SECTION 6A - ENGINE MECHANICAL (X22SE 2.2L)

Service Precaution

General Description

Engine Diagnosis

Cylinder Head Cover

Removal

Installation

Exhaust Manifold

Removal

Installation

Crankshaft Pulley

Removal

Installation

Intake Manifold

Removal

Installation

Cylinder Head Assembly

Removal

Installation

Timing Belt

Removal

Installation

Camshaft

Removal

Installation

Engine Assembly

Engine and Associated Parts

Removal

Installation

Cylinder Head

Cylinder Head and Associated Parts

Disassembly

Inspection and Repair

Reassembly

Valve Spring, Valve, Valve Guide

Valve Spring, Valve, Valve Guide and

Associated Parts

Disassembly

Inspection and Repair

Reassembly

Camshaft

Camshaft and Associated Parts

Disassembly

Reassembly

Crankshaft

Crankshaft and Associated Parts

Disassembly

Inspection and Repair

Reassembly

Piston and Connecting Rod

Piston, Connecting Rod and

Associate Parts

Disassembly

Inspection and Repair

Reassembly

Cylinder Block

Cylinder Block and Associated Parts

Disassembly

Inspection and Repair

Reassembly

Cylinder Head Cover

Cylinder Head Cover and

Associated parts

Removal

Installation

Balance Unit Assembly

Balance Unit Assembly Associated Parts

Disassembly

Adjustment

Reassembly

Main Data and Specifications

Special Tools

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL

RESTRAINT SYSTEM (SRS). REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN

ORDER TO DETERMINE WHETHER YOU ARE

PERFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING. WHEN YOU

ARE PERFORMING SERVICE ON OR NEAR THE

SRS COMPONENTS OR THE SRS WIRING, REFER

TO THE SRS SERVICE INFORMATION. FAILURE TO

FOLLOW WARNINGS COULD RESULT IN

POSSIBLE AIR BAG DEPLOYMENT, PERSONAL

INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM

REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

ISUZU will call out those fasteners that require a

replacement after removal. ISUZU will a lso call out

the fasteners that require thread lockers or thread

sealant. UNLESS OTHERWISE SPECIFIED, do not

use supplemental coatings (Paints, greases, or

other corrosion inhibitors) on threaded fasteners or

fastener joint interfaces. Generally, such coatings

adversely affect the fastener torque and the joint

c lamping for ce, and may damage the fastener . When

you install fasteners, use the correct tightening

sequence and specifications. Following these

instructions can help you avoid damage to parts

and systems.

General Description

Engine Cleanliness And Care

An automobile engine is a combination of many

machined, honed, polished and lapped surfaces with

tolerances that are measured in the thousandths of a

millimeter (ten thousandths of an inch). Accordingly,

when any internal engine parts are serviced, care and

cleanliness are important. Throughout this section, it

should be understood that proper cleaning and

protection of machined surfaces and friction areas is

part of the repair procedure. This is considered

standard shop practice even if not specifically stated.

• A liberal coating of engine oil should be applied to all

friction areas during assembly to protect and

lubricate the surfaces on initial operation.

• Whenever valve train components, pistons, piston

rings, connecting rods, rod bearings, and crankshaft

journal bearings are removed f or service, the y should

be retained in order.

• At the time of installation, they should be installed in

the same locations and with the same mating

surfaces as when removed.

• Battery cables should be disconnected before any

major work is perf ormed on the engine. Failure to

disconnect cables may result in damage to wire

harness or other electrical parts.

• The four cylinders of this engine are identified by

numbers; cylinders 1, 2, 3 and 4, as counted from

crankshaft pulley.

General Information on Engine Service

The following information on engine service should be

noted carefully, as it is important in preventing damage

and contributing to reliable engine performance:

• When raising or supporting the engine for any

reason, do not use a jack under the oil pan. Due to

the small clearance between the oil pan and the oil

pump strainer, jacking against the oil pan may cause

damage to the oil pick up unit.

• The 12–v olt electrical system is capable of damaging

circuits. When performing any work where electrical

terminals could possibly be grounded, the ground

cable of the battery should be disconnected at the

battery.

• Any time the intake air duct or air cleaner is removed,

the inta ke opening should be covered. This will

protect against accidental entrance of foreign

material into the cylinder which could cause

extensive damage when the engine is started.

Cylinder Block

The cylinder block is made of cast iron. The crankshaft

is supported by five bearings. The bearing cap is made

of nodular cast iron.

Cylinder Head

The cylinder head is made of aluminum alloy casting

with a spark plug in the center.

Valve Train

Valv e system is direct–acting inv ertered bucket tappet.

The valves clearance adjustment are hydraulic.

Hydraulic v alve lash adjustment, no adjustment

necessary.

Intake Manifold

The intake manifold is made of aluminum alloy.

Exhaust Manifold

The exhaust manifold is made of high Si–Mo nodular

iron.

Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade

that meets the cylinder bore diameter. Each piston has

two compression rings and one oil ring. The piston pin is

made of case–harded steel. The connecting rods are

made of cast iron. The connecting rod bearings are

made of steel backed with babbitt metal.

Crankshaft and Bearings

The crankshaft is made of nodular cast iron. Pins and

journals are graded for correct size selection for their

bearing.

Balance Shaft

Type is lanchester (twin counter–rotating shafts). The

balance shafts are made of cast iron and gears are hard

faced. The housing is made of cast iron. Backlash

adjustment method is shim–balancer housing to block

(selective fit).

Engine Diagnosis

Hard Starting

1. Starting Motor Does Not Turn Over

Trouble Shooting Procedure

Turn on headlights and starter switch.

2. Ignition Trouble — Starting Motor Turns Over But

Engine Does Not Start

Spark Test

Disconnect a high tension cable from any spark plug.

Connect the spark plug tester J–26792 (ST–125), crank

the engine, and check if a spark is generated in the

spark plug tester. Before cranking the engine, make

sure that the spark plug tester is properly grounded. To

avoid electrical shock, do not touch the high tension

cable while the engine is running.

3. Troub l e In Fuel System

Condition Possible cause Correction

Headlights go out or dim

considerably Battery run down or under charged Recharge or replace battery

Terminals poorly connected Clean battery posts and terminals

and connect properly

Starting motor coil circuit shorted Overhaul or replace

Starting motor defective Overhaul or replace

Condition Possible cause Correction

Spark jumps across gap Spark plug defective Clean, adjust spark gap or replace

Ignition timing incorrect Refer to Ignition System

Fuel not reaching fuel injector(s) or

engine Refer to item 3 (Trouble in fuel

system)

Valve timing incorrect Adjust

Engine lacks compression Refer to item 4 (Engine lacks

compression)

No sparking takes place Ignition coil disconnected or broken Connect properly or replace

Electronic Ignition System with

module Replace

Poor connections in engine harness Correct

Powertrain Control Module cable

disconnected or defective Correct or replace

Condition Possible cause Correction

Starting motor turns over and spark

occurs b ut engine does not start. Fuel tank empty Fill

Water in fuel system Clean

Fuel filter clogged Replace filter

Fuel pipe clogged Clean or replace

Fuel pump defectiv e Replace

Fuel pump circuit open Correct or replace

Evaporative Emission Control

System circuit clogged Correct or replace

Multiport Fuel Injection System

faulty Refer to “Electronic Fuel Injection"

section

4. Engine Lacks Compression

Engine Compression Test Procedure

1. Start and run the engine until the engine reaches

normal operat ing temperat ure.

2. Turn the engine off.

3. Remove all the spark plugs.

4. Remove ignition coil fuse (15A) and disable the

ignition system.

5. Remove the fuel pump rela y from the rela y and fuse

box.

6. Engage the starter and check that the cranking

speed is approximately 300 rpm.

7. Install cylinder compression gauge into spark plug

hole.

8. With the throttle valve opened fully, keep the starter

engaged until the compression gage needle

reaches the maximum level. Note the reading.

9. Repeat the test with each cylinder.

The pressure difference between the individual

cylinders should not exceed 100kPa (14.5psi).

Condition Possible cause Correction

Engine lacks compression Spark plug loosely fitted or spark

plug gasket defective Tighten to specified torque or

replace gas ket

Valve timing incorrect Adjust

Cylinder head gasket defective Replace gasket

Valve incorrectly seated Lap valve

Valve stem seized Replace valve and valve guide

Valve spring weakened Replace

Cylinder or piston rings worn Overhaul engine

Piston ring seized Overhaul engine.

Rough Engine Idling or Engine Stalling

Condition Possible cause Correction

Trouble in fuel injection sys tem Idle air control valve defective Replace

Throttle shutting off incomplete Correct or replace

Throttle position sensor circuit open

or shorted Correct or replace

Fuel injector circuits open or shorted Correct or replace

Fuel injectors damaged Replace

Fuel pump relay defective Replace

Manifold Absolute Pressure Sensor

cable disconnected or broken Correct or replace

Manifold Absolute Pressure Sensor

defective Replace

Engine Coolant Temperature Sensor

cable disconnected or broken Correct or replace

Engine Coolant Temperature Sensor

defective Replace

Intake Air Temperature sensor cable

disconnected or broken Correct or replace

Intake Air Temperature sensor

defective Replace

Knock Sensor (KS) circuits open or

shorted Correct or replace

KS defective Replac e

KS Module circuits open or ground Correct or replace

KS Module defective Replace

Vehicle Speed Sensor circuit open

or shorted Correct or replace

Vehicle Speed Sensor defective Replace

Trouble in emission control system Powertrain Control Module defective Replace

Exhaust Gas Recirculation Valve

faulty Replace

Canister purge solenoid circuit open Correct

Canister purge solenoid defective Replace

Evaporative Emission Canister

Purge contr ol valve defe ct ive Replace

Trouble in ignition system Refer to Hard Start Troubleshooting

Guide

Others Engine lacks compression Refer to Hard Start Troubleshooting

Guide

Valve incorrectly seated Lap valve

Air Cleaner Filter clogged Replace filter element

Valve timing incorrect Readjust

Idle air control valve broken Replace

Rough Engine Running

Condition Possible cause Correction

Engine misfires regularly Ignition coil layer shorted Replace

Spark plugs fouling Clean or install hotter type plug

Spark plug(s) insulator nose leaki ng Replace

Fuel injector(s) defective Replace

Engine control module faulty Replace

Engine knocks regularly Spark plugs running too hot Install colder type spark plugs

Powertrain control module faulty Replace

Engine lacks power Spark plugs fouled Clean

Fuel injectors defective Replace

Manifold Absolute Pressure (MAP)

Sensor or Manifold Absolute

Pressure Sensor circuit defective

Correct or replace

Engine Coolant Temperature Sensor

or Engine Coolant Temperature

Sensor circuit defective

Correct or replace

Engine Control Module faulty Replace

Intake Air Temperature Sensor or

Intake Air Temperature Sensor

circuit defective

Correct or replace

Throttle Position Sensor or Throttle

Position Sensor circuit defective Correct or replace

Knock Sensor or Knock Sensor

circui ts defective Correct or replace

Knock Sensor Module or Knock

Sensor Module circuits defective Correct or replace

Hesitation

Condition Possible cause Correction

Hesitation on acceleration Throttle Position Sensor adjustment

incorrect Replace throttle valve assembly

Throttle P osition Sensor circuit open

or shorted Correct or replace

Excessiv e play in accelerator

linkage Adjust or replace

Manifold Absolute Pressure (MAP)

Sensor circuit open or shorted Correct or replace

MAP Sensor defective Replace

Intake Air Temperature (IAT) Sensor

circuit open or shorted Correct or replace

Knock Sensor (KS) Circuit open or

shorted Correct or replace

KS defective Replac e

KS Module circuits open or shorted Correct or replace

KS Module defective Replace

IAT Sensor defective Replace

Hesitation at high speeds

(Fuel pressure too low) Fuel tank strainer clogged Clean or replace

Fuel pipe clogged Clean or replace

Fuel filter clogged Replace

Defective fuel pump system Check and replace

Fuel Pressure Control Valve leaking Replace

Hesitation at high speeds

(Fuel injector not working normally) Power supply or ground circuit for

Multiport Fuel Injection System

shorted or open

Check and correct or replace

Cable of Multiport Fuel Injection

System disconnected or defective Correct or replace

Hesitation at high speeds Engine Control Module defective Replace

Throttle P osition Sensor circuit open

or shorted Correct or replace

Throt tle Position Sens or defect ive Replace

Engine Coolant Temperature Sensor

circuit open or shorted Correct or replace

Engine Coolant Temperature Sensor

defective Replace

MAP Sensor cable open or shorted Correct or replace

MAP Sensor defective Replace

IAT Sensor circuit open or shorted Correct or replace

IAT Sensor defective Replace

KS Circuit open or shorted Correct or replace

KS defective Replac e

KS Module circuit open or shorted Correct or replace

KS Module defective Replace

Throttle valve not wide opened Check and correct or replace

Air Cleaner Filter clogged Replace filter element

Power supply voltage too low Check and correct or replace

Engine Lac ks Power

Condition Possible cause Correction

Trouble in fuel system Fuel Pressure Control Valve not

working normally Replace

Fuel injector clogged Clean or replace

Fuel pipe clogged Clean

Fuel filter clogged or fouled Replace

Fuel pump drive circuit not working

normally Correct or replace

Fuel tank not sufficiently breathing

due to clogged Evaporative

Emission Control System circuit

Clean or replace

Water in fuel system Clean

Inferior quality fuel in fuel system Use fuel of specified octane rating

Engine Control Module supplied

poor voltage Correct circuit

Throttl e Position Sensor cable

disconnected or broken Correct or replace

Throt tle Position Sens or defect ive Replace

Manifold Absolute Pressure Sensor

not working normally Replace

Intake Air Temperature Sensor not

working normally Replace

Engine Coolant Temperature Sensor

circuit open or shorted Correct or replace

Engine Coolant Temperature Sensor

defective Replace

Engine Contro l Modu le defective Replac e

Trouble in intake or exhaust system Air Cleaner Filter clogged Replace filter element

Air duct kinked or flattened Correct or replace

Ignition failure ———— Refer to Hard Start Troubleshooting

Guide

Heat range of spark plug inadequate Install spark plugs of adequate heat

range

Electronic Ignition System with

module Replace

Engine Noisy

Abnormal engine noise often consists of various noises

originating in rotating parts, sliding parts and other

moving parts of the engine. It is, therefore, advisable to

locate the source of noise systematically.

Engine overheating Level of Engine Coolant too low Replenish

Thermo switch or fan motor

defective Replace

Thermostat defective Replace

Engine Coolant pump defective Correct or replace

Radiator clogged Clean or replace

Radiator filler cap defective Replace

Level of oil in engine crankcase too

low or wrong oil in engine Change or replenish

Resistance in exhaust system

increased Clean exhaust system or replace

defective parts

Throt tle Position Sens or adjustment

incorrect Adjust Wide Open Throttle switch

setting

Throttle P osition Sensor circuit open

or shorted Correct or replace

Cylinder head gasket damaged Replace

Engine overcooling Thermostat defective Replace (Use a thermostat set to

open at 92°C (197.6°F))

Engine lacks compression ———— Refer to Hard Start

Others Tire inflation pressure abnormal Adjust to recommend pressures

Brake drag Adjust

Clutch slipping Adjust or replace

Level of oil in engine crankcase too

high Correct level of engine oil

Exhaust Gas Recirculation Valve

defective Replace

Condition Possible cause Correction

Noise from crank journals or from

crank bearings

(Faulty crank journals and crank

bearings usually make dull noise

that becomes more e vident when

accelerating)

Oil clearance increased due to worn

crank journals or crank bearings Replace crank bearings and

crankshaft or regrind crankshaft and

install the over size bearing

Crankshaft out of round Replace crank bearings and

crankshaft or regrind crankshaft and

install the over size bearing

Crank bearing seized Crank bearing seized Replace crank

bearings and crankshaft or regrind

crankshaft and install the over size

bearing

Troubleshooting Procedure

Short out each spark plug in sequence using insulated

spark plug wire removers . Locate cylinder with defective

bearing by listening for abnormal noise that stops when

spark plug is shorted out.

Troubleshooting Procedure

Abnormal noise stops when the spark plug on the

cylinder with defective part is shorted out.

Troubleshooting Procedure

Short out each spark plug and listen for change in

engine noise.

Condition Possible cause Correction

Noise from connecting rods or from

connecting rod bearings

(Faulty connecting rods or

connecting rod bearings usually

make an abnormal noise slightly

higher than the crank bearing noise,

which becomes more evident when

engine is accelerated)

Bearing or crankshaft pin worn Replace connecting rod bearings

and crankshaft or regrind crankshaft

and install the under size bearing

Crankpin out of round Replace connecting rod bearings

and crankshaft or regrind crankshaft

and install the under size bearing

Connecting rod bent Correct or replace

Connecting rod bearing seized Replace connecting rod bearings

and crankshaft or regrind crankshaft

and install the under size bearing

Condition Possible cause Correction

Piston and cylinder

(Faulty piston or cylinder usually

makes a combined mechanical

thumping noise which increases

when engine is suddenly

accelerated but diminishes gradually

as the engine warms up)

Piston clearance increased due to

cylinder wear Replace piston and cylinder body

Piston seized Replace piston and cylinder body

Piston ring broken Replace piston and cylinder body

Piston defective Replace pistons and others

Condition Possible cause Correction

Piston pin noise

(Piston makes noise each time it

goes up and down)

Piston pin or piston pin hole worn Replace piston, piston pin and

connecting rod assy

Troubleshooting Procedure

The slapping sound stops when spark plug on bad

cylinder is shorted out.

Condition Possible cause Correction

Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the

tension pulley or replace timing belt

Tensio ner bear i ng defective Repl ace

Timing belt defective Replace

Timing wheels defective Replace

Timing belt comes in contact with

timing cover Replace timing belt and timing cover

Valve noise Valve and valv e guide seized Replace valve and valve guide

Valve spring broken Replace

Valve seat off–posi ti oned Correct

Crankshaft noise Cranksh aft end play excessive

(noise occurs wh en clutc h is

engaged)

Replace thrust bearing

Engine knocking Preignition due to use of spark plugs

of inadequate heat range Install Spark Plugs of adequate heat

range

Fuel too low in octane rating Replace fuel

Wide Open Throttle enrichment

system failure Refer to Section 6E

Selection of transmission gear

incorrect Caution operator of incorrect gear

selection

Engine overheating Refer to “Engine Lacks Power"

Others Water pump defective Replace

Drive belt slipping Adjust tension of drive belt or

replac e dr i ve belt

Abnormal Combustion

Condition Possible cause Correction

Trouble in fuel injection system Fuel pressure control valve defective Replace

Fuel filter clogged Replace

Fuel pump clogged Clean or replace

Fuel tank or fuel pipe clogged Clean or replace

Fuel injector clogged Clean or replace

Fuel pump relay defective Replace

Power supply cable for fuel pump

loosely connected or defective Reconnect, correct or replace

Manifold Absolute Pressure Sensor

circuit open or shorted Correct or replace

Manifold Absolute Pressure Sensor

defective Replace

Engine Coolant Temperature (ECT)

Sensor circuit open or shorted Correct or replace

ECT Sensor defe ctive Replace

Throt tle Position Sens or adjustment

incorrect Reconnect

Throt tle Position Sens or defect ive Replace

Throttle Position Sensor connector

loosely connected Reconnect

Vehicle Speed Sensor cable loosely

connected or defective Correct or replace

Vehicle Speed Sensor loosely fixed Fix tightly

Vehicle Speed Sensor in wrong

contact or defective Replace

Engine Control Module cable loosely

connected or defective Correct or replace

Trouble in emission control system Heated Oxygen Sensor circuit open Correct or replace

Heated Oxygen Sensor defective Replace

Signa l vacuum h ose l oos el y fitt ed or

defective Correct or replace

Exhaust Gas Recirculation Valve

defective Replace

ECT Sensor circuit open or shorted Correct or replace

ECT Sensor defe ctive Replace

Evaporator system Refer to Section 6E

Trouble in ignition system ———— Refer to “Engine Lacks Power"

Trouble in cylinder head parts Carbon deposits in combustion

chamber Remove carbon

Carbon deposit on valve, valve seat

and valve guide Remove carbon

Engine Oil Consumption Excessive

Condition Possible cause Correction

Oil leaking Oil pan drain plug loose Retighten or replace gasket

Oil pan setting bolts loosened Retighten

Oil pan gasket broken Replace gasket

Front cover retaining bolts loose or

gasket broken Retighten or replace gasket

Head cover retaining bolts loose or

gasket broken Retighten or replace gasket

Oil filter adapter cracked Replace

Oil filter attachings bolt loose or

rubber gasket broken Retighten or replace oil filter

Crankshaft front or rear oil seal

defective Replace oil seal

Oil pressure un it loose o r broken Retighten or replace

Blow–by gas hose broken Replace hose

Engine/Transmission coupling area Replace oil seal

Oil leaking into combustion

chambers due to poor seal in valve

system

Valve stem oil seal defective Replac e

Valve stem or valve guide worn Replace valve and valve guide

Oil leaking into combustion

chambers due to poor seal in

cylinder parts

Cylind ers and pis to ns wor n

excessively Rebore cylinder and replace pistons

and others

Piston ring gaps incorrectly

positioned Correct

Piston rings set with wrong side up Correct

Piston ring sticking Rebore cylinder and replace pistons

and others

Piston ring and ring groove worn Replace pistons and others

Return ports in oil rings clogged Clean piston and replace rings

Crank case ventilation, Positive

Crankcase Ve nti lat ion Sys tem

malfunctioning

Positiv e Crankcase Ventilation Hose

clogged Clean

Others Improper oil viscosity Use oil of recommended S.A.E.

viscosity

Continuous high speed driving and/

or severe usage such as trailer

towing

Continuous high speed operation

and/or severe usage will normally

caus e increased oil consumption

Fuel Consumption Excessive

Oil Problems

Engine Oil Pressure Check

1. Check for dirt, gasoline or water in the engine oil.

a Check the viscosity of the oil.

b Change the oil if the viscosity is outside the

specified standard.

cRefer to the “Maintenance and Lubrication"

section of this manual.

2. Check the engine oil level.

The lev el should fall somewhere between the “ADD"

and the “FULL" marks on the oil level dipstick.

If the oil level does not reach the “ADD" mark on the

oil level dipstick, engine oil must be added.

3. Remove the oil pressure unit.

4. Install an oil pressure gauge.

5. Start the engine and allow the engine to reach

normal operating temperature (About 80°C).

6. Measure the oil pressure.

Oil pressure should be:

150 kPa (21.8 psi) at idle speed.

7. Stop the engine.

8. Remove the oil pressure gauge.

9. Install the oil pressure unit.

10. Start the engine and check for leaks.

Condition Possible cause Correction

Trouble in fuel system Mixture too rich or too lean due to

trouble in fuel injection system Refer to “Abnormal Combustion"

Fuel cut function does not act Refer to “Abnormal Combustion"

Trouble in ignition system Misfiring or abnormal combustion

due to trouble in ignition system Refer to Hard Start or Abnormal

Combustion Troubleshooting Guide

Others Engine idle speed too high Reset Idle Air Control Valve

Returning of accelerator contr ol

sluggish Correct

Fuel system leakage Correct or replace

Clutch slipping Correct

Brake drag Correct

Selection of transmission gear

incorrect Caution operator of incorrect gear

selection

Excessiv e Exhaust Gas

Recirculation flow due to trouble in

Exhaust Gas Recirculation system

Refe r to Abnormal Combustion

Condition Possible cause Correction

Oil pressure too low Wrong oil in use Replace with correct engine oil

Relief valve sticking Replace

Oil pump not operating properly Correct or replace

Oil pump strainer clogged Clean or replace strainer

Oil pump worn Replace

Oil pressure gauge defective Correct or replace

Crankshaft bearing or connecting

rod bearing w orn Replace

Oil contamination Wrong oil in use Replace with new engine oil

Oil filter clogged Replace oil filter

Cylinder head gasket damage Replace gasket

Burned gases leaking Replace piston and piston rings or

rebore cylinders

Oil not reaching valve system Oil passage in cylinder head or

cylinder body clogged Clean or correct

Malfunction Indicator Lamp

The instrument panel “CHECK ENGINE" Malfunction

Indicator Lamp (MIL) illuminates by self diagnostic

system when the system checks the starting of engine,

or senses malfunctions.

Condition Possible cause Correction

“CHECK ENGINE" MIL does not

illuminate at the starting of engine Bulb defective Replace

MIL circuit open Correct or replace

Command signal circuit to operate

self diagnostic system shorted Correct or replace

Powertrain Control Module (PCM)

cable loosely connected,

disconnected or defective

Correct or replace

PCM defective Replac e

“CHECK ENGINE" MIL illuminates,

and stays on Deterioration heated oxygen sensor

of internal element Replace

Heated oxygen sensor connector

terminal improper contact Reconnect prope r ly

Heated oxygen sensor lead wire

shorted Correct

Heated oxygen sensor circuit open Correct or replace

Deterioration engine coolant

temperature sensor of internal

element

Replace

Engine coolant temperature sensor

connector terminal improper contact Reconnect prope rly

Engine coolant temperature sensor

lead wire shorted Correct

Engine coolant temperature sensor

circuit open Correct or replace

Throttle position sensor open or

shorted circuits Correct or replace

Deterioration of crankshaft position

sensor Replace

Crankshaft position sens or circuit

open or shorted Correct or replace

Vehicle speed sensor circuit open Correct or replace

Manifold absolute pressure sensor

circuit open or shorted Correct or replace

Intake air temperature sensor circuit

open or shorted Correct or replace

Fuel injector circuit open or shorted Correct or replace

PCM driver transistor defective Replace PCM

Malfunctioning of PCM RAM

(Random Access Memory) or ROM

(Read Only Memory)

Replace PCM

Cylinder Head Cover

Removal

1. Disco nne ct batte ry ground ca ble.

2. Disconnect PCV hose from cylinder head cover.

3. Remove intake duct.

4. Remove left side ground cable from cylinder head

cov er and disconnect ground cab le connector on the

left side wheel arch. Remo ve right side ground

cable from generator stay and disconnect ground

cable connector on the right side wheel arch.

5. Disconnect three(black, green and blue colors)

engine wire harness connectors from chassis

harness of left rear side of compartment.

6. Disconnect cooling fan wire harness connector from

cooling fan on left side top of fan shroud.

7. Mov e drive belt tensioner to loose side using wrench

then remove drive belt.

033RW001

8. Remove PCV hose from cylinder block.

9. Remove intake duct stay from cylinder head.

10. Remove two bolts for remove ignition cable cover

from cylinder head cover.

11. Disconnect ignition cable from ignition plug.

12. Disconnect camshaft position sensor harness and

crankshaft angle sensor harness from behind

generator.

13. Remov e f our bolts and remove the cr ankshaft pulley

020RW014

14. Remove timing belt front cover.

15. Loose fixing bolt of timing belt rear cover then

remove the camshaft angle sensor.

020RW012

16. Remove ten cylinder head cover fixing bolts and

remove the cylinder head cover.

Installation

1. Install the camshaft position sensor and tighten

timing rear cover bolt.

Torque: 8 N·m (0.8Kg·m/5.9 lbft)

020RW012

2. Install the cylinder head cover and tighten bolts to

the specified torque.

Torque: 8 N·m (0.8Kg·m/5.9lbft)

3. Install the timing belt front cover then tighten fixing

bolts to the specified torque.

Torque: 6 N·m (0.6Kg·m/4.4lbft)

4. Insta ll the cr ankshaft pulley, tighten fixing bolts to

the specified torque.

Torque: 20 N·m (1.4Kg·m/14lbft)

020RW014

5. Mo v e driv e bel t tensio ner to loose si de usi ng wren ch

then install the drive belt to normal position.

033RW001

6. Connect ignition cable to ignition plug.

7. Install ignition cable cover to cylinder head cover

and tighten two bolt to the specified torque.

Torque: 3 N·m (0.3Kg·m/2lbft)

8. Install intake duct bracket to cylinder block.

9. Install PCV hose flange to cylinder bloc k to the

specified torque.

Torque: 25 N·m (2.5Kg·m/18lbft)

020RW015

10. Connect cooling fan wire harness connector to

cooling fan on left side top of fan shroud.

11. Connect left side ground cable to cylinder head

cover and connect other side connector to left side

wheel arch terminal.

Connect right side ground cable to generator stay

and connect other side connector to right side wheel

arch terminal.

12. Connect three(black, green and blue colors) engine

wire harness connector to chassis harness of left

rear side of engine compartment.

13. Install intake duct.

14. Connect PCV hose to cylinder head cover.

15. Connect battery ground cable.

Exhaust Manifold

Removal

1. Disco nne ct batte ry ground ca ble.

2. Disconnect PCV hose from air intake duct.

3. Remove a nut from air intake duct bracket and

loosen hose clamp on throttle body. Remove air

intake duct assembly with air cleaner cover.

4. Remove air intake duct bracket with ground cable.

5. Remove four fixing bolts on exhaust manifold heat

protector.

6. Remove fixing f our nuts from flange of front exhaust

pipe and remove fixing bolts from silencer side.

027RW005

7. Remove ten exhaust manifold fixing nuts then

remove exhaust manifold.

Installation

1. Install e x haust manifold and tighten fixing nuts to be

tightened in three steps.

•Tightening sequence:

Step1: J G H B D C J G B D

Step2: A B C D E F G H J K

Step3: A B C D E F G H J K

•Tightening torque:

Step1: 14 N·m (10 Ibft)

Step2: 20 N·m (14 Ibft)

Step3: 20 N·m (14 Ibft)

011RW029

2. Install front exhaust pipe to exhaust manifold and

tighten fixing nut to the specified torque.

Torque: 25 N·m (2.6Kg·m/18 lbft)

027RW005

3. Tighten silencer side bolt to the specified torque.

Torque: 68 N·m (6.9Kg·m/50lbft)

4. Install exhaust manifold heat protector and tighten

bolt.

Torque: 8 N·m (0.8Kg·m/5.9lbft)

5. Install intake duct bracket with ground cable.

6. Install intake duct assembly to throttle body and air

cleaner then tighten nut to the intake duct bracket

and clamp on the throttle body side, also clamp air

cleaner cover.

7. Connect PCV hose to air intake duct.

8. Connect battery ground cable.

Crankshaft Pulley

Removal

1. Disco nne ct batte ry ground ca ble.

2. Move drive belt tensioner to loose side by using

wrench then remove drive belt.

033RW001

3. Remove four crankshaft pulley fixing bolts, remove

crankshaft pulley.

020RW014

Installation

1. Install the crankshaft pulley to crankshaft flange.

2. Tighten four bolt to the specified torque.

Torque: 20 N·m (2.0Kg·m/14lbft)

020RW014

3. Move drive belt tensioner to loose side by using

wrench, then install drive belt to normal position.

033RW001

4. Connect battery ground cable.

Intake Manifold

Removal

1. Disco nne ct batte ry ground ca ble.

2. Remove PCV hose from air intake duct.

3. Remove a nut from air intake duct bracket and

loosen hose clamp on throttle body. Remove air

intake duct assembly with air cleaner cover.

4. Drain engine coola n t.

5. Remove water hoses from throttle body.

6. Disconnect the connector for throttle position

sensor, idle air control valve sensor from throttle

body.

7. Remove fuel pipe joint eye bolts from fuel rail and

disconnect wire harness from fuel injector.

042RW001

8. Disconnect hose from fuel pressure regulator then

remove fuel rail assembly.

9. Remove throttle valve control cable from throttle

body.

10. Remove fixing bolts f or generator bracket.

065RW025

11. Remove water pipe fixing bolt then remove water

pipe.

12. Remove fixing bolt from brac ket (Between cylinder

block and intake manifold) of intake manifold side.

025RW002

13. Remove ignition coil bracket fixing bolt.

14. Remove bolt and seven nuts, and remove intake

manifold.

027RW002

Installation

1. Install intake manifold with gasket to cylinder head,

tighten bolt and nuts to the specified torque.

Torque: 22 N·m (2.2Kg·m/16lbft)

027RW002

2. Insta ll ignition coil bracket fixing bolt.

3. Install intake manifold bracket, tighten bolt.

Torque: 22 N·m (2.2Kg·m/16lbft)

025RW002

4. Install water pipe to intake manifold.

5. Install generator bracket and tighten generator

bracket bolts.

Torque

Long bolts: 35 N·m (3.6Kg·m/25lbft)

Short bolts: 20 N·m (2.0Kg·m/14lbft)

065RW025

6. Install fuel rail assembly to intake manifold and

connect hose between fuel pressure regulator and

throttle body.

7. Install fuel pipe and tighten joint eye bolt and

connect fuel injector harness.

Torque: 25 N·m (2.5Kg·m/18lbft)

042RW001

8. Connect the connector f or throttle position sensor

and idle air control valve sensor to throttle body.

9. Install water hoses to throttle body.

10. Install intake duct assembly to throttle body and air

cleaner then tighten nut to the intake duct bracket

and clamp on the throttle body side and air cleaner

side.

Torque: 7 N·m (0.7Kg·m/5.1lbft)

11. Install PCV hose to air intake duct.

12. Install throttle valve control cable to throttle body.

13. Confirm the free play of throttle valve control cable.

Free play: 5.7 to 6.3 mm

14. Fill engine coolant to full lev el from radiator filler

neck.

15. Connect battery ground cable.

Cylinder Head Assembly

Removal

1. Disco nne ct batte ry ground ca ble.

2. Disconnect connector of intake air temperature

sens or from intake air duct.

3. Remove PCV hose from air intake duct.

4. Remove nut from air intake duct bracket and loosen

hose clamp on throttle body. Remove air intake duct

assembly with air cleaner cover.

5. Remove intake air duct bracket from cylinder head.

6. Drain engine coola n t.

7. Mov e drive belt tensioner to loose side using wrench

then remove drive belt.

033RW001

8. Remove radiator upper hose from engine side.

9. Remove four nuts of exhaust front pipe.

10. Remove three bolts from generator bracket then

remove the generator with brac kets.

065RW025

11. Disconnect crankshaft angle sensor connector.

12. Disconnect knock sensor connector.

13. Remove heater hose from adapter side.

14. Remove heater hose from water pipe side.

15. Remov e water hose between water pipe and throttle

body.

16. Remove fuel pipe joint eye bolts from fuel rail

assembly and remov e fuel pipe brac ket with electric

ground cable.

042RW001

17.Disconnect connector for evaporation valve.

18.Remove canister hose.

19.Remove fixing nut of intake manifold stay from

cylinder block side.

025RW002

20.Remove two bolts from intake manifold for water

pipe support and remove cylinder head assembly.

21.Remove engine harness cover and disconnect three

connectors from chassis harness on left rear side

engine compartment.

22.Disconnect connector for power steering pump

pressure switch.

23.Remove four bolts and remove crankshaft pulley.

020RW014

24.Remove two bolts and nut then remove timing belt

front cover.

25.Remove ventilation hose from cylinder block side

and from cylinder head side.

26.Remove two bolts, ignition cable cover and remove

ignition cables from spark plug.

27.Disconnect camshaft angle sensor connector.

28.Remove ten bolts and remove cylinder head cover.

29.Remove fixing bolt of timing belt tensioner then

remove timing belt tensioner.

020RW010

30.Remove timing belt.

CAUTION:

• Do not bend or twist belt, otherwise its core could

be damaged. The belt should not be bent at a

radius less than 30 mm.

• Timing belt drive gear counterhold with 5–8840–

2598–0.

• Do not allow oil or other chemical substances to

come in contact with the belt. They will shorten

the life.

• Do not attempt to pry or stretch the belt with a

screw driver or any other tool during installation.

• Store timing belt in cool and dark place. Never

expose the belt direct sunlight or heat.

31. Remove tw o idle pulleys, the left side with idle pulley

bracket.

32. Remove two bolts and stud bolt and remove timing

belt rear cover.

33. Remove camshaft angle se nso r

34. Disconnect engine oil pressure switch connector.

050RW005

35. Remove camshaft assembly exhaust side.

36. Use 5–8840–2600–0 to remove ten cylinder head

fixing bolts

012RW007

Installation

1. Put cylinder head gasket on the cylinder block.

012RW011

2. Install the cylinder head assembly, tighten cylinder

head bolts by four steps tightening method in the

following sequence to the specified torque.(use 5–

8840–2600–0)

Torque: 25 N·m (2.5Kg·m/18lbft) + 90°

°°

° + 90°

°°

° + 90°

°°

012RW006

3. Install camshaft assembly exhaust side and tighten

camshaft bracket bolts in the sequence to the

specified torque.

Torque: 8 N·m (0.8Kg·m/5.9lbft)

015RW014

4. Connect engine oil pressure switch connector.

5. Install camshaft angle sensor.

6. Install the timing belt rear cover and tighten three

bolts to the specified torque.

Torque

M6 bolt: 6 N·m (0.6Kg·m/4.4lbft)

M8 bolt: 8 N·m (0.8Kg·m/5.8lbft)

020RW012

7. Install left side idle pulley with idle pulley bracket,

tighten to the specified torque and install right side

idle pulley and tighten to the specified torque.

Torque: 25 N·m (2.5Kg·m/18lbft)

020RW016

8. Install timing belt tensioner then tighten it

temporarily until make alignment timing belt.

9. Install the cylinder head cov er and tighten fixing bolt

temporally.

10. Install the timing belt and perform timing belt setting

procedure as follows.

1. Bring the engine top dead center No.1 cylinder

compression stroke b y rotating the engine in the

direction of normal operation.

The engine is in this position when the notches

on the camshaft pulleys align with the marks on

the cylinder head cover(1), Check the

crankshaft pulley timing mark is aligned (2) also

check for water pump positioning ensure tabs

are aligned (3).

• Rotate the engine two full turns in the

direction of normal operation until the engine

is again at top dead centre, No.1 cylinder

firing being careful that all movement is in a

clockwise direction.

• If the engine is turned too far, do not turn

backwards, but continue to turn in the same

direction until the marks are again in line.

014RW067

014RW066

014RW063

2. Place 5–8840–2659–0 to between intake and

exhaust of camshaft drive gear to prevent

camshaft drive gear movement during timing

belt setting.

014RW065

3. Set the timing belt shown in the illustration,

ensure that tension side of the timing belt is taut

and move the timing belt tension adjustment

le v er clockwise, until the pointer of the tensioner

is flowing.

014RX061

F or used timing belt(ov er 60 minutes from ne w):

the pointer will be approx. 4 mm(0.16 in) to the

left of the center of the “V" notch when viewed

from the front of the engine.

014RW069

For new timing belt: The pointer must be at the

center of “V" notch when viewed from the front

of the engine.

014RW062

4. Tighten fixing bolt of timing belt tensioner to the

specified torque.

Torque: 25 N·m (2.5Kg·m/18lbft)

020RW010

11. Tighten cylinder head cover to the specified torque.

Torque: 8 N·m (0.8Kg·m/5.9lbft)

12. Connect cam s haft ang le sen so r connec to r.

13. Install the ignition cable to spark plug.

14. Install ignition cable cover and tighten two bolts.

Torque: 3 N·m (0.3Kg·m/2lbft)

15. Install ventilation hoses to cylinder b lock side and

cylinder head side.

16. Install timing belt front cover and tighten two bolts to

the specified torque.

Torque: 6 N·m (0.6Kg·m/4.4lbft)

17. Install crankshaft pulley and tighten four bolts.

Torque: 20 N·m (2.0Kg·m/14lbft)

020RW014

18. Connect connector for power steering pump

pressure switch.

19. Connect engine harness connector to chassis

harness of the left rear of engine compartment and

install engine harness cover.

20. Install two bolts to intake manifold for water pipe

support.

21. Install fixing nut of intake manifold stay to cylinder

block.

025RW002

22. Install canister hose.

23. Connect connector for evaporation valve.

24. Install fuel pipe joint eye bolts to fuel rail assembly

and install fuel pipe bracket with electric ground

cable.

Torque: 25 N·m (2.5Kg·m/18lbft)

042RW001

25. Install water hose between water pipe and throttle

body.

26. Install heater hose to water pipe side.

27. Install heater hose to adapter side.

28. Connect knock sensor connector.

29. Connect crankshaft angle sensor connector.

30. Install generator with brack et and tighten three bolts.

Torque

35 N·m (3.6Kg·m/25lbft) for Long bolt

20 N·m (2.0Kg·m/14lbft) for Short bolt

065RW025

31. Install e xhaust front pipe to exhaust manifold and

tighten four nuts to the specified torque.

Torque: 25 N·m (2.5Kg·m/18lbft)

027RW005

32. Install radiator upper hose to engine.

33. Mov e drive belt tensioner to loose side using wrench

then install the drive belt to normal position.

033RW001

34. Install intake air duct bracket to cylinder head.

35. Install air intake duct assembly with air cleaner

cover to throttle body and tighten nut to the air

intake duct bracket then tighten hose clamp.

Torque

7 N·m (0.7Kg·m/5.1lbft) for nut

3 N·m (0.3Kg·m/2.2lbft) for hose clamp bolt

36. Install PCV hose to air intak e duct.

37. Connect connector of intake air temperature sensor

on intake air duct.

38. Connect battery ground cable.

39. Fill engine coolant to full level in the engine coolant

reservoir tank.

Timing Belt

Removal

1.Disconnect battery ground cable.

2.Move drive belt tensioner to loose side using wrench

then remove drive belt.

033RW001

3.Remove engine harness cover and disconnect three

connectors from left rear side of engine

compartment.

4.Remove four bolts and remove crankshaft pulley.

020RW014

5.Disconnect three connectors of engine harness

from chassis harness of left rear side of engine

compartment.

6.Remove nut and remove engine harness cover from

front of engine.

7.Remove two bolts then remove timing belt front

cover.

8.Remove fixing bolt of timing belt tensioner then

remove timing belt tensioner (1).

020RW010

9.Remove timing belt.

CAUTION:

• Do not bend or twist belt, otherwise its core could

be damaged. The belt should not be bent at a

radius less than 30 mm.

• Timing belt drive gear counterhold with 5–8840–

2598–0.

• Do not allow oil or other chemical substances to

come in contact with the belt. They will shorten

the life.

• Do not attempt to pry or stretch the belt with a

screw driver or any other tool during installation.

• Store timing belt in cool and dark place. Never

expose the belt direct sunlight or heat.

Installation

1. Install timing belt tensioner then tighten it

temporarily until make alignment timing belt.

020RW010

2. Install the timing belt and perform timing belt setting

proce dur e as follows:

1. Bring the engine top dead center No.1 cylinder

compression stroke by rotating the engine in the

direction of normal operation.

The engine is in this position when the notches

on the camshaft pulleys align with the marks on

the cylinder head cover(1), Check the

crankshaft pulley timing mark is aligned (2) also

check for water pump positioning ensure tabs

are align ed (3).

014RW067

014RW066

014RW063

2. Place 5–8840–2659–0 between intake and

exhaust of camshaft drive gear for prevent to

camshaft drive gear movement during timing

belt se ttin g.

014RW065

3. Set the timing belt shown in the illustration,

ensure that tension side of the timing belt is taut

and move the timing belt t ension adjustment

le v er clockwise, until the pointer of the tensioner

is flowing.

014RW064

014RX061

F or used timing belt(ov er 60 minutes from new):

The pointer will be approx. 4 mm(0.16 in) to the

left of the center of the “V" notch when viewed

from the front of the engine.

014RW069

For new timing belt: The pointer must be at the

center of “V" notch when viewed from the front

of the engine.

014RW062

3. Tighten fixing bolt (1) of timing belt tensioner to the

specified torque.

Torque: 25 N·m (2.5Kg·m/18lbft)

020RW010

4. Install timing belt front cov er and tighten two bolts to

the specified torque.

Torque: 6 N·m (0.6Kg·m/4.4lbft)

5. Install engine harness cover to front top of engine

and tighten nut to the specified torque.

Torque: 6 N·m (0.6Kg·m/4.4lbft)

6. Install crankshaft pulley and tighten four bolts.

Torque: 20 N·m (2.0Kg·m/14lbft)

020RW014

7. Mo v e driv e bel t tensio ner to loose si de usi ng wren ch

then install drive belt to normal position.

033RW001

8. Connect engine harness three connector to chassis

harness of left rear side of engine compartment.

9. Connect battery ground cable.

Camshaft

Removal

1.Disconnect battery ground cable.

2.Remove cylinder head cover.

Refer to removal procedure for Cylinder Head Cover

in this manual.

3.Remove timing belt tensioner and remove timing

belt.

020RW010

4.Use adjustable wrench to hexagonal portion of

camshaft, and remove fixing bolt from front end of

camshaft.

014RW074

5.Remove camshaft drive gear from intake and

exhaust camshaft.

6.Remove twenty fixing bolts from intake and exhaust

camshaft bracket on the cylinder head, then remove

camshafts.

011RW015

CAUTION:

• Do not damage camshaft lobe and journal.

• Do not damage hydraulic lash adjuster(HLA) and

do not allow into foreign materials into cylinder

head.

7. Remove oil seal from camshaft.

Installation

1. Clean surface of camshaft bracket and HLA.

2. Apply engine oil to journal surface of camshaft

bracket and HLA.

3. Install camshaft to cylinder head.

4. Install camshaft bracket according to numerical as

shown in the illustration.

The bracket number is:

• Exhaust: 1 to 5 from front

• Intake: 6 to 10 from front.

014RW052

015RW014

Camshaft oil seal installation area on the cylinder

body of No.1, No.6 and camshaft bracket rear side

plug portion must be applied HN1023 or equivalent

as in the illustration.

014RW073

5. Tighten camshaft bracket bolts to the specified

torque by sequence in the illustration.

Torque: 8 N·m (0.8Kg·m/5.9lbft)

6. Use 5–8840–2658–0 for installation camshaft oil

seal.

014RW075

014RW071

7.Install the camshaft drive gear. Align the timing mark

between notch on the camshaft drive gear(1) and

lug on the camshaft bracket(2).

014RW076

Also align a guide hole on the camshaft drive gear

marked “IN" for intake and “EX" for exhaust to guide

pin on the camshaft when instaling the camshaft

drive gear.

014RW072

8.Tighten camshaft bracket fixing bolt to the specified

torque.

Torque: 50 N·m (5.1Kg·m/36lbft)

015RW014

9.Install timing belt.

Refer to installation procedure for Timing Belt in this

manual.

10. Install cylinder head cov er.

Refer to installation procedure for Cylinder Head

Cover in this manual.

11. Connect battery ground cable.

Engine Assembly

Engine and Associated Parts

755RX032

Removal

1. Disconnect battery ground and positive cable.

2. Remove battery.

3. Make alignment mark on the engine hood and

hinges bef ore remov al in order to return the hood to

original position exactly.

4. Remove engine hood.

5. Drain engine coolant from radiator.

6. Disconnect throttle valve control cable from throttle

valve on intake manifold.

7. Remove air duct with air cleaner cover.

8. Remove air cleaner assembly.

9. Disconnect three engine harness connectors from

chassis harness of left rear side engine

compartment.

10. Disconnect v acuum hose on the brake booster.

11. Disconnect cooling fan harness connector on the

left of fan shroud.

12. Disconnect ground cable connector from left and

right of front wheel arch upper side.

13. Remove clutch piping bracket from right side of

clutch housing.

14. Remove fuel piping bracket from transmission.

15. Remove four nuts from e xhaust front pipe exhaust

manifold side and remove two bolts from rear side of

exhaust front pipe. Remove exhaust front pipe.

027RW005

16.Remove transmission mounting fixing bolts and nut

from cross member.

022RW014

17.Remove transmission front under cover from front

portion of clutch housing.

18.Disconnect two fuel pipes at right side of

transmission by quick type fuel hose connector.

CAUTION: Plug fuel pipe on engine side and fuel

hose from fuel tank.

19. Disconnect canister hose next to fuel piping

connector.

20. Remove propeller shaft fixing bolt from rear side

transmission.

21. Remove fixing bolts between clutch housing and

transmission , then move transmission.

22. Remove power steering pump assembly then place

the power steering pump along with piping.

23. Disconnect two chassis harness connectors from

right rear side engine compartment (under fuse box)

and remove two harness clips.

24. Remove engine ground cable from chassis frame.

25. Remove radiator lower hose from engine side.

26. Remove two heater hoses from right side panel.

27. Remove radiator grille.

28. Remove harness clip from behind right horn.

29. Remove engine mounting bolt from chassis frame

side.

022RW005

022RW006

30. Lift up the engine assembly.

Installation

CAUTION: When assembling the engine and

transmission, confirm that dowels have been

mounted in the specified positions at the engine

side. If assembled in the condition that dowels

have not been mounted in the specified position,

transmission damage can result.

1. positi on the engine asse mbly in the engine

compartment.

2. Tighten engine mounting bolt to frame side to the

specified torque.

Torque: 41 N·m (4.2Kg·m/30lbft)

022RW005

022RW006

3. Install harness clip behind right horn.

4. Install the radiator grille and install flasher lamp

assembly.

5. Install two heater hoses to right side panel.

6. Install radiator lower hose to engine.

7. Install engine ground cable to chassis frame.

8. Connect two chassis harness connectors to right

rear side engine room(under fuse box) and install

two harness clips.

9. Install power steering pump assembly and tighten

fixing bolts.

10. Install transmission assembly, refer to installation

procedure for Transmission section in this manual.

11. Install propeller shaft, refer to installation procedure

for Propeller section in this manual.

12. Connect canister hose next to fuel piping connector.

13. Connect two fuel pipes at right side transmission by

quick type connector.

14. Install transmission front under cov er to front portion

of clutch housing.

15. Install transmission mounting fixing bolts and nuts to

cross member.

Torque: 50 N·m (5.1Kg·m/36lbft)

022RW014

16.Install exhaust front pipe to exhaust manifold and

silencer, then tighten fixing nuts and bolts to the

specified torque.

Torque

25 N·m (2.5Kg·m/18lbft) for nut

68 N·m (6.9Kg·m/50lbft) for bolt

027RW005

17.Install fuel piping bracket to transmission.

18.Install clutch piping bracket to right side of clutch

housing.

19.Connect ground cable connector to left and right of

front wheel arch upper side.

20.Connect cooling fan harness connector on the left of

fan shroud.

21.Connect vacuum hose to the brake booster.

22.Connect three engine harness connectors to

chassis harness of left rear side of engine

compartment.

23.Install air cleaner assembly.

24.Install air duct with air cleaner cover to specified

torque.

Torque

7 N·m (0.7Kg·m/5.1lbft) for air duct fixing

3 N·m (0.3Kg·m/2.2lbft) for air duct clamp bolt

25.Connect throttle valve control cable to throttle valve

on the intake manifold.

Confirm the free play of throttle valve control cable.

Free play: 5.7 to 6.3 mm

26.Install engine hood to original position.

Refer to installation procedure for Body section in

this manual.

27. Install battery, connect positive cable and ground

cable.

28. Fill engine coolant to full level in the coolant

reservoir tank.

Cylinder Head

Cylinder Head and Associated Parts

011RW010

Legend

EndOFCallout

Disassembly

NOTE:

• During disassembly, be sure that the valve train

components are kept together and identified so that

they can be reinstalled in their original locations.

• Bef ore removing the cylinder head from the engine

and before disassembling the valve mechanism,

perform a compression test and note the results.

1. Remove camshaft pulley fixing bolt (2), then pulley

(3).

2. Remove camshaft bracket fixing bolt (5), camshaft

bracket, then camshaft exhaust (6), and intake side

(7).

(1) Cylinder Head Bolt

(2) Camshaft Pulley Fixing Bolt

(3) Camshaft Pulley

(4) Camshaft Oil Seal

(5) Camshaft Bracket Bolt

(6) Camshaft Exhaust

(7) Cam s haft Inta ke

(8) Tappet (HLA)

(9) Split Collar

(10) Valve Spring and Spring Upper Seat

(11) Valve

3. Remove cylinder head.

Use 5–8840 –260 0–0.

4. Valve spring, valve spring caps, compress valve

spring — use 5–8840–2546–0 (1) and Adapter 5–

8840–2662–0 (2).

Valve keepers.

011RW014

5. Valves, valve stem seals — use commercially

available remover pliers. Valv e spring seats from

cylinder head.

011RW013

Inspection and Repair

1. Check length and width of cylinder head sealing

surfaces f or def ormation and diagonals for warpage

— use straight edge and feeler gauge.

011RW011

2. Height of cylinder head (sealing surface to sealing

surface).

Dimension (I) – 134 mm

011RW012

Reassembly

1.Valves, valve stem seals. Refer to Valve Spring, Oil

Controller, Valve, Valve Guide in this section.

2.Valve spring, valve spring caps. Refer to Valve

Spring, Oil Controller, Valve, Valve Guide in this

section.

3.Install tappet (HLA).

4.Cylinder head with new cylinder head bolts to

cylinder block.

Tighten the bolts in 4 steps.

1st step: 25 N·m (2.5Kg·m/18lbft)

2nd step: 90°°°°

3rd step: 90°°°°

4th step: 90°°°°

011RW014

5.Camshaft in cylinder head. Refer to Camshaft in this

section.

6.Camshaft pulley. Refer to Camshaft in this section.

Valve Spring, Valve, Valve Guide

Valve Spring, Valve, Valve Guide and Associated Parts

011RW024

Legend

EndOFCallout

(1) Camshaft Pulley Fixing Bolts

(2) Camshaft Pulley

(3) Camshaft Bracket Fixing Bolt

(4) Camshaft Assembly Intake

(5) Camshaft Assembly Exhaust

(6) Cylinder Head Bolt

(7) Cylin der Head

(8) Tappet

(9) Split Collar

(10) Spring Upper Seat

(11) Valve Spring

(12) Oil Seal

(13) Spring Lower Seat

(14) Valve Guide

(15) Valve

Disassembly

1.Remove camshaft pulley (1), (2).

2.Remove camshaft assembly (Intake) (3), (4).

3.Remove camshaft assembly (Exhaust side) (5).

4.Remove cylinder head (6), (7).

5.Remove tappet (8).

6.Use 5–8840–2546–0 valve spring compressor and

5–8840–2662–0 adapter to remove split collar (9).

011RW014

7.Remove spring upper seat and valve spring (10),

(11).

8.Valve, valve guide – use commercially available

remover pliers.

Valve spring lower seat from cylinder head.

011RW013

Inspection and Repair

1.Use a internal micrometer to measure the diameter

valve guide.

Valve stem play

Intake : 0.03 to 0.057 mm (0.0012 to 0.0022in)

Exhaust : 0.04 to 0.067 mm (0.0016 to 0.0026in)

011RW020

Valve Guide

CAUTION: Taking care not to damage the valve seat

contact surface, when removing carbon adhering to

the valve head. Carefully inspect the valve stem for

scratching or abnormal wear . If these conditions are

present, the valve and the valve guide must be

replaced as a set.

Valve Seat

Valve seat width in cylinder head

Intake: 1.0 to 1.5 mm (0.039 to 0.0585 in)

Exhaust: 1.7 to 2.2 mm (0.0663 to 0.0858 in)

Valve Seat Insert Correction

Remove the carbon from the valve seat insert surface .

Valve Seat Insert Replacement

1. Arc weld the rod at several points. Be careful not to

damage the aluminum section.

2. Allow the rod to cool for a few minutes. This will

cause the valve seat to shrink.

3.Strike the rod and pull it out.

014RS015

4.Carefully clean the valve seat press–fit section on

the cylinder head side.

5.Heat the press–fit section with steam or some other

means to cause expansion. Cool the valve seat with

dry ice or some other means.

6.Insert the press–fit section into the valve seat

horizontally.

7.Lap the valve and the seat.

Reassembly

1.Install oil controller (3) and spring lower seat (2).

Using oil controller replacer 5–8840–2663–0, drive

in a new oil controller.

014RS019

2.Install valve to valve guide. Before install valve guide

apply engine oil to the outside of the valve stem.

3.Install valve spring to cylinder head. Attach the valve

spring to the lower spring seat.

4.Install lower valve spring seat, valve spring and

upper valve spring seat then put split collars on the

upper spring seat, using 5–8840–2546–0 valve

spring compressor for install the split collars.

011RW014

5.Install tappet.

6.Install camshaft assembly.

•Refer to installation procedure for Camshaft in

this manual.

Camshaft

Camshaft and Associated Parts

011RW023

Legend

EndOFCallout

Disassembly

1. Remove fixing bolt (1) for camshaft pulley (2).

2. Remove oil seal (3).

014RW035

(1) Camshaft Pulley Fixing Bolt

(2) Camshaft Pulley

(3) Oil Seal

(4) Camshaft Bracket

(5) Camshaft Bracket Fixing Bolt

(6) Camshaft Assembly Exhaust

(7) Camshaft Assembly Intake

3. Remove oil seal (3).

4. Remove twenty fixing bolts (5) from inlet and

exhaust camshaft bracket, then camshaft brackets

(4).

011RW015

5. Remove camshaft assembly (6), (7).

Reassembly

1. Install camshaft drive gear assembly and tighten

three bolts to specified torque.

Torque: 50 N·m (5.1Kg·m/37lbft) + 60°

°°

° + 15°

°°

2. Install camshaft assembly and camshaft brackets,

tighten twenty bolts on one side bank to the

specified torque.

1. Apply engine oil to camshaft journal and bearing

surface of camshaft brac ket.

2. Align timing mark on intake camshaft and

exhaust camshaft to timing mark on camshaft

drive gear (one dot).

3. Tighten twenty bolts on numerical order one

side bank shown in the illustration.

Torque: 8 N·m (0.8Kg·m/6lbft)

4. If it required to replace oil seal of camshaft driv e

gear, use 5–8840–2658–0 for install the oil seal.

5. Tighten bolt for camshaft drive gear assemb ly

pulley to the specified torque.

Torque: 50 N·m (5.1Kg·m/37lbft) + 60°

°°

° + 15°

°°

014RW036

Crankshaft

Crankshaft and Associated Parts

015RW008

Legend

EndOFCallout

Disassembly

1.Remove cylinder head assembly (1). Refer to

“Cylinder head" in this manual.

2.Remove oil pan (3).

CAUTION: Take care not to damage or deform the

sealing flange surface of crankcase.

3.Remove oil pan support (4).

4.Remove oil strainer (5).

5.Remove oil pump assembly (5).

6.Balance unit assembly.

7.Remove piston and connecting rod assembly (7).

Refer to “Piston, Piston Ring and Connecting Rod"

in this manual.

(1) Cylinder Head Assembly

(2) Oil Pump Assembly

(3) Pan

(4) Pan Support

(5) Oil Strainer

(6) Balance Unit Assemb ly

(7) Piston and Connecting Rod Assembly

(8) M ain Bearing Cap

(9) Crankshaft

(10) Cylinde r Bl ock Assembly

8. Remove flywheel.

9. Remove rear oil seal and oil baffle plate.

10. Remove main bearing cap (8).

11. Remove crankshaft (9).

12. Remove crankshaft pulse pickup sensor disc.

Inspection and Repair

1. Crankshaft

Set the dial indicator as shown in the illustration and

measure the crankshaft thrust clearance. If the

thrust clearance exceeds the specified limit, replace

the thrust bearings as a set.

Thrust Clearance

Standard : 0.01 mm–0.02 mm

(0.0004 in–0.0008 in)

Limit : 0.21 mm (0.0118 in)

014RW079

Main Bearing Clearance

1. Remove the bearing caps and measure the oil

clearance.

2. Remove the main bearing cap fixing bolts.

Arrange the removed main bearing caps in the

cylinder number order.

Remove the main bearings.

3. Remove the crankshaft.

Remove the main bearings.

4. Clean the upper and lower bearings as well as the

crankshaft main journal.

5. Check the bearings for damage or excessive wear.

The bearings must be replaced as a set if damage

or excessive wear is discovered during inspection.

6. Set the upper bearings and the thrust washers to

their original position s.

Carefully install the crankshaft.

7. Set the lower bearings to the bearing cap original

position.

8. Apply plastigage to the crankshaft journal unit as

shown in the illustration.

014RW055

9. Install main bearing caps, and tighten each bolt to

the specified torque.

Main bearing caps bolts.

Torque:

1st step: 50 N·m (5.1Kg·m/37lbft)

2nd step: 45°

°°

3rd step: 15°

°°

Torque : 39 N·m (4.0Kg·m/29lbft)

10. Measure the plastigage width and determine the oil

clearance. If the oil clearance e xceeds the specified

limit, replace the main bearings as a set and/or

replace the crankshaft.

Standard : 0.015 mm–0.04 mm

(0.0007 in–0.0016 in)

Limit : 0.12 mm (0.0047 in)

014RW077

11. Clean the plastigage from the bearings and the

crankshaft.

Remove the crankshaft and the bearings.

Crankshaft (12) Inspection

Inspect the surface of the crankshaft journal and crank

pins for excessive wear and damage. Inspect the oil

seal fitting surfaces for excessive wear and damage.

Inspect the oil ports f or obstructions.

Inspection and Repair

1. Carefully set the crankshaft. Slowly rotate the

crankshaft and measure the runout. If the

crankshaft runout exceeds the specified limit, the

crankshaft must be replaced.

Runout : 0.03 mm (0.0012 in)

014RW078

2. Measure the diameter and the unev en wear of main

journal and crank pin. If the crankshaft wear

exceeds the specified limit, crankshaft must be

replaced.

Main journal diameter : 57.934 mm–57.980 mm

(2.259 in–2.261 in)

Crank pin diameter : 48.939 mm–48.982 mm

(1.909 in.–1.91 in.)

015RS009

Cran ks ha f t Be aring Selection

When installing new crankshaft bearings or replacing

bearings, refer to the selection table below. Select and

install the new crankshaft bearings.

NO TE: Take care to ensure the bearings are positioned

correctly.

Crankshaft pulse pickup sensor disc inspection and

repair.

Inspect the crankshaft pulse pickup sensor disc for

excessive wear and damage.

Replace the crankshaft pulse pickup sensor disc if the

inspection exceeds wear and damage.

015RW039

Reassembly

1. Crankshaft (12).

• Install the crankshaft pulse pickup sensor disc.

Torque: 13 N·m (1.3Kg·m/10lbft)

• Install the main bearings to the cylinder block and

the main bearing caps.

• Be sure that they are positioned correctly.

• Apply ne w engine oil to the upper and lower main

bearing faces.

NO TE: Do not apply engine oil to the main bearing

b a ck face s.

• Carefully mount the crankshaft.

• Apply engine oil to the thrust washer.

• Assemble the thrust washer to the No.3 bearing

journal. The oil grooves must face the crankshaft.

• Tighten the crankshaft baring cap bolts in 3

steps:

1st step: 50 N·m (5.1Kg·m/36lbft)

2nd step: 45°

°°

3rd step: 15°

°°

Crankshaft grinding dimensions mm (in)

Production and Service

Crankshaft bearing journal dia.

Stan dard si ze

white 57.974 to 57.981 (2.260–2.261)

green 57.981 to 57.988 (2.261–2.2615)

brown 57.988 to 57.995 (2.2615–2.2618)

Undersize 0.25 (0.0097)

green/blue 57.732 to 57.738 (2.2515–2.2517)

brown/blue 57.738 to 57.745 (2.2517–2.252)

Undersize 0.5 (0.0195)

green/white 57.482 to 57.488 (2.2418–2.242)

brown/white 57.488 to 57.495 (2.242–2.2423)

Guide bearing width

Standard size 25.950 to 26.002 (1.012–1.014)

Undersize 0.25 (0.0097) 26.150 to 26.202 (1.019–1.021)

Undersize 0.5 (0.0195) 26.350 to 26.402 (1.027–1.029)

2. Rear oil seal (10).

• Coat lip of seal rings thinly with protective grease.

• Install seal ring into cylinder bl ock, use 5–8840–

2660–0 (1) and 5–8840–2597–0 (2).

015RW009

3. Flywheel (9).

1. Thoroughly clean and remove the oil from the

threads of crankshaft.

2. Remov e the oil from the crankshaft and flywheel

mounting faces.

3. Mount the flywheel on the crankshaft and then

install the washer.

4. Use stopper (5–8840–2661–0) to hold the

crankshaft.

015RW010

5. Prevent from rotating.

Tighten the flywheel bolts in 3 steps:

1st step: 65 N·m (6.6Kg·m/48lbft)

2nd step: 30°

3rd step: 15°

NO TE: Do not reuse the bolt.

4. Piston and connecting rod assembly (8)

• Apply engine oil to the cylinder bores, the

connecting rod bearings and the crankshaft pins.

Check to see that the piston ring end gaps are

correctl y pos iti on ed.

• Piston rings position (A) every 180°.

Oil scraper rings (B) — offset 25 to 50 mm/1 to 2

in. to left and right from gap of intermediate ring.

015RW026

• Insert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor.

The front marks must be facing the front of the

engine.

• Match the numbered caps with the numbers on

the connecting rods. Align the punched marks on

the connecting rods and caps.

• Arrow (1) on piston head points to engine timing

side, bead on connecting rod points to flywheel

side.

015RW038

•Tighten the bolts in 3 steps:

1st step: 35 N·m (3.6Kg·m/25lbft)

2nd step: 45°°°°

3rd step: 15°°°°

5.Install the balance unit assembly and tighten the

bolts in 2 steps:

1st step: 20 N·m (2.0Kg·m/14lbft)

2nd step: 45°°°°

Refer to the “Balance Unit Assembly" section of this

manual.

6.Install oil pump assembly (5), refer to “Oil Pump" in

this manual.

7.Install oil strainer.

Torque: 8 N·m (0.8Kg·m/5.8lbft)

8.Install oil pan support and tighten the bolts to the

specified torque.

Torque: 20 N·m (2.0Kg·m/14lbft)

9.Install oil pan.

1.Completely remove all residual sealant,

lubricant and moisture from the sealing

surfaces. The surfaces must be perfectly dry.

2.Apply a correct width bead of sealant (TB–

1207C or its equivalent) to the contact surfaces

of the oil pan. There must be no gaps in the

bead.

3.The oil pan support must be installed within 5

minutes after sealant application.

4.Tighten the bolts in to steps.

1st step: 8 N·m (0.8Kg·m/5.8lbft)

2nd step: 30°°°°

10.Install cylinder head assembly, refer to “Cylinder

Head" in this manual.

Piston and Connecting Rod

Piston, Connecting Rod and Associate Parts

015RW037

Legend

EndOFCallout

Disassembly

1.Remove cylinder head assembly (1), refer to

“Cylinder Head Removal" in this manual.

2.Remove cylinder head gasket (2).

3.Remove oil pan assembly and oil pan support (3)

4. Remove oil strainer.

5. Remove balance unit assembly.

6. Remove connecting rod cap with connecting rod

lower.

(1) Cylinder Head Assembly

(2) Cylin der Head Gasket

(3) Oil Pan Assembly

(4) Pan Support

(5) Oil Strainer

(6) Bal anc e Unit Asse mbly

(7) Piston and Connecting Rod Assembly

(8) P is ton Rin g

(9) P is ton Pi n

(10) Piston

(11) Connecting Rod

(12) Connecting Rod Cap

7. Remove piston and connecting rod assembly (7).

NOTE: Before removing piston and connecting rod

assembly, measure thrust clearance.

• Remov e any ridge or carbon build up from the top

end of the cylinde r.

8. Remove the piston rings (8) with a piston ring

expander. Arrange the removed piston rings in the

cylinder number order.

015RW024

9. Remove the piston pin (9).

• Heat the connecting rod and the piston pin with

oil heater, when it temperature is keep at 280°Χ–

320°C.

• Push the piston pin with brass bar.

NOTE: Keep the parts removed from each cylinder

separate. All parts must be reinstalled in their original

positions.

10. Piston (10).

11. Connecting rod (11).

Inspection and Repair

Pistons (10)

Carefully clean away all the carbon adhering to the

piston head and the piston ring grooves.

NOTE: Never use a wire brush to clean the pistons.

Damage will result. Visually check each piston for

cracking, scoring, and other signs of excessive wear. If

any of the above conditions are found, the piston must

be replaced.

Piston Rings (8)

Any worn or damaged part discovered during engine

overhaul must be replaced with a new one.

1. Ring end gap measurement

• Insert the piston ring into the bore.

• Push the ring by the piston, at a right angle to the

wall, into the point at which the cylinder bore

diameter is the smallest.

• Measure the ring end gap.

2. Measure the clearance between the piston ring

groov e and the piston ring with a feeler gauge. If the

piston ring groove / piston ring clearance exceeds

the specified limit, the piston must be replaced.

Compression Ring Clearance

Standard : 0.02 mm–0.04 mm

(0.0008 in.–0.0016 in)

015RW025

Compression Ring

1st ring

Standard: 0.30 mm–0.50 mm

(0.0118 in–0.0195 in)

2nd ring

Standard: 0.30 mm–0.50 mm

(0.0118 in–0.0195 in)

Oil ring

Standard: 0.40 mm–1.40 mm

(0.0156 in–0.0546 in)

Piston Pin (9)

NOTE: Do not reuse the old piston pin.

1. Use a micrometer to measure the new piston pin

outside diameter in both di rections a t three different

positions.

2. Measure the inside diameter of the connecting rod

small end. If the fitting interference between the

small end and pin does not conform to the specified

value, the connecting rod must be replaced.

Standard : 0.02 mm–0.041 mm

(0.0008 in–0.0016 in)

014RW077

3. Insert the new pin into the piston and rotate it. If the

pin rotates smoothly with no backlash, the clearance

is normal. If there is backlash or roughness,

measure the clearance. If the clearance exceeds the

specified limit, the piston must be replaced.

Clearance

Standard : 0.011 mm–0.014 mm

(0.0004 in.–0.0005 in)

Connecting Rods (11)

1. Measure the oil clearance between the connecting

rod and the crankshaft.

1. Remove the connecting rod cap nuts and the

rod caps (12).

Arrange the removed rod caps in the cylinder

number order.

2. Clean the rod bearings and the crankshaft pins.

3. Carefully check the rod bearings. If even one

bearing is found to be damaged or badly worn,

the entire bearing assembly must be replaced

as a set. Reinstall the bearings in their original

positions. Apply plastigage to the crank pin.

4. Reinstall the rod caps (12) to their original

positions.

Tighten the rod cap nuts.

1st step: 35 N·m (3.6Kg·m/26lbft)

2nd step: 45°

°°

3rd step: 15°

°°

NO TE: Do not allow the crankshaft to rotate.

5. Remove the rod caps.

6. Measure the width of the plastigage and

determine the oil clearance. If the oil clearance

exceeds the limit, replace the rod bearing as a

set.

Standard : 0.006 mm–0.031 mm

(0.0002 in–0.0012 in)

Limit : 0.12 mm (0.0047 in)

7. Clean the plastigage from the bearings and the

crankshaft pins.

Reassembly

1. Install connecting rod

2. Install piston

3. Install piston pin

• Apply a thin coat of engine oil to the piston pin.

Try to insert the piston pin into the piston pin hole

with normal finger pressure.

NOTE: When changing piston / connecting rod

combinations, do not change the piston / piston pin

combination and do not reuse the old piston pin.

• Attach the piston to the connecting rod with the

piston front mark and the connecting rod front

mark on the same side.

• Heat the connecting rod small end to a suitable

temperature to ensure smooth installation.

4. Install piston ring with the piston ring expander.

• New piston rings with “Top" uppermost — use

commercially available pliers.

• Position ring gaps:

1 — Compression rings 180°to each other as

illustrated.

2 — Offset oil control rings 25 to 50 mm/1 to 2 in.

from gap of second compression ring.

015RW026

• After installation, apply engine oil to the entire

circumference of the piston rings. Check to see

that all the rings rotate smoothly.

5. Install piston and connecting rod assembly.

• Insert the bearings into the connecting rods and

caps. Apply new engine oil to the bearing faces

and nuts.

• Tighten the connecting rod cap nuts in 3 steps:

1st step : 35 N·m (3.6Kg·m/26lbft)

2nd step: 45°

°°

3rd step: 15°

°°

Crankshaft grinding dimensions mm (in)

(continued)

Production and Service

Con–rod bearing journal dia.

Stan dard si ze

(no color code) 48.970 to 48.988 (1.9098–1.9105)

Undersize 0.25 (0.0097)

blue 48.720 to 48.738 (1.9001–1.9008)

Undersize 0.5 (0.0195)

white 48.470 to 48.488 (1.8903–1.891)

Con–rod bearing journal width

Stan dard si ze

(no color code) 26.460 to 26.580 (1.0319–1.036)

Undersize 0.25 (0.0097)

blue 26.460 to 26.580 (1.0319–1.036)

Undersize 0.5 (0.0195)

white 26.460 to 26.580 (1.0319–1.036)

Con–rod width 26.338 to 26.390 (1.0271–1.0292)

NOTE: Do not apply engine oil to the bearing back

faces.

6.Oil gallery, refer to “Crankshaft and Main Bearing" in

this manual.

7.Oil strainer and O-ring.

8.Install balance unit assembly, refer to “Balance Unit

Assembly: in this manual.

9.Install oil pan support assembly,

10. Install cylinder head gasket.

11. Install cylinder head assembly.

•Refer to “Cylinder Head" in this manual.

Cylinder Block

Cylinder Block and Associated Parts

015RW008

Legend

EndOFCallout

(1) Cylinder Head Assembly

(2) Oil Pump Assembly

(3) Oil Pan

(4) Oil Pan Support

(5) Oil Strainer

(6) Balance Unit Assemb ly

(7) Piston and Connecting Rod Assembly

(8) M ain Bearing Cap

(9) Crankshaft

(10) Cy li nde r Block

Disassembly

1.Remove cylinder head assembly.

2.Remove cylinder head gasket.

3.Remove oil pan assembly.

4.Remove oil pan support.

5.Remove oil strainer.

6.Remove oil pump assembly.

7.Remove balance unit assembly.

8.Remove piston and connecting rod assembly.

9.Remove flywheel.

10.Remove rear oil seal retainer assembly.

11.Remove main bearing cap.

12.Remove crankshaft.

13.Remove cylinder block.

Inspection and Repair

1.Remove the cylinder head gasket and any other

material adhering to the upper surface of the

cylinder block. Be very careful not to allow any

material to accidentally drop into the cylinder block.

Be very careful not to scratch the cylinder block.

2.Carefully remove the oil pump, rear oil seal retainer,

and crankcase assembly installation surface seal.

3.Wipe the cylinder block clean.

4.Visually inspect the cylinder block. If necessary, use

a flaw detector to perform a dye penetrate and

hydraulic (or air pressure) test. If cracking or other

damage is discovered, the cylinder block must either

be repaired or replaced.

Flatness

1.Using a straight edge and feeler gauge, check that

the upper surface of the cylinder block is not

warped.

CAUTION: Be very careful not to allow any material

to accidentally drop into the upper surface of the

cylinder block. Be very careful not to scratch the

upper surface of the cylinder block.

2.The cylinder block must be reground or replaced if

the warpage exceeds the limit.

Warpage

Limit : 0.40 mm (0.0156 in)

Maximum repairable limit: 0.40 mm (0.0156 in)

012RW013

Cylinder Bore

Use a cylinder gauge to measure the cylinder bore

diameter in both the axial and thrust directions. Each

measurement should be made at six points.

CAUTION: Be very careful not to allow any material

to accidentally drop into the upper surface of the

cylinder block. Be very careful not to scratch the

upper surface of the cylinder block.

If the measurement exceeds the specified limit, the

cylinder block must be replaced.

Diameter

Grade 1 : 85.975 mm–85.985 mm

(3.3530 in–3.3534 in)

Grade 2 : 85.985 mm–86.025 mm

(3.3534 in–3.3550 in)

Oversize : 0.5 mm (0.0195 in)

NOTE: For information on piston diameter, please refer

to the section “Inspection of the Piston and Connecting

Rod Assembly" in this manual.

Reassembly

1.Install cylinder block.

2.Install crankshaft.

•Install the main bearings to the cylinder block and

the main bearing caps.

•Be sure that they are positioned correctly.

•Apply new engine oil to the upper and lower main

bearing faces.

NOTE: Do not apply engine oil to the bearing back

faces.

•Carefully mount the crankshaft.

•Apply engine oil to the thrust washer.

3.Install rear oil seal.

•Coat lip of seal rings thinly with protective grease.

•Install seal ring into cylinder block, use 5–8840–

2660–0 (1) and 5–8840–2597–0 (2).

015RW009

4.Install flywheel

1.Thoroughly clean and remove the oil from the

threads of crankshaft.

2.Remove the oil from the crankshaft and flywheel

mounting faces.

3.Mount the flywheel on the crankshaft and then

install the washer.

4.Use stopper (5–8840–2661–0) to hold the

crankshaft.

Prevent from rotating.

Tighten the flywheel bolts in 3 steps:

1st step: 65 N·m (6.6Kg·m/48lbft)

2nd step: 30°

3rd step: 15°

NOTE: Do not reuse the bolt.

015RW010

5.Install piston and connecting rod assembly.

•Apply engine oil to the cylinder bores, the

connecting rod bearings and the crankshaft pins.

NOTE: Do not apply engine oil to the bearing back

faces.

•Position ring gaps:

1 — Compression rings 180° to each other as

illustrated (A).

2 — Offset oil control rings 25 to 50 mm/1 to 2 in.

from gap of second compression ring (B).

015RW026

6.Install balance unit assembly and tighten the bolts in

2 steps in the order shown:

1st step : 20 N·m (2.0Kg·m/14lbft)

2nd step : 45°°°°

7.Install oil pump assembly, refer to “Oil Pump" in this

manual.

8. Install oil strainer.

9.Install oil pan support.

10.Install oil pan assembly.

1.Completely remove all residual sealant,

lubricant and moisture from the sealing

surfaces. The surfaces must be perfectly dry.

2.Apply a correct width bead of sealant (TB–

1207C or its equivalent) to the contact surfaces

of the crankcase. There must be no gaps in the

bead.

3.The oil pan must be installed within 5 minutes

after sealant application.

4.Tighten the bolts and nuts to the specified

torque in 2 steps:

1st step : 8 N·m (0.8Kg·m/5.8lbft)

2nd step : 30°°°°

11.Install cylinder head gasket.

12.Install cylinder head assembly, refer to “Cylinder

Head" in this manual.

Cylinder Head Cover

Cylinder Head Cover and Associated parts

010RW004

Legend

EndOFCallout

(1) Ignition Cable Cover

(2) Spark Plug (3) Cylinder Head Cover

Removal

1. Remove two bolts and remove ignition cable cover

(1) from cylinder head cover (3).

2. Disconnect ignition cable and remove spark plag

(2).

3. Disconnect ignition cable from ignition plug.

4. Disconnec t camshaft angle sensor harness and

crankshaft angle sensor harness from behind

generator.

5. Remove f our bolts and remov e the crankshaft pulle y.

020RW014

6. Remove timing belt front cover.

7. Loose fixing bolt of timing belt rear cover, then

remove the camshaft angle sensor.

020RW012

8. Remove ten cylinder head cover fixing bolts and

remove the cylinder head cover.

Installation

1. Install the camshaft angle sensor and tighten timing

rear cover bolt.

Torque: 8 N·m (0.8Kg·m/5.9lbft)

020RW012

2. Install the cylinder head cover and tighten bolts to

the specified torque.

Torque: 8 N·m (0.8Kg·m/5.9lbft)

3. Install the timing belt front cover then tighten fixing

bolts to the specified torque.

Torque: 6 N·m (0.6Kg·m/4.4lbft)

4. Install the crankshaft pulley, tighten fixing bolts to

the specified torque.

Torque: 20 N·m (2.0Kg·m/14lbft)

020RW014

5. Mov e drive belt tensioner to loose side using wrench

then install the drive belt to normal position.

033RW001

6. Connect ignition cable to ignition plug.

7. Install ignition cable cover to cylinder head cover

and tighten two bolts to the specified torque.

Torque: 3 N·m (0.3Kg·m/2lbft)

Balance Unit Assembly

Balance Unit Assembly Associated Parts

051RW012

Legend

EndOFCallout

(1) Oil Pan

(2) Oil Pan Support

(3) Oil Strainer

(4) Balance Unit Assemb ly

(5) Shim

Disassembly

1. Remove the oil pan.

2. Remove the oil pan support.

3. Remove the oil strainer (1) from oil pump and the oil

baffle plate (2).

051RW009

Adjustment

1. Turn crankshaft in engine rotational direction to

alignment mark (2) 1st cylinder “TDC".

014RW066

2. In this crankshaft position, the flattened side

(arrows) of both balancer shafts must face

downward and must be on a horizontal line.

051RW010

3. Screw measuring device 5–8840–2671–0 (3) with

long knurled bolt (1) into 1st balancer shaft (intake

side) and tighter hard–tight measuring arm (5) must

point in “9 o'clock" direction shown in this illustration.

Install dial gauge holder with dial gauge (4) on

cylinder block.

051RW007

4. Place pre tensioned probe (6) of gauge on

measuring arm of measuring device 5–8840–2671–

0. The probe must be set precisely between the

notch marks, square to th e plane surface (7).

051RW006

5. Determine the left and right stops by turning the

knur le d bolt (2 ).

Set the dial of the gauge to zero.

Use the knurled bolt (2) to move the 2nd balancer

shaft (exhaust sid e) back and forth. A gain —

simultaneously read off the tooth backlash from the

gauge.

The permissible tooth backlash is: 0.02 mm to

0.06mm (0.0008 to 0.0024in).

051RW007

6. The tooth backlash must be measured in 4 different

positions — turn the crankshaft further at the

fastening bolt of the timing belt drive gear by 45° in

the engine rotational direction until the measuring

arm (2) is at “6 o'clock".

051RW008

7. Then loosen the knurled bolt (3) fix the measuring

arm at “9 o'clock" again and repeat the

measurement.

051RW007

8. If the value determi ned in one of the 4

measurements lies outside the tolerance 0.02mm to

0.06mm (0.00 08 to 0.0024in), the tooth backlash

must be adjusted.

9.Remove balance unit from cylinder block/crankshaft

bearing caps and remove with balancer piece. The

balancer piece has a number (code), for easy

assignment. The tooth backlash can be adjusted by

using a balancer piece with a different thickness.

CAUTION: The next larger or smaller balancer

alters the tooth backlash by 0.02mm (0.0008in).

Example of selection of balancer piece: The

installed balancer piece with the code “70" gave a

tooth backlash of 0.08mm (0.0031in).

If a balancer piece with the code “67" is now

installed, the tooth backlash will be approx. 0.06mm

(0.0024in).

NOTE: Only one balancer piece may be installed.

Reassembly

1.Turn crankshaft in engine rotational direction to

alignment mark (2) 1st cylinder “TDC".

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2.Turn balancer shafts until the flattened sides

(arrows) of both balancer shafts face downward and

are on a horizontal line.

051RW010

3.Install selected balancer piece (2) with balancer

shaft unit to cylinder block/crankshaft bearing cap —

tighten all fixing bolts to the specified torque.

Torque: 20 N·m (2.0Kg·m/15lbft)

4.After installing the balancer shaft unit, recheck the

tooth backlash and readjust if necessary.

CAUTION: If the balancer shaft unit has to be

replaced, use the thickest balancer piece with the

code “85" for the initial assembl y — this guarantees

tooth backlash in all conditions.

5. Install oil strainer to oil pump with new seal ring and

insert fixing bolts with locking agent to the specified

torque.

Torque: 8 N·m (0.8Kg·m/6lbft)

Code Thic kness of balancer piece in mm

55 0.535 to 0.565

58 0.565 to 0.595

61 0.595 to 0.625

64 0.625 to 0.655

67 0.655 to 0.685

70 0.685 to 0.715

73 0.715 to 0.745

76 0.745 to 0.775

79 0.775 to 0.805

82 0.805 to 0.835

85 0.835 to 0.865

6. Ins tall oil pan su ppo rt.

Torque: 20 N·m (2.0Kg·m/14lbft)

• Adjust surfaces of the cylinder block and the oil

pan support.

035RW026

7. Install oil pan.

1st step: 8 N·m (0.8Kg·m/5.8lbft)

2nd step: 30°

°°

Main Data and Specifications

Torque Specifications

Camshaft bracket, Timing gear camshaft side, Cylinder head

011RX001

Timing gear crankshaft (center bolt), Timing belt cover front, Timing belt cover rear, Timing belt tensioner,

Camshaft angle sensor

020RX001

Crankshaft main bearing, Oil pan support, Oil pan, Balance unit assembly, Connrod Cap, Oil pump, Oil

strainer

015RX004

Spark plug, Throttle body, EGR valve adaptor assembly, Bypass housing assembly, Thermostat assembly,

inlet manifold assembly, Exhaust manifold assembly, heat shield, Ignition cable co ver

011RX002

Engine mount

022RX003

Special Tools

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–2597–0

Installer; Rear crankshaft

seal ring

5–8840–2658–0

Remover/Installer;

Crankshaft carrier seal

5–8840–2546–0

Compressor; Valve

spring (1)

(Use w it h

5–8840–2 662– 0 (2) )

5–8840–2662–0

Adapter; Compressor

Valve spring

5–8840–2659–0

Locking tool camshaft

gear

5–8840–2660–0

Instal ler; Rear cr anksha ft

seal

5–8840–2661–0

Locking device; Flywhee l

5–8840–2663–0

Installer sleeve; Valve

stem seal

5–8840–2600–0

Socket wrench; Cylind er

head bolt

5–8840–2598–0

Holding wrench; Driven

gear fix

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–2671–0

Screw measuring device

ILLUSTRATION TOOL NO.

TOOL NAME