Scheme 137
Scheme 138
Scheme 139
- Apply a thin coat of engine oil to camshaft journals, and install the camshaft.
- Install the camshaft cap. Apply liquid gasket to the mating surfaces of camshaft cap. Liquid gasket: THREE BOND 1280B (Part No. K0877YA018) NOTE: Apply a coat of liquid gasket of 3 mm (0.12 in) in diameter (A) along the edge (B) of camshaft cap (C) mating surface. Install within 5 min. after applying liquid gasket. Temporarily tighten the bolts (a) through (d) in alphabetical sequence. Install the valve rocker assembly. INSTALLATION, Valve Rocker Assembly .> Tighten the TORX® bolts (e) through (j) in alphabetical sequence using the ST. ST 499497000 TORX® PLUS Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) Tighten the bolts (k) through (r) in alphabetical sequence. Tightening torque: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb) Tighten the bolts (s) and (t) in alphabetical sequence. NOTE: Use a new seal washer. Install and tighten the seal washer. Tightening torque: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb)
- Apply a coat of engine oil to oil seal periphery and oil seal lips and install the oil seal (A) on camshaft using ST1 and ST2. NOTE: Use a new oil seal. ST1 499597000 OIL SEAL GUIDE ST2 499587500 OIL SEAL INSTALLER
- Install the plug (A) using ST. ST 499587700 CAMSHAFT OIL SEAL INSTALLER
- Adjust the valve clearance. ADJUSTMENT, Valve Clearance .>
- Install the rocker cover and rocker cover gasket, and then connect PCV hose. NOTE: Use a new rocker cover gasket. Tighten the bolts in two stages in alphabetical sequence as shown in figure. Tightening torque: 1st 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) RH side LH side
- Install the oil level gauge guide. (LH side only)
- Install the camshaft position sensor support. (LH side only)
- Install the tensioner bracket. Tightening torque: 24.5 N.m (2.5 kgf-m, 18.1 ft-lb)
- Install the timing belt cover No. 2 (RH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
- Install the timing belt cover No. 2 (LH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
- Install the cam sprocket. INSTALLATION, Cam Sprocket .>
- Install the timing belt. INSTALLATION, Timing Belt .>
- Install the timing belt cover. INSTALLATION, Timing Belt Cover .>
- Install the crank pulley. INSTALLATION, Crank Pulley .>
- Install the V-belts. INSTALLATION, V-belt .>
Scheme 140
Scheme 141
- Measure the bend, and repair or replace if necessary. Service limit: 0.025 mm (0.00098 in)
- Check the journal for damage and wear. Replace if faulty.
- Measure the outer diameter of camshaft journal and inner diameter of cylinder head journal, and confirm the difference (oil clearance) between the two values. If the oil clearance exceeds the standard, replace the camshaft or cylinder head as necessary. OIL CLEARANCE SPECIFICATION Unit: mm (in) Oil clearance Standard 0.055 - 0.090 (0.0022 - 0.0035) Camshaft journal O.D. 31.928 - 31.945 (1.2570 - 1.2577) Journal hole I.D. 32.000 - 32.018 (1.2598 - 1.2605)
- Check the cam face condition, and remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the standard, replace it. Cam height H: CAM HEIGHT SPECIFICATION Part Unit: mm (in) Intake Constant Standard 40.075 - 40.175 (1.5778 - 1.5817) Low speed Standard 35.182 - 35.282 (1.3851 - 1.3891) High speed Standard 40.315 - 40.415 (1.5872 - 1.5911) Exhaust Standard 40.088 - 40.188 (1.5783 - 1.5822) Cam base circle diameter A: Intake 34.00 mm (1.3386 in) Exhaust 34.00 mm (1.3386 in) Base circle step of adjacent intake cams (low speed and high speed): 0.03 mm (0.001 in) or less
- Measure the thrust clearance of camshaft with setting the dial gauge at end of camshaft. If the thrust clearance exceeds the limit, replace the camshaft caps and cylinder head as a set. If necessary, replace the camshaft. Standard: 0.030 - 0.090 mm (0.0012 - 0.0035 in)
Note. Perform the work with the engine installed to body when replacing a single part. Refer to "Valve Clearance" for preparation. VALVE CLEARANCE. >
Scheme 142
- Remove the V-belts. REMOVAL, V-belt .>
- Remove the crank pulley. REMOVAL, Crank Pulley .>
- Remove the timing belt cover. REMOVAL, Timing Belt Cover .>
- Remove the timing belt. REMOVAL, Timing Belt .>
- Remove the cam sprocket. REMOVAL, Cam Sprocket .>
- Remove the intake manifold. REMOVAL , Intake Manifold .>
- Remove the bolt which installs the A/C compressor bracket on cylinder head.
- Remove the valve rocker assembly. REMOVAL, Valve Rocker Assembly .>
- Remove the camshaft. REMOVAL, Camshaft .>
- Remove the cylinder head bolts in alphabetical sequence as shown in the figure. NOTE: Leave bolts (a) and (c) engaged by three or four threads to prevent the cylinder head from falling.
- While tapping the cylinder head with a plastic hammer, separate it from cylinder block.
- Remove the bolts (a) and (c) to remove cylinder head.
- Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.
- Similarly, remove the right side cylinder head.
Scheme 143
- Install the cylinder head and gaskets on cylinder block. CAUTION: Be careful not to scratch the mating surface of cylinder block and cylinder head. NOTE: Use a new gasket.
- Tighten the cylinder head bolts. Apply a thin coat of engine oil to washer and bolt thread. Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-lb) in alphabetical order. Then tighten all bolts to 69 N.m (7.0 kgf-m, 51 ft-lb) in alphabetical sequence. Loosen all the bolts by 180° in reverse order of installation, and loosen again by 180° in the same order. Tighten all bolts to 42 N.m (3.9 kgf-m, 31 ft-lb) in alphabetical order. Tighten all bolts by 80 to 90° in alphabetical sequence. Tighten all bolts by 40 to 45° in alphabetical sequence. CAUTION: The tightening angle of the bolt should not exceed 45°. Further tighten the bolts (a) and (b) by 40 - 45°. CAUTION: Make sure the total "re-tightening angle" of the step (6) and (7) does not exceed 90°.
- Install the camshaft. INSTALLATION, Camshaft .>
- Install the valve rocker assembly. INSTALLATION .>
- Install the A/C compressor bracket on cylinder head.
- Install the intake manifold. INSTALLATION , Intake Manifold .>
- Install the cam sprocket. INSTALLATION, Cam Sprocket .>
- Install the timing belt. INSTALLATION, Timing Belt .>
- Adjust the valve clearance. ADJUSTMENT, Valve Clearance .>
- Install the rocker cover and rocker cover gasket, and then connect PCV hose. NOTE: Use a new gasket.
- Install the timing belt cover. INSTALLATION, Timing Belt Cover .>
- Install the crank pulley. INSTALLATION, Crank Pulley .>
- Install the V-belts. INSTALLATION, V-belt .>
Scheme 144
- Place the cylinder head on the ST. ST 498267800 CYLINDER HEAD TABLE
- Set the ST on valve spring. Compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST 499718000 VALVE SPRING REMOVER NOTE: Keep all the removed parts in order for re-installing in their original positions. Mark each valve to prevent confusion. Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals.
Scheme 145
Scheme 146
- Installation of valve spring and valve: Place the cylinder head on the ST. ST 498267800 CYLINDER HEAD TABLE Coat the stem of each valve with engine oil and insert the valve into the valve guide. NOTE: When inserting the valve into valve guide, use special care not to damage the oil seal lip. Install the valve spring and retainer. NOTE: Be sure to install the valve spring with its close-coiled end facing the seat on cylinder head. Set the ST on valve spring. ST 499718000 VALVE SPRING REMOVER Compress the valve spring and fit the valve spring retainer key. After installing, tap the valve spring retainers lightly with a plastic hammer for better seating.
Scheme 147
- Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface.
- Place the cylinder head on the ST. ST 498267800 CYLINDER HEAD TABLE
- Measure the warping of the cylinder head surface that mates with the cylinder block using a straight edge and thickness gauge. If the warping exceeds the limit, correct the surface by grinding it with a surface grinder. Warping limit: 0.035 mm (0.0014 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder head: 97.5 mm (3.839 in) NOTE: Uneven torque for the cylinder head bolts can cause warping. When reassembling, pay special attention to the torque so as to tighten evenly.
Note. Before conducting this procedure, drain the engine oil completely.
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Scheme 160
- Remove the intake manifold. REMOVAL , Intake Manifold .>
- Remove the V-belts. REMOVAL, V-belt .>
- Remove the crank pulley. REMOVAL, Crank Pulley .>
- Remove the timing belt cover. REMOVAL, Timing Belt Cover .>
- Remove the timing belt. REMOVAL, Timing Belt .>
- Remove the cam sprocket. REMOVAL, Cam Sprocket .>
- Remove the crank sprocket. REMOVAL, Crank Sprocket .>
- Remove the generator and A/C compressor with their brackets.
- Remove the rocker cover.
- Remove the cylinder head bolts in alphabetical order shown in the figure. NOTE: Leave bolts (a) and (d) engaged by three or four threads to prevent the cylinder head from falling.
- While tapping the cylinder head with a plastic hammer, separate it from cylinder block.
- Remove the bolts (a) and (d) to remove cylinder head.
- Remove the cylinder head gasket. NOTE: Do not scratch the mating surface of cylinder head and cylinder block.
- Similarly, remove the right side cylinder head.
- Remove the clutch cover. (MT model)
- Remove the flywheel (MT model) or drive plate (AT model). Using the ST, lock the crankshaft. ST 498497100 CRANKSHAFT STOPPER MT model AT model
- Remove the oil separator cover.
- Remove the water by-pass pipe for heater.
- Remove the water pump after loosening the bolts in alphabetical sequence as shown in the figure.
- Remove the bolts which install oil pump onto cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
- Remove the oil pump from cylinder block using a flat tip screwdriver. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
- Remove the oil pan. Set the part so that the cylinder block (LH) is on the upper side. Remove the bolts which secure oil pan to cylinder block. Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan. CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter.
- Remove the oil strainer stay.
- Remove the oil strainer.
- Remove the baffle plate.
- Remove the oil filter. REMOVAL , Engine Oil Filter .>
- Remove the water pipe.
- Remove the service hole plug using a hexagon wrench (14 mm).
- Remove the service hole cover.
- Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.
- Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
- Similarly remove the piston pins from #3 and #4 pistons.
- Remove the cylinder block connecting bolt on the RH side.
- Loosen the cylinder block connecting bolt on the LH side by 2-3 turns.
- Set the part so that the cylinder block (LH) is on the upper side, and remove the cylinder block connecting bolt.
- Separate the cylinder block (RH) and (LH). NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.
- Remove the rear oil seal.
- Remove the crankshaft along with the connecting rods.
- Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: Do not confuse the combination of crankshaft bearings. Press the bearing at the end opposite to locking lip.
- Draw out each piston from cylinder block using wooden bar or hammer handle. NOTE: Do not confuse the combination of piston and cylinder.
Scheme 161
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Scheme 185
- Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal.
- Position the crankshaft and O-ring on the cylinder block (RH).
- Apply liquid gasket to the mating surfaces of cylinder block (RH), and position the cylinder block (LH). Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent NOTE: Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.
- Apply a coat of engine oil to the washer and bolt thread. NOTE: Use a new seal washer.
- Tighten the 10 mm cylinder block connecting bolts on the LH side (A - D) in alphabetical order. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
- Tighten the 10 mm cylinder block connecting bolts on the RH side (E - J) in alphabetical order. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
- Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order. Tightening torque: 18 N.m (1.8 kgf-m, 13 ft-lb)
- Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order. Tightening torque: 18 N.m (1.8 kgf-m, 13 ft-lb)
- Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order. (A), (C): Angle tightening Tightening angle: 90° (B), (D): Torque tightening Tightening torque: 40 N.m (4.1 kgf-m, 29.6 ft-lb)
- Tighten the RH side cylinder block connecting bolts (E - J) in alphabetical order. Tightening angle: 90°
- Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A - H) in alphabetical sequence. Tightening torque: (A) - (G): 25 N.m (2.5 kgf-m, 18.1 ft-lb) (H): 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
- Apply a coat of engine oil to the oil seal periphery, then install the rear oil seal using ST1 and ST2. NOTE: Use new rear oil seal. ST1 499597100 OIL SEAL GUIDE ST2 499587200 OIL SEAL INSTALLER
- Position the top ring gap at (A) or (B) in the figure. NOTE: Assemble so that the piston ring mark "R" faces the top side of the piston.
- Position the second ring gap at 180° on the reverse side the top ring gap. NOTE: Assemble so that the piston ring mark "R" faces the top side of the piston.
- Position the upper rail gap at (C) in the figure.
- Align the upper rail spin stopper (E) to the side hole (D) on the piston.
- Position the expander gap at (F) in the figure.
- Position the lower rail gap at (G) in the figure. NOTE: Make sure ring gaps do not face the same direction. Make sure ring gaps are not within the piston skirt area.
- Install the snap ring. Before installing the piston to the cylinder block, install the snap rings to the piston holes on the opposite side of the service holes on the cylinder block. NOTE: Use new snap rings.
- Install the piston. Set the parts so that the #1 and #2 cylinders are on the upper side. Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET Tightening torque: N.m (kgf-m, ft-lb) T: 70 (7.1, 50.6) Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE CAUTION: Piston front mark faces towards the front of engine.
- Install the piston pin. Apply a coat of engine oil to ST3. Insert ST3 into the service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole. Install the snap ring. NOTE: Use new snap rings. Apply liquid gasket to the threaded portion of the service hole plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Install the service hole plug and gasket. NOTE: Use a new gasket. Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
- Install the water pipe. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
- Install the baffle plate. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
- Install the O-ring to the oil strainer, then install it to the cylinder block. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
- Install the oil strainer stay. Tighten the oil strainer together with the baffle plate. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
- Apply liquid gasket to the mating surfaces, and install the oil pan. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1207C (Part No. 004403012) or equivalent Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
- Apply liquid gasket to the mating surfaces and the threaded portion of bolt (A) shown in the figure (when reusing the bolt), and then install the oil separator cover. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: Mating surface THREE BOND 1217G or equivalent (A) bolt threads (when reusing bolts) THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
- Install the flywheel. (MT model) B: INSTALLATION , Flywheel .> To lock the crankshaft, use the ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb)
- Install the drive plate. (AT model) To lock the crankshaft, use the ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb)
- Install the clutch cover. (MT model)
- Installation of oil pump: Replace the front oil seal with a new part using ST. ST 499587100 OIL SEAL INSTALLER Apply liquid gasket to the matching surface of oil pump. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent Apply a coat of engine oil to the inside of oil seal. Install the oil pump to cylinder block. Be careful not to damage the oil seal during installation. NOTE: Make sure the oil seal lip is not folded. Align the flat surface of oil pump's inner rotor with crankshaft before installation. Use new O-rings and oil seals. Apply liquid gasket to the three bolts thread shown in figure, (when reusing bolts) Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: T: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
- Install the water pump and gasket. Tightening torque: First: 12 N.m (1.2 kgf-m, 8.7 ft-lb) Second: 12 N.m (1.2 kgf-m, 8.7 ft-lb) NOTE: When installing the water pump, tighten bolts in two stages in alphabetical order as shown in the figure. Use a new gasket.
- Install the water by-pass pipe for heater.
- Install the oil filter. INSTALLATION , Engine Oil Filter .>
- Tighten the cylinder head bolts. INSTALLATION, Cylinder Head .>
- Install the oil level gauge guide and tighten the bolts. (LH side only)
- Install the crank sprocket. INSTALLATION, Crank Sprocket .>
- Install the cam sprocket. INSTALLATION, Cam Sprocket .>
- Install the timing belt. INSTALLATION, Timing Belt .>
- Adjust the valve clearance. ADJUSTMENT, Valve Clearance .>
- Install the rocker cover gasket to the rocker cover, install it to the cylinder head, and then connect the PCV hose. NOTE: Use a new gasket.
- Install the timing belt cover. INSTALLATION, Timing Belt Cover .>
- Install the crank pulley. INSTALLATION, Crank Pulley .>
- Install the generator and A/C compressor brackets on cylinder head.
- Install the V-belts. INSTALLATION, V-belt .>
- Install the intake manifold. INSTALLATION , Intake Manifold .>
Scheme 186
- Remove the connecting rod cap.
- Remove the connecting rod bearing. NOTE: Arrange the removed connecting rod, connecting rod cap and bearing in order, to prevent confusion.
- Remove the piston rings using piston ring expander.
- Remove the oil ring by hand. NOTE: Arrange the removed piston rings in proper order, to prevent confusion.
- Remove the snap ring.
Scheme 187
- Apply oil to the surfaces of the connecting rod bearings.
- Install the connecting rod bearings on connecting rods and connecting rod caps.
- Position each connecting rod with the marking side facing forward, and install it.
- Install the connecting rod cap with connecting rod nut. Make sure the arrow on connecting rod cap faces toward front during installation. NOTE: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod nuts, apply oil on the threads.
- Install the expander, lower rail and upper rail by hand. Install the second ring and top ring using piston ring expander. Tightening torque: N.m (kgf-m, ft-lb) T: 45 (4.6, 33.3)