Engine Mechanical (Except Wrx): Other Subaru XV GP

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.

When lifting up the vehicle, make sure to support the vehicle at the jack-up points.

1. Be careful not to let any oil or grease contact the clutch disc or flywheel.
2. Remove contamination including dirt and corrosion before removal, installation, disassembly or assembly.
3. Keep the removed parts in order and protect them from dust and dirt.
4. All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.
5. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil when being assembled.
6. Bolts, nuts and washers should be replaced with new parts as required.
7. 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 142

Tightening torque

13 N.m (1.3 kgf-m, 9.6 ft-lb)

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1. Install the idler pulley to the generator bracket and chain cover. NOTE: When installing the idler pulley, be careful of the idler pulley cover direction. Tightening torque: T1: 25 N.m (2.5 kgf-m, 18.4 ft-lb) T2: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
2. Install the V-belt tensioner assembly onto the generator bracket. 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. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
3. Install the cap to the V-belt tensioner assembly.
4. Install the V-belts. < Refer to «INSTALLATION»(ref-560356-S29649282662013061300000) , V-belt. >

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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. < Refer to «REMOVAL»(ref-560356-S25885296382013061300000) , 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.

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1. Remove the timing chain RH. < Refer to «REMOVAL»(ref-560356-S25807723062013061300000) , Timing Chain RH. >
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 down the chain lever tensioner LH, 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 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 180°, 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). ST1 18355AA000 PULLEY WRENCH ST2 18334AA030 PULLEY WRENCH PIN SET

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. 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 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).
2. 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
3. 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
4. Using ST and by turning the crankshaft approximately 200° 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
5. 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).
6. 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)
7. Install O-rings to the cylinder block LH. NOTE: Use new O-rings.
8. 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)
9. 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.
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 timing chain RH. < Refer to «INSTALLATION»(ref-560356-S41552764042013061300000) , Timing Chain RH. >

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 timing chain LH. < Refer to «INSTALLATION»(ref-560356-S24789413482013061300000) , Timing Chain LH. >
2. 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).
3. 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
4. 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).
5. 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)
6. 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)
7. 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.
8. 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
9. Install the chain cover. < Refer to «INSTALLATION»(ref-560356-S35441513312013061300000) , Chain Cover. >

CAM SPROCKET RH

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

1. Intake cam sprocket RH

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1. Remove the chain cover. < Refer to «REMOVAL»(ref-560356-S25885296382013061300000) , Chain Cover. >
2. Remove the timing chain RH. < Refer to «REMOVAL»(ref-560356-S25807723062013061300000) , Timing Chain RH. >
3. 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
4. Remove the intake cam sprocket RH.

1. Exhaust cam sprocket RH

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1. Remove the chain cover. < Refer to «REMOVAL»(ref-560356-S25885296382013061300000) , Chain Cover. >
2. Remove the timing chain RH. < Refer to «REMOVAL»(ref-560356-S25807723062013061300000) , Timing Chain RH. . >
3. 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
4. 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.

1. Intake cam sprocket LH

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1. Remove the chain cover. < Refer to «REMOVAL»(ref-560356-S25885296382013061300000) , Chain Cover. >
2. Remove the timing chain LH. < Refer to «REMOVAL»(ref-560356-S21445579382013061300000) , Timing Chain LH . >
3. 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
4. Remove the intake cam sprocket LH.

1. Exhaust cam sprocket LH

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1. Remove the chain cover. < Refer to «REMOVAL»(ref-560356-S25885296382013061300000) , Chain Cover. >
2. Remove the timing chain LH. < Refer to «REMOVAL»(ref-560356-S21445579382013061300000) , Timing Chain LH. >
3. 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
4. Remove the exhaust cam sprocket LH.

1. Intake cam sprocket RH

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1. 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.
2. 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)
3. Install the timing chain RH. < Refer to «INSTALLATION»(ref-560356-S41552764042013061300000) , Timing Chain RH . >
4. Install the chain cover. < Refer to «INSTALLATION»(ref-560356-S35441513312013061300000) , Chain Cover. >

1. Exhaust cam sprocket RH

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1. 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.
2. 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)
3. Install the timing chain RH. < Refer to «INSTALLATION»(ref-560356-S41552764042013061300000) , Timing Chain RH .>
4. Install the chain cover. < Refer to «INSTALLATION»(ref-560356-S35441513312013061300000) , Chain Cover. >

1. Intake cam sprocket LH

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1. 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.
2. 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)
3. Install timing chain LH. < Refer to «INSTALLATION»(ref-560356-S24789413482013061300000) , Timing Chain LH . >
4. Install the chain cover. < Refer to «INSTALLATION»(ref-560356-S35441513312013061300000) , Chain Cover. >

1. Exhaust cam sprocket LH

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1. 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.
2. 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)
3. Install timing chain LH. < Refer to «INSTALLATION»(ref-560356-S24789413482013061300000) , Timing Chain LH . >
4. Install the chain cover. < Refer to «INSTALLATION»(ref-560356-S35441513312013061300000) , Chain Cover. >

ROCKER COVER RH

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. Remove the air cleaner case. < Refer to «REMOVAL»(ref-560358-S34919400752013061300000) , Air Cleaner Case. > Remove the clip (A) from the air intake boot, and loosen the clamp (B) which holds air intake boot to the throttle body. Remove the air intake boot from the throttle body, and move the air intake boot to the left side wheel apron. Remove the front exhaust pipe. < Refer to «REMOVAL»(ref-560376-S32386970822013061300000) , Front Exhaust Pipe. >
2. Remove the #1 ignition coil and the #3 ignition coil. < Refer to «REMOVAL»(ref-560355-S05940411192013061300000) , Ignition Coil. >
3. Remove the intake manifold protector RH.
4. Remove the rocker cover RH.
5. 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. Remove the battery. < Refer to «REMOVAL»(ref-560379-S28864293722013061300000) , Battery. > Remove the V-belt covers. Remove the air intake duct. < Refer to «REMOVAL»(ref-560358-S09391633272013061300000) , Air Intake Duct. > Align the timing mark (A) of crank pulley to the timing gauge (B) 0° of chain cover as shown in the figure, and turn the crankshaft by 180° clockwise from that position. NOTE: This procedure is required to prevent the rocker cover LH and the cam lobe of camshaft LH contacting with each other when removing the rocker cover LH.
2. Remove the #2 ignition coil and the #4 ignition coil. < Refer to «REMOVAL»(ref-560355-S05940411192013061300000) , Ignition Coil. >
3. Remove the intake manifold protector LH.
4. Remove the rocker cover LH.
5. 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.

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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: 3.5±0.5 mm (0.1378±0.0197 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 intake manifold protector RH. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
6. Install the #1 ignition coil and the #3 ignition coil. < Refer to «INSTALLATION»(ref-560355-S00816282892013061300000) , Ignition Coil. >
7. When working on the vehicle Install the front exhaust pipe. < Refer to «INSTALLATION»(ref-560376-S08119204982013061300000) , Front Exhaust Pipe. > Install the air intake boot. < Refer to «INSTALLATION»(ref-560358-S35284385082013061300000) , Air Intake Boot. > Install the air cleaner case. < Refer to «INSTALLATION»(ref-560358-S30733303802013061300000) , Air Cleaner Case. >

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1. Align the timing mark (A) of crank pulley to the timing gauge (B) of chain cover as shown in the figure, and turn the crankshaft by 180° clockwise from that position. NOTE: This procedure is required only when working on the vehicle. This procedure is required to prevent the rocker cover LH and the cam lobe of camshaft LH contacting with each other when installing the rocker cover LH.
2. 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).
3. Install the rocker cover gasket LH to the rocker cover LH. NOTE: Use a new rocker cover gasket LH.
4. 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: 3.5±0.5 mm (0.1378±0.0197 in)
5. 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)
6. Install the intake manifold protector LH. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
7. Install the #2 ignition coil and the #4 ignition coil. < Refer to «INSTALLATION»(ref-560355-S00816282892013061300000) , Ignition Coil. >
8. When working on the vehicle Install the air intake duct. < Refer to «INSTALLATION»(ref-560358-S15714713712013061300000) , Air Intake Duct. > Install the V-belt cover. Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb) Install the battery. < Refer to «INSTALLATION»(ref-560379-S35296038422013061300000) , Battery. >

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. < Refer to REMOVAL , Cam Carrier RH > < Refer to DISASSEMBLY , Cam Carrier RH . >

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. < Refer to REMOVAL , Cam Carrier LH . > < Refer to DISASSEMBLY , Cam Carrier LH . >

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

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

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1. Remove the engine from the vehicle. < Refer to «REMOVAL»(ref-560356-S11535048802013061300000) , Engine Assembly. >
2. Remove the chain cover. < Refer to «REMOVAL»(ref-560356-S25885296382013061300000) , Chain Cover. >
3. Remove the timing chain RH. < Refer to «REMOVAL»(ref-560356-S25807723062013061300000) , Timing Chain Assembly RH. >
4. Remove the cam sprocket RH. < Refer to «REMOVAL»(ref-560356-S23318856192013061300000) , Cam Sprocket RH. > NOTE: This procedure is required only when disassembling the cam carrier RH.
5. Remove the rocker cover RH. < Refer to «REMOVAL»(ref-560356-S30174910732013061300000) , Rocker Cover RH. >
6. Remove the clip holding the engine harness from cam carrier RH.
7. Disconnect the water pipe hose from oil pan upper, and remove the water pipe assembly. (CVT model)
8. Remove the fuel pipe RH and the fuel injector RH. Disconnect the connector from fuel injector RH. Disconnect the quick connector from fuel pipe RH. NOTE: Disconnect the quick connector as shown in the figure. Remove the bolts securing the fuel pipe RH, and remove the fuel pipe RH and the fuel injector RH.
9. Insert the steel rods into ST, and set the engine so that the camshaft RH is facing up. CAUTION: If the engine is standing on one side without inserting the steel rod into ST, engine may lose balance and fall down. Be sure to insert the steel rod into ST to extend the length. Use the steel rod with enough strength. Be careful not to pinch the engine harness with ST. ST 499817100 ENGINE STAND
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 215

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Scheme 218

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Scheme 225

1. Remove the engine from the vehicle. < Refer to «REMOVAL»(ref-560356-S11535048802013061300000) , Engine Assembly. >
2. Remove the chain cover. < Refer to «REMOVAL»(ref-560356-S25885296382013061300000) , Chain Cover. >
3. Remove the timing chain LH. < Refer to «REMOVAL»(ref-560356-S21445579382013061300000) , Timing Chain Assembly LH. >
4. Remove the cam sprocket LH. < Refer to «REMOVAL»(ref-560356-S29424984112013061300000) , Cam Sprocket LH. > NOTE: This procedure is required only when disassembling the cam carrier LH.
5. Remove the rocker cover LH. < Refer to «REMOVAL»(ref-560356-S04542806292013061300000) , Rocker Cover LH. >
6. Remove the clip holding the engine harness from cam carrier LH.
7. Remove the preheater hose from intake manifold clip (A), and disconnect the preheater hose from throttle body.
8. Disconnect the water pipe hose from oil pan upper, and remove the water pipe assembly.
9. Remove the fuel pipe LH and the fuel injector LH. Disconnect the connector from fuel injector LH. Disconnect the quick connector from fuel pipe LH. NOTE: Disconnect the quick connector as shown in the figure. Remove the bolts securing the fuel pipe LH, and remove the fuel pipe LH and the fuel injector LH.
10. Insert the steel rods into ST, and set the engine so that the camshaft LH is facing up. CAUTION: If the engine is standing on one side without inserting the steel rod into ST, engine may lose balance and fall down. Be sure to insert the steel rod into ST to extend the length. Use the steel rod with enough strength. Be careful not to pinch the engine harness with ST. ST 499817100 ENGINE STAND
11. 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.
12. Remove the O-ring and the roller rocker arm from cylinder head LH. NOTE: Be careful not to confuse the roller rocker arms.
13. 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.
14. Remove the liquid gasket from cam carrier LH and cylinder head LH.

Scheme 226

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Scheme 232

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Scheme 234

Scheme 235

1. Insert the steel rods into ST, and set the engine so that the camshaft RH is facing up. CAUTION: If the engine is standing on one side without inserting the steel rod into ST, engine may lose balance and fall down. Be sure to insert the steel rod into ST to extend the length. Use the steel rod with enough strength. Be careful not to pinch the engine harness with ST. ST 499817100 ENGINE STAND
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. 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. Install the cam sprocket RH. < Refer to «INSTALLATION»(ref-560356-S14002478632013061300000) , Cam Sprocket RH. > NOTE: This procedure is required only when the cam carrier RH is removed for disassembly.
8. Check the cam clearance. < Refer to «INSPECTION»(ref-560356-S22253887942013061300000) , Cam Clearance. >
9. Install the timing chain RH. < Refer to «INSTALLATION»(ref-560356-S41552764042013061300000) , Timing Chain Assembly RH. >
10. Install the fuel pipe RH and the fuel injector RH. Install the fuel pipe RH and the fuel injector RH, and install the bolts which secure the fuel pipe RH. NOTE: Use new O-rings, rubbers and seal rings. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) Connect the quick connector to the fuel pipe RH. 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. Connect the connectors to the fuel injector RH.
11. Connect the water pipe hose to oil pan upper, and install the water pipe assembly. (CVT model) Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
12. Secure the engine harness to the cam carrier RH with a clip.
13. Install the rocker cover RH. < Refer to «INSTALLATION»(ref-560356-S41994986182013061300000) , Rocker Cover RH. >
14. Install the chain cover. < Refer to «INSTALLATION»(ref-560356-S35441513312013061300000) , Chain Cover. >
15. Install the engine to the vehicle. < Refer to «INSTALLATION»(ref-560356-S07921548712013061300000) , Engine Assembly. >

Scheme 236

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Scheme 245

1. Insert the steel rods into ST, and set the engine so that the camshaft LH is facing up. CAUTION: If the engine is standing on one side without inserting the steel rod into ST, engine may lose balance and fall down. Be sure to insert the steel rod into ST to extend the length. Use the steel rod with enough strength. Be careful not to pinch the engine harness with ST. ST 499817100 ENGINE STAND
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. 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. Install the cam sprocket LH. < Refer to «INSTALLATION»(ref-560356-S27443416722013061300000) , Cam Sprocket LH. > NOTE: This procedure is required only when the cam carrier LH is removed for disassembly.
8. Check the cam clearance. < Refer to «INSPECTION»(ref-560356-S22253887942013061300000) , Cam Clearance. >
9. Install timing chain LH. < Refer to «INSTALLATION»(ref-560356-S24789413482013061300000) , Timing Chain Assembly LH. >
10. Install the fuel pipe LH and the fuel injector LH. Install the fuel pipe LH and the fuel injector LH, and install the bolts which secure the fuel pipe LH. NOTE: Use new O-rings, rubbers and seal rings. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) Connect the quick connector to the fuel pipe LH. 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. Connect the connectors to the fuel injector LH.
11. 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)
12. Connect the preheater hose to throttle body and install the preheater hose to intake manifold clip (A).
13. Secure the engine harness to the cam carrier LH with a clip.
14. Install the rocker cover LH. < Refer to «INSTALLATION»(ref-560356-S22070146122013061300000) , Rocker Cover LH. >
15. Install the chain cover. < Refer to «INSTALLATION»(ref-560356-S35441513312013061300000) , Chain Cover. >
16. Install the engine to the vehicle. < Refer to «INSTALLATION»(ref-560356-S07921548712013061300000) , Engine Assembly. >

Scheme 246

Scheme 247

Scheme 248

1. 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.
2. Remove the intake camshaft RH and the exhaust camshaft RH from cam carrier RH.
3. Remove the filter from cam carrier RH.
4. 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 249

Scheme 250

Scheme 251

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 252

Scheme 253

Scheme 254

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 range A 2±0.5 mm (0.0787±0.0197 in) Mating surfaces of range A 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)

Scheme 255

Scheme 256

Scheme 257

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 ranges A and C 3.5±0.5 mm (0.1378±0.0197 in) Mating surfaces of range B 3 +0.5 -0 mm ( 0.1181+0.0197 -0 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 258

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Scheme 265

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). Camshaft cam lobe overall height H: Intake Standard 40.77 - 40.87 mm (1.605 - 1.609 in) Exhaust Standard 40.15 - 40.25 mm (1.581 - 1.585 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 266

Scheme 267

1. Remove the engine from the vehicle. < Refer to «REMOVAL»(ref-560356-S11535048802013061300000) , Engine Assembly. >
2. Remove the intake manifold. < Refer to «REMOVAL»(ref-560357-S21824144702013061300000) , Intake Manifold. >
3. Remove the tumble generator valve assembly RH. < Refer to «REMOVAL»(ref-560357-S08210786542013061300000) , Tumble Generator Valve Assembly. >
4. Remove the chain cover. < Refer to «REMOVAL»(ref-560356-S25885296382013061300000) , Chain Cover. >
5. Remove the rocker cover RH. < Refer to «REMOVAL»(ref-560356-S30174910732013061300000) , Rocker Cover RH. >
6. Remove the cam carrier RH. < Refer to «REMOVAL»(ref-560356-S07532194102013061300000) , Cam Carrier RH. >
7. Remove the EGR pipe assembly from the water pipe assembly and the cylinder block RH.
8. Loosen the bolts holding the cylinder head RH equally, a little at a time in numerical sequence as shown in the figure, and while leaving the cylinder head bolts (1) and (4) engaged by three or four threads, remove the other cylinder head bolts. NOTE: Leaving the cylinder head bolts (1) and (4) engaged by three or four threads prevents the cylinder head RH from falling.
9. While tapping the cylinder head RH with a plastic hammer, separate it from cylinder block RH.
10. Remove the bolts (1) and (4) to remove cylinder head RH.
11. Remove the cylinder head gasket RH. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.
12. Remove the liquid gasket from cylinder head RH and cam carrier RH.

Scheme 268

1. Remove the engine from the vehicle. < Refer to «REMOVAL»(ref-560356-S11535048802013061300000) , Engine Assembly. >
2. Remove the intake manifold. < Refer to «REMOVAL»(ref-560357-S21824144702013061300000) , Intake Manifold. >
3. Remove the tumble generator valve assembly LH. < Refer to «REMOVAL»(ref-560357-S08210786542013061300000) , Tumble Generator Valve Assembly. >
4. Remove the chain cover. < Refer to «REMOVAL»(ref-560356-S25885296382013061300000) , Chain Cover. >
5. Remove the rocker cover LH. < Refer to «REMOVAL»(ref-560356-S04542806292013061300000) , Rocker Cover LH. >
6. Remove the cam carrier LH. < Refer to «REMOVAL»(ref-560356-S24421500472013061300000) , Cam Carrier LH. >
7. Remove the A/C compressor. < Refer to «REMOVAL»(ref-560371-S20254169722013061300000) , Compressor. >
8. Loosen the bolts holding the cylinder head LH equally, a little at a time in numerical sequence as shown in the figure, and while leaving the cylinder head bolts (1) and (4) engaged by three or four threads, remove the other cylinder head bolts. NOTE: Leaving the cylinder head bolts (1) and (4) engaged by three or four threads prevents the cylinder head LH from falling.
9. While tapping the cylinder head LH with a plastic hammer, separate it from cylinder block LH.
10. Remove the cylinder head bolts (1) and (4) to remove cylinder head LH.
11. Remove the cylinder head gasket LH. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.
12. Remove the liquid gasket from cylinder head LH and cam carrier LH.

Scheme 269

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Scheme 271

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

1. 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.
2. 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)
3. Attach the cylinder head gasket RH. NOTE: Check that liquid gasket RH is squeezed out from the cylinder head gasket.
4. 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 29 N.m (3.0 kgf-m, 21.4 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 180° in numerical order as shown in the figure, and then loosen all cylinder head bolts 180° further in numerical order 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. ST 499817100 ENGINE STAND Tightening angle: 80°±2° Using angle gauge, tighten the cylinder head bolts (2 places) with specified angle in numerical order as shown in the figure. ST 499817100 ENGINE STAND Tightening angle: 75°±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. ST 499817100 ENGINE STAND Tightening angle: 30°±2°
5. Install the EGR pipe assembly to the water pipe assembly and the cylinder block RH. NOTE: Use a new gasket. Tightening torque: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 51 N.m (5.2 kgf-m, 37.6 ft-lb)
6. Install the cam carrier RH. < Refer to «INSTALLATION»(ref-560356-S07770636982013061300000) , Cam Carrier RH. >
7. Install the rocker cover RH. < Refer to «INSTALLATION»(ref-560356-S41994986182013061300000) , Rocker Cover RH. >
8. Install the chain cover. < Refer to «INSTALLATION»(ref-560356-S35441513312013061300000) , Chain Cover. >
9. Install the tumble generator valve assembly RH. < Refer to «INSTALLATION»(ref-560357-S26073606342013061300000) , Tumble Generator Valve Assembly. >
10. Install the intake manifold. < Refer to «INSTALLATION»(ref-560357-S29938581632013061300000) , Intake Manifold. >
11. Install the engine to the vehicle. < Refer to «INSTALLATION»(ref-560356-S07921548712013061300000) , Engine Assembly. >

Scheme 277

Scheme 278

Scheme 279

Scheme 280

Scheme 281

Scheme 282

1. 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.
2. 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)
3. Attach the cylinder head gasket LH. NOTE: Check that liquid gasket is squeezed out from the cylinder head gasket LH.
4. 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. Mount the cylinder head LH onto the cylinder block LH, then tighten all bolts with a torque of 29 N.m (3.0 kgf-m, 21.4 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 180° in numerical order as shown in the figure, and then loosen all cylinder head bolts 180° further in numerical order 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. ST 499817100 ENGINE STAND Tightening angle: 80°±2° Using angle gauge, tighten the cylinder head bolts (2 places) with specified angle in numerical order as shown in the figure. ST 499817100 ENGINE STAND Tightening angle: 75°±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. ST 499817100 ENGINE STAND Tightening angle: 30°±2°
5. Install the A/C compressor. < Refer to «INSTALLATION»(ref-560371-S34964128762013061300000) , Compressor. >
6. Install the cam carrier LH. < Refer to «INSTALLATION»(ref-560356-S34216933562013061300000) , Cam Carrier LH. >
7. Install the rocker cover LH. < Refer to «INSTALLATION»(ref-560356-S22070146122013061300000) , Rocker Cover LH. >
8. Install the chain cover. < Refer to «INSTALLATION»(ref-560356-S35441513312013061300000) , Chain Cover. >
9. Install the tumble generator valve assembly LH. < Refer to «INSTALLATION»(ref-560357-S26073606342013061300000) , Tumble Generator Valve Assembly. >
10. Install the intake manifold. < Refer to «INSTALLATION»(ref-560357-S29938581632013061300000) , Intake Manifold. >
11. Install the engine to the vehicle. < Refer to «INSTALLATION»(ref-560356-S07921548712013061300000) , Engine Assembly. >

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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. 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. < Refer to «INSPECTION»(ref-560356-S30896304822013061300000) , Cylinder Head. >
6. For cylinder head LH, remove the valve oil seal in the same manner.

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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. < Refer to «INSPECTION»(ref-560356-S30896304822013061300000) , 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: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 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)

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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. < Refer to «INSPECTION»(ref-560356-S14999464952013061300000) , 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)

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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 94.1 mm (3.705 in) When the valve is replaced, lap the valve. Refer to "VALVE SEAT" for lapping. < Refer to «INSPECTION»(ref-560356-S14999464952013061300000) , 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. < Refer to «INSPECTION»(ref-560356-S14999464952013061300000) , 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. < Refer to «INSPECTION»(ref-560356-S14999464952013061300000) , 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. 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. 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. 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. < Refer to «INSPECTION»(ref-560356-S14999464952013061300000) , Cylinder Head. >

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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. < Refer to «INSPECTION»(ref-560356-S14999464952013061300000) , 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. < Refer to «INSPECTION»(ref-560356-S22253887942013061300000) , 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. < Refer to «INSPECTION»(ref-560356-S14999464952013061300000) , Cylinder Head. > If the valve shim has to be replaced, check the cam clearance and replace with the suitable valve shim. < Refer to «INSPECTION»(ref-560356-S22253887942013061300000) , Cam Clearance. > Clearance between valve and valve shim: Standard 0.030 - 0.115 mm (0.0012 - 0.0045 in)

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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 27.9 - 28.1 mm (1.098 - 1.106 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 60° (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 60° (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 60° (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 311

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 41.06 mm (1.617 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 552 - 610 N (56.29 - 62.20 kgf, 124.11 - 137.15 lbf)/22.0 mm (0.866 in) Valve spring squareness: Standard 2.5°, 1.8 mm (0.071 in) or less

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1. Remove the engine from the vehicle. < Refer to «REMOVAL»(ref-560356-S11535048802013061300000) , Engine Assembly. >
2. Remove the intake manifold. < Refer to «REMOVAL»(ref-560357-S21824144702013061300000) , Intake Manifold. >
3. Remove the tumble generator valve assembly. < Refer to «REMOVAL»(ref-560357-S08210786542013061300000) , Tumble Generator Valve Assembly. >
4. Remove the chain cover. < Refer to «REMOVAL»(ref-560356-S25885296382013061300000) , Chain Cover. >
5. Remove the rocker cover. < Refer to «REMOVAL»(ref-560356-S08488034122013061300000) , Rocker Cover. >
6. Remove the cam carrier. < Refer to «REMOVAL»(ref-560356-S02091001602013061300000) , Cam Carrier. >
7. Remove the cylinder head. < Refer to «REMOVAL»(ref-560356-S00759055592013061300000) , Cylinder Head. >
8. Remove the crank sprocket. < Refer to «REMOVAL»(ref-560356-S33902047272013061300000) , Crank Sprocket. >
9. Remove the engine rear hanger from cylinder block RH.
10. 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.
11. Remove the O-ring from the cylinder block and PCV connector.
12. Remove the knock sensor from cylinder block LH.
13. Remove the PCV hose from the PCV valve.
14. Remove the PCV valve from the cylinder block RH.
15. Remove the crankshaft position sensor plate with drive plate. (CVT model) < Refer to «REMOVAL»(ref-560362-S22439106892013061300000) , Drive Plate. >
16. Remove the clutch disc and cover. (MT model) < Refer to «REMOVAL»(ref-560360-S25153288442013061300000) , Clutch Disc and Cover. >
17. Remove the crankshaft position sensor plate with flywheel. (MT model) < Refer to «REMOVAL»(ref-560360-S29887308622013061300000) , Flywheel. >
18. 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.
19. Set the cylinder block so that the oil pan is on the upper side, remove the ST1, ST2, ST3 and ST4 from cylinder block and oil pan upper. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 18362AA020 ADAPTER ST4 499817100 ENGINE STAND
20. Remove the thermostat cover from oil pan upper, and then remove the thermostat.
21. Remove the oil pan upper with oil pan from cylinder block.
22. Remove the O-ring from the cylinder block.
23. Install the mounting bolts for the A/C compressor and the generator bracket at the locations shown in the figure. NOTE: This procedure is required to prevent the knock pin damage when the cylinder block is raised in the next step. Use the same length bolt for the four bolts.
24. Raise the cylinder block so that the rear oil seal is on the lower side.
25. Remove the #1 and #4 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) and #4 connecting rod cap (B) 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 ST, loosen the #4 connecting rod cap bolt, and remove the #4 connecting rod cap bolt and #4 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. Using the ST, turn the crankshaft clockwise and separate the positions of the #4 pin (A) of crankshaft and the large end (B) of #4 connecting rod. ST 18252AA000 CRANKSHAFT SOCKET Push the #4 connecting rod in the direction of the arrow, and remove the #4 piston with #4 connecting rod from the cylinder block.
26. Remove the #2 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 #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, loosen the #2 connecting rod cap bolt, and remove the #2 connecting rod cap bolt and #2 connecting rod cap. ST 18270AA020 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 clockwise and separate the positions of the #2 pin (A) of crankshaft and the large end (B) of #2 connecting rod. ST 18252AA000 CRANKSHAFT SOCKET Push the #2 connecting rod in the direction of the arrow, and remove the #2 piston with #2 connecting rod from the cylinder block. 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.
27. Set the cylinder block so that the oil pan side faces upward, and remove the mounting bolts for A/C compressor and the generator bracket attached to the locations shown in the figure.
28. Set the part so that the cylinder block RH is on the upper side, and separate the cylinder block. 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. Remove the bolt shown in the figure. 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.
29. Remove the crankshaft from cylinder block LH, and remove the rear oil seal.
30. Remove the O-ring from the cylinder block LH.
31. 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).
32. Remove the liquid gasket from cylinder block.

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1. Apply engine oil to the crankshaft bearing, and install the crankshaft bearing to the cylinder block. 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.
2. Install O-rings to the cylinder block LH. NOTE: Use new O-rings.
3. Apply engine oil to the crankshaft journal, and set the crankshaft to cylinder block LH.
4. Apply liquid gasket to the mating surface of cylinder block RH as shown in the figure. CAUTION: 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)
5. Install the cylinder block RH to the cylinder block LH.
6. 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. Install the cylinder head bolt at the locations shown in the figure. NOTE: This procedure is required to tighten the cylinder block mounting bolts with specified angle using ST. 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° Remove the cylinder head bolt attached at the locations shown in the figure. 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)
7. Set the part so that the oil pan side of cylinder block is on the upper side.
8. 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
9. Install the mounting bolts for the A/C compressor and the generator bracket at the locations shown in the figure. NOTE: This procedure is required to prevent the knock pin damage when the cylinder block is raised in the next step. Use the same length bolt for the four bolts.
10. Raise the cylinder block so that the rear oil seal is on the lower side.
11. Adjust the positions of piston ring gap for each piston. NOTE: Check that the piston ring mark of compression ring faces the top side of the piston. Set the ring gap of the top ring to the position (A) in the figure. Position the ring gap of second ring at (B) in the figure on the 180° opposite direction of (A). Set the ring gap of the upper rail to the position (C) in the figure. Align the upper rail spin stopper (E) to the side hole (D) on the piston. Position the ring gap of expander at (F) in the figure on the 180° opposite direction of (C). Set the ring gap of lower rail at position (G), located 120° clockwise from (C) in the figure. Check that the positions of piston ring gap are properly adjusted. NOTE: When checking the positions of piston ring gap, also check that the piston ring gaps are not positioned within the range of piston skirt extended line.
12. 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 22 N.m (2.2 kgf-m, 16.2 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 22 N.m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure. ST 18270AA020 SOCKET Turn the crankshaft clockwise so that the #3 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 #3 connecting rod with #3 piston into cylinder block. CAUTION: Be careful not to damage the cylinder liner and #3 pin of crankshaft by the #3 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 #3 pin of crankshaft and the large end (A) of #3 connecting rod are positioned as shown in the figure using ST, while pressing the #3 piston crown, and then set the #3 connecting rod cap and #3 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 #3 connecting rod cap seat and the connecting rod cap bolt threads. ST 18252AA000 CRANKSHAFT SOCKET Using ST, tighten the #3 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 22 N.m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure. ST 18270AA020 SOCKET Turn the crankshaft clockwise so that the #4 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 #4 connecting rod with #4 piston into cylinder block. CAUTION: Be careful not to damage the cylinder liner and #4 pin of crankshaft by the #4 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 #4 pin of crankshaft and the large end (A) of #4 connecting rod are positioned as shown in the figure using ST, while pressing the #4 piston crown, and then set the #4 connecting rod cap and #4 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 #4 connecting rod cap seat and the connecting rod cap bolt threads. ST 18252AA000 CRANKSHAFT SOCKET Using ST, tighten the #4 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 22 N.m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure. ST 18270AA020 SOCKET Install the cam carrier mounting bolts at the locations shown in the figure. NOTE: This procedure is required to tighten the connecting rod cap bolts with specified angle using ST. Turn the crankshaft so that the #1 connecting rod cap (A) and #4 connecting rod cap (B) is located at the position shown in the figure using ST. ST 18252AA000 CRANKSHAFT SOCKET Using angle gauge and ST, 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: 137°±2° 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 angle gauge and ST, 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: 137°±2° Remove the cam carrier mounting bolts attached at the locations shown in the figure.
13. Set the cylinder block so that the oil pan side faces upward, and remove the mounting bolts for A/C compressor and the generator bracket attached to the locations shown in the figure.
14. 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)
15. Set the thermostat to the oil pan upper, and install the thermostat cover. NOTE: Use a new gasket. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
16. Install the ST1, ST2, ST3 and ST4 to the cylinder block and oil pan upper. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 18362AA020 ADAPTER ST4 499817100 ENGINE STAND Tightening torque: 35 N.m (3.6 kgf-m, 25.8 ft-lb)
17. 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)
18. Install the crankshaft position sensor plate with drive plate. (CVT model) < Refer to «INSTALLATION»(ref-560362-S17820920942013061300000) , Drive Plate. >
19. Install the crankshaft position sensor plate with flywheel. (MT model) < Refer to «INSTALLATION»(ref-560360-S19325099502013061300000) , Flywheel. >
20. Install the clutch disc and cover. (MT model) < Refer to «INSTALLATION»(ref-560360-S42734343342013061300000) , Clutch Disc and Cover. >
21. 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)
22. Install the PCV hose to the PCV valve.
23. 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 76.5 - 91.5° (shaded area). Tightening torque: 24 N.m (2.4 kgf-m, 17.7 ft-lb)
24. Install the O-ring to the cylinder block and PCV connector. NOTE: Use new O-rings.
25. 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)
26. Install the engine rear hanger to the cylinder block RH. Tightening torque: 21 N.m (2.1 kgf-m, 15.5 ft-lb)
27. Install the crank sprocket. < Refer to «INSTALLATION»(ref-560356-S28605402642013061300000) , Crank Sprocket. >
28. Install the cylinder head. < Refer to «INSTALLATION»(ref-560356-S23059314262013061300000) , Cylinder Head. >
29. Install the cam carrier. < Refer to «INSTALLATION»(ref-560356-S35987744802013061300000) , Cam Carrier. >
30. Install the rocker cover. < Refer to «INSTALLATION»(ref-560356-S17306104352013061300000) , Rocker Cover. >
31. Install the chain cover. < Refer to «INSTALLATION»(ref-560356-S35441513312013061300000) , Chain Cover. >
32. Install the tumble generator valve assembly. < Refer to «INSTALLATION»(ref-560357-S26073606342013061300000) , Tumble Generator Valve Assembly. >
33. Install the intake manifold. < Refer to «INSTALLATION»(ref-560357-S29938581632013061300000) , Intake Manifold. >
34. Install the engine to the vehicle. < Refer to «INSTALLATION»(ref-560356-S07921548712013061300000) , Engine Assembly. >

Scheme 389

Scheme 390

Scheme 391

Scheme 392

Scheme 393

1. Remove the water jacket spacer from the cylinder block RH and cylinder block LH. (XV model)
2. Remove the oil separator cover from cylinder block RH.
3. Remove the liquid gasket from cylinder block RH.
4. Remove the cylinder block plug (A) and the main gallery plug (B) from cylinder block RH.
5. 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.
6. Remove the cylinder block plate from cylinder block LH.
7. Remove the main gallery plug from cylinder block LH.
8. Remove the liquid gasket from the thread holes of the cylinder block LH and main gallery plug.

Scheme 394

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 395

Scheme 396

Scheme 397

Scheme 398

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±0.0197 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)
5. Install the water jacket spacer to the cylinder block RH and cylinder block LH. (XV model)

Scheme 399

Scheme 400

Scheme 401

Scheme 402

Scheme 403

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 piston rings onto the piston. Install the oil rings in the order of expander, lower rail and upper rail by hand. NOTE: Oil ring consists of the upper rail, expander and lower rail. Install the compression rings in the order of second ring and top ring, using piston ring expander. NOTE: Install so that the compression ring mark faces the top side of the piston.

Scheme 404

Scheme 405

Scheme 406

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 84.005 - 84.015 mm (3.3073 - 3.3077 in) Cylinder bore size mark B Standard 83.995 - 84.005 mm (3.3069 - 3.3073 in) Cylindricality of cylinder liner: Limit 0.015 mm (0.0006 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: 38.0 mm (1.50 in) Piston outer diameter: Standard size (grade A) Standard 83.975 - 83.985 mm (3.3061 - 3.3065 in) Standard size (grade B) Standard 83.965 - 83.975 mm (3.3057 - 3.3061 in) 0.25 mm (0.0098 in) oversize Standard 84.215 - 84.235 mm (3.3155 - 3.3163 in) 0.50 mm (0.0197 in) oversize Standard 84.465 - 84.485 mm (3.3254 - 3.3262 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 0.020 - 0.040 mm (0.00079 - 0.00157 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. 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 84.505 mm (3.3270 in)

Scheme 407

Scheme 408

Scheme 409

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 410

Scheme 411

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 - 0.35 mm (0.0079 - 0.0138 in) Compression ring (second ring) Standard 0.40 - 0.50 mm (0.0157 - 0.0197 in) Oil ring (upper rail and lower rail) Standard 0.20 - 0.50 mm (0.0079 - 0.0197 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 0.030 - 0.070 mm (0.0012 - 0.0028 in)

Scheme 412

Scheme 413

Scheme 414

Scheme 415

Scheme 416

Scheme 417

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 22 N.m (2.2 kgf-m, 16.2 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 angle gauge and ST, 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. ST 18270AA020 SOCKET Tightening angle: 137°±2° 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 22 N.m (2.2 kgf-m, 16.2 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 angle gauge and ST, 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. ST 18270AA020 SOCKET Tightening angle: 137°±2° 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) 47.976 - 48.000 (1.8888 - 1.8898) 0.03 (0.0012) Undersize 1.511 - 1.515 (0.0595 - 0.0596) 47.946 - 47.970 (1.8876 - 1.8886) 0.05 (0.0020) Undersize 1.521 - 1.525 (0.0599 - 0.0600) 47.926 - 47.950 (1.8868 - 1.8878) 0.25 (0.0098) Undersize 1.621 - 1.625 (0.0638 - 0.0640) 47.726 - 47.750 (1.8790 - 1.8799) Connecting rod bearing oil clearance: Standard 0.017 - 0.047 mm (0.0007 - 0.0019 in) Completely remove the plastigauge. In the same manner, check oil clearance of the #2, #3 and #4 connecting rod bearings.

Scheme 418

Scheme 419

Scheme 420

Scheme 421

Scheme 422

1. Check the connecting rod bushing for damage.
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 bushing and piston pin as a set. For replacement procedure of connecting rod bushing, refer to the following. Remove the connecting rod bushing from connecting rod small end with ST and press. NOTE: Be careful not to confuse the direction of the ST, because it is used in opposite directions for extraction and press-fit. ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER Press the connecting rod bushing with ST and the press, after applying engine oil on the periphery of connecting rod bushing. NOTE: Position the clinch portion of connecting rod bushing as shown in the figure. Be careful not to confuse the direction of the ST, because it is used in opposite directions for extraction and press-fit. ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER Make two 3 mm (0.12 in) holes in the pressed connecting rod bushing by aligning with the pre-manufactured holes on the connecting rod small end. Ream the inside of connecting rod bushing using the reamer. Insert the reamer in the connecting rod bushing, and turn slowly clockwise while pushing lightly. Bring the reamer back while rotating it clockwise. NOTE: Use a ø22 reamer. Apply engine oil to the reamer. If the inner surface of valve guide is damaged, the edge of reamer should be slightly ground with oil stone. If the inner surface of connecting rod bushing becomes lustrous and the reamer does not chip, use a new reamer or remedy the reamer. After completion of reaming, clean the connecting rod bushing to remove chips.

Scheme 423

Scheme 424

Scheme 425

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 #1, #2, #3, #4 #5 Standard Standard Standard Standard Standard Standard Standard size 1.492 - 1.508 (0.0587 - 0.0594) 47.976 - 48.000 (1.8888 - 1.8898) 2.495 - 2.513 (0.0982 - 0.0989) 2.493 - 2.511 (0.0981 - 0.0989) 67.985 - 68.009 (2.6766 - 2.6775) 67.985 - 68.009 (2.6766 - 2.6775) 0.03 (0.0012) Undersize 1.511 - 1.515 (0.0595 - 0.0596) 47.946 - 47.970 (1.8876 - 1.8886) 2.519 - 2.522 (0.0992 - 0.0993) 2.517 - 2.520 (0.0991 - 0.0992) 67.955 - 67.979 (2.6754 - 2.6763) 67.955 - 67.979 (2.6754 - 2.6763) 0.05 (0.0020) Undersize 1.521 - 1.525 (0.0599 - 0.0600) 47.926 - 47.950 (1.8868 - 1.8878) 2.529 - 2.532 (0.0996 - 0.0997) 2.527 - 2.530 (0.0995 - 0.0996) 67.935 - 67.959 (2.6746 - 2.6755) 67.935 - 67.959 (2.6746 - 2.6755) 0.25 (0.0098) Undersize 1.621 - 1.625 (0.0638 - 0.0640) 47.726 - 47.750 (1.8790 - 1.8799) 2.629 - 2.632 (0.1035 - 0.1036) 2.627 - 2.630 (0.1034 - 0.1035) 67.735 - 67.759 (2.6667 - 2.6677) 67.735 - 67.759 (2.6667 - 2.6677) Cylinder Block MECHANICAL Crankshaft pin: Cylindricality Limit 0.006 mm (0.0002 in) Out-of-roundness Limit 0.005 mm (0.0002 in) Grinding limit (dia.) To 47.726 mm (1.8790 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). Remove the liquid gasket from cylinder block. Clean each crankshaft bearing and crankshaft journal. Set each crankshaft bearing to the cylinder block. 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. 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. Install the cylinder head bolt at the locations shown in the figure. NOTE: This procedure is required to tighten the cylinder block mounting bolts with specified angle using ST. 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° Remove the cylinder head bolt attached at the locations shown in the figure. 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.