SECTION 6A - ENGINE MECHANICAL

General Description

Service Information

Service Standard

Servicing

Tightening Torque

Special Tools

Engine Assembly

Engine Mount (RH)

Engine Mount (LH)

Intercooler

Cylinder Head Cover

Intake Manifold

Exhaust Manifold

Turbocharger

Cylinder Head

Cylinder Head Gasket

Camshaft

Timing Gear

Valve Stem Seal, Valve Spring and Adjuster

Valve Clearance Adjustment

Oil Rail and Injector

Crank Case

Crankshaft

Piston and Connecting Rod

Cylinder Block

Oil Pump Assembly

Oil Filter Cartridge

Oil Cooler

Techline

GENERALDESCRIPTION

Cylinder Head Gasket

The cylinder head gasket is laminated steel sheets.

Three grades of the gasket according to the measured

piston head projection from the cylinder block are

provided to give the engine a minimum compression

ratio fluctuation.

Tightening Method for

Special Bolt

The cylinder head fixing bolts, flywheel bolts and

connecting rod cap fixing bolts are tightened by the

angular Tightening Method.

Piston

Auto-thermatic pistons having steel struts with a 0.4

mm offset from the piston pin center line, are applied to

reduce thermal expansion and resulting engine noise

when the engine is cold.

Bearings

The crankshaft bearings and connecting rod bearings

are of aluminum having a high bearing surface.

These bearings are especially sensitive to foreign

material such as metal scraps. So, it is very important

that the oil ports and other related surfaces are kept

clean and free of foreign material.

Crankshaft bearings are selected for optimum bearing

and journal clearance which reduces vebration and

noise.

MY1998-2002 Euro-2

MY2003 Euro-3

F06R200004

SERVICE INFORMATION

MAIN DATA AND SPECIFICATION

Engine type Diesel, four cycle water cooled inline

Camshaft type DOHC

Number of cylinders 4

Bore x stroke (mm) 95.4 x 104.9

Total piston displacement (cc) 2999

Compression ratio(to 1) 19.0

MY2003 Euro-3 18.5

Engine weight (dry) N (kg/lb) 2492 (254/560) (A/T)

MY2003 Euro-3 2422 (247/545) (A/T)

2649 (270/593) (M/T)

MY2003 Euro-3 2697 (275/606) (M/T)

Engine idling speed (Reference) RPM 720

Compression pressure kpa (kg/cm2/psi)-rpm 3040 (31/441)-200

Firing order 1-3-4-2

VALVE SYSTEM

Intake valves open at: B.T.D.C. 3 deg.

close at: A.B.D.C. 58 deg.

Exhaust valves open at: B.B.D.C. 57 deg.

close at: A.T.D.C. 5 deg.

Valve clearance (at cold) mm (in)

intake: 0.15 (0.006)

exhaust: 0.25 (0.01)

Oil filter Full flow and bypass combined type

Oil capacity (Original factory fill or rebuilt engine) 9.0 liters

Oil capacity (Service change)

with filter change 6.0 liters

without filter change 5.0 liters

Oil cooler Water cooled type

Inter cooler Air cooled type

Turbocharger method

Control method Wastegate control

Lubrication Pressurised control

Cooling method Coolant cooled

Crankshaft

As tufftriding (Nitrizing treatment) is applied to increase

crankshaft strength, crankpins and journals should not

be reground.

Piston Cooling

An oiling jet device for piston cooling is provided in the

lubricating oil circuit from the cylinder block oil gallery

via a check valve.

Take care not to damage any oiling jet when removing

and installing piston and connecting assembly.

Fuel Injection System

The injection system is oil rail type.

Quick On Start 4 System

QOS4 preheating system which features a quick-on

glow plug with thermometer control of the glowing time

and the afterglow time function, is applied.

Techline

Engine Cooling

Starting System

Cooling system Coolant forced circulation

Radiator (2 tube in row) Tube type corrugated

Heat radiation capacity J/h (kcal/h) 318 x 106(76000)

Heat radiation area m2(ft2) 15.63 (1.454)

Front area m2(ft2) 0.309 (2.029)

Dry weight N (kg/lb) 83 (8.5/18.7)

Radiator cap

Valve opening pressurekPa (kg/cm2/ psi)93.3 – 122.7 (0.95 – 1.25/13.5 – 17.8)

Radiator Coolant Volume lit (Imp.qt./US qt.)M/T2.5 (2.2/2.6)A/T2.4 (2.1/2.5)

Coolant pump Centrifugal impeller type

Pulley ratio( : 1)1.2

Coolant total capacity MY1998-2002 Euro-2: 9.3 Litres

MY2003 Euro-3: 9.8 Litres

Model HITACHI S14-0

Rating

Voltage V 12

Output kW 2.8

Time sec 30

Number of teeth of pinion 9

Rotating direction (as viewed from pinion) Clockwise

Weight (approx.) kg(lb) 5.0(11)

No-load characteristics

Voltage/current V/A 11/160 or less

Speed rpm 4000 or more

Load characteristics

Voltage/current V/A 8.76/300

Torque N·m(kg·m/lb·ft) 7.4 (0.75/5.4) or more

Speed rpm 1700 or more

Locking characteristics

Voltage/current V/A 2.5/1100 or less

Torque N·m(kg·m/lb·ft) 18.6 (1.9/14) or more

Charging System

Model (HITACHI) LR190-750B LR1100 – 731

Rated voltage V 12

Rated output A 90 100

Rotation direction Clockwise

(As viewed from pulley)

Pulley effective diameter mm (in) 69 (2.72)

Weight kg(lb) 5.3(11.7)

SERVICE STANDARD

Engine mm (in)

Parts Items Service standard Service limit Remarks

Cylinder Head

Valve Spring

Valve and

Valve guide

Camshaft

0.075 (0.0030) or less

95.0 (3.740)

45.7 (1.8)

—

241 (54.2)

6.959 – 6.977

(0.27 – 0.272)

6.692 – 6.970

(0.271 – 0.272)

0.023 – 0.056

(0.0009 – 0.0022)

0.03 – 0.063

(0.0011 – 0.0024)

8.0 (0.312)

1.1 (0.0433)

1.2 (0.0472)

45°

2.1 (0.0827)

0.08 (0.00314)

46.67 (1.8374)

46.77 (1.8413)

29.939 – 29.960

(1.167 – 1.168)

0.02 (0.0008) or less

0.40 – 0.082

(0.0016 – 0.0032)

0.50 (0.0197)

—

44.8 (1.765)

1.6 (0.063)

210 (47.22)

6.92 (0.270)

6.90 (0.269)

0.19 (0.0074)

0.20 (0.0079)

—

1.6 (0.0630)

1.1 (0.0433)

—

2.6 (0.1024)

2.0 (0.00797)

46.57 (1.8335)

46.67 (1.8374)

29.84 (1.1748)

0.10 (0.0039)

0.12 (0.0047)

Cannot be

reground

Cylinder head lower surface for flatness

Cylinder head height

Free height

Squareness

Spring tension (when assembled) N( lb)

Diameter of Valve stem IN

Valve and valve guide clearance IN

Valve guide upper end height

(Measured from the Cylinder head upper

face)

Valve guide margin

Valve thickness IN

Valve seat contact surface angle

Valve seat contact width IN

End play

Cam lobe height IN

Journal diameter

Runout

Camshaft oil clearance

Parts Items Service standard Service limit Remarks

Tappet

Crankshaft

Piston,

Piston pin,

Piston ring

and

Connecting

rod

32.977 – 32.990

(1.2983 – 1.2988)

0.01 – 0.039

(0.0004 – 0.0015)

0.04 – 0.20

(0.0016 – 0.0079)

0.037 – 0.068

(0.0015 – 0.0027)

0.05 (0.0020) or less

69.917 – 69.932

(2.7526 – 2.7532)

52.915 – 52.930

(2.0933 – 2.0839)

95.320 – 95.349

(3.7527 – 3.7539)

0.11 – 0.92

(0.0043 – 0.0362)

0.25 – 0.40

(0.0098 – 0.0157)

0.20 – 0.35

(0.0079 – 0.0138)

0.10 – 0.30

(0.0039 – 0.0118)

0.05 – 0.09

(0.0020 – 0.0035)

0.03 – 0.07

(0.00118 – 0.00276)

30.995 – 31.000

(1.203 – 1.205)

0.008 – 0.020

(0.0003 – 0.00079)

0.005 – 0.018

(0.0002 – 0.0007)

0.08 (0.031) or less

0.05 (0.0020) or less

0.230 (0.0091)

0.022 – 0.042

(0.0009 – 0.0017)

32.950 (1.2972)

0.10 (0.0039)

0.30 (0.00118)

0.11 (0.0043)

0.08 (0.0031)

69.91 (2.7524)

52.90 (2.0827)

—

1.5 (0.0590)

0.15 (0.0059)

30.97 (1.2078)

0.05 (0.0020)

0.04 (0.0016)

0.20 (0.00787)

0.15 (0.0059)

0.35 (0.0138)

0.0060

(0.0024)

Uneven

wear limit

0.05 (0.002)

Uneven

wear limit

0.08 (0.0031)

Per 100

(3.94)

Per 100

(3.94)

Outside diameter

Oil clearance

Thrust clearance

Main bearing oil clearance

Crankshaft runout

Main journal diameter

Crank pin diameter

Piston diameter

Piston clearance

Piston ring gap 1st

2nd

Oil

Piston ring clearance 1st/2nd

Oil

Piston pin diameter

Piston pin clearance

(Between connecting rod and piston pin)

Piston pin clearance

(Between piston and piston pin)

Connecting rod alignment Bend

Twist

Connecting rod thrust clearance

Oil clearance

(Between crank pin and Connecting rod)

mm (in)

Parts Items Service Standard Service Limit Remarks

Cylinder

Block Warpage

(Upper surface of the cylinder head)

Cylinder Bore Diameter

—

95.421 – 95.450

(3.7567 – 3.7579)

0.20 (0.0079) —

Balance

Shaft Bore

Cylinder Block (right side) Front

Centre

Rear

Crankcase (left side) Front

Centre

Rear

50.000 – 50.030

(1.9685 – 1.9696)

50.000 – 50.030

(1.9685 – 1.9696)

13.020 – 13.044

(0.5126 – 0.5135)

51.000 – 51.021

(2.0079 – 2.0087)

46.00 – 46.021

(1.8110 – 1.8119)

13.020 – 13.044

(0.5126 – 0.5135)

— —

Engine Cooling

Parts Items Service Standard Service Limit Remarks

Thermostat Valve opening temperature

Valve full open temperature and lift

83 – 87 °C

(181 – 189 °F)

More than

9.5 mm (0.374 in) at

100 °C (212 °F)

— —

Radiator Cap Valve opening pressure 88.2 – 117.6 kPa

(12.8 – 17.0 psi) — —

SERVICING

Servicing refers to general maintenance procedures to

be performed by qualified service personnel.

MODEL IDENTIFICATION

Engine Serial Number

The engine number is stamped on the rear left hand

side of the cylinder body.

AIR CLEANER

Oil Wetted (Viscous) Type Paper Element.

The air cleaner has an oil wetted paper element. No

servicing is required until the replacement interval is

reached.

Never attempt to clean the element, no matter how dirty

it may appear. The element is designed to provide

normal filtering efficiency until it becomes due for

replacement.

Refer to the Item “Service and Maintenance” in the

Owner’s and Driver’s Manual for general service

information.

LUBRICATING SYSTEM

Main Oil Filter (Cartridge Type Paper Element)

Replacement Procedure

1. Loosen the drain plug to drain the engine oil.

2. Wait a few minutes and then retighten the drain

plug.

3. Loosen the used oil filter (2) by turning it counter-

clockwise with the filter wrench.

4. Clean the oil filer gasket fitting face.

This will allow the new oil filter to seat properly.

5. Apply a light coat of engine oil to the O-ring.

6. Turn the new oil filter until the filter O-ring is fitted

against the sealing face.

7. Use the filter wrench to turn the filter additional one

and 1/4 turns.

Filter Wrench: 5-5540-0203-0

012RW115

012RW062

MY2003 Euro-3

050R200001

Techline

8. Check the engine oil level and replenish to the

specified level if required.

9. Start the engine and check for oil leakage from the

main oil filter.

FUEL SYSTEM

Fuel filter

Replacement Procedure

1. Loosen the used fuel filter by turning it

counterclockwise with the filter wrench.

Filter Wrench : 5-8840-0203-0

2. Clean the filter cover fitting faces.

This will allow the new fuel filter to seat properly.

3. Apply a light coat of engine oil to the O-ring.

4. Turn the fuel filter until the sealing face comes in

contact with the O-ring.

5. Turn the fuel filter with a filter wrench 2/3 of a turn

until sealed.

Filter Wrench: 5-8840-0203-0

Legend

(1) Priming pump

6. Operate the priming pump until the air is discharged

completely from fuel system.

NOTE: The use of an Isuzu genuine fuel filter is

strongly recommended.

COOLING SYSTEM

Coolant Level

Check the coolant level and replenish the radiator

reserve tank as necessary.

If the coolant level falls below the “‘MIN” line, carefully

check the cooling system for leakage. Then add

enough coolant to bring the level up to the “MAX” line.

NOTE: Do not overfill the reserve tank.

012RW112

012RW078

012RW111

012RW080

Remove the radiator filler cap only when absolutely

necessary.

Always check the coolant level when the engine is cold.

Always refer to the chart at the left to determine the

correct cooling water to antifreeze solution mixing ratio.

Cooling System Inspection

Install a radiator filler cap tester to the radiator. Apply

testing pressure to the cooling system to check for

leakage.

The testing pressure must not exceed the specified

pressure.

Testing Pressure: 196 kPa (2 kg/cm2/28.45 psi)

Radiator Cap Inspection

The radiator filler cap is designed to maintain coolant

pressure in the cooling system at 103 kPa (1.05

kg/cm2/15 psi).

Check the radiator filler cap with a radiator filler cap

tester.

The radiator filler cap must be replaced if it fails to hold

the specified pressure during the test procedure.

Radiator Filler Cap Pressure Valve: 88.2 – 117.6 kPa

(0.899 – 1.199 kg/cm2/12.8 – 17.1 psi)

Negative Valve (Reference): 1.0 – 3.9 kPa

(0.01 – 0.04 kg/cm2/0.14 – 0.57 psi)

Thermostat Operating Test

1. Completely submerge the thermostat in water.

2. Heat the water.

Stir the water constantly to avoid direct heat being

applied to the thermostat.

3. Check the thermostat initial opening temperature.

Thermostat Initial Opening Temperature:

83 – 87°C (181 – 189°F)

4. Check the thermostat full opening temperature.

Thermostat Full Opening Temperature:

100°C (212°F)

Valve Lift at Fully Open Position: 9.5 mm (0.374

in)

110RS005

110RS006

031RS003

COOLANT SPECIFICATION

50% water and 50% coolant conforming to Holden

HN2217 specification.

COOLANT CAPACITY

MY1998-2002 Euro-2: Approximately 9.3 litres

MY2003 Euro-3: Approximately 9.8 litres

Drive Belt Adjustment

Check the drive belt tension

Depress the drive belt mid-portion with a 98 N (10 kg/

22 lb) force.

Drive Belt Deflection: 10 mm (0.39 in)

Check the drive belt for cracking and other damage.

Legend

(1) Crankshaft pulley

(2) Generator pulley

(3) Cooling fan pulley

(4) A/C compressor pulley

(5) Belt tensioner pulley

Cooling Fan Pulley Drive Belt

Fan belt tension is adjusted by moving the generator.

Depress the drive belt mid-portion with a 98 N (10 kg/

22 lb) force.

Legend

(1) Crankshaft pulley

(2) Generator pulley

(3) Cooling fan pulley

Compressor Pulley Drive Belt

Move the tensioner pulley as required to adjust the

compressor drive belt tension.

Depress the drive belt mid-portion with a 98 N (10 kg/

22 lb) force.

Legend

(1) Crankshaft pulley

(2) Generator pulley

(3) Cooling fan pulley

(4) A/C compressor pulley

(5) Belt tensioner pulley

012RW110

012RW084

012RW110

VALVE CLEARANCE ADJUSTMENT

1. Install 2.80 mm valve adjuster (shim) first when

reassembling the engine.

Thickness mark faces down.

2. Measure the valve clearance after installing cam

carrier assy with camshafts.

3. Change the adjuster using a special tool when the

clearance is out of tolerance.

Valve Clearance Adjusting Tool: 5-8840-2590-0

VALVE CLEARANCE (When cold condition)

Inlet 0.15 ± 0.05 mm

Exh 0.25 ± 0.05 mm

COMPRESSION PRESSURE

MEASUREMENT

1. Start the engine and allow it to idle until the coolant

temperature reaches 70 – 80°C (158 – 176°F).

2. Remove the following parts.

•Glow plugs

•Fuel cut solenoid connector

•QOS (Quick-On Start System) fuse in the fuse

box.

3. Set the adapter and compression gauge to the No.

1 cylinder glow plug hole.

Compression Gauge

(with Adapter): 5-8840-2008-0

4. T urn the engine over with the starter motor and take

the compression gauge reading.

Compression Pressure at 200 rpm

Standard: 3040 kPa (31 kg/cm2/441 psi)

Limit: 2160 kPa (22 kg/cm2/313 psi)

5. Repeat the procedure (Steps 3 and 4) for the

remaining cylinders.

QUICK-ON START 4 SYSTEM

Quick-On Start System Inspection Procedure

1. Disconnect the ECT-sensor connection around the

thermostat outlet pipe.

2. Turn the starter switch to the “ON” position.

If the Quick-On Start 4 System is operating

properly, the glow relay will make a clicking sound

within seven seconds after the starter switch is

turned on.

3. Measure the glow plug terminal voltage with a

circuit tester immediately after turning the starter

switch to the “ON” position.

Glow Plug Terminal Voltage: approx. 12V

NOTE: Electrical power to the quick-on start system will

be cut after the starter has remained in the “ON”

position for twenty seconds.

Turn the starter switch to the “OFF” position and back

to the “ON” position.

This will reset the Quick-On Start 4 System.

014RW150

TIGHTENING TORQUE

Timing Gear Case, Timing Gear N·m (kg·m/lb·ft)

75(7.6/55)

Apply engine oil to

thread and seat

8(0.8/69lb•in)

20(2.0/14)

51(5.2/38)

25(2.5/18)

020R200001

Cylinder Head, Flywheel, Crank Case, Oil Pan N·m (kg·m/lb·ft)

012R200008

1st

49N•m(5.0kg•m/36 Ib ft)

167(17.0/123)

8(0.8/69lb•in)

20(2.0/14)

30(3.1/22)

24(2.4/17)

2nd

60°

1st

59N•m(6.0kg•m/43 Ib ft)

Apply engine oil to thread

2nd

60°-90°

3rd

60°-90°

1st

29N•m(3.0kg•m/22 Ib ft)

2nd

45°-60°

3rd

60°

22(2.2/16)

Intake / Exhaust Manifold N·m (kg·m/lb·ft)

025R200009

MY2003 Euro-3

20(2.0/14)

22(2.2/16)

30(3.1/22)

27(2.8/20)

30(3.1/22)

20(2.0/14)

Timing Pulley N·m (kg·m/lb·ft)

020R200002

20(2.0/14)

40(4.1/30) 60°-90°

1st 2nd

10(1.0/87lb•in)

20(2.0/14)

50(5.1/37)

20(2.0/14)

9(0.9/78lb•in)

Engine Electricals N·m (kg·m/lb·ft)

060R200291

15(1.5/11)

85(8.7/63)

40(4.1/30)

24(2.4/17)

20(2.0/14)

Injector

N.m (kg m/lb ft)

20N.m (2.0kg.m/14 lb.ft)

7N.m (0.7kg.m/61 lb.in)

20N.m (2.0kg.m/14 lb.ft)

Recheck tightening torque

after tightening the oil rail

Apply engine oil to the

stud bolt threads

Tighten 30N.m (3.1kg.m/22lb.ft)

Loosen then tighten again to

25N.m (2.5kg.m/18 lb.ft)

Apply engine oil

to both sides

25N.m (2.5kg.m/18ft.lb) Without

spacer type

E06R200027

With

spacer type

High Pressure Oil Pipe N·m (kg·m/lb·ft)

78(8.0/58)

052R200003

Air Duct and Intercooler MY1998-2002 Euro-2 N·m (kg·m/lb·ft)

3(0.3/26lb•in)

4(0.4/35lb•in)

20(2.0/14)

4(0.4/35lb•in)

20(2.0/14)

135R200004

Air Duct and Intercooler MY2003 Euro-3 N·m (kg·m/lb·ft)

4(0.4/35lb•in)

3(0.3/29lb•in)

20(2.0/14)

135R200005

Engine Mount Bracket N·m (kg·m/lb·ft)

50(5.1/37)

50(5.1/37) 127(13.0/94)

127(13.0/94)

40(4.1/30)

022R200002

Exhaust System N·m (kg·m/lb·ft)

150R200031

43(4.4/32)

16(1.6/12)

43(4.4/32)

67(6.8/49)

43(4.4/32)

901RT034

Illustration Tool No. Tool Name

SPECIALTOOLS

5-8840-0203-0 Filter Wrench

5-8840-2441-0 Valve Spring Compressor

5-8840-2033-0 Stem Seal Installer

5-8840-9018-0 Piston Ring Compressor

5-8840-0075-0 Turbocharger Pressure Gauge

9-8523-1212-0 Valve Guide Replacer

F06RV038

5884020330

901LX017

901RX00001

901RW182

Techline

Illustration Tool No. Tool Name

SPECIAL TOOLS

5-8840-2590-0 Valve Clearance Adjusting Tool

5-8840-2592-0 Camshaft Stopper

5-8840-2591-0 Camshaft Gear Tool

5-8840-2675-0

5-8531-7002-0

Compression Gauge

Adapter: Compression Gauge

5-8840-2153-0 Seal Cutter

F06RW056

F06RV037

901LX057

901LX056

F06RW057

901RT042

Illustration Tool No. Tool Name

SPECIAL TOOLS

5-8840-0266-0 Angle Gauge

5-8840-2360-0 Rear Oil Seal Remover

5-8840-2359-0 Rear Oil Seal Installer

5-8840-2061-0 Front Oil Seal Installer

901LX030

901LX040

901LX025

901LX039

901RV061

9-8522-0021-0 Crankshaft Gear Installer

ENGINE ASSEMBLY

MY1998-2002 Euro-2

MY2003 Euro-3

F06R200004

REMOVAL

1.Remove battery.

2.Drain engine coolant

3.Disconnect window washer hose and remove

engine hood.

4.Radiator Hose

1)Disconnect upper and lower hoses from engine

side.

5.Fan Shroud

1)Disengage clips and remove upper and lower

fan shrouds.

6.Cooling Fan Assembly

1)Remove cooling fan assembly fixing nuts,

cooling fan assembly.

7.Radiator Assembly

1)Remove bracket and radiator assembly.

8.Air Cleaner Cover & Air Duct

9.Intercooler Assembly

1)Refer to “Intercooler” in this manual.

10. Engine Ground Cable

1) Disconnect ground cable from A/C compressor

bracket.

11. AC Generator Harness

1) Disconnect B terminal and harness connector

from AC generator .

12. A/C Compressor Assembly

1) Disconnect magnetic clutch harness connector.

2) Remove A/C compressor fixing bolt (rear under

side of compressor).

3) Remove fixing bolts (upper and front lower side

of compressor) and set A/C compressor

assembly with pipe lines on battery carrier.

13Vacuum Hose

1)Disconnect vacuum hose from vacuum pump.

14.Starter Harness

1)Disconnect B terminal and put cable harness

close to chassis side.

2)Disconnect S terminal connector.

15.Engine Harness

1)Disconnect engine harness close to engine side.

16.Fuel Pipe

1)Remove fuel pipe from fuel pump and take care

not to spill fuel and let dust enter.

17.Engine Ground Cable

1)Disconnect ground cable from left rear side of

timing gear case.

18.Vacuum Hose: Vacuum Tank

Disconnect vacuum hose from vacuum pump side.

19.Glow Plug Harness

20.Transmission Assembly

1)Set transmission support tool under the

transmission.

2)Remove transmission rear mount.

3)Remove transmission fixing bolt from rear of

engine assembly except two bolts.

4)Carefully hang up engine assembly with a hoist.

5)Remove remaining two transmission fixing bolts.

6)Remove transmission assembly.

7)Remove heater hose.

8)Disconnect wire harness connector for shift on

the fly.

9)Remove vacuum hose.

21.Prepare Engine Stand

22.Engine Assembly

1)Remove engine mount fixing bolts.

2)Carefully hang up the engine assembly.

3)Take out the engine assembly making sure not

to damage the brake oil pipe and other pipe etc.

INSTALLATION

1.Engine assembly

1)Install engine in mounting position by using

hoist.

2.Transmission Assembly

1)Refer to transmission installation steps in

Section 7C.

3.Engine Mounting

1)After all fixing bolts (left: two bolts, rights: two

bolts) were inserted in every hole, tighten fixing

bolts to the specified torque.

Torque: 40 N·m (4.1 kg·m/30 lb·ft)

4.Glow Plug Harness

5.Vacuum Hose

1)Connect Vacuum Hose to Vacuum Pump

6.Engine Ground Cable

7.Fuel Pipe

1)Install fuel pipe to fuel pump.

8.Engine Harness

9.Starter Harness

10.A/C Compressor Assembly

1)Tighten temporarily the fixing bolts (upper and

front lower sides of compressor.)

2)Tighten fixing bolt (rear under side of

compressor) to the specified torque.

3)Tighten fixing bolts (front upper and lower sides

of compressor) to the specified torque.

Torque: 40 N·m (4.1 kg·m/30 lb·ft)

Legend

(1)Tensioner

(2)Bolt

(3)Bracket

(4)A/C compressor

(5)Bolt

11.A.C Generator Harness

12.Engine Ground Cable

1)Tighten ground cable to A/C compressor

bracket.

13.Air Cleaner cover & Duct

14.Intercooler Assembly

1)Refer to “Intercooler” in this manual.

15. Radiator Assembly

1) Install rubber cushion in under left and right part

of radiator and position radiator.

2) Fix radiator with bracket.

16. Cooling Fan Assembly

1) Install cooling fan assembly and tighten fixing

bolts to the specified torque.

Torque: 8 N·m (0.8 kg·m/69 lb in)

17. Fan Shroud

18. Radiator Hose

1) Connect upper and lower hose to engine side.

2) Pour coolant into radiator.

19. Install battery.

20. Connect window washer hose and install engine

hood.

MY2003 Euro-3

F06R200005

ENGINE MOUNT (RH)

REMOVAL

1. Disconnect battery ground cable

2. Hang the engine assembly.

3. Rubber engine mount.

1) Remove bolts from chassis frame bracket.

2) Remove nuts from rubber engine mount and

engine mounting bracket.

4. Remove bolt which is fixed between engine and

mounting bracket then remove the engine mounting

bracket.

INSTALLATION

•Tighten the fixing bolts to the specified torque.

1. Engine mounting bracket to cylinder block.

Torque : 40 N·m (4.1 kg·m/30 lb ft) (for M10)

127 N·m (13.0 kg·m/94 lb ft) (for M14)

2. Rubber engine mount to chassis frame and engine

mounting bracket.

Torque :40 N·m (4.1 kg·m/30 lb ft)

022RW018

Legend

(1) Rubber Engine Mount (LH)

(2) Engine Mounting Bracket (LH)

(3) Rubber Engine Mount (RH)

(4) Engine Mounting Bracket (RH)

ENGINE MOUNT (LH)

REMOVAL

1. Disconnect battery ground cable

2. Hang the engine assembly.

3. Rubber engine mount.

1) Remove bolts from chassis frame bracket.

2) Remove nuts from rubber engine mount and

engine mounting bracket.

4. Remove bolt which is fixed between engine and

mounting bracket then remove the engine mounting

bracket.

INSTALLATION

•Tighten the fixing bolts to the specified torque.

1. Engine mounting bracket to cylinder block.

Torque : 40 N·m (4.1 kg·m/30 lb ft) (for M10)

127 N·m (13.0 kg·m/94 lb ft) (for M14)

2. Rubber engine mount to chassis frame and engine

mounting bracket.

Torque :40 N·m (4.1 kg·m/30 lb ft)

022RW018

Legend

(1) Rubber Engine Mount (LH)

(2) Engine Mounting Bracket (LH)

(3) Rubber Engine Mount (RH)

(4) Engine Mounting Bracket (RH)

INTERCOOLER

REMOVAL

1. Disconnect the battery ground cable.

2. Remove air cleaner cover and air duct.

3. Remove intercooler cover.

4. Remove intercooler assembly.

1) Remove rubber hose from between intercooler

outlet and intake manifold inlet.

2) Remove rubber hose from between

turbocharger outlet and intercooler inlet.

3) Remove intercooler assembly fixing bolts from

the bracket, remove intercooler assembly.

INSTALLATION

1. Intercooler assembly

1) Connect outlet hose to intake manifold.

Torque : 4 N·m (0.4 kg·m/35 lb in)

2) Connect inlet hose from turbocharger to

intercooler.

Torque : 4 N·m (0.4 kg·m/35 lb in)

3) Install intercooler and tighten fixing bolts to the

specified torque.

Torque : 20 N·m (2.0 kg·m/14 lb ft)

2. Install intercooler cover.

3. Install air cleaner cover and air duct.

4. Connect the battery ground cable.

MY2003 Euro-3

3 3

135R200003

Legend

(1) Air Cleaner Cover & Air Duct (2) Intercooler Cover

(3) Intercooler Assembly

Techline

CYLINDER HEAD COVER

REMOVAL

1.Disconnect battery ground cable.

2.Remove clip, remove air cleaner cover and air duct.

3.Remove intercooler assembly.

Refer to “Intercooler” in this manual.

4. Remove PCV hose.

5. Remove bolts which fix noise insulator cover then

remove noise insulator cover and insulator.

6. Remove high pressure oil pipe at cylinder head

side.

Take care when removing the injector oil pipe,

because sometimes, during removal, your hand

can be injured by the remaining high pressure oil.

INSTALLATION

1. Cylinder head cover.

1) Install the cylinder head cover gasket to cylinder

head cover.

2) The gasket must be set perfectly with no loose

areas.

3) Apply liquid gasket (TB1207B or equivalent) to

the rubber seal of the camshaft end, injector

harness gasket area and No. 1 camshaft

bracket.

4) Tighten cylinder head cover fixing bolts to the

specified torque.

Torque : 9 N·m (0.9 kg·m/78 lb in)

2. Fill with about 300 cc of engine oil from the high

pressure oil pipe installation port of the oil rail using

an oil rail filler. If assembled without filling the oil rail

with oil, the time for starting the engine will be

longer.

3. Install the high pressure oil pipe immediately and

tighten the sleeve nut to the specified torque.

Torque : 78 N·m (8.0 kg·m/58 lb ft)

010R200006

Legend

(1) Noise Insulator Cover

(2) Insulator

(3) Bolt

(4) Oil Seal

(5) Gasket

(6) Cylinder Head Cover

(7) Bolt

3~52~32~3 3~5

3~51~2

012RW119

NOTE:Do not scratch the oil seal on the cylinder head

during installation of the high pressure oil pipe.

4.Install the noise insulator and its cover on the

cylinder head cover.

NOTE:Do not catch the injector harness with the noise

insulator cover.

5.Connect the PCV hose.

6.Install the intercooler assembly.

Refer to “Intercooler” in this manual.

7. Install air cleaner cover and air duct.

8. Connect battery ground cable.

INTAKE MANIFOLD

REMOVAL

1.Drain engine coolant and disconnect water hose

from thermostat hosing.

2.Remove intercooler assembly

Refer to “Intercooler” in this manual.

3.Remove bracket bolt of oil level gauge guide tube.

4.Remove PCV Hose.

5.Remove hoses from EGR, EGR vacuum sensor

and inlet/outlet of heater.

6.Disconnect harness connector form MAPsensor,

EGR vacuum sensor, ETC sensor, water

temperature unit, IATsensor and EVRV.

7.Remove high pressure oil pipe.

8.Remove the two way valve.

9.Remove fuel pipe from between intake manifold

and high pressure oil pump.

10.Remove fixing bolts and nuts on the intake

manifold, then remove the intake manifold

assembly.

INSTALLATION

1.Install the intake manifold, tighten bolts and nuts to

the specified torque.

Torque : 20 N·m (2.0 kg·m/14 lb ft) for bolt and nut

2.Install the fuel pipe and tighten to the specified

torque.

Torque :

M16 bolt (apply engine oil) 4 N·m (0.4 kg·m/35

lb in)

Cap nut (M10) 13N·m (1.3 kg·m/113 lb in)

Fuel pipe (M10 apply engine oil) 14 N·m (1.4

kg·m/122 lb in)

3.Install two way valve.

Torque : 20 N·m (2.0 kg·m/14 lb ft)

4.Fill with about 300 cc of engine oil from the high

pressure oil pipe installation port of the oil rail using

an oil filler. If assembled without filling the oil rail

with oil, the time for starting the engine will be

longer.

5.Install the high pressure oil pipe immediately and

tighten the sleeve nut to the specified torque.

Torque : 78 N·m (8.0 kg·m/58 lb ft)

6.Reconnect harness connector to MAPsensor, EGR

vacuum sensor, ETCsensor, Water temperature

unit, IATsensor and EVRV.

7.Connect the hoses to EGR valve, EGR vacuum

sensor, and water inlet/outlet pipe for heater.

8.Connect PCV hose.

9.Install the oil level gauge guide tube and tighten

bracket bolt.

10.Install the intercooler assembly.

Refer to “Intercooler” in this manual.

11. Connect the hose to the thermostat housing and fill

with engine coolant.

MY2003 Euro-3

025R200005

Legend

(1) Intake Manifold

(2) Throttle Valve Assembly

(3) EGR Valve

(4) Gasket

EXHAUST MANIFOLD

MY2003 Euro-3

025R200004

Legend

(1) Exhaust Manifold

(2) Gasket

(3) T urbocharger Assembly

(4) Water Hose

(5) Water Hose

(6) Heat Protector

(7) Oil Pipe

(8) Oil Pipe

(9) Gasket

REMOVAL

1. Remove the hose from both turbocharger outlet and

intake manifold inlet side, then remove intercooler

assembly.

2. Loosen belt tensioner, remove A/C compressor

assembly.

3. Remove heat protector from turbocharger.

4. Remove water hoses and oil pipes from

turbocharger.

5. Remove turbocharger assembly from exhaust

manifold.

6. Remove exhaust manifold fixing nuts, then remove

exhaust manifold.

INSTALLATION

1. Install gasket on the exhaust manifold and tighten

to the specified torque.

Torque : 30 N·m (3.1 kg·m/22 lb ft)

2. Install turbocharger on the exhaust manifold.

Torque : 27 N·m (2.8 kg·m/20 lb ft)

3. Install water hoses and oil pipes.

4. Install heat protector to turbocharger.

Torque : 9 N·m (0.9 kg·m/78 lb in)

5. Install A/C compressor assembly and readjust belt

tensioner.

6. Install the intercooler assembly in the normal

position.

Connect both hoses to turbocharger and intake

manifold.

TURBOCHARGER

MY2003 Euro-3

025R200004

Legend

(1) Exhaust Manifold

(2) Gasket

(3) T urbocharger Assembly

(4) Water Hose

(5) Water Hose

(6) Heat Protector

(7) Oil Pipe

(8) Oil Pipe

(9) Gasket

Techline

REMOVAL

1.Remove battery.

2.Drain engine coolant.

3.Remove air cleaner cover with air duct.

4.Remove intercooler assembly.

Refer to “Intercooler” in this manual.

5. Remove water pipe for turbocharger inlet.

6. Remove oil pipe for turbocharger.

1) Remove eye bolt from turbocharger.

2) Plug oil port on the turbocharger to prevent entry

of foreign materials.

7. Remove oil drain pipe from turbocharger.

8. Remove water outlet pipe.

9. Remove heat protector.

10. Remove exhaust adaptor.

11. Remove turbocharger assembly from exhaust

manifold.

MY2003 Euro-3

025R200006

INSTALLATION

1.Install turbocharger assembly to exhaust manifold,

tighten to the specified torque.

Torque : 27 N·m (2.8 kg·m/20 lb ft)

2.Install exhaust adaptor.

Torque : 27 N·m (2.8 kg·m/20 lb ft)

3.Install heat protector.

4.Install water outlet pipe with gasket.

Torque : 20 N·m (2.0 kg·m/14 lb ft)

5.Install turbocharger oil drain pipe.

Torque : 9 N·m (0.9 kg·m/78 lb in)

6.Install oil supply pipe to turbocharger.

1)Fill with 100 cc engine oil at the turbocharger oil

supply hole before installing the oil pipe.

2)Turn the turbocharger by hand to lubricate

turbocharger shaft.

3)Install oil supply pipe with new gasket to the

turbocharger and tighten oil supply pipe bolts to

the specified torque.

Torque :22 N·m (2.2 kg·m/16 lb ft) for M10

54 N·m (5.5 kg·m/40 lb ft) for M14

7.Install water inlet pipe with new gasket, tighten to

the specified torque.

Torque : 20 N·m (2.0 kg·m/14 lb ft)

8.Install intercooler assembly.

Refer to “Intercooler” in this manual.

9. Install air cleaner cover with air duct, connect both

side hoses.

10. Fill with engine coolant.

11. Install the battery and connect battery cables.

MY2003 Euro-3

025R200007

MY2003 Euro-3

025R200007

MY2003 Euro-3

025R200006

CYLINDER HEAD

012RW096

Legend

(1)Glow Plug

(2)Plate

(3)Cylinder Head Bolt

(4)Cylinder Head

NOTE:

•During disassembly, be sure that the valve train

components are kept together and identified so that

they can be re-installed in their original locations.

•Before removing the cylinder head from the engine

and before disassembling the valve mechanism, do

a compression test and note the results.

DISASSEMBLY

1.Injector Assy

2.Glow Plug and Glow Plug Connector

3.Cylinder Head Assembly

•Refer to “Cylinder Head Gasket”

CLEAN

•Cylinder head

Carefully remove all varnish, soot and carbon on

the bare metal. Do not use a motorized wire brush

on any gasket sealing surface.

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part

replacements if excessive wear or damage is

discovered during inspection.

1. Cylinder head gasket and mating surfaces for

leaks, corrosion and blow-by. If the gasket has

failed, determine the cause;

– Improper installation

– Loosen or warped cylinder head

– Insufficient torque on head bolts

– Warped cylinder block surface

2.Cylinder head for cracks, especially between valve

seats and in the exhaust ports.

3.Cylinder head deck for corrosion, sand particles in

head and porosity.

CAUTION: Do not attempt to weld the cylinder

head. Replace it.

4.Cylinder head lower surface for flatness.

Use a straight edge and a feeler gauge to measure

the cylinder head lower surface warpage.

If the measured values exceed the specified limit,

the cylinder head must be replaced.

Cylinder Head Lower Face Warpage:

Standard: 0.075 mm (0.0029 in) or less

Limit: 0.2 mm (0.0079 in)

Cylinder Head Height:

Standard: 95 mm (3.740 in)

5.Water jacket sealing plugs seating surfaces.

6.Use a straight edge and a feeler gauge to measure

the manifold cylinder head fitting face warpage.

If the measured values exceed the specified limit,

the manifold must be replaced.

Exhaust Manifold Warpage:

Standard: 0.05 mm (0.0020 in) or less

Limit: 0.20 mm (0.0079 in)

CAUTION: Do not attempt to weld the cylinder

head. Replace it.

REASSEMBLY

1.Cylinder Head

•Refer to “Cylinder Head Gasket”.

2. Glow Plug and Glow Plug Connector

•Tighten glow plugs.

Torque: 15 N·m (1.5 kg·m/11 lb ft)

011RW006

012RW053

CYLINDER HEAD GASKET

With

spacer type

Without

spacer type

011R200002

Legend

(1) Cylinder Head Noise Insulator Cover

(2) Insulator

(3) Bolt and Gasket

(4) Oil Seal

(5) Gasket

(6) Cylinder Head Cover

(7) Bolt, Stud and Rubber Mounting

(8) Injector Clamp

(9) Oil Rail

(10) Injector Assembly

(11) Camshaft Carrier

(12) Cylinder Head Bolt

(13) Cylinder Head Assembly

(14) Cylinder Head Gasket

(15) Cylinder Block

REMOVAL

1.Disconnect battery ground cable.

2.Drain engine coolant.

3.Remove air cleaner and air duct.

4.Remove intercooler assembly.

Refer to “Intercooler” in this manual.

5. Remove oil level gauge guide assembly.

6. Remove PCV hose.

7. Remove EGR vacuum hose.

8. Disconnect harness connector around the cylinder

head.

9. Remove A/C compressor assembly.

10. Remove A/C compressor bracket.

11. Remove generator assembly and take out fan belt.

12. Remove heat protector and remove valve

assembly.

13. Remove water hose and oil pipe from turbocharger.

14. Remove turbocharger assembly.

15. Remove water hose between thermostat and

radiator.

16. Remove cylinder head noise insulator cover.

NOTE: Do not make damage to the harness.

17. Remove high pressure pipe.

18. Remove timing belt cover.

19. Remove CMP sensor bracket.

20. Remove timing belt tensioner and remove timing

belt.

21. Remove camshaft pulley.

22. Remove front plate.

23. Remove water pipe between cylinder head and

water pump.

24. Remove fuel pipe between fuel pump and intake

manifold.

25. Remove fuel return pipe.

26. Remove intake manifold assembly.

27. Disconnect glow plug wiring and remove glow plug.

28. Remove cylinder head cover.

29. Drain oil from oil rail.

30. Disconnect injector harness connector.

31. Disconnect harness connector from oil pressure

sensor and oil temperature sensor on the oil rail.

32. Disconnect injector harness assembly.

33. Remove injector clamp.

34. Remove injector spacer (If equipped.).

35. Remove injector assembly.

36. Remove oil rail assembly.

37. Remove camshaft carrier.

38. Remove cylinder head assembly.

39. Remove cylinder gasket.

INSTALLATION

1. Install cylinder head gasket with top mark up.

NOTE: Determine cylinder head gasket grade by

measuring projection of piston head.

2. Selection cylinder head gasket.

1) Measure the piston head projection by dial

gauge.

2) Measure the projection of piston head at the

nearest possible point to the cylinder bore.

3) Obtain the largest measurement from among all

cylinders.

4) Determine cylinder head gasket grade by

maximum value of measuring projection of

piston head.

Legend

(1) Top Mark

(2) Grade Mark

012RW073

011RW043

Cylinder head gasket and piston projection mm

CAUTION:

•The projection of each piston should be 0.333

mm or more and less than 0.483 mm.

•Maximum difference in projection between

pistons should be less than 0.1 mm.

•If the piston projection is without standard,

reassemble the engine all over again.

3.Install cylinder head assembly, tighten bolts by

angular tightening method.

Torque:

1st step;49 N·m (5.0 kg·m/36 lb ft)

2nd step;60°

3rd step;60°

CAUTION: The cylinder head bolts cannot be

reused.

4.Install camshaft carrier assembly.

Refer to “Camshaft” in this manual.

5.Install oil rail and injector assembly.

Refer to “Oil rail and injector” in this manual.

6.Install injector harness to connect harness

connector.

Note: Apply liquid gasket (TB 1207B or equivalent) to

the rubber seal of the camshaft end, injector harness

gasket area and No. 1 camshaft bracket. Refer to the

Cylinder head cover.

7.Install cylinder head cover.

Torque: 9 N·m (0.9 kg·m/78 lb in)

8.Install glow plug to tighten specified torque.

Torque: 15 N·m (1.5 kg·m/11 lb ft) and connect

glow plug harness.

9.Install intake manifold.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

10.Install fuel return pipe.

11.Install fuel pipe in between fuel pump and intake

manifold.

12.Install water pipe in between cylinder head and

water pump.

Tighten flange bolt to the specified torque.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

13.Install front plate.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

14.Install camshaft pulley, tighten with angular

tightening method.

1st step40 N·m (4.1 kg·m/30 lb ft)

2nd step60°

NOTE:Apply engine oil to camshaft pulley bolt.

15.Align timing mark oil pump pulley and camshaft

pulley to front plate then put the timing belt and

tighten tensioner bolt.

Torque:20 N·m (2.0 kg·m/14 lb ft) for M8

50 N·m (5.1 kg·m/37 lb ft)

16.Install CMPsensor bracket.

17.Install timing belt cover.

Torque: 9 N·m (0.9 kg·m/78 lb in)

18. Fill with about 300 cc of engine oil from the high

pressure oil pipe installing port of oil rail using an oil

filler.

If assembled without filling the oil rail with oil, the

time for engine start will be longer.

19. Immediately install high pressure oil pipe to tighten

with specified torque.

Torque: 78 N·m (8.0 kg·m/58 lb ft)

20. Install cylinder head noise insulator cover.

Torque: 9 N·m (0.9 kg·m/78 lb in)

Grade A Grade B Grade C

011RW042

Grade Piston projection Gasket

thickness

A more 0.333 to less 0.383 1.35

B more 0.383 to less 0.433 1.40

C more 0.433 to less 0.483 1.45

Legend

(1)Cylinder Head Noise Insulator Cover

(2)Insulator

(3)Bolt

(4)Oil Seal

(5)Gasket

(6)Cylinder Head Cover

(7)Bolt, Stud and Rubber Mounting

21.Install water hose between thermostat and radiator.

22.Install turbocharger assembly to exhaust manifold.

Torque: 27 N·m (2.8 kg·m/20 lb ft)

23.Install water hose and oil pipe for turbocharger.

24.Install exhaust valve assembly and heat protector.

Torque: 57 N·m (5.8 kg·m/42 lb ft) for valve

Torque: 9 N·m (0.9 kg·m/78 lb in) for heat protector

25.Install generator assembly.

Torque: 40 N·m (4.1 kg·m/30 lb ft) for ACG bracket

Torque: 40 N·m (4.1 kg·m/30 lb ft) between ACG and

bracket

Torque: 20 N·m (2.0 kg·m/14 lb ft) between ACG

and adjuster plate

26.Fix the A/C compressor bracket and install A/C

compressor.

Torque: 46 N·m (4.7 kg·m/34 lb ft) for A/C bracket

Torque: 20 N·m (2.0 kg·m/14 lb ft) for belt tensioner

27.Reconnect harness connector around cylinder

head.

28.Connect EGR vacuum hose.

29.Install oil level gauge guide assembly.

Tighten nuts lower portion and tighten bolt.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

30.Install intercooler assembly.

Refer to “Intercooler” in this manual.

31. Install air duct between air cleaner and

turbocharger.

32. Fill engine coolant.

33. Reconnect battery.

MY2003 Euro-3

025R200007

MY2003 Euro-3

025R200006

010R200006

CAMSHAFT

With

spacer type

Without

spacer type

11 10 9

012R200004

Legend

(1) Nut and Washer

(2) Injector Clamp

(3) Nut

(4) Bolt

(5) Oil Rail Assembly

(6) Spacer (If equipped) and Bolt

(7) Injector Assembly

(8) Camshaft

(9) Camshaft Carrier

(10) Plug

(11) Oil Seal

(12) Camshaft Bracket

(13) Gasket

(14) Gasket

DISASSEMBLY

1. Injector clamp

2. Injector assembly

3. Oil rail assembly

4. Camshaft bracket

5. Camshaft

6. Oil seal

7. Plug

NOTE: Before starting disassembly above, drain oil

from oil rail to prevent oil from entering the cylinder.

REASSEMBLY

1. Camshaft

1) Before reassembling the camshaft to the

camshaft carrier, align the holes between the

main gear and the sub gear on the intake side of

the camshaft gear with a special tool.

2) Set lock pin to gear holes from sub gear side.

Camshaft Gear Tool: 5-8840-2591-0

Legend

(1) Locking pin

(2) Special tool

3) Apply engine oil to the camshaft gear tooth.

4) Apply engine oil to the journal on the camshaft

carrier.

5) Align the timing mark on the intake and exhaust

camshaft gear and put on the camshaft carrier.

Legend

(1) Locking pin

(2) Intake side camshaft gear

(3) Exhaust side camshaft gear

6) Apply liquid gasket (TB1207B or equivalent) to

No. 1 camshaft bracket matching surface.

7) Set No. 1 to No. 5 camshaft bracket on camshaft

carrier.

8) Temporarily tighten bracket bolts B and C.

Temporal Torque: 20 N·m (2.0 kg·m/14 lb ft)

9) Put gasket on the cylinder head.

10) Install camshaft carrier onto the cylinder head

and tighten bolts to specified torque.

Torque: A; 22 N·m (2.2 kg·m/16 lb ft)

B; 38 N·m (3.9 kg·m/28 lb ft)

C; 22 N·m (2.2 kg·m/16 lb ft)

D; 38 N·m (3.9 kg·m/28 lb ft)

•Remove locking pin.

014RW183

014RW184

AA AA A

AAAA

011RW035

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part

replacements if excessive wear or damage is

discovered during inspection.

1. Camshaft Journal diameter

1) Use a micrometer to measure each camshaft

journal diameter in two directions (1) and (2). If

the measured value is less than the specified

limit, the camshaft must be replaced.

Standard: 29.939 – 29.96 mm (1.1787 – 1.1795 in)

Limit: 29.84 mm (1.17 in)

2. Cam Height

1) Measure the cam height (H) with a micrometer.

If the measured value is less than the specified

limit, the camshaft must be replaced.

Standard: IN 46.62 mm (1.8354 in)

EX 46.72 mm (1.8394 in)

Limit: IN 46.57 mm (1.8335 in)

EX 46.67 mm (1.8374 in)

3. Cam Run-Out

1) Mount the camshaft on V-blocks.

2) Measure the cam height (H) with a micrometer.

If the measured value is less than the specified

limit, the camshaft must be replaced.

Standard: 0.02 mm (0.0008 in) or less

Limit: 0.10 mm (0.0039 in)

4. Camshaft oil clearance

1) Clean the camshaft, camshaft bracket and

camshaft carrier.

2) Put camshaft carrier on the cylinder head.

3) Put camshaft on the camshaft carrier.

4) Put plastigauge on the camshaft journal.

5) Install camshaft bracket to original position and

tighten bolts to specified torque in the numerical

order shown in the illustration.

Torque: A; 22 N·m (2.2 kg·m/16 lb ft)

B; 38 N·m (3.9 kg·m/28 lb ft)

C; 22 N·m (2.2 kg·m/16 lb ft)

D; 38 N·m (3.9 kg·m/28 lb ft)

(1) Ft Rr

(2)

014RW179

012RW059

014RW171

AA AA A

AAAA

110RW035

NOTE: Do not allow the camshaft to rotate.

6) Remove the camshaft bracket and measure the

plastigauge width and determine the oil

clearance. If the oil clearance exceeds the

specified limit, replace the camshaft carrier

and/or camshaft.

Oil clearance.

Standard: 0.040 – 0.082 mm (0.0016 – 0.0032 in)

Limit: 0.12 mm (0.0047 in)

7) Clean the plastigauge from the camshaft bracket

and camshaft carrier.

5. Camshaft thrust clearance.

1) Clean the camshaft, camshaft bracket and

camshaft carrier.

2) Put camshaft carrier on the cylinder head.

3) Put camshaft on the camshaft carrier.

4) Put plastigauge on the camshaft journal.

5) Install camshaft bracket to original position and

tighten bolts to specified torque in the numerical

order shown in the illustration.

Torque: A; 22 N·m (2.2 kg·m/16 lb ft)

B; 38 N·m (3.9 kg·m/28 lb ft)

C; 22 N·m (2.2 kg·m/16 lb ft)

D; 38 N·m (3.9 kg·m/28 lb ft)

6) Use a dial indicator to measure the camshaft

thrust clearance. If the camshaft thrust

clearance exceeds the specified limit, replace

the camshaft carrier and/or camshaft.

Camshaft thrust clearance

Standard: 0.1 mm (0.0002 in)

Limit: 0.2 mm (0.0078 in)

20 8

23 22

16 1

24 21

011RW041

014RW185

AA AA A

AAAA

011RW035

20 8

23 22

16 1

24 21

011RW041

014RW001

TIMING GEAR

REMOVAL

1. Loosen fixing bolt for generator and remove

generator assembly.

2. Remove fixing nuts, then remove cooling fan

assembly and fan pulley.

3. Remove crankshaft damper pulley.

4. Belt cover

1) Disconnect harness connector of CMP

(camshaft position) sensor.

2) Remove CMP sensor.

3) Remove belt cover.

5. Loosen belt tensioner to remove timing belt.

6. Remove camshaft pulley.

7. Remove high pressure oil pump pulley.

8. Remove front plate.

9. Remove vacuum pump.

10. Remove power steering pump.

11. Remove timing gear case cover assembly.

12. Idle gear A.

1) Set two bolts to sub gear of idle gear A and turn

it to align the tooth of idle gear A then lock them

by bolt as show in the illustration.

2) Remove idle gear A fixing bolts.

3) Remove idle gear A.

Legend

(1) Sub-Gear

(2) Main Gear

(3) Bar

(4) Locking Bolt

020RW028

Legend

(1) Idle Gear A

(2) High Pressure Oil Pump Gear

(3) Vacuum Pump Gear

(4) Power Steering Pump Gear

(5) Balance Gear LH

(6) Idle Gear C

(7) Crankshaft Gear

(8) Balance Gear RH

(9) Idle Gear B

014RW177

Legend

(1) Bolt

(2) Retainer

(3) Idle Gear A

(4) Idle Gear A Shaft

(5) Align Mark

(6) Crankshaft Gear

(7) O-Ring

13. Idle gear C

1) Use the special tool on idle gear C, turning the

sub gear to align the teeth, then set lock pin.

2) Remove idle gear C fixing bolt then remove the

idle gear C with flange.

Camshaft Gear Tool : 5-8840-2591-0

Legend

(1) Lock pin

(2) Camshaft Gear Tool

Legend

(1) Bolt

(2) Retainer

(3) Idle Gear C

(4) Idle Gear C Shaft

(5) Align Mark

(6) Align Mark

(7) Idle Gear A

(8) Balance Shaft Gear LH

(9) Timing Mark

14. Idle gear B

1) Loosen idle gear B fixing bolt to remove idle

gear B with flange.

Legend

(1) Bolt

(2) Retainer

(3) Idle Gear B

(4) Idle Gear B Shaft

(5) Align Mark

014R200007

014RW181

12345

014RW175

014R200008

15. High pressure oil pump

1) Remove oil pump gear fixing bolt then remove

oil pump.

Legend

(1) O-Ring

(2) High Pressure Oil Pump Gear

(3) Bolt

(4) Timing Mark

16. Remove balance shaft gear LH. and RH.

17. Remove crankshaft gear.

INSTALLATION

1. Crankshaft gear

1) Force key into the crankshaft and insert

crankshaft gear with the crankshaft gear key

groove set on the key.

Legend

(1) Crankshaft Gear Installer

(2) Crankshaft Gear

2. Balance shaft gear

1) Install the balance shaft gear RH to balance

shaft, tighten center bolt to the specified torque.

Torque : 32 N·m (3.3 kg·m/24 lb ft)

2) Install thrust plate for balance shaft LH before

installing the balance shaft gear LH.

Torque : 25 N·m (2.5 kg·m/18 lb ft)

3) Install balance shaft gear LH to balance shaft,

tighten center bolt to the specified torque.

Torque : 32 N·m (3.3 kg·m/24 lb ft)

Legend

(1) Center Bolt

(2) Plate

(3) Balance Shaft Gear RH

(4) Timing Mark

GEAR:O/PUMP

IDLE GEAR A

040RW005

012RW066

014RW173

3. Idle gear A

1) Insert idle gear A shaft to align alignment mark

between idle gear A shaft and timing gear case.

2) Apply engine oil to the shaft surface.

3) Install the idle gear A to align the timing mark

with the crankshaft gear.

4) Install the flange, tighten bolts to the specified

torque.

Torque: 25 N·m (2.5 kg·m/18 lb ft)

Legend

(1) Bolt

(2) Retainer

(3) Idle Gear A

(4) Idle Gear A Shaft

(5) Align Mark

(6) Crankshaft Gear

(7) O-Ring

NOTE: Conform not difference timing marks between

each others.

4. Idle gear C

1) Insert idle gear C shaft to align alignment mark

between idle gear C shaft and timing gear case.

2) Apply engine oil to the shaft surface.

3) Align timing mark on idle gear C with balance

shaft gear LH and idle gear A timing marks, then

insert idle gear C.

4) Set position of idle gear C flange with a dowel

pin, tighten bolt to the specified torque.

Torque: 25 N·m (2.5 kg·m/18 lb ft)

Legend

(1) Bolt

(2) Retainer

(3) Idle Gear C

(4) Idle Gear C Shaft

(5) Align Mark

(6) Align Mark

(7) Idle Gear A

(8) Balance Shaft Gear LH

(9) Timing Mark

5. Idle gear B

1) Insert idle gear B shaft to align alignment mark

between idle gear B shaft and timing gear case.

2) Apply engine oil to the shaft surface.

3) Align timing mark on idle gear B with balance

shaft gear RH and crankshaft gear timing marks,

then insert idle gear B.

4) Install flange and tighten the bolt to the specified

torque.

Torque: 51 N·m (5.2 kg·m/38 lb ft)

014R200007

12345

014RW175

Legend

(1) Bolt

(2) Retainer

(3) Idle Gear B

(4) Idle Gear B Shaft

(5) Align Mark

6. High pressure oil pump

1) Install O-ring on the high pressure oil pump.

2) Install the high pressure oil pump to the timing

gear case, tighten the nut to the specified

torque. Apply Loctite No. 262 to the stud bolts.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

NOTE: Be sure to set O-ring completely.

Legend

(1) O-ring (large)

(2) High pressure oil pump

(3) Nut

(4) O-ring (small)

7. High pressure oil pump

1) Install O-ring on the oil pump shaft with grease

and install the gear with the idle gear A timing

mark set at the oil pump gear timing mark.

2) Tighten center bolt to the specified torque.

Torque: 75 N·m (7.6 kg·m / 55 lb ft)

NOTE: Be sure to align timing marks with each other.

Legend

(1) O-ring

(2) High Pressure Oil Pump Gear

(3) Center Bolt

(4) Timing Mark

8. Remove lock from idle gear.

1) Remove lock bolt from idle gear A and remove

lock pin from idle gear C.

9. Timing gear case assembly

1) Clean fixing surface of timing gear case.

2) Install the gasket on the idle gear rear side end.

3) Apply liquid gasket (TB1207C or equivalent) to

the timing gear case fitting surface.

NOTE: Be sure to apply liquid gasket evenly.

4) Install timing gear case and tighten bolts to the

specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

NOTE: Must install within 5 minutes after applying liquid

gasket.

014R200008

040RW007

GEAR:O/PUMP

IDLE GEAR A

040RW005

10. Vacuum pump

1) Install vacuum pump and tighten bolts to

specified torque.

Torque: 25 N·m (2.5 kg·m / 18 lb ft)

2) Install noise insulator cover.

11. Power steering pump (P/S)

1) Install P/S pump.

Torque: 22 N·m (2.2 kg·m / 16 lb ft)

12. Install front plate.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

13. High pressure oil pump pulley.

1) Install oil pump pulley and tighten to specified

torque.

Torque:10 N·m (1.0 kg·m / 87 lb in)

2~2.5mm

Apply liquid gasket around inside

of the bolt hole

Bolt hole

Inside

Outside

F06HX00001

052RW001

430RW017

012RW035

14. Camshaft pulley

1) Align TDC mark with crankshaft pulley and gear

case cover.

2) Set camshaft stopper on the end of intake and

exhaust camshaft.

Camshaft Stopper: 5-8840-2592-0

3) Install key to camshaft and install camshaft

pulley.

4) Apply engine oil to camshaft pulley fixing bolt

and tighten bolt with angular tightening method.

First step: 40 N·m (4.1 kg·m / 30 lb ft)

Second step: 60° to 90°

15. Timing belt

1) Install tensioner and tighten the bolt temporarily.

2) Align timing mark with camshaft pulley timing

mark and timing gear case timing mark.

3) Set No.1 cylinder TDC position.

4) Install the timing belt in the following order

camshaft pulley, oil pump pulley, tensioner.

NOTE:

1) It is recommended for easy installation that the belt

be secured with a double clip after it is installed to

each pulley.

2) The “ISUZU” mark should be read from the front of

the engine when installing the timing belt.

5) Install the belt tensioner.

6) Conform not phase difference each pulley.

7) Tension the timing belt with two turns of the

crankshaft.

8) Tighten the tensioner bolt in order A to B to the

specified torque.

Torque: Bolt A 50 N·m (5.1 kg·m/37 lb ft)

Bolt B 20 N·m (2.0 kg·m/14 lb ft)

Legend

(1) Align Mark

(2) Camshaft Pulley

(3) Timing Belt

(4) Oil Pump Pulley

(5) Tension Bolt B

(6) Tensioner Assy

(7) Tensioner Bolt A

(8) Tensioner Spring

16. CMP sensor bracket

1) Install CMP sensor bracket and tighten bolt to

the specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

17. Timing belt cover

1) Install timing belt cover and tighten bolt to the

specified torque.

Torque: 9 N·m (0.9 kg·m / 78 lb in)

2) Tighten CMP sensor to the specified torque.

Torque: 9 N·m (0.9 kg·m / 78 lb in)

012RW036

012RW099

F06R200006

18. Crankshaft damper pulley

1) Insert damper pulley with the crankshaft key

groove set on the key.

2) Tighten damper pulley bolt to the specified

torque.

Torque: 216 N·m (22 kg·m / 159 lb ft)

19. Cooling fan Assembly

1) Install the cooling fan assembly to the fan pulley,

tighten the nuts to the specified torque.

Torque: 8 N·m (0.8 kg·m / 69 lb in)

20. AC generator drive belt.

1) Temporarily tighten generator fixing bolts and

belt tensioner adjustment plate.

2) Tension the generator drive belt then tighten the

generator fixing bolt.

Torque: 40 N·m (4.1 kg·m / 30 lb ft)

3) Tighten the belt tensioner adjustment plate bolt.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

012RW039

014RW163

012RW032

VALVE STEM SEAL, VALVE SPRING AND ADJUSTER

REMOVAL

1.Disconnect battery ground cable.

2.Drain engine coolant.

3.Remove the air duct from between air cleaner and

turbocharger.

4.Remove intercooler assembly.

Refer to “Intercooler” in this manual.

5. Remove oil level gauge guide assembly.

6. Disconnect PCV hose.

7. Disconnect EGR vacuum hose.

8. Disconnect harness connectors around the cylinder

head such as the injector, CMP sensor, MAP

sensor, EGR sensor, EVRV, IAT sensor, A/C

compressor, TP stepping motor, TP sensor and fuel

temperature sensor etc.

9. Remove A/C compressor assembly.

10. Remove A/C compressor bracket.

11. Remove generator assembly and take out drive

belt.

12. Remove heat protector, remove exhaust valve

assembly.

13. Remove water cooling hose and lubrication pipe for

turbocharger.

14. Remove turbocharger assembly.

15. Remove hose between thermostat and radiator.

16. Remove noise insulator cover of cylinder head.

NOTE: Do not damage injector harness.

17. Remove high pressure oil pipe.

18. Remove timing belt cover.

19. Remove CMP sensor bracket.

20. Remove timing belt tensioner then remove timing

belt.

21. Remove camshaft pulley.

22. Remove front plate.

23. Remove engine coolant pipe between cylinder

head and water pump.

011RW031

Legend

(1) Adjuster

(2) Tappet

(3) Split Collar

(4) Spring Seat Upper

(5) Valve Spring

(6) Spring Seat Lower

(7) Valve Stem Seal

(8) Valve Guide

(9) Valve Seat

(10) Valve

24.Remove fuel pipe between fuel pump and intake

manifold.

25.Remove fuel return pipe from rear of cylinder head.

26.Remove intake manifold assembly.

27.Disconnect glow plug harness and remove glow

plug.

28.Remove cylinder head cover.

29.Remove injector harness connector.

30.Disconnect harness connector from oil pressure

sensor and oil temperature sensor on the oil rail.

31.Remove injector harness assembly.

32.Remove injector clamp.

33.Remove injector is fixed bolts.

34.Remove injector assembly.

35.Remove oil rail.

36.Remove camshaft carrier assembly with camshaft.

37.Remove cylinder head assembly.

38.Disassemble valve spring according to the following

method.

1)Use valve spring compressor then remove split

collars.

2)Valve spring compressor: 5-8840-2441-0

NOTE: Put removed valve spring in order of cylinder

number.

39.Valve stem seal.

1)Use a screwdriver or pliers to remove valve

stem seal.

NOTE: Do not reuse removed valve stem seal.

INSPECTION AND REPAIR

Make the necessary adjustments, repairs and part

replacements if excessive wear or damage is

discovered during inspection.

Valve spring

CAUTION: Visually inspect the valve springs and

replace them if damage or abnormal wear is

evident.

1. Free height

1) Measure the free height of the springs. The

springs must be replaced if the height is below

the specified limit.

Standard: 45.85 mm (1.8051in)

Limit: 43.9 mm (1.7283 in)

2. Squareness

1) Measure the valve spring squareness with a

steel square.

2) Replace the valve springs if the measured value

exceeds the specified limit.

Limit: 1.6 mm (0.063 in)

014rw042

014rs004

014rs005

3.Spring tension

1)Use a spring tester to compress the springs to

the installed height. Measure the compressed

spring tension.

2)Replace the springs if the measured tension is

below the specified limit.

Standard: 236.0 N (24 kg/53 lb)

Limit: 205.0 N (21 kg/46 lb)

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.

1. Valve Guide Clearance

1) Measure the valve stem diameter with a

micrometer.

If the valve stem diameter is less than the

specified limit, the valve and the valve guide

must be replaced as a set.

Diameter of Valve stem:Inlet

Standard: 6.959 – 6.977 mm (0.2740 – 0.2747 in)

Limit: 6.92 mm (0.2724 in)

Diameter of Valve stem:Exhaust

Standard: 6.952 – 6.97 mm (0.2737 – 0.2744 in)

Limit: 6.90 mm (0.2717 in)

2) Measure the inside diameter of the valve guide

with a micrometer.

3) Subtract the measured outer diameter of the

valve stem from the measured inner diameter of

the valve guide.

If the valve exceeds the specified limit, the valve

and the valve guide must be replaced as a set.

Inlet clearance

Standard: 0.023 – 0.053 mm (0.0009 – 0.0021 in)

Limit: 0.19 mm (0.0075 in)

Exhaust clearance

Standard: 0.03 – 0.063 mm (0.0012 – 0.0025 in)

Limit: 0.20 mm (0.0079 in)

014RS006

014RS007

Valve Guide Replacement

1. Using the special tool, drive out the valve guide

from the combustion chamber side.

Valve guide replacer: 9-8523-1212-0

2. Apply engine oil to the outside of the valve guide.

Using the special tool, drive in a new valve guide

from cylinder head upper face side, and check the

valve guide height.

Valve guide replacer: 9-8523-1212-0

Height: 8.0 mm (0.315 in)

NOTE: If the valve guide has been removed, both the

valve and the valve guide must be replaced as a set.

Valve Thickness

1. Measure the valve thickness.

2. If the measured value is less than the specified

limit, the valve and the valve guide must be

replaced as a set.

Inlet

Standard: 1.2 mm (0.0472 in)

Limit: 1.1 mm (0.0433 in)

Exhaust

Standard: 1.2 mm (0.0472 in)

Limit: 1.1 mm (0.0433 in)

Contact surface angle on valve seat on

valve

1. Measure contact surface angle on valve seat.

2. If the measured value exceeds the limit, replace

valve, valve guide and valve seat as a set.

Standard: 68°

011RW001

012RW052

012RW060

014RW018

Valve Depression

1. Measure the valve stem height from the upper

surface of the cylinder head as shown in the

illustration.

Standard:

Intake side 35.59 mm (1.4012 in)

Exhaust side 35.49 mm (1.3972 in)

Limit:

Intake side 35.74 mm (1.4071 in)

Exhaust side 35.64 mm (1.4031 in)

Legend

(1) Intake Side

(2) Exhaust Side

Valve Contact Width

1. Check the valve contact faces for roughness and

unevenness. Make the valve contact surfaces

smooth.

2. Measure the valve contact width.

If the measured value exceeds the specified limit,

the valve seat insert must be replaced.

Inlet

Standard: 2.1 mm (0.0827 in)

Limit: 2.6 mm (0.1024 in)

Exhaust

Standard: 2.0 mm (0.0787 in)

Limit: 2.5 mm (0.0984 in)

Valve Seat Insert Replacement

Valve Seat Insert Removal

1. Arc weld the entire inside circumference of the

valve seat insert.

2. Allow the valve seat insert to cool for a few minutes.

This will invite contraction and make removal of the

valve seat insert easier.

3. Use a screwdriver to pry the valve seat insert free.

Take care not to damage the cylinder head.

4. Carefully remove carbon and other foreign material

from the cylinder head insert bore.

011RW044

014RS015

Valve Seat Insert Installation

1. Carefully place the attachment (1) (having a smaller

outside diameter than the valve seat insert) on the

valve seat insert (2).

Legend

(1) Attachment

(2) Valve Seat Insert

(3) Bench Press

NOTE: The smooth side of the attachment must contact

the valve seat insert.

2. Use a bench press (3) to gradually apply pressure

to the attachment and press the valve seat insert

into place.

Note: Do not apply an excessive amount of pressure

with the bench press. Damage to the valve seat insert

will result.

Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert

surface.

2. Use a valve cutter (15°, 45° and 75° blades) to

minimize scratches and other rough areas. This will

bring the contact width back to the standard value.

Remove only the scratches and rough areas. Do

not cut away too much. Take care not to cut away

unblemished areas of the valve seat surface.

Valve Seat Angle: 45°

NOTE: Use an adjustable valve cutter pilot.

Do not allow the valve cutter pilot to wobble inside the

valve guide.

3. Apply abrasive compound to the valve seat insert

surface.

4. Insert the valve into the valve guide.

5. Turn the valve while tapping it to fit the valve seat

insert.

6. Check that the valve contract width is correct.

7. Check that the valve seat insert surface is in

contact with the entire circumference of the valve.

012RW055

150°

90°

30°

012RW056

014RS014

INSTALLATION
1.Valve stem seal
1)Use the special tool to install the stem seal to the
valve guide.
Stem Seal Installer: 5-8840-2033-0
2.Valve spring.
1)Install the lower valve seat spring, valve spring,
then the upper valve spring seat.
2)Use valve spring compressor to compress the
spring then install the split collar.
Valve spring compressor: 5-8840-2441-0
NOTE: Make sure the split collar installs completely.
3.Install cylinder head assembly.
Refer to “Cylinder Head” in this manual.
4.Install the camshaft carrier with camshaft.
Refer to “Camshaft” in this manual.
5.Install oil rail assembly.
Refer to “Oil rail and injector” in this manual.
6.Install injector assembly.
Refer to “Oil rail and injector” in this manual.
7.Install the injector harness assembly.
Refer to “Injector” in this manual.
8.Reconnect harness connecter to oil pressure
sensor and oil temperature sensor on the oil rail.
9.Reconnect Injector harness connecter to injector.
Refer to “Injector” in this manual.
10.Install cylinder head cover with gasket.
Refer to “Cylinder Head Cover” in this manual.
11.Install glow plug with specified torque.
Torque: 15 N·m (1.5 kg·m / 11 lb ft)
12.Install the intake manifold assembly.
Refer to “Intake Manifold” in this manual.
13.Install the fuel pipe.
14.Install the water pipe between the cylinder head
and water pump.
Torque: 20 N·m (2.0 k·m / 14 lb ft)
15.Install the front plate.
16.Install the camshaft pulley.
Refer to “Timing Gear” in this manual.
17.Install timing belt and set the tensioner.
Refer to “Timing Belt” in this manual.
18.Install CMPsensor bracket.
Torque: 20 N·m (2.0 kg·m / 14 lb ft)
19.Install timing belt cover.
Torque: 9 N·m (0.9 kg·m / 78 lb in)
20.Fill the oil rail with engine oil then immediately
install the high pressure oil pipe with the specified
torque.
Torque: 78 N·m (8.0 kg·m / 58 lb ft)
21.Install the noise insulator cover.
22.Reconnect hose between thermostat and radiator.
23.Install turbocharger assembly.
Refer to “Turbocharger” in this manual.
24.Install water hose and oil pipe for turbocharger.
Refer to “Turbocharger” in this manual.
25.Install the valve assembly and install heat protector.
26.Install generator and set the fan belts.
27.Install A/C compressor bracket, compressor
assembly and set drive belt.
28.Reconnect harness connector around cylinder
head.
29.Reconnect vacuum hose to EGR valve.
30.Reconnect PCV hose.
31.Install oil level gauge guide assembly.
32.Install intercooler assembly.
Refer to “Intercooler” in this manual.
33. Install the air duct assembly.
34. Fill engine coolant.
35. Connect battery ground cable.
014RW042

VALVE CLEARANCE ADJUSTMENT

NOTE:

1.Valve clearance should be inspected and adjusted

while the engine is cool.

2.The tightening of the camshaft bearing cap and

camshaft carrier assembly should be checked

before inspecting and adjusting valve clearance.

INSPECTION

1.Remove cylinder head noise insulator cover and

cylinder head cover.

Refer to “Cylinder Head” in this manual.

2. Disconnect all harness connecters of the injector

and remove harness assembly.

3. Drain oil from oil rail assembly.

4. Remove injector clamp nuts and fixing bolts to take

out injector assembly.

5. Loosen oil rail bolts, remove oil rail assembly.

6. Set cylinder No.1 to the TDC at the compression

stroke. Make sure that there is play in cylinder No.1

tappets on inlet and exhaust sides and that there is

no play in cylinder No.4 tappets.

7. Measure valve clearance at No.1 TDC (Refer to the

black circles indicated in the illustration).

Standard Valve clearance:

Intake valve: 0.15 mm (0.0059 in) ± 0.05 mm (0.0020 in)

Exhaust valve: 0.25 mm (0.0098 in) ± 0.05 mm (0.0020 in)

8. Turn the crankshaft one turn to set No.4 cylinder

TDC at the compression stroke.

9. Measure valve clearance at No.4 TDC (Refer to the

black circles indicated in the illustration).

Standard Valve clearance:

Intake valve: 0.15 mm (0.0059 in) ± 0.05 mm (0.0020 in)

Exhaust valve: 0.25 mm (0.0098 in) ± 0.05 mm (0.0020 in)

10. If measured value is outside standard value,

readjust the valve clearance.

ADJUSTMENT

For valve clearance adjustment, follow the procedure

given below.

1. Set cylinder No.1 or No.4 to the TDC at the

compression stroke.

Set the valve clearance adjusting tool on the tappet

requiring adjustment.

After making sure of the correct setting of the

special tool, depress the tappet by turning the bolt.

Valve Clearance Adjusting Tool: 5-8840-2590-0

NOTE: Before depressing the tappet, set the tappet

notch in the direction where adjuster can be easily

taken out.

2. Take out the adjuster using a small screw driver and

finger magnet.

No.1

No.2

No.1 TDC

No.3 No.4

EXH

011RW045

No.1

No.2

No.4 TDC

No.3 No.4

EXH

011RW046

014RW150

Techline

3.Determine the thickness of the adjuster as follows.

1)Measure the thickness of the removed adjuster

with a micrometer.

2)Calculate the thickness of a new adjuster.

Calculation

TA:Thickness of new adjuster

M: Valve clearance measurement.

TO:Thickness of the removed adjuster

For intake side:TA=TO+(M–0.15) mm

For exhaust side:TA=TO+(M–0.25) mm

Select a new adjuster whose thickness is as

close to the estimated value as possible.

4.Install oil rail and tighten it temporarily.

5.Install injector assembly.

NOTE:

1)Do not forget to insert the O-ring between injector

and oil rail.

2)Install the injector to the same position as before

removal.

6.Install the injector fixing bolts and temporarily

tighten.

7.Install the injector clamp and tighten temporarily.

8.Tighten injector fixing bolts to the specified torque.

Torque: 6.5 N·m (0.7 kg·m / 61 lb in)

9.Tighten injector clamp nut to the specified torque

with special method.

Torque: 30 N·m (3.1 kg·m /22 lb ft) then loosen one

turn and tighten again to specified torque.

Torque: 25 N·m (2.5 kg·m / 18 lb ft)

10. Tighten oil rail to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

11.Install injector harness and reconnect connector.

12.Install cylinder head cover.

Refer to ”Cylinder Head” in this manual.

13.Fill with about 300cc of engine oil at the high

pressure oil pipe installation port on the oil rail using

an oil filler.

If assembled without filling the oil rail with oil, the

time for engine starting will be longer.

14.Immediately install high pressure oil pipe to tighten

with specified torque.

Torque: 78 N·m (8.0 kg·m / 58 lb ft)

15.Install cylinder head noise insulator cover.

Refer to “Cylinder Head” in this manual.

Techline

OILRAILAND INJECTOR

REMOVAL

Prior to removal, be sure to confirm and record the

group code of the injector installed using Tech2.

1.Disconnect battery ground cable.

2.Remove air cleaner cover and air duct.

3.Remove intercooler.

Refer to “Intercooler” in this manual.

4.Remove PCV hose and pipe.5. Remove cylinder head noise insulator cover.

6.Remove high pressure oil pipe.

CAUTION:

1) Sleeve nut should be loosened with cloth tied

around it to prevent oil from spurting due to the

remaining pressure.

2) The high pressure pipe should be disconnected

with a cloth tied around the intake manifold

glow plug to prevent oil from flowing out of the

oil rail.

7. Loosen eye bolt of fuel pipe at fuel pump side.

NOTE: Cloth should be put around the loosened eye

bolt to prevent fuel from flowing out.

8. Remove fuel return hose at chassis side.

9. Remove PCV hose to cylinder head cover.

10. Remove cylinder head cover.

11. Drain the oil from oil rail assembly.

12. Record the identification marking of injector for

each cylinder which is indicated on the upper

portion of injector.

There are nine kinds of identification marking

available, one alphabet letter and one numeral

letter.

In case three kinds of markings are given, one

alphabet letter (sometimes printed) and one

numeral letter, top priority is given to the one

alphabet letter and one numeral letter.

With

spacer type

Without

spacer type

012R200005

Legend

(1) Injector Clamp

(2) Injector Assembly

(3) Oil Rail Assembly

(4) Camshaft Bracket

(5) Camshaft

(6) O-Ring

(7) Drain Plug

Techline

(For example)

If you find identification marking “A”, “RA” and “2”

on the injector, you can use injector grade “A”. (The

“RA” is sometimes printed, but can be ignored)

Legend

(1)Part Number

(2)Two Alphabet Letter

(3)Serial Number

(4)Bar Code

(5)One Alphabet Letter

(6)One Numeral Letter

13.Remove harness connector from each injector.

14.Loosen nuts and bolts for oil rail.

15.Remove injector fixing bolts.

16.Remove injector clamp.

17.Remove injector assembly.

NOTE: Do not drop O-ring

INSTALLATION

1.Install oil rail, tighten temporarily

2.Install injector assembly.

NOTE: Do not forget to install O-ring between injector

and oil rail.

3.Apply oil and install injector fixing bolts, tighten

temporarily.

4.Apply oil and install injector clamp, tighten nut

temporarily.

5.Tighten injector bolts to the specified torque.

Torque: 7 N·m (0.7 kg·m / 61 lb in)

6.Tighten injector clamp nut to the specified torque

with special method.

Torque: 30 N·m (3.1 kg·m / 22 lb ft) then loose a

time again tighten as following torque.

Torque: 25 N·m (2.5 kg·m / 18 lb ft)

7.Tighten oil rail to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

8.Install injector harness assembly, reconnect

harness connecter to injector.

9.Record the identification marking of injector for

each cylinder that is indicated on the upper portion

of injector.

Legend

(1)Part Number

(2)Two Alphabet Letter

(3)Serial Number

(4)Bar Code

(5)One Alphabet Letter

(6)One Numeral Letter

10.Install cylinder head assembly.

Refer to “Cylinder Head” in this manual.

11. Fill with about 300cc of engine oil from the high

pressure oil pipe at the high pressure oil pipe

installation port on the oil rail using an oil filler.

If assembled without filling the oil rail with oil, the

055RW021-1

Identification One Alphabet One Numeral

Marking Letter Letter

Grade A1

AA2

BB2

CC2

time for engine starting will be longer.

12.Immediately install high pressure oil pipe and

tighten to specified torque.

Torque: 78 N·m (8.0 kg·m / 58 lb ft)

13.Install cylinder head noise insulator cover.

Refer to “Cylinder Head” in this manual.

14.Install intercooler assembly.

Refer to “Intercooler” in this manual.

15.Install air cleaner cover and air duct.

16.Use TECH2 to rewrite injector data to ECM.

For rewriting method refer to section “Data

Programming in Case of ECM Change” of 6E 4JX1

engine driveability and emissions in this manual.

NOTE:

1) On completion of servicing, bleed air from the

engine inside fuel passage by means of the priming

pump. (The priming pump should be operated more

times than in the case of conventional engines.)

2) As air is in the oil rail, it takes more time to start the

engine. Rough idling may occur while the air is

being bled completely after starting the engine, but

it does not indicate trouble.

The air will be bled and normal engine status will be

reached while the vehicle is driven for about 5 km

or engine is operated for about 5 minutes at 1500 to

2000 rpm.

3) The injector spare part will be provided for group

number B1, B2 and B3 only.

CRANK CASE

REMOVAL

1.Drain engine oil.

2.Remove transmission assembly.

3.Remove crankshaft damper pulley.

4.Remove timing belt cover, timing belt, pulley and

front plate.

5.Remove timing gear case cover.

6.Remove timing gears.

NOTE: Do not forget to set lock bolt for idle gear Aand

lock pin for idle gear C.

7.Remove timing gear case.

8.Remove oil level gauge guide assembly.

9.Remove flywheel assembly.

CAUTION:

1) The flywheel heavy; be careful not to drop it.

2) Be careful no to let it slip because the hexagon

of the bolt is thin.

10. Remove rear plate (for A/T) or flywheel housing (for

MT).

11. Remove retainer.

NOTE:

1) Be careful not to damage the oil seal; it can be

reused.

2) Inspect installation portion for distortion and flow on

the slinger; also inspect for flow on the oil seal lip.

3) If there is some flow oil seal/slinger, replace a set.

12. Remove bolts from thrust plate of balance shaft LH

then remove balance shaft.

13. Loosen crank case fixing bolts.

14. Use seal cutter to take off the liquid gasket.

Seal cutter: 5-8840-2153-0

15. Remove crank case assembly.

CAUTION:

Do not give shock to crank case for prevention take

off applied vibration insulation material on the

crank case.

012RW029

Legend

(1) Crank Case

(2) Oil Pan

(3) Drain Plug

INSTALLATION

1.Install relief valve (if it was removed).

Torque: 30 N·m (3.1 kg·m / 22 lb ft)

2.Apply oil and insert O-ring to strainer, install strainer

and tighten to specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

3.Apply liquid gasket (TB1207B or equivalent) to

surface of oil pan and tighten bolt to the specified

torque.

Torque: 22 N·m (2.2 kg·m / 16 lb ft)

4.Apply engine oil to the balance shaft (left) and insert

it into crank case.

NOTE:

•Do not damage bearing when inserting the balance

shaft.

•Make sure it rotates smoothly.

5.Tighten thrust plate of balance shaft LH.

Torque: 25 N·m (2.5 kg·m / 18 lb ft)

6.Set O-ring port of oil gallery on the cylinder block.

7.Apply liquid gasket (TB1207C or equivalent) to

crankcase fixing surface then tighten bolts to the

specified torque.

Torque: 24 N·m (2.4 kg·m / 17 lb ft)

NOTE: Make sure there is no oil, dust or scratches on

the surface coated with liquid gasket and mount within

five minutes of gasket application.

8.Install retainer with oil seal.

9.Install rear plate (A/T) or flywheel housing (MT),

tighten bolt to the specified torque.

Torque: 97 N·m 9.9 kg·m / 72 lb ft)

10.Install flywheel assembly with applied engine oil to

the bolt, tighten the bolt using angular tightening

method.

1st step: 59 N·m (6.0 kg·m / 43 lb ft)

2nd step: 60°to 90°

3rd step: 60°to 90°

11.Install oil level gauge guide assembly.

12.Install timing gear case.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

13.Install timing gears

Refer to “Timing Gear” in this manual.

14.Remove lock bolt from idle gear Aand remove lock

pin from idle gear C.

15.Install timing gear case cover.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

16.Install oil pump pulley.

Torque: 10 N·m (1.0 kg·m / 87 lb in)

17.Install camshaft pulley tighten bolt with angular

tightening method.

Torque:

1st step: 40 N·m (4.1 kg·m / 30 lb ft)

2nd step: 60°to 90°

18.Install timing belt and belt tensioner.

Refer to “Timing Gear” in this manual.

19. Install crankshaft damper pulley.

Torque: 216 N·m (22 kg·m / 159 lb ft)

20. Fill engine oil.

2~2.5mm

Apply liquid gasket around inside

of the bolt hole

Bolt hole

Inside

Outside

F06HX00001

2~2.5mm

Apply liquid gasket around inside

of the bolt hole

Bolt hole

Inside

Outside

F06HX00001

CRANKSHAFT

11 16

012RW023

Legend

(1) Cylinder Head

(2) Cylinder Head Gasket

(3) Flywheel

(4) Cylinder Block Rear Plate (for A/T) or Flywheel

Housing (for M/T)

(5) Crankshaft Rear Oil Seal

(6) Retainer

(7) Timing Gear Case

(8) Crankshaft Front Oil Seal

(9) Timing Gear Case

(10) Gasket

(11) Balance Shaft

(12) Crank Case

(13) Piston Cooling Oil Pipe

(14) Main Bearing Cap

(15) Crankshaft

(16) Crankshaft Timing Gear

(17) Piston and Connecting Rod Assembly

(18) Cylinder Block

Techline

DISASSEMBLY

1.Cylinder Head

1)Refer to “Cylinder head” in this manual.

2. Crankshaft Front Oil Seal

1) Use a plastic hammer and a screwdriver to tap

around the oil seal to free it from the gear case

cover.

Take care not to damage the oil seal fitting

surfaces.

3. Crankshaft Timing Gear

4. Timing Gear Case

5. Flywheel

6. Cylinder Block Rear Plate

7. Crankshaft Rear Oil Seal

1) Use special tool to remove the crankshaft rear

oil seal.

Oil Seal Remover: 5-8840-2360-0

8. Crank Case

9. Piston Cooling Oil Pipe

10. Piston and Connecting Rod Assembly

11. Main Bearing Cap Assembly

12. Crankshaft

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part

replacements if excessive wear or damage is

discovered during inspection.

1. Crankshaft Thrust clearance

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 bearing as a set.

Standard : 0.04 – 0.20 mm (0.0016 – 0.0079 in)

Limit: 0.30 mm (0.0118 in)

2. Main bearing clearance

1) Remove the main bearing caps in the sequence

shown in the illustration.

Arrange the removed main bearing caps in the

cylinder number order.

2) Remove the crankshaft. Remove the main

bearings.

3) Clean the upper and lower bearings as well as

the crankshaft main journal.

4) 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.

5) Set the upper bearings and the thrust washers

to their original positions. Carefully install the

crankshaft.

6) Set the lower bearings to the bearing cap

original position.

015LV002

012RW063

3710 62

012RW026

7) Apply plastigage to the crankshaft journal unit as

shown in the illustration.

8) Install the main bearing caps. Apply engine oil to

the bolt threads and the seats. Tighten the bolts

to the specified torque.

Torque: 167 N·m (17 kg·m/123 lb ft)

NOTE: Do not allow the crankshaft to rotate.

9) Remove the main bearing caps.

10) Measure the plastigage width and determine the

oil clearance. If the oil clearance exceeds the

specified limit, replace the main bearings as a

set and/or replace the crankshaft.

11) Clean the plastigage from the bearings and the

crankshaft.

Remove the crankshaft and the bearings.

Standard: 0.031 – 0.063 mm (0.0012 – 0.0025 in)

Limit: 0.11 mm (0.0043 in)

3. Run-out

1) Carefully set the crankshaft on the V-blocks.

Slowly rotate the crankshaft and measure the

runout. If the crankshaft runout exceeds the

specified limit, the crankshaft must be replaced.

Standard: 0.05 mm (0.0020 in) or less

Limit: 0.08 mm (0.0031 in)

Measure the diameter and the uneven wear of

main journal and crank pin.

If the crankshaft wear exceeds the specified

limit, crankshaft must be replaced.

Main journal diameter

Standard: 69.917 – 69.932 mm (2.7526 – 2.7532 in)

Limit: 69.91 mm (2.7524 in)

Crank pin diameter

Standard: 52.915 – 52.930 mm (2.0833 – 2.0839 in)

Limit: 52.90 mm (2.0827 in)

Uneven wear limit

Standard: 0.05 mm (0.0020 in) or less

Limit: 0.08 mm (0.0031 in)

014RW055

014RW077

012RW068

Crankshaft inspection

Inspect the surface of the crankshaft journals and crank

pins for excessive wear and damage.

Inspect the oil seal fitting surfaces for excessive wear

and damage.

Inspect the oil ports for obstructions.

Crankshaft tufftriding inspection

1. Use an organic cleaner to thoroughly clean the

crankshaft. There must be no traces of on the

surfaces to be inspected.

2. Prepare a 5 – 10% solution of ammonium cupric

chloride (dissolved in distilled water).

3. Use a syringe to apply the solution to the surface to

be inspected.

Hold the surface to be inspected perfectly

horizontal to prevent the solution from running.

NOTE: Do not allow the solution to come in contact with

the oil ports and their surrounding area (Approximately

10 mm).

Judgment

1. Wait for thirty or forty seconds.

If there is no discoloration after thirty or forty

seconds, the crankshaft is usable.

If discoloration appears (the surface being tested

will become the color of copper), the crankshaft

must be replaced.

2. Steam clean the crankshaft surface immediately

after completing the test.

NOTE: The ammonium cupric chloride solution is highly

corrosive. Because of this, it is imperative that the

surfaces being tested be cleaned immediately after

completing the test.

CRANKSHAFT BEARING SECTION

When installing new crankshaft bearings, refer to the

selection table below.

Select and install the new crankshaft bearings, paying

close attention to the cylinder body journal hole

diameter grade mark and the crankshaft journal

diameter grade mark.

NOTE: Although all upper journal bearings (cylinder

body side) have oil grooves and holes, all lower

bearings (bearing cap side) have no groove and hole.

Play close attention to the distinction during the

installation procedure.

012RW045

The portion to be tested

must be held horizontally

so as not to let the test

solution flow.

The sliding surface

of the pin

or journal.

Test liquid should

not be applied to

the area around the

oil port.

Approximately

10mm

F06MV020

012RW038

Crankshaft Bearing Bore Grade Mark Position

Crankshaft bearing bore grade marks 1or 2are

stamped on the rear right hand side of the cylinder

body.

Example:

No. 1 Bearing No. 2 Bearing No. 3 Bearing No. 4 Bearing No. 5 Bearing

Housing Housing Housing Housing Housing

Legend

(1) No. 1 Main bearing bore grade

(2) No. 2 Main bearing bore grade

(3) No. 3 Main bearing bore grade

(4) No. 4 Main bearing bore grade

(5) No. 5 Main bearing bore grade

Crankshaft Journal Grade Mark Position

The crankshaft journal grade marks (1 or –) are

stamped on each crankshaft journal wave.

The crankshaft journal and bearing clearance must be

the same for each position after installation of the

crankshaft and the crankshaft bearings.

Legend

(1) Crankshaft journal outside diameter grade

1 2 1 1 2

11122

2345

012RW114

015RW078

012RW069

Main Bearing Crankshaft

Bore Diameter mm(in) Main Journal Diameter mm(in) Crankshaft Oil Clearance

Grade Inside Diameter Grade Outside Diameter Bearing mm(in)

1 or - 69.927 – 69.932 4 0.045 – 0.061

(2.7530 – 2.7532) (0.0018 – 0.0024)

1 73.992 – 74.000 2 or - - 69.922 – 69.927 4 0.050 – 0.066

(2.9131 – 2.9134) (2.7528 – 2.7530) (0.0020 – 0.0026)

3 or - - - 69.917 – 69.922 5 0.052 – 0.068

(2.7526 – 2.7528) (0.0020 – 0.0027)

1 or - 69.927 – 69.932 2 0.042 – 0.059

(2.7530 – 2.7532) (0.0017 – 0.0023)

2 73.983 – 73.992 2 or - - 69.922 – 69.927 3 0.044 – 0.061

(2.9127 – 2.9131) (2.7528 – 2.7530) (0.0017 – 0.0024)

3 or - - - 69.917 – 69.922 4 0.046 – 0.063

(2.7526 – 2.7528) (0.0018 – 0.0025)

1 or - 69.927 – 69.932 1 0.037 – 0.053

(2.7530 – 2.7532) (0.0015 – 0.0021)

3 73.975 – 73.983 2 or - - 69.922 – 69.927 2 0.039 – 0.055

(2.9124 – 2.9127) (2.7528 – 2.7530) (0.0015 – 0.0022)

3 or - - - 69.917 – 69.922 2 0.044 – 0.060

(2.7526 – 2.7528) (0.0017 – 0.0024)

REASSEMBLY

1. Crankshaft

1) Install the main bearings to the cylinder body

and the main bearing caps.

2) Be sure that they are positioned correctly.

3) Apply new engine oil to the upper and lower

main bearing faces.

4) Carefully mount the crankshaft.

5) Apply engine oil to the thrust washer.

6) Assemble the thrust washer to the No. 3 bearing

journal. The oil grooves must face the

crankshaft.

7) Install the bearing caps with the bearing cap

head arrow mark facing the front of the engine.

8) Apply engine oil to the main bearing cap bolts.

9) Tighten the main bearing cap bolts to the

specified torque a little at a time in the sequence

shown in the illustration.

Torque: 167 N·m (17.0 kg·m/123 lb ft)

NOTE: Check to see that the crankshaft turns smoothly

by rotating it manually.

012RW047

84159

610

012RW027

2.Piston and Connecting Rod Assembly

1)Apply engine oil to the cylinder bores, the

connecting rod bearings and the crankshaft pins

and each piston ring and piston.

2)Align the front mark (2) of piston and front mark

(3) of connecting rod then assemble them.

3)The N mark of the piston ring is faced toward the

top, check to see that the piston ring end gap is

correctly positioned.

Legend

(1)1st piston ring end gap

(2)2nd piston ring end gap

(3)Oil ring end gap

4)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.

Piston Ring Compressor: 5-8840-9018-0

5)Match the numbered caps with the numbers on

the connecting rods. Align the punched marks

on the connecting rods and caps.

6)Apply engine oil to the threads and seating faces

of the nuts.

7)Tighten the cap nuts in 2 steps, using angular

tightening method as shown in the following

specifications.

1st step: 29 N·m (3.0 kg·m/22 lb ft)

2nd step: 45°– 60°

After tightening the cap nuts, check to see that

the crankshaft rotates smoothly

3.Piston Cooling Oil Pipe

If the piston cooling oil pipe is forcibly assembled,

the end of the oil jet may bend. It could make it

impossible to supply oil to the piston cooling holes,

which will sometimes cause piston seizure.

Sufficient care should be taken to pipe assembly

work.

1)Tighten the bolt and oil jet plug to the specified

torque.

Torque:

M6: 8 N·m (0.8 kg·m/69 lb in)

M8: 20 N·m (2.0 kg·m/14 lb ft)

Oiling Jet Plug: 30 N·m (3.1 kg·m/22 lb ft)

4.Crank case

1)Refer to “Crank case” in this manual.

5. Apply liquid gasket (TB-1207C or equivalent) to

retainer then install it to rear end of cylinder block

within 5 minutes.

6. Crankshaft Rear Oil Seal

1) Tighten the adapter to the crankshaft rear and

section with 2 bolts.

2) Insert the oil seal into the peripheral section of

the adapter.

NOTE: Apply oil to the oil seal lip.

3) Insert the sleeve into the adapter and tighten it

with a bolt (M12 x 1.75L = 70) until the adapter

hits the sleeve.

4) Remove the adapter and the sleeve.

5) Check the dimension of the oil seal setting from

rear end of crankshaft.

Standard Dimension = 12.5 ± 0.3 mm

Oil Seal Installer: 5-8840-2359-0

015RW051

015RW083

7.Cylinder Block Rear Plate (A/T)

Align the rear plate with the cylinder block dowel

pins.

Tighten the rear plate to the specified torque.

Torque: 97 N·m (9.9 kg·m/72 lb ft)

8.Flywheel housing (M/T)

Align the flywheel housing with the cylinder block

dowel pins.

Tighten the bolt to the specified torque.

Torque: 97 N·m (9.9 kg·m/72 lb ft)

9. Flywheel

1) Thoroughly clean and remove the oil from the

threads of crankshaft and flywheel fixing

surface.

2) Mount the flywheel on the crankshaft and then

install the washer.

3) Align the timing mark, cut out on the flywheel is

at lowest position for M/T model and

identification hole on the boss is highest position

for A/T model when cylinder No. 1 is at the TDC.

For M/T Model

For A/T model

4) Tighten the flywheel bolts in 2 steps using

angular tightening method.

Torque: 1st step 59 N·m (6.0 kg·m/43 lb ft)

Torque: 2nd step 60° – 90°

Torque: 3rd step 60° – 90°

10. Timing Gear Case

1) Cut away the gasket protruding between the

cylinder block and the crank case fitting surfaces

(as shown in the illustration).

12.5 + 0.3

–

012RW067

Timing mark

278

015RW121

Timing mark

304

015RW120

201RW021

Techline

2) Apply liquid gasket (TB1207B or equivalent)

between the cylinder block and the crankcase

fitting surfaces.

3) Install the timing gear case to the cylinder body.

4) Tighten the timing gear case bolt together with

the timing gear case gasket to the specified

torque.

Torque: 20 N·m (2.0 kg·m/14 lb·ft)

11. Crankshaft Gear

1) Set key to crankshaft key groove.

2) The timing mark on the crankshaft gear must be

facing outward.

3) Use the crankshaft gear installer to install the

crankshaft gear.

Crankshaft installer: 9-8522-0021-0

Legend

(1) Crankshaft Gear Installer

(2) Crankshaft Gear

12. Installation of the Timing Gear

1) Align teeth on the scissors gear and lock them

before install timing gear.

2) Align timing marks on each timing gear and

assemble them.

3) Refer to timing gear detail in this manual.

13. Timing Gear Case Cover

1) Remove lock bolt from idle gear A and remove

lock pin from idle gear C.

2) Install oil pump gear oil seal before assembling

timing gear case cover.

3) Clean fitting surface and apply liquid gasket

(TB1207C or equivalent) to fitting surface.

4) Tighten bolts to specified torque.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

012RW066

2~2.5mm

Apply liquid gasket around inside

of the bolt hole

Bolt hole

Inside

Outside

F06HX00001

012RW024

012RW064

14.Crankshaft Front Oil Seal

1)Set oil seal with special tool.

2)Install front oil seal to timing gear case cover.

Crankshaft Front Oil Seal Installer: 5-8840-2061-0

NOTE: Apply oil to the oil seal lip.

3)Remove special tool and check oil seal position

from front surface of timing gear case.

Oil Seal Position: 0.5 – 2.5 mm (0.0197 –0.0984 in)

15.Cylinder Head

1)Refer to “Cylinder head” in this manual.

015RW074

PISTON AND CONNECTING ROD

012RW061

Legend

(1) Cylinder Head Assembly

(2) Crank Case

(3) Connecting Rod Bearing Cap

(4) Connecting Rod

(5) Piston Ring

(6) Piston Pin

(7) Piston Pin Snap Ring

(8) Piston

DISASSEMBLY

1.Cylinder Head Assembly

1)Refer to “Cylinder head” in this manual.

2. Crank Case Assembly

1)Refer to “Crank Case” in this manual.

3. Connecting Rod Bearing Cap

4. Piston and Connecting Rod

1) Remove carbon deposits from the upper portion

of the cylinder wall with a scraper before

removing the piston and connecting rod.

5. Piston Ring

Remove the piston rings with a piston ring

expander.

Arrange the removed piston rings in the cylinder

number order.

6. Piston Pin Snap Ring

1) Use a pair of pliers to remove the piston pin

snap rings.

7. Piston Pin

1) Remove piston pin from piston assembly.

NOTE: Keep the parts removed from each cylinder

separate. All parts must be reinstalled in their original

positions.

8. Piston

9. Connecting Rod

INSPECTION AND REPAIR

PISTON AND PISTON RING

Pistons

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 present, the piston

must be replaced.

Piston Diameter

1. Measure the piston outside diameter with

micrometer at the piston grading position.

Piston Grading Position: 69.75 mm (2.7461 in)

from piston head

Piston Outside Diameter mm(in)

Grade Mark Outside Diameter

A 95.320 – 95.329 (3.7527 – 3.7531)

B 95.330 – 95.339 (3.7531 – 3.7535)

C 95.340 – 95.349 (3.7535 – 3.7539)

015RW082

015RW077

015LV014

Legend

(1) Piston Grade

(2) Piston Front Mark

(3) Part Number

The grade for piston outside diameter is stamped

on the piston head.

Measure the cylinder bore diameter at measuring

points.

If the piston clearance does not conform to the

specified value, the pistons most be replaced.

Piston Clearance:

0.092 – 0.110 mm (0.0036 – 0.0043 in)

Cylinder Bore Diameter mm(in)

Grade Mark Cylinder Bore Diameter

A 95.421 – 95.430 (3.7567 – 3.7571)

B 95.431 – 95.440 (3.7571 – 3.7575)

C 95.441 – 95.450 (3.7575 – 3.7579)

Legend

Measuring point 1 = 20 mm

2 = 90 mm

3 = 160 mm

Piston rings

Any worn or damaged part discovered during engine

overhaul must be replaced with a new one.

1. Ring end gap measurement

1) Insert the piston ring into the cylinder bore.

2) Push the ring by the piston, at the right angle to

the wall, into the point at which the cylinder bore

diameter is the smallest.

3) Measure the ring end gap.

NOTE: The piston ring is stamped with a discerning

mark on the upper face of piston ring.

015RW080

012RW071

321

012RW117

012RW051

Discerning Mark

Piston Ring Discerning Mark

1st compression ring 1N

2nd compression ring 2N

Ring End Gap mm(in)

Piston Ring Standard Gap Limit

1st 0.25 – 0.40

compression ring (0.0098 – 0.0157)

2nd 0.20 – 0.35 1.5

compression ring (0.0079 – 0.0138) (0.0590)

Oil ring 0.10 – 0.30

(0.0039 – 0.0118)

2. Measure the clearance between the piston ring

groove and the piston ring with a feeler gauge. If the

piston ring groove/piston ring clearance exceeds

the specified limit, the piston and/or piston rings

must be replaced. mm(in)

Standard Limit

1st 0.05 – 0.09

Compression (0.0020 – 0.0035)

ring 2nd 0.05 – 0.09 0.15

(0.0020 – 0.0035) (0.0059)

Oil ring 0.03 – 0.07

(0.0012 – 0.0028)

Piston pin

Visually inspect the piston pin for cracks, flaws, and

other damage and replace if necessary.

1. Use a micrometer to measure the piston pin outside

diameter in both directions at three different

positions. If the measurement exceeds the

specified limit, the piston pin must be replaced.

Standard: 30.995 – 31.000 mm (1.2212 – 1.2214 in)

Limit: 30.97 mm (1.2202 in)

012RW037 015RW076

012RW082

2. Measure the inside diameter of the connecting rod

small end. If the clearance between the small end

and pin does not conform to the specified value, the

connecting rod or bushing and pin must be

replaced.

Standard: 0.008 – 0.020 mm (0.0003 – 0.0008 in )

Limit: 0.05 mm (0.0020 in)

3. Insert the piston 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 and the

piston pin must be replaced.

Standard: 0.005 – 0.018 mm (0.0002 – 0.0007 in )

Limit: 0.04 mm (0.0016 in)

Bushing replacement

Removal: Use a suitable bar and bench press or

hammer

Installation: Align the bushing with a connecting rod

oil port. After installing a new bushing,

finish the bushing bore with a pin hole

grinder.

Connecting rods

1. Check the connecting rod alignment with a

connecting rod aligner.

If either the bend or the twist exceeds the specified

limit, the connecting rod must be replaced.

Bend per 100 mm (3.937 in)

Standard: 0.08 mm (0.0031 in) or less

Limit: 0.20 mm (0.0079 in)

Twist per 100 mm (3.937 in)

Standard: 0.05 mm (0.0020 in) or less

Limit: 0.15 mm (0.0059 in)

2. Measure the connecting rod thrust clearance.

Use a feeler gauge to measure the thrust clearance

at the big end of the connecting rod.

If the clearance exceeds the specified limit, the

connecting rod must be replaced.

Standard: 0.230 mm (0.0091 in)

Limit: 0.350 mm (0.0138 in)

012RW074

012RW123

012RW001

3. Measure the oil clearance between the connecting

rod and the crankshaft.

1) Remove the connecting rod cap nuts and the

rod caps.

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 to their original positions.

5) Tighten the cap nuts in 2 steps, using angular

tightening method as shown in the following

specifications.

1st step: 29 N·m (3.0 kg·m/22 lb ft)

2nd step: 45°– 60°

NOTE: Do not allow the crankshaft to rotate

6) Remove the rod caps.

7) Measure the smallest width of the plastigage

and determine the oil clearance. If the oil

clearance exceeds the limit, replace the rod

bearings as a set.

8) Clean the plastigage from the bearings and the

crankshaft pins

Standard: 0.022 – 0.042 mm (0.0009 – 0.0017 in)

Limit: 0.100 mm (0.0039 in)

REASSEMBLY

1. Connecting Rod

2. Piston

3. Piston Pin

1) Apply a coat of engine oil to the piston pin and

the piston pin hole.

4. Piston Pin Snap Ring

1) Try to insert the piston pin into the piston pin

hole with normal finger pressure.

2) Weight each piston and connecting rod

assembly.

3) Select piston and connecting rod combinations

so that the weight variation of the different four

assemblies is held within the specified limits.

Variance in weight after assembly: Less than 3g

(0.1058 oz)

NOTE: When changing piston/connecting rod

combinations, do not change the piston/piston pin

combination.

4) Attach the piston to the connecting rod with the

piston front mark (2) and the connecting rod

front mark (3) on the same side.

014RW055

012RW075

014RW077

5. Piston Ring

1) Install the piston rings with the piston ring

expander.

The compression ring must be set with the 1N,

2N mark facing up.

2) Discerning mark is stamped as shown in the

illustration (1).

Marked 1N: 1st compression ring

Marked 2N: 2nd compression ring

3) Install piston rings in the following sequence.

1) Oil ring

(1)After installing the expander ring then assemble

the oil ring.

2) 2nd compression ring

3) 1st compression ring

1) The compression ring must be set with the 1N or

2N mark facing up.

2) 1st compression ring:1N

3) 2nd compression ring: 2N

4) After installation, apply engine oil to the entire

circumference of the piston rings.

Check to see that all the rings rotate smoothly.

5) Insert the bearings into the connecting rods and

caps.

Apply new engine oil to the bearing faces.

Cap side bearings have no oil hole.

Connecting rod side bearing’s oil hole should be

aligned with oil hole on the connecting rod.

6. Piston and Connecting Rod

1) Apply engine oil to the cylinder bores, the

connecting rod bearings and the crankshaft

pins.

2) Check to see that the piston ring end gaps are

correctly positioned.

012RW037

015RW051

012RW058

Legend

(1)1st compressor ring gap

(2)2nd compressor ring gap

(3)Oil ring gap

3)Insert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor.

4)The front marks must be facing the front of the

engine.

Piston Ring Compressor : 5-8840-9018-0

7.Connecting Rod Bearing Cap

1)Apply engine oil to thread and seat of bearing

cap bolts.

2)Tighten the cap bolts in 2 steps, using angular

tightening method as shown in the following

specifications.

1st step: 29 N·m (3.0 kg·m/22 lb ft)

2nd step: 45°– 60°

After tightening the cap bolts, check to see that

the crankshaft rotates smoothly.

8.Crank Case Assembly

1)Refer to “Crank Case” in this manual.

9. Cylinder Head Assembly

1)Refer to “Cylinder head” in this manual.

015RW083

CYLINDER BLOCK

11 16

012RW023

Legend

(1) Cylinder Head

(2) Cylinder Head Gasket

(3) Flywheel

(4) Cylinder Block Rear Plate (A/T)

Flywheel Housing (M/T)

(5) Crankshaft Rear Oil Seal

(6) Retainer

(7) Timing Gear Case Cover

(8) Crankshaft Front Oil Seal

(9) Timing Gear Case

(10) Gasket

(11) Balance Shaft

(12) Crank Case

(13) Piston Cooling Oil Pipe

(14) Main Bearing Cap

(15) Crankshaft

(16) Crankshaft Timing Gear

(17) Piston and Connecting Rod Assembly

(18) Cylinder Block

DISASSEMBLY

1.Cylinder Head Assembly

Refer to “Cylinder Head” in this manual.

2.Cylinder Head Gasket.

3.Flywheel

4.Cylinder Block Rear Plate (A/T), or Flywheel

housing (M/T).

5.Crankshaft Rear Oil Seal.

Install the special tool as shown in the illustration

and remove the oil seal.

Oil Seal Remover: 5-8840-2360-0

6.Retainer

7.Timing Gear Case Cover

8.Crankshaft Front Oil Seal

1)Use a plastic hammer and a screwdriver to tap

around the oil seal to free it from the gear case

cover.

9.Timing Gears

Refer to “Timing Gear” in this manual.

10. Timing gear case

11. Gasket

12. Balance shaft (right)

13. Crank case assembly

14. Piston cooling oil pipe

15. Piston assembly

16. Main bearing cap

17. Crankshaft assembly

18. Cylinder block side cover right and left

19. Cylinder block

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part

replacements if excessive wear or damage is

discovered during inspection.

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 liquid gasket, which was used

when assembled, from gear case, rear oil seal

retainer and crank case.

3. Wipe the cylinder block clean and visually check it.

4. Use a straight edge and a feeler gauge to measure

the four sides and the two diagonals of the cylinder

block upper face.

If the measured values exceed the limit, the cylinder

block must be replaced.

Limit: 0.20 mm (0.0079 in)

015RV002

012RW122

Cylinder Bore Measurement

1. Use a cylinder gauge to measure the cylinder bore

measuring direction for thrust and radial at

measuring points.

Legend

Measuring Point 1; 20 mm

2; 90 mm

3; 160 mm

2. Select the right piston grade by the averaged

cylinder bore measurement (maximum and

minimum value eliminated).

Cylinder bore diameter mm(in)

Grade mark Standard

A 95.421 – 95.430 (3.7567 – 3.7571)

B 95.431 – 95.440 (3.7571 – 3.7575)

C 95.441 – 95.450 (3.7575 – 3.7579)

3. If measured values exceed the limit, replace or

adjust the cylinder block honing or boring.

Limit 95.950 mm (3.7776 in)

4. Boring of the cylinder bore is allowed until it is

0.5 mm (0.0197 in) diameter and oversized piston

is available as a service part.

Boring Cylinder Block

1. Use an oversized piston on the basis of above

mentioned cylinder using the largest inside

diameter.

2. Measure the piston outside diameter at right angles

with piston pin at a piston grade measuring point

69.75 mm (2.7461 in) from piston top surface and

calculate a inside diameter for cylinder boring.

3. Calculation of cylinder bore boring.

D + C – H (mm)

D; Outside diameter piston (mm)

C; Clearance between Cylinder bore and piston

0.092 – 0.110 mm (0.0036 – 0.0043 in)

H; Honing allowance

Less than 0.03 mm (0.0012 in)

The oversize pistons are available three grades.

4. Honing the cylinder bore after boring.

5. Measure cylinder bore after honing.

Difference between each cylinder bore

Less than 0.02 mm (0.0008 in)

Cylinder bore and piston grade (After boring) mm(in)

Grade Oversize Piston Bore

Mark Outside Diameter Diameter

A95.820 – 95.829 95.921 – 95.930

(3.7724 – 3.7728) (3.7764 – 3.7768)

B95.830 – 95.839 95.931 – 95.940

(3.7728 – 3.7732) (3.7768 – 3.7772)

C95.840 – 95.849 95.941 – 95.950

(3.7732 – 3.7736 ) (3.7772 – 3.7776)

REASSEMBLY

1. Cylinder Block

2. Piston Cooling Oil Pipe

1) Fix the cooling jet pipes with knock pins on the

cylinder block.

2) Install the oil pipe for piston cooling in the

cylinder block, tightening a relief valve (1) and

four joint bolts (2) to the specified torque.

If oil jet pipe is forcibly assembled, the end of oil

jet may bend. It could make it impossible to

supply oil to the piston cooling hole, sometimes

causing piston seizure.

Sufficient care should be taken to pipe assembly

work.

321

012RW117

Oil pipe fixing bolts

M8: 20 N·m (2.0 kg·m/14 lb ft)

M6: 8 N·m (0.8 kg·m/69 lb in)

Relief valve fixing bolts : 30 N·m (3.1 kg·m/22 lb ft)

CAUTION: After installing the piston assembly,

check and see that there is appropriate clearance

between pistons and oil jet pipes by rotating

crankshaft slowly.

3. Crankshaft

1) Install the main bearings to the cylinder body

and the main bearing caps.

2) Be sure that they are positioned correctly.

3) Apply new engine oil to the upper and lower

main bearing faces.

4) Carefully mount the crankshaft.

5) Apply engine oil to the thrust washer.

6) Assemble the thrust washer to the No. 3

bearing journal. The oil grooves must face the

crankshaft.

4. Main Bearing Cap Assembly

1) Install the main bearing caps with the main

bearing cap head arrow mark facing the front of

the engine.

2) Apply engine oil to the main bearing cap bolts.

3) Tighten the main bearing cap bolts to the

specified torque a little at a time in the sequence

shown in the illustration.

Torque: 167 N·m (17.0 kg·m/123 lb ft)

012RW076

012RW038

012RW047

1 2 3 4 5

012RW025

NOTE:Check to see that the crankshaft turns

smoothly by rotating it manually.

4.Piston Assembly

1)Refer to “Piston and connecting rod” in this

manual.

5.Cylinder Block Side Cover Right and Left

6.Balance ShaftRight.

Apply new engine oil to the balance shaft (right) and

insert it into cylinder block.

7.Timing Gear Case

1)Cut out the liquid gasket forced out from

between the contact surface of cylinder block

and crankshaft.

2)Apply liquid gasket (TB1207B or equivalent) to

the fitting surface of the cylinder block and

crankcase.

3)Install timing gear case with gasket to cylinder

block and tighten to specified torque.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

8.Crankshaft Gear

Force key into crankshaft and force in crankshaft

gear along the key groove using a special tool (1)

with the crank gear (2) timing mark facing outside.

9.Install timing gear align the timing mark on each

timing gear.

For alignment of timing marks refer to “Timing

Gear” in this manual.

NOTE: Remove the locking bolt or pin from idle gear A

and idle gear C.

10. Assembling the gear case cover.

1) Install the oil seal on the oil pump assembly

before installing the gear case cover.

2) Apply liquid gasket to timing gear case.

NOTE: Be sure to apply liquid gasket evenly.

84159

610

012RW027

012RW064

012RW066

2~2.5mm

Apply liquid gasket around inside

of the bolt hole

Bolt hole

Inside

Outside

F06HX00001

11.Use the special tool to install the crankshaft front oil

seal to timing gear case.

Front Oil Seal Installer: 5-8840-2061-0

1)Check fit-of the oil seal and gear case cover at

the front end.

Standard: 0.5 – 2.5 mm (0.0197 – 0.0984 in)

NOTE:Apply engine oil to oil seal lip before installation

of the seal.

12.Install the oil pan assembly to original position and

tighten to specified torque.

Torque: 22 N·m (2.2 kg·m/16 lb ft)

13.Crankshaft Rear Oil Seal

1)Tighten the adapter to the crankshaft rear end

with 2 bolts.

2)Insert the oil seal into the adapter.

NOTE: Apply oil to oil seal lip.

3)Insert the sleeve into the adapter and tighten it

with a bolt (M12 x 1.75L= 70) until the adapter

hits the sleeve.

4)Remove the adapter and the sleeve.

5)With the seal pressed in, check the dimension of

the oil seal outside end and crankshaft end.

Standard Dimension = 12.5 ±0.3 mm

Oil Seal Installer: 5-8840-2359-0

14.Cylinder Block Rear Plate (A/TModel)

1)Tighten the cylinder block rear plate fixing bolts

to the specified torque.

Torque: 97 N·m (9.9 kg·m/72 lb ft)

15.Flywheel Housing (M/TModel)

1)Install flywheel housing aligned with the dowel

pin on the cylinder block.

2)Tighten the flywheel housing fixing bolts to the

specified torque.

Torque: 97 N·m (9.9 kg·m/72 lb ft)

16.Flywheel

1)Refer to “Crankshaft” in this manual.

17. Cylinder Head Assembly

1)Refer to “Cylinder Head” in this manual.

015RW074

12.5 + 0.3

–

012RW067

OILPUMPASSEMBLY

012RW097

Legend

(1) Flywheel

(2) Rear Plate (A/T)

(3) First Oil Pump Assembly

(4) Second Oil Pump Assembly

(5) O-Ring (For first oil pump)

(6) O-Ring (For second oil pump)

REMOVAL

1. Disconnect battery ground cable

2. Lift up car

3. Drain engine oil

NOTE: Install drain plug with new gasket.

4. Flywheel

5. Rear Plate (A/T) or Flywheel Housing (M/T)

6. First Oil Pump Assembly and Second Oil Pump

Assembly

1) Remove oil pump assembly from cylinder block

and crankcase.

INSTALLATION

1. First oil pump assembly

1) Set O-ring to oil pump.

2) Install oil pump drive gear to the rear end of the

balance shaft RH.

3) Apply engine oil to pump gear, install pump gear

to rear end of cylinder block with specified

torque.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

2. Second oil pump assembly

1) Set O-ring to oil pump.

2) Install oil pump drive gear to the rear end of the

balance shaft LH.

3) Apply engine oil to pump gear, install pump gear

to rear end of crank case with specified torque.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

3. Install rear plate (A/T) or flywheel housing (M/T)

Torque: 97 N·m (9.9 kg·m/72 lb ft)

4. Install flywheel

1) Apply engine oil to bolt and tighten with angular

tightening method.

1st step: 59 N·m (6.0 kg·m/43 lb ft)

2nd step: 60° to 90°

3rd step: 60° to 90°

OILCOOLER

MY2003 Euro-3 1

050R200001

Legend

(1) Oil Cooler Assembly

(2) Oil Filter Cartridge

OILFILTER CARTRIDGE

REMOVAL

1. Place a receptacle beneath the oil filter to contain

the drained oil.

2. Remove the oil filter cartridge using filter wrench.

Filter wrench : 5-8840-0203-0

INSTALLATION

1, Lightly apply oil to the O-ring of oil filter cartridge.

2. Turn the new oil filter cartridge by hand until the

sealing face is fitted against the O-ring.

3. Use the filter wrench to turn the oil filter an

additional one and 1/8 turns.

4. Start the engine and check for oil leakage from oil

filter.

6A – 100 ENGINE MECHANICAL

REMOVAL

1. Disconnect battery ground cable

2. Drain engine coolant

3. Remove front exhaust pipe

4. Remove heat protector

5. Remove exhaust valve assembly

6. Oil cooler assembly

1) Remove water hoses from inlet and outlet pipe.

2) Put rag beneath side of oil cooler to prevent oil

leaking.

3) Remove fixing bolts and oil cooler assembly.

INSTALLATION

1. Oil Cooler

1) Tighten oil cooler fixing bolt to the specified

torque and connect water hose.

Torque: 29 N·m (3.0 kg·m/22 lb ft)

2. Exh. Valve Assembly

1) Install exhaust valve assembly with gasket and

tighten fixing bolts to the specified torque.

Torque: 57 N·m (5.8 kg·m/42 lb ft)

3. Heat Protector

4. Front Exhaust Pipe

1) Install front exhaust pipe and tighten fixing bolts

to the specified torque.

Exh. Valve Side: 67 N·m (6.8 kg·m/49 lb ft)

Intermediate Pipe Side: 43 N·m (4.4 kg·m/32 lb ft)

5. Fill engine coolant.

6. Connect battery ground cable.

7. Start engine and check for oil and water leakage

carefully.