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Engine Mechanical: Removal & Installation Suzuki Aerio I

Mechanical 96 illustrations ~5548 words

Installation

Reference: AIR CLEANER ELEMENT INSPECTION AND CLEANING

Reverse removal procedure for installation.

Reverse removal procedure for installation.

Scheme 21

Scheme 21: Installation
Scheme 21: Installation
  1. Install air cleaner outlet hose (1) by aligning match marks (2) as shown in figure.

Scheme 22

Scheme 22: Removal
Scheme 22: Removal
  1. Remove engine cover bolts (1).
  2. Remove engine cover (2) from cylinder head cover.

Scheme 23

Scheme 23: Installation
Scheme 23: Installation
  1. Install engine cover (2) from cylinder head cover.
  2. Install engine cover bolts (1). Tightening torque Engine cover bolt a: 8 N.m (0.8 kg-m, 5.8 lb-ft)

Throttle Body Removal and Installation

Reference: THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Reference: THROTTLE BODY ON-VEHICLE INSPECTION

Scheme 24

Scheme 24: Removal
Scheme 24: Removal

Scheme 25

Scheme 25
Scheme 25
  1. Disconnect negative cable at battery.
  2. Drain coolant. WARNING: To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.
  3. Remove engine cover referring to «ENGINE COVER REMOVAL AND INSTALLATION»(ref-251061-S38205840632007032000000) .
  4. Remove air cleaner outlet hose (referring to «AIR CLEANER OUTLET HOSE REMOVAL AND INSTALLATION»(ref-251061-S24859413062007032000000) ).
  5. Remove generator drive belt referring to «GENERATOR DRIVE BELT REMOVAL AND INSTALLATION»(ref-251067-S00664805372007032000000) .
  6. With hose connected, detach P/S pump from its bracket.
  7. Disconnect accelerator cable (1) from throttle valve lever (2).
  8. Disconnect couplers of TP sensor (3), IAC valve (4) and ground connector (5).
  9. Disconnect coolant hoses (6) and breather hose (7) from throttle body.
  10. Remove throttle body from intake manifold.

Reference: THROTTLE BODY CLEANING

Scheme 26

Scheme 26: Installation
Scheme 26: Installation

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28
  1. Clean mating surfaces and install throttle body gasket to intake manifold. Use new gasket.
  2. Install throttle body to intake manifold and tighten bolts and nuts.
  3. Connect coolant hoses (6) and breather hose (7).
  4. Connect couplers of TP sensor (3), IAC sensor (4) and ground terminal (5).
  5. Connect accelerator cable (1) to throttle valve lever (2).
  6. Install P/S pump to its bracket referring to «P/S PUMP REMOVAL AND INSTALLATION»(ref-251091-S26800418822007032000000) .
  7. Install generator drive belt referring to «GENERATOR DRIVE BELT REMOVAL AND INSTALLATION»(ref-251067-S00664805372007032000000) .
  8. Install air cleaner outlet hose referring to «AIR CLEANER OUTLET HOSE REMOVAL AND INSTALLATION»(ref-251061-S24859413062007032000000) .
  9. Install engine cover referring to «ENGINE COVER REMOVAL AND INSTALLATION»(ref-251061-S38205840632007032000000) .
  10. Refill cooling system referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-251063-S04981760882007032000000) .
  11. Connect negative cable at battery.
  12. Start engine and check for engine coolant leakage.

Intake Manifold Removal and Installation

Reference: THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Scheme 29

Scheme 29: Removal
Scheme 29: Removal

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32
  1. Disconnect negative cable at battery.
  2. Drain cooling system. WARNING: To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.
  3. Remove engine cover referring to «ENGINE COVER REMOVAL AND INSTALLATION»(ref-251061-S38205840632007032000000) .
  4. Remove air cleaner outlet hose referring to «AIR CLEANER OUTLET HOSE REMOVAL AND INSTALLATION»(ref-251061-S24859413062007032000000) .
  5. Disconnect accelerator cable (2) from throttle valve lever (1).
  6. Disconnect accelerator cable (2) with cable bracket (3) from intake manifold.
  7. Disconnect the following electric lead wires: IAC valve coupler (4) TP sensor coupler (5) EGR valve coupler (6) EVAP canister purge valve coupler (7) MAP sensor coupler (8) Ground terminal (9) from throttle body
  8. Disconnect the following hoses: Brake booster hose (10) from intake manifold PCV hose (11) from PCV valve Fuel pressure regulator vacuum hose (12) from intake manifold Coolant hoses from (13) throttle Breather hose (14) from throttle body Vacuum hose (15) from EVAP canister purge valve
  9. Remove intake manifold front stiffener (16).
  10. Remove rear stiffener (17), and disconnect coolant pipe (18) from intake manifold.
  11. Remove intake manifold (2) with throttle body from cylinder head, and then its gasket (1).

Scheme 33

Scheme 33: Installation
Scheme 33: Installation

Scheme 34

Scheme 34
Scheme 34

Scheme 35

Scheme 35
Scheme 35
  1. Install new intake manifold gasket (1) to cylinder head.
  2. Install intake manifold (2) with throttle body. Tighten bolts and nuts to specified torque. Tightening torque Intake manifold bolt and nut a: 25 N.m (2.5 kg-m, 18.0 lb-ft)
  3. Connect coolant pipe (1) to intake manifold and install rear stiffener (2). Tighten bolts to specified torque. Tightening torque Intake manifold rear stiffener bolt a: 25 N.m (2.5 kg-m, 18.0 lb-ft)
  4. Install intake manifold front stiffener (1). Tighten bolts to specified torque. Tightening torque Intake manifold front stiffener bolt a: 55 N.m (5.5 kg-m, 40.0 lb-ft)
  5. Connect the following hoses: Brake booster hose (2) to intake manifold PCV hose (3) to PCV valve Fuel pressure regulator vacuum hose (4) to intake manifold Coolant hoses (5) to throttle body Breather hose (6) to throttle body Vacuum hose (7) to EVAP canister purge valve
  6. Connect the following electric lead wires: IAC valve (8) TP sensor (9) EGR valve (10) EVAP canister purge valve (11) MAP sensor (12) Ground terminal (13) to throttle body
  7. Connect accelerator cable (14) to throttle valve lever (15) and install its bracket (16) to intake manifold. Adjust accelerator cable play, referring to «ACCELERATOR CABLE ADJUSTMENT»(ref-251061-S37871809172007032000000) .
  8. Install air cleaner outlet hose referring to «AIR CLEANER OUTLET HOSE REMOVAL AND INSTALLATION»(ref-251061-S24859413062007032000000) .
  9. Install engine cover referring to «ENGINE COVER REMOVAL AND INSTALLATION»(ref-251061-S38205840632007032000000) .
  10. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
  11. Refill cooling system referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-251063-S04981760882007032000000) .
  12. Connect negative cable at battery.
  13. Start engine and check for engine coolant leaks.

Scheme 36

Scheme 36: Removal
Scheme 36: Removal
  1. Disconnect negative cable at battery.
  2. Remove engine cover referring to «ENGINE COVER REMOVAL AND INSTALLATION»(ref-251061-S38205840632007032000000) .
  3. Disconnect ignition coil couplers.
  4. Remove ignition coils.
  5. Remove oil level gauge.
  6. Disconnect breather hose (2) and PCV hose (3) from cylinder head cover (4).
  7. Remove cylinder head cover (4).
  8. Remove PCV valve (1) from cylinder head cover (4), if equipped.

Scheme 37

Scheme 37: Installation
Scheme 37: Installation

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39
  1. Install PCV valve to cylinder head cover referring to «PCV VALVE REMOVAL AND INSTALLATION»(ref-251059-S37054888892007032000000) .
  2. Remove oil, old sealant and dust from sealing surfaces on cylinder head and cover. After cleaning, apply sealant "A" to cylinder head sealing surface area as shown in figure. "A": Sealant 99000-31250
  3. Install new O-rings (3) and new cylinder head cover gasket (2) to cylinder head cover (1). NOTE: Be sure to check each of these parts for deterioration or any damage before installation and replace if found defective.
  4. Install new cylinder head side seal (4) and cylinder head cover to cylinder head.
  5. Tighten nuts (2) to specified torque. Use new seal washers (1). Tightening torque Cylinder head cover nut a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
  6. Install oil level gauge (3).
  7. Connect breather hose (4) and PCV hose (5) to cylinder head cover.
  8. Install ignition coils and connect ignition coil couplers.
  9. Install engine cover referring to «ENGINE COVER REMOVAL AND INSTALLATION»(ref-251061-S38205840632007032000000) .
  10. Connect negative cable at battery.

Scheme 40

Scheme 40: Cylinder Block Heater (If Equipped) Components
Scheme 40: Cylinder Block Heater (If Equipped) Components

Cylinder Block Heater (If Equipped) Removal and Installation

Reference: CYLINDER BLOCK HEATER (IF EQUIPPED) COMPONENTS

Scheme 41

Scheme 41: Removal
Scheme 41: Removal
  1. Disconnect negative (-) cable battery.
  2. Drain coolant. WARNING: To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.
  3. Disconnect cylinder block heater connector and remove cylinder block heater (1).

Reference: CYLINDER BLOCK HEATER (IF EQUIPPED) INSPECTION

Reverse removal procedure for installation noting the following.

Scheme 42

Scheme 42: Installation
Scheme 42: Installation

Scheme 43

Scheme 43
Scheme 43
  1. Install cylinder block heater (1) in the direction as shown in the figure.
  2. Apply thread lock cement to block heater bolts (1). "A": Thread lock cement 99000-32020
  3. Tighten cylinder block heater bolts (1) to specified torque. Tightening torque Cylinder block heater bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)

Cylinder Block Heater Harness (If Equipped) Removal and Installation

Reference: CYLINDER BLOCK HEATER (IF EQUIPPED) COMPONENTS

Scheme 44

Scheme 44: Removal
Scheme 44: Removal
  1. Disconnect cylinder block heater connector (1) from block heater.
  2. Unclamp cylinder block heater harness (2) and then remove it.

Reference: CYLINDER BLOCK HEATER HARNESS (IF EQUIPPED) INSPECTION

Scheme 45

Scheme 45: Installation
Scheme 45: Installation
  1. Connect cylinder block heater connector to block heater.
  2. Install clips (1) with open end facing left side and clip (2) with open end facing upward and clamp (7) to body.
  3. Fix cylinder block heater harness with clips (1 and 2) and clamp (7) securely.
  4. Fix cylinder block heater harness to engine harness (3) with clamps (4) at white tape parts (5).
  5. Check to make sure that harness protector (6) is installed as shown and its open end faces downward.

Timing Chain Cover Removal and Installation

Reference: TIMING CHAIN COVER COMPONENTS

Scheme 46

Scheme 46: Removal
Scheme 46: Removal

Scheme 47

Scheme 47
Scheme 47

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49

Scheme 50

Scheme 50
Scheme 50
  1. Remove engine assembly from vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .
  2. Remove oil pan referring to «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-251062-S40140775192007032000000) .
  3. Remove cylinder head cover referring to «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-251061-S36816345782007032000000) .
  4. Remove crankshaft pulley bolt. To lock crankshaft pulley (1), use special tool (camshaft pulley holder) with it as shown in figure. Special Tool (a): 09917-68221 NOTE: Be sure to use the following bolts instead of pins for fixing special tool to crankshaft pulley. Bolt size: M8, P1.25 L = 25 mm (0.98 in.) Strength: 7T
  5. Remove crankshaft pulley (1). To remove crankshaft pulley, use special tools (Steering wheel remover, Bearing puller attachment) with it as shown in figure. Special Tool 09944-36011 09926-58010
  6. Remove A/C compressor bracket (1).
  7. Remove generator belt idler pulley (1), water pump pulley (2) and generator belt tensioner (3).
  8. Remove timing chain cover (1) bolts (3) and nut (2).

Reference: TIMING CHAIN COVER CLEANING AND INSPECTION

Reverse removal sequence to install timing chain cover (1) noting the following points.

Scheme 51

Scheme 51: Installation
Scheme 51: Installation

Scheme 52

Scheme 52
Scheme 52

Scheme 53

Scheme 53
Scheme 53

Scheme 54

Scheme 54
Scheme 54
  1. Apply sealant "A" and "B" to area as shown in figure. "A": Sealant 99000-31250 "B": Sealant 99000-31140 Sealant amount for timing chain cover "a": 3 mm (0.12 in.) "b": 2 mm (0.08 in.) "c": 6 mm (0.24 in.) "d": 16 mm (0.63 in.) "e": 14 mm (0.55 in.) "f": 65 mm (2.56 in.) "g": 73 mm (2.87 in.) "h": 4 mm (0.16 in.)
  2. Apply engine oil to oil seal lip, then install timing chain cover (1). Tighten bolts and nut to specified torque. NOTE: Before installing timing chain cover, check that pin is securely fitted. Tightening torque Timing chain cover bolt and nut a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
  3. Install generator belt idler pulley (1). Tighten nut to specified torque. Tightening torque Generator belt idler pulley nut a: 42 N.m (4.2 kg-m, 30.5 lb-ft)
  4. Install generator belt tensioner (2). Tighten bolts to specified torque. Tightening torque Generator belt tensioner bolt b: 25 N.m (2.5 kg-m, 18.5 lb-ft)
  5. Install water pump pulley (3).
  6. Install A/C compressor bracket (1) if equipped. Tighten bracket bolts to specified torque. Tightening torque A/C compressor bracket bolt a: 55 N.m (5.5 kg-m, 40.0 lb-ft)
  7. Install cylinder head cover referring to «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-251061-S36816345782007032000000) .
  8. Install oil pan. Refer to «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-251062-S40140775192007032000000) for installation.
  9. Install crankshaft pulley. To lock crankshaft pulley (1), use special tool (camshaft pulley holder) with it as shown in figure. Special Tool (A): 09917-68221 NOTE: Be sure to use the following bolts instead of pins for fixing special tool to crank pulley. Bolt size: M8, P1.25 L = 25 mm (0.98 in.) Strength: 7T Tightening torque Crankshaft pulley bolt a: 150 N.m (15.0 kg-m, 108.5 lb-ft)
  10. Install engine assembly to vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .

2nd Timing Chain and Chain Tensioner Removal and Installation

Reference: 2nd Timing Chain and Chain Tensioner Components

Scheme 55

Scheme 55: Removal
Scheme 55: Removal

Scheme 56

Scheme 56
Scheme 56

Scheme 57

Scheme 57
Scheme 57

Scheme 58

Scheme 58
Scheme 58
  1. Remove engine assembly from vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .
  2. Remove oil pan. Refer to «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-251062-S40140775192007032000000) for removal.
  3. Remove cylinder head cover. Refer to «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-251061-S36816345782007032000000) for removal.
  4. Remove timing chain cover. Refer to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-251061-S00834920012007032000000) for removal.
  5. Turn crankshaft to meet following conditions. Key (I) on crankshaft is positioned as shown. Arrow mark on idler sprocket (II) points upward. Marks on sprockets (III) match with marks on cylinder head. Note that this step must be followed for reinstallation of timing chain.
  6. Remove timing chain tensioner adjuster No.2 (1) and gasket. To remove them, slacken 2nd timing chain by turning intake camshaft counterclockwise a little while pushing back pad.
  7. Remove intake (1) and exhaust (2) camshaft timing sprocket bolts. To remove them, fit a spanner to hexagonal part (3) at the center of camshaft to hold it stationary.
  8. Remove camshaft timing sprockets and 2nd timing chain (4). CAUTION: After 2nd timing chain is removed, never turn intake camshaft, exhaust camshaft and crankshaft independently more than such an extent as shown. If turned, interference may occur between piston and valves and valves themselves, and parts related to piston and valves may be damaged.

Reference: 2nd Timing Chain and Chain Tensioner Inspection

Scheme 59

Scheme 59: Installation
Scheme 59: Installation

Scheme 60

Scheme 60
Scheme 60

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Scheme 61

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Scheme 62

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Scheme 63

Scheme 64

Scheme 64
Scheme 64

Scheme 65

Scheme 65
Scheme 65

Scheme 66

Scheme 66
Scheme 66
  1. Check that match mark (1) on crank timing sprocket is in match with timing mark (2) on lower crankcase as shown in figure.
  2. Check that arrow mark (1) on idler sprocket faces upward as shown in figure.
  3. Check that knock pins of intake (2) and exhaust (3) camshafts are aligned with timing marks on cylinder head as shown in figure.
  4. Install 2nd timing chain by aligning yellow plate (1) of 2nd timing chain and match marks on idler sprocket.
  5. Install sprockets to intake and exhaust camshafts by aligning dark blue plate of 2nd timing chain, match marks on intake sprocket and exhaust sprocket respectively. CAUTION: Do not turn more than allowable turning range. If turned excessively, valve and piston may get damaged. NOTE: As an arrow mark is provided on both sides, camshaft timing sprocket has no specific installation direction.
  6. Install intake (1) and exhaust (2) camshaft timing sprocket bolts. To install it, fit a spanner to hexagonal part (3) at the center of camshaft to hold it stationary. Tightening torque Camshaft timing sprocket bolt a: 80 N.m (8.0 kg-m, 57.5 lb-ft)
  7. Push back plunger (1) into tensioner body (2) and hold it at the position by inserting stopper (3) into body.
  8. Install timing chain tensioner adjuster No. 2 (1) with new gasket. Tightening torque Timing chain tensioner adjuster No. 2 bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft) Timing chain tensioner adjuster No. 2 nut b: 45 N.m (4.5 kg-m, 33.0 lb-ft)
  9. Pull out stopper (2) from timing chain tensioner adjuster No. 2.
  10. Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on cylinder block as shown in figure. Check that timing marks of cylinder head and cylinder block are in match with match marks on sprockets respectively.
  11. Apply oil to timing chains, tensioner, tensioner adjusters, sprockets, and guides.
  12. Install timing chain cover. Refer to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-251061-S00834920012007032000000) for installation.
  13. Install cylinder head cover. Refer to «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-251061-S36816345782007032000000) for installation.
  14. Install oil pan. Refer to «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-251062-S40140775192007032000000) for installation.
  15. Install engine assembly to vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .

1st Timing Chain and Chain Tensioner Removal and Installation

Reference: 1st Timing Chain and Chain Tensioner Components

Scheme 67

Scheme 67: Removal
Scheme 67: Removal

Scheme 68

Scheme 68
Scheme 68
  1. Remove engine assembly from vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .
  2. Remove oil pan. Refer to «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-251062-S40140775192007032000000) for removal.
  3. Remove cylinder head cover. Refer to «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-251061-S36816345782007032000000) for removal.
  4. Remove timing chain cover. Refer to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-251061-S00834920012007032000000) for removal.
  5. For reinstallation of timing chain, turn crankshaft so that timing marks on cylinder head and lower crankcase match with those on sprockets as shown in figure.
  6. Remove 2nd timing chain. Refer to «2nd Timing Chain and Chain Tensioner Removal and Installation»(ref-251061-S41490753382007032000000) for removal.
  7. Remove timing chain guide No.1 (1).
  8. Remove timing chain tensioner adjuster No.1 (2).
  9. Remove timing chain tensioner (3).
  10. Remove idler sprocket (4) and 1st timing chain (5).
  11. Remove crankshaft timing sprocket (6).

Reference: 1st Timing Chain and Chain Tensioner Inspection

Scheme 69

Scheme 69: Installation
Scheme 69: Installation

Scheme 70

Scheme 70
Scheme 70

Scheme 71

Scheme 71
Scheme 71

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Scheme 72
Scheme 72

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Scheme 73

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Scheme 77

Scheme 77
Scheme 77
  1. Check that match mark (1) on crankshaft timing sprocket is in match with timing mark (2) on lower crankcase.
  2. Install crankshaft timing sprocket (2) as shown in figure.
  3. Apply oil to bush of idler sprocket (1).
  4. Install idler sprocket and sprocket shaft.
  5. Install 1st timing chain by aligning dark blue plate (4) of 1st timing chain (3) and match mark (2) on idler sprocket (1).
  6. Bring yellow plate (4) of 1st timing chain (3) into match with match mark (2) on crankshaft timing sprocket (1).
  7. Apply engine oil to sliding surface of timing chain tensioner (1) and then install it as shown in figure. Tighten tensioner nut to specified torque. Tightening torque Timing chain tensioner nut a: 25 N.m (2.5 kg-m, 18.0 lb-ft)
  8. With latch of tensioner adjuster No.1 returned and plunger (1) pushed back into body, insert stopper (4) into latch (2) and body (3). After inserting it, check to make sure that plunger will not come out.
  9. Install timing chain tensioner (2) adjuster No.1 (1). Tightening torque Timing chain tensioner adjuster No.1 bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
  10. Pull out stopper (3) from adjuster No.1.
  11. Apply engine oil to sliding surface of timing chain guide No.1 (1) and then install it. Tighten guide bolts to specified torque. Tightening torque Timing chain guide No. 1 bolt a: 9 N.m (0.9 kg-m, 6.5 lb-ft)
  12. Check that dark blue and yellow plates of 1st timing chain are in match with match marks on sprockets respectively.
  13. Install 2nd timing chain. Refer to «2nd Timing Chain and Chain Tensioner Removal and Installation»(ref-251061-S41490753382007032000000) for installation.
  14. Install timing chain cover. Refer to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-251061-S00834920012007032000000) for installation.
  15. Install cylinder head cover. Refer to «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-251061-S36816345782007032000000) for installation.
  16. Install oil pan. Refer to «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-251062-S40140775192007032000000) for installation.
  17. Install engine assembly to vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .

Camshafts and Valve Lash Adjusters Removal and installation

Reference: CAMSHAFTS AND VALVE LASH ADJUSTERS COMPONENTS

Scheme 78

Scheme 78: Removal
Scheme 78: Removal

Scheme 79

Scheme 79
Scheme 79

Scheme 80

Scheme 80
Scheme 80

Scheme 81

Scheme 81
Scheme 81
  1. Remove engine assembly from vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .
  2. Remove oil pan. Refer to «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-251062-S40140775192007032000000) for removal.
  3. Remove cylinder head cover. Refer to «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-251061-S36816345782007032000000) for removal.
  4. Remove timing chain cover. Refer to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-251061-S00834920012007032000000) for removal.
  5. Remove 2nd timing chain. Refer to «2nd Timing Chain and Chain Tensioner Removal and Installation»(ref-251061-S41490753382007032000000) for removal.
  6. Remove CMP sensor. Refer to «CMP (CAMSHAFT POSITION) SENSOR REMOVAL AND INSTALLATION»(ref-251060-S38494016652007032000000) for removal.
  7. To secure work in the following steps, reinstall mounting member, engine front torque bush, rear mounting and rear mounting No.2 bracket.
  8. Set key on crankshaft in position as shown by turning crankshaft. This is to prevent interference between valves and piston.
  9. Loosen camshaft housing bolts in such order as indicated in figure and remove them.
  10. Remove camshaft housings.
  11. Remove camshafts.
  12. Remove valve lash adjusters (2). NOTE: Never disassemble hydraulic valve lash adjuster. Don't apply force (1) to body of adjuster, oil in high pressure chamber in adjuster will leak. Immerse removed adjuster (2) in clean engine oil (1) and keep it there till reinstalling it so as to prevent oil leakage. If it is left in air, place it with its bucket body facing down. Don't place on its side or with bucket body facing up.

Reference: CAMSHAFT AND VALVE LASH ADJUSTER INSPECTION

Scheme 82

Scheme 82: Installation
Scheme 82: Installation

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Scheme 89
  1. Before installing valve lash adjuster to cylinder head (1), fill oil passage of cylinder head with engine oil according to following procedure. Pour engine oil through oil holes (2) and check that oil comes out from oil holes in sliding part of valve lash adjuster. Perform this check on both intake and exhaust sides.
  2. Install valve lash adjusters to cylinder head. Apply engine oil around valve lash adjuster and then install it to cylinder head.
  3. Match match mark (1) on crank timing sprocket and mating surface of cylinder block and lower crankcase (2).
  4. Install camshafts. Apply oil to sliding surface of each camshaft and camshaft journal then install them by aligning match marks on cylinder head and camshafts as shown in figure. NOTE: Install camshaft in such direction that its end with groove for CMP sensor installation comes to exhaust side.
  5. Install camshaft housing pins (3) as shown in figure.
  6. Check position of camshaft housings. Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install housings as indicated by these marks.
  7. Apply sealant "A" to exhaust camshaft end housing (1) sealing surface area as shown in figure. "A": Sealant 99000-31250
  8. After applying oil to housing bolts, tighten them temporarily first. Then tighten them by following numerical order in figure. Tighten a little at a time and evenly among bolts and repeat tightening sequence two or three times before they are tightened to specified torque. Tightening torque Camshaft housing bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
  9. Install CMP sensor. Refer to «CMP (CAMSHAFT POSITION) SENSOR REMOVAL AND INSTALLATION»(ref-251060-S38494016652007032000000) for installation.
  10. Install 2nd timing chain. Refer to «2nd Timing Chain and Chain Tensioner Removal and Installation»(ref-251061-S41490753382007032000000) for installation.
  11. Install timing chain cover. Refer to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-251061-S00834920012007032000000) for installation.
  12. Install cylinder head cover. Refer to «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(ref-251061-S36816345782007032000000) for installation.
  13. Install oil pan. Refer to «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-251062-S40140775192007032000000) for installation.
  14. Install engine assembly to vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) . CAUTION: Don't turn camshafts or start engine (i.e., valves should not be operated) for about half an hour after reinstalling hydraulic valve lash adjusters and camshafts. As it takes time for valves to settle in place, operating engine within half an hour after their installation may cause interference to occur between valves themselves or valves and piston. If air is trapped in valve lash adjuster, valve may make tapping sound when engine is operated after valve lash adjuster is installed. In such a case, run engine for about half an hour at about 2,000 to 3,000 RPM, and then air will be purged and tapping sound will cease. Should tapping sound not cease, it is possible that valve lash adjuster is defective. Replace it if defective. If defective adjuster can't be located by hearing among 16 of them, check as follows. Stop engine and remove cylinder head cover. Push adjuster downward by hand (with less than 20 kg or 44 lbs force) when cam crest is not on adjuster to be checked and check if clearance exists between cam and adjuster. If it does, adjuster is defective and needs replacement.

Valves and Cylinder Head Removal and Installation

Reference: VALVES AND CYLINDER HEAD COMPONENTS

Scheme 90

Scheme 90: Removal
Scheme 90: Removal

Scheme 91

Scheme 91
Scheme 91

Scheme 92

Scheme 92
Scheme 92

Scheme 93

Scheme 93
Scheme 93

Scheme 94

Scheme 94
Scheme 94
  1. Remove engine assembly from vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .
  2. Remove timing chain cover. Refer to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-251061-S00834920012007032000000) for removal.
  3. Remove 2nd timing chain and 1st timing chain. Refer to «2nd Timing Chain and Chain Tensioner Removal»(ref-251061-S41490753382007032000000) and Installation and «1ST TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION»(ref-251061-S13444480352007032000000) for removal.
  4. Remove camshafts and valve lash adjuster. Refer to «CAMSHAFTS AND VALVE LASH ADJUSTERS REMOVAL AND INSTALLATION»(ref-251061-S21325609992007032000000) for removal.
  5. Remove intake manifold rear stiffener (1).
  6. Disconnect coolant pipe (1) from intake manifold.
  7. Remove engine RH mounting bracket (1).
  8. Remove P/S pump bracket (1).
  9. Loosen cylinder head bolts in such order as numbered in figure and remove them. NOTE: Don't forget to remove bolt (M6) (3) as shown in figure.
  10. Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary.
  11. Remove cylinder head with intake manifold, exhaust manifold and water outlet cap. Use lifting device, if necessary.

Reference: VALVES AND CYLINDER HEAD DISASSEMBLY AND ASSEMBLY

Scheme 95

Scheme 95: Installation
Scheme 95: Installation

Scheme 96

Scheme 96
Scheme 96

Scheme 97

Scheme 97
Scheme 97

Scheme 98

Scheme 98
Scheme 98

Scheme 99

Scheme 99
Scheme 99

Scheme 100

Scheme 100
Scheme 100
  1. Match match mark (1) on crank timing sprocket and mating surface (2) of cylinder block and lower crankcase.
  2. Clean mating surface of cylinder head and cylinder block (2). Remove oil, old gasket and dust from mating surface.
  3. Install knock pins (3) to cylinder block.
  4. Install new cylinder head gasket (1) to cylinder block. Top mark (6) provided on gasket comes to crankshaft pulley side (4), facing up (toward cylinder head side).
  5. Install cylinder head to cylinder block. Apply engine oil to cylinder head bolts and tighten them gradually as follows. Tighten all bolts to 53 N.m (5.3 kgf-m, 38.5 lb-ft) according to numerical order in figure. In the same manner as in step a ), retighten them to 84 N.m (8.4 kgf-m, 61.0 lb-ft). Loosen all bolts until tightening torque is reduced to 0 according to numerical order in figure. Tighten all bolts to 53 N.m (5.3 kgf-m, 38.5 lb-ft) according to numerical order in figure. In the same manner as in step b ), retighten them to specified torque. Tightening torque Cylinder head bolt a: 105 N.m (10.5 kg-m, 76.0 lb-ft) Cylinder head bolt (hex hole bolt) b: 11 N.m (1.1 kg-m, 8.0 lb-ft) NOTE: Be sure to tighten M6 bolt (3) after securing other bolts.
  6. Install engine RH mounting bracket (1) using new bracket bolts. Tighten bracket bolts to specified torque. Tightening torque Engine RH mounting bracket bolt a: 55 N.m (5.5 kg-m, 40.0 lb-ft)
  7. Install P/S pump bracket.
  8. Install camshafts and valve lash adjuster. Refer to «CAMSHAFTS AND VALVE LASH ADJUSTERS REMOVAL AND INSTALLATION»(ref-251061-S21325609992007032000000) for installation.
  9. Install 1st timing chain. Refer to «1st Timing Chain and Chain Tensioner Removal and Installation»(ref-251061-S13444480352007032000000) for installation.
  10. Install 2nd timing chain. Refer to «2nd Timing Chain and Chain Tensioner Removal and Installation»(ref-251061-S41490753382007032000000) for installation.
  11. Install timing chain cover. Refer to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-251061-S00834920012007032000000) for installation.
  12. Install engine assembly to vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .

Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS COMPONENTS

Removal

  1. Remove engine assembly from vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .
  2. Remove oil pump with oil pump strainer. Refer to «OIL PUMP REMOVAL AND INSTALLATION»(ref-251062-S11400554142007032000000) for removal.
  3. Remove cylinder head. Refer to «VALVES AND CYLINDER HEAD REMOVAL AND INSTALLATION»(ref-251061-S23990090282007032000000) for removal.
  4. Mark cylinder number on all pistons, connecting rods and connecting rod caps.
  5. Remove connecting rod bearing caps.
  6. Clean carbon from top of cylinder bore before removing piston from cylinder.
  7. Push piston and connecting rod assembly out through the top of cylinder bore.

Reference: PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS DISASSEMBLY AND ASSEMBLY

Scheme 101

Scheme 101: Installation
Scheme 101: Installation

Scheme 102

Scheme 102
Scheme 102

Scheme 103

Scheme 103
Scheme 103
  1. Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins. NOTE: Do not apply oil between connecting rod and bearing or between bearing cap and bearing.
  2. When installing piston and connecting rod assembly into cylinder bore, point front mark (3) on piston head to crankshaft pulley side (1).
  3. Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) to compress rings. Guide connecting rod into place on crankshaft. Using a hammer handle, tap piston head to install piston into bore. Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore. Special Tool (A): 09916-77310
  4. Install connecting rod bearing cap (1) as follows. Point arrow mark (2) on cap to crankshaft pulley side. Apply engine oil to connecting rod bolts (3). Tighten all connecting rod bolts to 15 N.m (1.5 kgf-m, 11.0 lb-ft). Retighten them by turning through 45°. Repeat step d ) once again. Tightening torque Connecting rod bolt a: 15 N.m (1.5 kgf-m, 11.0 lb-ft) 45° and 45° by the specified procedure NOTE: If connecting rod bolt is reused, make sure to check connecting rod bolt for deformation referring to " «CONNECTING ROD BOLT DEFORMATION (PLASTIC DEFORMATION TIGHTENING BOLT)»(ref-251061-S08201919042007032000000) " under «PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS INSPECTION AND CLEANING»(ref-251061-S19702484192007032000000) .
  5. Install cylinder head. Refer to «VALVES AND CYLINDER HEAD REMOVAL AND INSTALLATION»(ref-251061-S23990090282007032000000) for installation.
  6. Install oil pan. Refer to «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(ref-251062-S40140775192007032000000) for installation.
  7. Install engine assembly to vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .

Main Bearings, Crankshaft and Cylinder Block Removal and Installation

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

Scheme 104

Scheme 104: Removal
Scheme 104: Removal

Scheme 105

Scheme 105
Scheme 105

Scheme 106

Scheme 106
Scheme 106

Scheme 107

Scheme 107
Scheme 107
  1. Remove engine assembly from vehicle. Refer to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .
  2. Remove clutch and flywheel (M/T) or drive plate (A/T). For clutch removal, refer to «CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION»(ref-251087-S31535220782007032000000) . Special Tool (A): 09924-17810
  3. Remove throttle body, intake manifold, exhaust manifold.
  4. Remove oil pan.
  5. Remove oil pump with oil pump strainer.
  6. Remove cylinder head cover.
  7. Remove timing chain cover. Refer to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-251061-S00834920012007032000000) for removal.
  8. Remove timing chain guide, chain tensioner, tensioner adjusters, 2nd timing chain and 1st timing chain.
  9. Remove cylinder head assembly.
  10. Remove pistons and connecting rods.
  11. Remove CKP sensor (1).
  12. Remove water pump (1) and heater outlet pipe.
  13. Remove engine front mounting bracket (2).
  14. Loosen crankcase bolts, in sequence shown in figure and remove them.
  15. Remove crankshaft from cylinder block.

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK INSPECTION

Note. All parts to be installed must be perfectly clean. Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, piston rings and cylinder bores. Journal bearings, crankcase (bearings caps), connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb combination and try to see that each part goes back to where it came from, when installing. Clean mating surface of cylinder block and lower crankcase, remove oil, old sealant and dust from mating surface.

Scheme 108

Scheme 108: Installation
Scheme 108: Installation

Scheme 109

Scheme 109
Scheme 109

Scheme 110

Scheme 110
Scheme 110

Scheme 111

Scheme 111
Scheme 111

Scheme 112

Scheme 112
Scheme 112

Scheme 113

Scheme 113
Scheme 113

Scheme 114

Scheme 114
Scheme 114

Scheme 115

Scheme 115
Scheme 115

Scheme 116

Scheme 116
Scheme 116
  1. Fit main bearings to cylinder block (1). One of two halves of main bearing (4) has oil groove (3). Install this half with oil groove to cylinder block and another half without oil groove to lower crankcase. Make sure that two halves are painted in the same color.
  2. Install new O-ring (2) to cylinder block.
  3. Install knock pins (5) to cylinder block.
  4. Fit thrust bearings (1) to cylinder block between No.2 and No.3 cylinders. Face oil groove (2) sides to crank webs.
  5. Put crankshaft (1) with oil pump chain to cylinder block.
  6. Apply sealant "A" to lower crankcase (1) mating surface area as shown in figure. "A": Sealant 99000-31250 Sealant amount for lower crankcase Width "a": 3 mm (0.12 in.) Height "b": 2 mm (0.08 in.)
  7. Install lower crankcase (1) to cylinder block. After applying engine oil to all crankcase bolts ((1) - (22)), tighten them gradually as follows. Tighten bolts ((1) - (10)) to 40 N.m (4.0 kgf-m, 29.0 lb-ft) according to numerical order as shown. Loosen bolts ((1) - (10)) until tightening torque is reduced to 0 (zero) in reverse order of tightening. In the same manner as in step a ), tighten them to 40 N.m (4.0 kgf-m, 29.0 lb-ft). In the same manner as in step a ), tighten them to the specified torque. Tighten bolts ((11) - (22)) to the specified torque according to numerical order as shown. Tightening torque Crankcase bolt with 10 mm thread diameter ((1) - (10)): 58 N.m (5.8 kg-m, 42.0 lb-ft) Crankcase bolt with 8 mm thread diameter ((11) - (22)): 25 N.m (2.5 kg-m, 18.0 lb-ft) NOTE: After tightening crankcase bolts, check to be sure that crankshaft rotates smoothly when turned by hand.
  8. Pull out dowel pin (2) from crankshaft (1) and then install rear oil seal (3) by using special tools and plastic hammer. Special Tool 09911-97710 09911-97810
  9. Install dowel pin.
  10. Install CKP sensor (1) and fix its wire harness with bracket. Tightening torque CKP sensor bolt a: 6 N.m (0.6 kg-m, 4.5 lb-ft)
  11. Install flywheel or drive plate. Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts (1) applied with sealant to specification. "A": Sealant 99000-31110 Special Tool (A): 09924-17810 Tightening torque Flywheel or drive plate bolt a: 70 N.m (7.0 kg-m, 51.0 lb-ft)
  12. Install engine front mounting bracket (1). Tighten bracket bolts to specified torque. Tightening torque Engine front mounting bracket bolt a: 55 N.m (5.5 kg-m, 40.0 lb-ft)
  13. Install water pump (2) and heater outlet pipe (3). Refer to «WATER PUMP REMOVAL AND INSTALLATION»(ref-251063-S08392765312007032000000) .
  14. Install pistons and connecting rods. Refer to «PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS REMOVAL AND INSTALLATION»(ref-251061-S15679650222007032000000) .
  15. Install oil pump. Refer to «OIL PUMP REMOVAL AND INSTALLATION»(ref-251062-S11400554142007032000000) .
  16. Install cylinder head assembly to cylinder. Refer to «VALVES AND CYLINDER HEAD REMOVAL AND INSTALLATION»(ref-251061-S23990090282007032000000) .
  17. Install, timing chain sprockets, timing chains, timing chain tensioners, tensioner adjusters, timing chain guides, timing chain cover, crankshaft pulley, water pump pulley. Refer to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(ref-251061-S00834920012007032000000) , «2nd TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION»(ref-251061-S41490753382007032000000) and «1ST TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION»(ref-251061-S13444480352007032000000) .
  18. Install oil pump strainer and oil pan.
  19. Install clutch to flywheel (for M/T vehicle). For clutch installation, refer to «CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION»(ref-251087-S31535220782007032000000) .
  20. Install engine assembly to vehicle. Refer to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(ref-251061-S06663757622007032000000) .

More articles — Engine Mechanical