0.0138 in)
3. Fit the compression ring straight into the piston ring groove, then check the clearance between compression ring and piston with a thickness gauge. If it is not within the standard, replace the compression ring. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Before inspecting the clearance, clean the piston ring groove and compression ring. Use compression ring with same size as piston when replacing compression ring. Clearance between compression ring and piston: Top ring Standard 0.040 - 0.080 mm (0.0016 - 0.0031 in) Second ring Standard 0.045 - 0.085 mm (0.0018 - 0.0033 in)

Scheme 869

Scheme 870

Scheme 871

Scheme 872

Scheme 873

Scheme 874

1. Check for bend or twist using a connecting rod aligner. If it exceeds the limit, replace the connecting rod. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Bend or twist per 100 mm (3.94 in) in length: Limit 0.10 mm (0.0039 in)
2. Check that the large or small end thrust surface of each connecting rod is not damaged.
3. Check each connecting rod bearing for scar, peeling, seizure, melting or wear, etc.
4. Check the thrust clearance of each connecting rod using a thickness gauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Clean the #1 connecting rod bearing and the #1 pin of crankshaft, and apply engine oil to the #1 pin of crankshaft. Set the #1 connecting rod bearing to the #1 connecting rod and #1 connecting rod cap. Set the #1 connecting rod, #1 connecting rod cap and #1 connecting rod cap bolt to the #1 pin of crankshaft. NOTE: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol. Use a new connecting rod cap bolt. Apply a coat of engine oil to the #1 connecting rod cap bolt thread. Using ST, tighten the #1 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 25 N.m (2.5 kgf-m, 18.4 ft-lb) in numerical order as shown in the figure. CAUTION: Make sure to hold the crankshaft securely during work. When holding the crankshaft, be careful not to damage the crankshaft. ST 18270AA020 SOCKET Using ST and angle gauge, tighten the #1 connecting rod cap bolts with specified angle in numerical order as shown in the figure. CAUTION: Make sure to hold the crankshaft securely during work. When holding the crankshaft, be careful not to damage the crankshaft. NOTE: Prevent angle gauge from rotating using a V-block, etc. ST 18270AA020 SOCKET Tightening angle: 90° +5° -0° In the same manner, install the #2, #3 and #4 connecting rods. Check the thrust clearance of each connecting rod using a thickness gauge. If it is not within the standard, replace the connecting rod. NOTE: Measure the thrust clearance of each connecting rod at several points, and replace the connecting rod if there is uneven wear. Connecting rod thrust clearance: Standard 0.070 - 0.330 mm (0.0028 - 0.0130 in)
5. Check the oil clearance on each connecting rod bearing using plastigauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Clean the #1 connecting rod bearing and the #1 pin of crankshaft. Set the #1 connecting rod bearing to the #1 connecting rod and #1 connecting rod cap. Place a plastigauge across the #1 pin of crankshaft, and set the #1 connecting rod, #1 connecting rod cap and #1 connecting rod cap bolt to the #1 pin of crankshaft. NOTE: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol. Use a new connecting rod cap bolt. Apply a coat of engine oil to the #1 connecting rod cap bolt thread. Using ST, tighten the #1 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 25 N.m (2.5 kgf-m, 18.4 ft-lb) in numerical order as shown in the figure. CAUTION: Make sure to hold the crankshaft securely during work. When holding the crankshaft, be careful not to damage the crankshaft. During tightening, be careful not to move the #1 connecting rod and the #1 connecting rod cap. ST 18270AA020 SOCKET Using ST and angle gauge, tighten the #1 connecting rod cap bolts with specified angle in numerical order as shown in the figure. CAUTION: Make sure to hold the crankshaft securely during work. When holding the crankshaft, be careful not to damage the crankshaft. During tightening, be careful not to move the #1 connecting rod and the #1 connecting rod cap. NOTE: Prevent angle gauge from rotating using a V-block, etc. ST 18270AA020 SOCKET Tightening angle: 90° +5° -0° Using ST, loosen the #1 connecting rod cap bolt, and remove the #1 connecting rod cap bolt and #1 connecting rod cap. CAUTION: Make sure to hold the crankshaft securely during work. When holding the crankshaft, be careful not to damage the crankshaft. During removal, be careful not to move the #1 connecting rod and the #1 connecting rod cap. ST 18270AA020 SOCKET Determine oil clearance of the #1 connecting rod bearing by matching the widest point of the plastigauge on #1 pin of crankshaft against scale printed on a package of the plastigauge. If it is not within the standard, replace the #1 connecting rod bearing. NOTE: Measure the outer diameter of crankshaft pin using micrometer, and select the suitable size connecting rod bearing when replacing the connecting rod bearing. Unit: mm (in) Bearing Connecting rod bearing thickness (at center) Crankshaft pin outer diameter Standard Standard Standard size 1.492 - 1.508 (0.0587 - 0.0594) 49.976 - 50.000 (1.9676 - 1.9685) 0.03 (0.0012) Undersize 1.511 - 1.515 (0.0595 - 0.0596) 49.946 - 49.970 (1.9664 - 1.9673) 0.05 (0.0020) Undersize 1.521 - 1.525 (0.0599 - 0.0600) 49.926 - 49.950 (1.9656 - 1.9665) 0.25 (0.0098) Undersize 1.621 - 1.625 (0.0638 - 0.0640) 49.726 - 49.750 (1.9577 - 1.9587) Connecting rod bearing oil clearance: Standard 0.025 - 0.055 mm (0.0010 - 0.0022 in) Completely remove the plastigauge. In the same manner, check oil clearance of the #2, #3 and #4 connecting rod bearings.

Scheme 875

Scheme 876

1. Check that the connecting rod bushing is not damaged.
2. Check the clearance between piston pin and connecting rod bushing. Check the clearance between piston pin and connecting rod bushing by measuring the outer diameter of piston pin and the inner diameter of connecting rod bushing respectively. Measure the outer diameter of piston pin with a micrometer. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Measure the outer diameter of the piston pin at the two locations as shown in the figure, and read the value of most worn location. Record the measured value. Using a caliper gauge, measure the inner diameter of connecting rod bushing. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Measure the inner diameter of the connecting rod bushing at the two locations as shown in the figure, and read the value of most worn location. Record the measured value. Calculate the clearance between piston pin and connecting rod bushing. Clearance between piston pin and connecting rod bushing: Standard 0.004 - 0.026 mm (0.0002 - 0.0010 in)
3. If the clearance between piston pin and connecting rod bushing is not within the standard, replace the connecting rod and piston pin as a set.

Scheme 877

Scheme 878

Scheme 879

1. Clean the crankshaft completely, and check it for cracks using liquid penetrant tester.
2. Using a dial gauge, check the crankshaft bend. If it exceeds the limit, grind to correct the crankshaft journal or replace the crankshaft. NOTE: Measurement should be performed at a temperature of 20°C (68°F). If a suitable V-block is not available, using just the #1 and #5 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge. When grinding to correct the crankshaft journal, refer to step 3 ). Crankshaft bend: Limit 0.035 mm (0.0014 in)
3. Using a micrometer, check the outer diameter of crankshaft pin, outer diameter of journal, cylindricality, and out-of-roundness. If it is not within the standard, replace the connecting rod bearing or crankshaft bearing, and grind to correct the crankshaft pin or journal or replace the crankshaft as required. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Select the suitable size connecting rod bearing or crankshaft bearing when replacing the connecting rod bearing or crankshaft bearing. When grinding to correct the crankshaft pin or journal, finish them to the suitable outer diameter as shown in the table below according to the undersize bearing to be used. Unit: mm (in) Bearing Connecting rod bearing thickness (at center) Crankshaft pin outer diameter Crankshaft bearing thickness (at center) Crankshaft journal outer diameter #1, #2, #3, #4 #5 Standard Standard Standard Standard Standard Standard size 1.492 - 1.508 (0.0587 - 0.0594) 49.976 - 50.000 (1.9676 - 1.9685) 2.495 - 2.513 (0.0982 - 0.0989) 2.493 - 2.511 (0.0981 - 0.0989) 67.985 - 68.009 (2.6766 - 2.6775) 0.03 (0.0012) Undersize 1.511 - 1.515 (0.0595 - 0.0596) 49.946 - 49.970 (1.9664 - 1.9673) 2.519 - 2.522 (0.0992 - 0.0993) 2.517 - 2.520 (0.0991 - 0.0992) 67.955 - 67.979 (2.6754 - 2.6763) 0.05 (0.0020) Undersize 1.521 - 1.525 (0.0599 - 0.0600) 49.926 - 49.950 (1.9656 - 1.9665) 2.529 - 2.532 (0.0996 - 0.0997) 2.527 - 2.530 (0.0995 - 0.0996) 67.935 - 67.959 (2.6746 - 2.6755) 0.25 (0.0098) Undersize 1.621 - 1.625 (0.0638 - 0.0640) 49.726 - 49.750 (1.9577 - 1.9587) 2.629 - 2.632 (0.1035 - 0.1036) 2.627 - 2.630 (0.1034 - 0.1035) 67.735 - 67.759 (2.6667 - 2.6677) Crankshaft pin: Cylindricality Limit 0.006 mm (0.0002 in) Out-of-roundness Limit 0.005 mm (0.0002 in) Grinding limit (dia.) To 49.726 mm (1.9577 in) Crankshaft journal: Cylindricality Limit 0.006 mm (0.0002 in) Out-of-roundness Limit 0.005 mm (0.0002 in) Grinding limit (dia.) To 67.735 mm (2.6667 in)
4. Inspect the crankshaft bearing for scar, peeling, seizure, melting or wear, etc.
5. Use a thickness gauge to check the thrust clearance of crankshaft at thrust of #5 crankshaft bearing. If it is not within the standard, replace the #5 crankshaft bearing. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Set all the crankshaft bearings onto the cylinder block, then mount the crankshaft on the cylinder block, and use a thickness gauge to measure the thrust clearance of crankshaft. Select the #5 crankshaft bearing of suitable size by referring to step 3 ) when replacing #5 crankshaft bearing. Crankshaft thrust clearance: Standard 0.130 - 0.308 mm (0.00512 - 0.01213 in)
6. Check the oil clearance on each crankshaft bearing using plastigauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Install the cylinder block LH to the engine stand. CAUTION: When the engine stand is not used, place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work. Be careful not to scratch the mating surface of cylinder block during work. Remove the liquid gasket from cylinder block. Clean each crankshaft bearing and crankshaft journal. Set each crankshaft bearing to the cylinder block. CAUTION: When performing the operation of the cylinder block RH, be careful of the following. Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work. Be careful not to scratch the mating surface of cylinder block during work. Set the crankshaft to the cylinder block LH. Place a plastigauge across the crankshaft journals and set the cylinder block RH to the cylinder block LH. Apply a coat of engine oil to the washers and cylinder block mounting bolt threads. NOTE: To prevent mixture of engine oil into the water jacket, do not apply a large amount. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Loosen all mounting bolts by 180° in numerical order as shown in the figure. CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Loosen the mounting bolts (4 places) by 180° in numerical order as shown in the figure. CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Tighten the mounting bolts (4 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Using angle gauge, tighten the mounting bolts (4 places) with specified angle in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Tightening angle: 60°±2° Loosen the mounting bolts (6 places) by 180° in numerical order as shown in the figure. CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Tighten the mounting bolts (6 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Using angle gauge, tighten the mounting bolts (6 places) with specified angle in numerical order as shown in the figure. CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block. Tightening angle: 60°±2° Loosen the cylinder block mounting bolts in numerical order as shown in the figure, and separate the cylinder block RH and LH. NOTE: Lift the cylinder block RH slightly, and confirm that the crankshaft is remaining in the cylinder block LH. If the cylinder block RH is lifted carelessly when separating, the crankshaft may stick to cylinder block RH, then fall off. Determine the crankshaft oil clearance by matching the widest point of the plastigauge on each journal against scale printed on a package of the plastigauge. If it is not within the standard, replace the crankshaft bearing, and grind to correct the crankshaft journal or replace the crankshaft as required. NOTE: Select the crankshaft bearing of suitable size by referring to step 3 ) when replacing crankshaft bearing. When grinding to correct the crankshaft journal, finish it to the suitable outer diameter by referring to step 3 ) according to the undersize bearing to be used. Crankshaft oil clearance: Standard 0.013 - 0.031 mm (0.00051 - 0.00122 in) Completely remove the plastigauge.