| •
|
Use fender covers to avoid damaging
painted surfaces. |
| •
|
To avoid damage, unplug the wiring
connectors carefully while holding the connector
portion. | |
| •
|
Mark all wiring and hoses to avoid
misconnection. |
| •
|
Turn the crankshaft pulley so that the
No.1 piston is at top dead center.
|
| •
|
Engine removal is required for this
procedure. | |
|
In case of removing the high pressure fuel
pump, high pressure fuel pipe, delivery pipe, and injector, there
may be injury caused by leakage of the high pressure fuel. So don’t
do any repair work right after engine
stops. |
| 1. |
Remove the engine assembly from the vehicle.
(Refer to Engine and transaxle assembly in this group)
|
| 2. |
Install the engine to an engine stand for
disassembly. |
| 3. |
Remove the intake manifold and exhaust
manifold. (Refer to Intake and exhaust system in this group)
|
| 4. |
Remove the timing chain. (Refer to Timing
system in this group) |
| 5. |
Remove the cylinder head assembly. (Refer to
Cylinder head in this group) |
| 6. |
AT : Remove the drive plate (A) and the
adapter plate (B).
MT : Remove the
flywheel. |
| 7. |
Remove the balance shaft & oil pump
assembly.
(Refer to Lubrication system in this
group) |
| 8. |
Remove the A/C compressor.
(Refer to HA
group) |
| 9. |
Remove the alternator.
(Refer to EE
group) |
| 10. |
Remove the water pump assembly.
(Refer to Cooling system in this
group) |
| 11. |
Remove the tensioner assembly integrated
bracket (A).
|
| 12. |
Remove the oil level gauge tube
(A).
|
| 13. |
Remove the knock sensor (A).
|
| 14. |
Remove the oil pressure sensor
(A).
|
| 15. |
Remove the CKPS (Crankshaft position sensor)
(A).
|
| 16. |
Remove the ladder frame (A).
|
| 17. |
Check the connecting rod end
play. |
| 18. |
Remove the connecting rod caps and check oil
clearance. |
| 19. |
Remove piston and connecting rod
assemblies.
| (1) |
Using a ridge reamer, remove all the
carbon from the top of the cylinder.
|
| (2) |
Push the piston, connecting rod assembly
and upper bearing through the top of the cylinder
block.
| • |
Keep the bearings,
connecting rod and cap together.
|
| • |
Arrange the piston and
connecting rod assemblies in the correct
order. | | | |
| 20. |
Remove crankshaft bearing cap and check oil
clearance. |
| 21. |
Check the crankshaft end
play. |
| 22. |
Lift the crankshaft (A) out of the engine,
being careful not to damage journals.
|
Arrange the main bearings and thrust
bearings in the correct
order. | |
| 23. |
Remove the oil jet (A).
|
| 24. |
Check fit between piston and piston
pin.
Try to move the piston back and forth on the
piston pin. If any movement is felt, replace the piston and pin as a
set. |
| 25. |
Remove piston rings.
| (1) |
Using a piston ring expander, remove the
2 compression rings. |
| (2) |
Remove oil ring.
|
Arrange the piston rings in the
correct order
only. | | |
| 26. |
Disconnect connecting rod from
piston. |
Connecting Rod
| 1. |
Check the connecting rod end
play.
Using a feeler gauge, measure the end play
while moving the connecting rod back and forth.
End play
:
Standard : 0.10~ 0.25mm (0.0039 ~
0.0098in.)
Limit : 0.35mm
(0.0138in.)
|
| A. |
If out-of-tolerance, install a new
connecting rod. |
| B. |
If still out-of-tolerance, replace the
crankshaft. | |
| 2. |
Check the connecting road bearing oil
clearance.
| (1) |
Check the matchmarks on the connecting
rod and cap are aligned to ensure correct
reassembly. |
| (2) |
Remove 2 connecting rod cap
bolts. |
| (3) |
Remove the connecting rod cap and
bearing half. |
| (4) |
Clean the crank pin and
bearing. |
| (5) |
Place plastigage across the crank
pin. |
| (6) |
Reinstall the bearing half and cap, and
torque the bolts.
Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m,
13.0~15.9lb-ft) + 88~92°
|
|
Do not turn the
crankshaft. | |
| (7) |
Remove 2 bolts, connecting rod cap and
bearing half. |
| (8) |
Measure the plastigage at its widest
point.
Standard
oil clearance
0.031 ~ 0.045mm (0.00122 ~
0.00177in.)
|
|
| (9) |
If the plastigage measures too wide or
too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the
color as shown in the next column), and recheck the
clearance.
|
Do not file, shim, or scrape the
bearings or the caps to adjust
clearance. | |
| (10) |
If the plastigage shows the clearance is
still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance
again.
|
If the proper clearance cannot be
obtained by using the appropriate larger or smaller
bearings, replace the crankshaft and start
over. |
|
If the marks are indecipherable
because of an accumulation of dirt and dust, do not
scrub them with a wire brush or scraper. Clean them only
with solvent or
detergent. |
Connecting Rod
Identification Mark
Connecting Rod Specifications
Class
|
Mark
|
Inside
Diameter
|
a
|
A
|
51.000 ~ 51.006mm
(2.00787 ~ 2.00811in.)
|
b
|
B
|
51.006 ~ 51.012mm
(2.00811 ~ 2.00834in.)
|
c
|
C
|
51.012 ~ 51.018mm
(2.00834 ~
2.00858in.)
|
Crankshaft Pin
Identification Mark
|
Conform to read stamping order as
shown arrow direction from
#1. |
Crankshaft Specifications
Class
|
Mark
|
Outside Diameter Of
Pin
|
I
|
1
|
47.966 ~ 47.972mm
(1.88842 ~ 1.88866in.)
|
II
|
2
|
47.960 ~ 47.966mm
(1.88819 ~ 1.88842in.)
|
III
|
3
|
47.954 ~ 47.960mm
(1.88795 ~
1.88819in.)
|
Connecting Rod
Bearing Identification Mark
Connecting Rod Bearing Specifications
Class
|
Mark
|
Thickness Of
Bearing
|
AA
|
Blue
|
1.515 ~ 1.518mm
(0.05965 ~ 0.05976in.)
|
A
|
Black
|
1.512 ~ 1.515mm
(0.05953 ~ 0.05965in.)
|
B
|
None
|
1.509 ~ 1.512mm
(0.05941 ~ 0.05953in.)
|
C
|
Green
|
1.506 ~ 1.509mm
(0.05929 ~ 0.05941in.)
|
D
|
Yellow
|
1.503 ~ 1.506mm
(0.05917 ~
0.05929in.)
|
Selection Chart For Connecting Rod Bearings
Crankshaft
Indentification Mark
|
Connecting Rod
Identification Mark
|
Assembing
Classification Of Bearing
|
I (1)
|
a
(A)
|
D
(Yellow)
|
b
(B)
|
C
(Green)
|
c
(C)
|
B
(None)
|
II (2)
|
a
(A)
|
C
(Green)
|
b
(B)
|
B
(None)
|
c
(C)
|
A
(Black)
|
III (3)
|
a
(A)
|
B
(None)
|
b
(B)
|
A
(Black)
|
c
(C)
|
AA
(Blue)
|
| |
| 3. |
Inspect the connecting rods.
| (1) |
When reinstalling, make sure that
cylinder numbers put on the connecting rod and cap at
disassembly match. When a new connecting rod is installed,
make sure that the notches for holding the bearing in place
are on the same side. |
| (2) |
Replace the connecting rod if it is
damaged on the thrust faces at either end. Also if step wear
or a severely rough surface of the inside diameter of the
small end is apparent, the rod must be replaced as
well. |
| (3) |
Using a connecting rod aligning tool,
check the rod for bend and twist. If the measured value is
close to the repair limit, correct the rod by a press. Any
connecting rod that has been severely bent or distorted should
be replaced.
Allowable bend of connecting rod
:
0.05mm (0.0020 in.) or less for
100mm (3.94 in.)
Allowable twist of connecting rod
:
0.10mm (0.0039 in.) or less for
100mm (3.94 in.)
| | |
Crankshaft
| 1. |
Check the crankshaft bearing oil
clearance.
| (1) |
To check main bearing-to-journal oil
clearance, remove the main caps and bearing
halves. |
| (2) |
Clean each main journal and bearing half
with a clean shop tower. |
| (3) |
Place one strip of plastigage across
each main journal. |
| (4) |
Reinstall the bearings and caps, then
torque the bolts.
Tightening torque
14.7N.m (1.5kgf.m, 10.8lb-ft) +
27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.1lb-ft) +
120~125°
|
|
Do not turn the
crankshaft. | |
| (5) |
Remove the cap and bearing again, and
measure the widest part of the plastigage.
Standard
oil clearance
0.020 ~ 0.038mm (0.00079 ~
0.00150in.)
|
|
| (6) |
If the plastigage measures too wide or
too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the
color as shown in the next column), and recheck the
clearance.
|
Do not file, shim, or scrape the
bearings or the caps to adjust
clearance. | |
| (7) |
If the plastigage shows the clearance is
still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance
again.
|
If the proper clearance cannot be
obtained by using the appropriate larger or smaller
bearings, replace the crankshaft and start
over. |
|
If the marks are indecipherable
because of an accumulation of dirt and dust, do not
scrub them with a wire brush or scraper. Clean them only
with solvent or
detergent. | |
Crankshaft Bore
Identification Mark
Letters have been stamped on the block as a
mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on
the crank (marks for main journal size), to choose the correct
bearings.
Cylinder Block Specifications
Calss
|
Mark
|
Inside
Diameter
|
a
|
A
|
56.000
~ 56.006mm
(2.20472 ~
2.20496in.)
|
b
|
B
|
56.006
~ 56.012mm
(2.20496 ~
2.20519in.)
|
c
|
C
|
56.012
~ 56.018mm
(2.20519 ~
2.20543in.)
|
Crankshaft Journal
Identification Mark
|
Conform to read stamping order as shown
arrow direction from #1. |
Crankshaft Specifications
Class
|
Mark
|
Outside Diameter Of
Journal
|
I
|
1
|
51.954
~ 51.960mm
(2.04543 ~
2.04567in.)
|
II
|
2
|
51.948
~ 51.954mm
(2.04519 ~
2.04543in.)
|
III
|
3
|
51.942
~ 51.948mm
(2.04496 ~
2.04519in.)
|
Crankshaft Bearing
Identification Mark
Crankshaft Bearing Specifications
Class
|
Mark
|
Thickness Of
Bearing
|
AA
|
Blue
|
2.026
~ 2.029mm
(0.07976 ~
0.07988in.)
|
A
|
Black
|
2.023
~ 2.026mm
(0.07965 ~
0.07976in.)
|
B
|
None
|
2.020
~ 2.023mm
(0.07953 ~
0.07965in.)
|
C
|
Green
|
2.017
~ 2.020mm
(0.07941 ~
0.7953in.)
|
D
|
Yellow
|
2.014
~ 2.017mm
(0.07929 ~
0.07941in.)
|
Selection Chart For Crankshaft Bearings
Crankshaft Identification
Mark
|
Crankshaft Bore
Identification Mark
|
Assembling Classification
Of Bearing
|
I (1)
|
a
(A)
|
D
(Yellow)
|
b
(B)
|
C
(Green)
|
c
(C)
|
B
(None)
|
II (2)
|
a
(A)
|
C
(Green)
|
b
(B)
|
B
(None)
|
c
(C)
|
A
(Black)
|
III (3)
|
a
(A)
|
B
(None)
|
b
(B)
|
A
(Black)
|
c
(C)
|
AA
(Blue)
|
|
| 2. |
Check crankshaft end play.
Using a dial indicator, measure the thrust
clearance while prying the crankshaft back and forth with a
screwdriver.
End
play
Standard : 0.07 ~ 0.25mm (0.0028 ~
0.0098in.)
Limit : 0.30mm
(0.0118in.)
|
If the end play is greater than maximum,
replace the thrust bearings as a set.
Thrust bearing
thickness
1.925 ~ 1.965mm (0.07579 ~
0.07736in.)
| |
| 3. |
Inspect main journals and crank
pins.
Using a micrometer, measure the diameter of
each main journal and crank pin.
Main journal
diameter :
51.942 ~ 51.960mm (2.04496 ~
2.04567in.)
Crank pin
diameter :
47.954 ~ 47.972mm (1.88795 ~
1.88866in.)
|
|
Cylinder Block
| 1. |
Remove gasket material.
Using a gasket scraper, remove all the gasket
material from the top surface of the cylinder
block. |
| 2. |
Clean cylinder block
Using a soft brush and solvent, thoroughly
clean the cylinder block. |
| 3. |
Inspect top surface of cylinder block for
flatness.
Using a precision straight edge and feeler
gauge, measure the surface contacting the cylinder head gasket for
warpage.
Flatness of
cylinder block gasket surface
Standard : Less than 0.05mm (0.0019in.)
for all
Less than 0.02 (0.0007in.) for 100mm
(3.9370in.) x 100mm (3.9370in.)
|
|
| 4. |
Inspect cylinder bore diameter.
Visually check the cylinder for vertical
scratchs.
If deep scratches are present, replace the
cylinder block. |
| 5. |
Inspect cylinder bore diameter.
Using a cylinder bore gauge, measure the
cylinder bore diameter at position in the thrust and axial
directions.
Standard
diameter
88.00 ~ 88.03mm (3.4645 ~
3.4657in.)
|
|
Measurement position points (from the
bottom of the cylinder block)
:
110.7mm(4.3582in.)/160mm(6.2992in.)/210mm(8.2677in.) | |
| 6. |
Check the cylinder bore size code on the
cylinder block.
Cylinder Bore Inner Diameter
Size Code
|
Cylinder Bore Inner
Diameter
|
A
|
88.00 ~
88.01mm (3.4645 ~ 3.4649in.)
|
B
|
88.01 ~
88.02mm (3.4649 ~ 3.4653in.)
|
C
|
88.02 ~
88.03mm (3.4653 ~
3.4657in.)
|
|
| 7. |
Check the piston size code on the piston top
face.
|
Stamp the grade mark of basic diameter
with rubber stamp. |
Piston Outer Diameter
Size Code
|
Piston Outer
Diameter
|
A
|
87.970 ~
87.980mm (3.46338 ~ 3.46377in.)
|
B
|
87.980 ~
87.990mm (3.46377 ~ 3.46417in.)
|
C
|
87.990 ~
88.000mm (3.46417 ~
3.46456in.)
|
|
| 8. |
Select the piston related to cylinder bore
class.
Clearance
: 0.020 ~ 0.040mm (0.00079 ~
0.00157in.)
| |
Piston And Rings
| 1. |
Clean piston
| (1) |
Using a gasket scraper, remove the
carbon from the piston top. |
| (2) |
Using a groove cleaning tool or broken
ring, clean the piston ring
grooves. |
| (3) |
Using solvent and a brush, thoroughly
clean the piston.
| |
| 2. |
The standard measurement of the piston outside
diameter is taken 17mm (0.67in.) from the top land of the
piston.
Standard
diameter
87.970 ~ 88.000mm (3.46338 ~
3.46456in.)
|
|
| 3. |
Calculate the difference between the cylinder
bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.020 ~ 0.040mm (0.00079 ~
0.00157in.)
| |
| 4. |
Inspect the piston ring side
clearance.
Using a feeler gauge, measure the clearance
between new piston ring and the wall of the ring
groove.
Piston ring
side clearance
Standard
No.1 : 0.050 ~ 0.080mm (0.00197 ~
0.00315in.)
No.2 : 0.040 ~ 0.080mm (0.00157 ~
0.00315in.)
Oil ring : 0.020 ~ 0.055mm (0.00079 ~
0.00217in.)
Limit
No.1 : 0.100mm (0.00394in.)
No.2 : 0.100mm (0.00394in.)
Oil ring : 0.100mm
(0.00394in.)
|
If the clearance is greater than maximum,
replace the piston. |
| 5. |
Inspect piston ring end gap.
To measure the piston ring end gap, insert a
piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a
piston. Measure the gap with a feeler gauge. If the gap exceeds the
service limit, replace the piston ring. If the gap is too large,
recheck the cylinder bore diameter against the wear limits, If the
bore is over the service limit, the cylinder block must be
replaced.
Piston ring
end gap
Standard
No.1 : 0.15 ~ 0.30mm (0.0059 ~
0.0118in.)
No.2 : 0.37 ~ 0.52m (0.0145 ~
0.0204in.)
Oil ring : 0.20 ~ 0.50mm (0.0079 ~
0.0197in.)
Limit
No.1 : 0.60mm (0.0236in.)
No.2 : 0.70mm (0.0275in.)
Oil ring : 0.80mm
(0.0315in.)
|
|
Piston Pins
| 1. |
Measure the diameter of the piston
pin.
Piston pin
diameter
21.997 ~ 22.000mm (0.86602 ~
0.86614in.)
|
|
| 2. |
Measure the piston pin-to-piston
clearance.
Piston
pin-to-piston clearance
0.003 ~ 0.010m (0.00012 ~
0.00039in.)
| |
| 3. |
Check the difference between the piston pin
diameter and the connecting rod small end diameter.
Piston
pin-to-connecting rod interference
0.005 ~ 0.014mm (0.00020 ~
0.00055in.)
| |
| •
|
Thoroughly clean all parts to
assembled. |
| •
|
Before installing the parts, apply fresh
engine oil to all sliding and rotating
surfaces. |
| •
|
Replace all gaskets, O-rings and oil
seals with new
parts. | |
| 1. |
Assemble the piston and connecting
rod.
| (1) |
Before pressing the piston pin, apply a
coat of lubricant oil to the piston pin outer and connecting
rod.
| • |
Take care that piston pin is
not to be damaged during pressing
process. |
| • |
When replace the piston pin,
check the piston pin outer diameter and connecting
rod small end inner diameter as
below. | |
Piston
pin outer diameter :
21.997 ~ 22.000mm (0.86602 ~
0.86614in)
Connecting rod small end inner diameter
:
22.005 ~ 22.011mm (0.86634 ~
0.86657in)
| |
| (2) |
Use a hydraulic press for
installation. |
| (3) |
The piston front mark and the connecting
rod front mark must face the timing chain side of the
engine.
| |
| 2. |
Install the piston rings.
| (1) |
Install the oil ring with coil spring by
hand. |
| (2) |
Using a piston ring expander, install
the 2 compression rings with the code mark facing
upward. |
| (3) |
Position the piston rings so that the
ring ends are as shown.
| |
| 3. |
Install the connecting rod
bearings.
| (1) |
Align the bearing claw with the groove
of the connecting rod or connecting rod
cap. |
| (2) |
Install the bearings(A) in the
connecting rod and connecting rod cap(B).
| |
| 4. |
Install the main bearings.
|
Upper bearings have an oil groove of oil
holes; Lower bearings do not. |
| (1) |
Align the bearing claw with the claw
groove of the cylinder block, push in the 5 upper
bearings(A).
|
| (2) |
Align the bearing claw with the claw
groove of the main bearing cap, and push in the 5 lower
bearings. | |
| 5. |
Install the thrust bearings.
Install the 2 thrust bearings(A) under the
No.3 journal position of the cylinder block with the oil grooves
facing outward.
|
| 6. |
Install the oil jet (A).
Tightening
torque
24.5 ~ 29.4Nm (2.5 ~ 3.0kgf.m, 18.1 ~
21.7lb-ft)
|
|
| 7. |
Place the crankshaft (A) on the cylinder
block.
|
| 8. |
Place the main bearing caps on cylinder
block. |
| 9. |
Install the main bearing cap
bolts.
|
Always use new main bearing cap
bolts. |
| •
|
The main bearing cap bolts are
tightened in 3 progressive
steps. |
| •
|
If any of the bearing cap bolts in
broken or deformed, replace
it. | |
| (1) |
Apply a light coat of engine oil on the
threads and under the bearing cap
bolts. |
| (2) |
Using the SST (09221-4A000), install and
uniformly tighten the 10 bearing cap bolts, in several passes,
in the sequence shown.
Tightening torque
14.7N.m (1.5kgf.m, 10.8lb-ft) +
27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.1lb-ft) +
120~125°
|
|
| (3) |
Check that the crankshaft turns
smoothly. | |
| 10. |
Check crankshaft end
play. |
| 11. |
Install piston and connecting rod
assemblies.
|
Before installing the pistons, apply a
coat of engine oil to the ring grooves and cylinder
bores. |
| (1) |
Remove the connecting rod caps, and slip
short sections of rubber hose over the threaded ends of the
connecting rod bolts. |
| (2) |
Install the ring compressor, check that
the bearing is securely in place, then position the piston in
the cylinder, and tap it in using the wooden handle of a
hammer. |
| (3) |
Stop after the ring compressor pops
free, and check the connecting rod-to-check journal alignment
before pushing the piston into
place. |
| (4) |
Apply engine oil to the bolt threads.
Using the SST (09221-4A000), install the rod caps with
bearings, and torque the bolts.
Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m,
13.0~15.9lb-ft) + 88~92°
|
|
Always use new connecting rod cap
bolts. |
|
Maintain downward force on the
ring compressor to prevent the rings from expanding
before entering the cylinder
bore. |
| |
| 12. |
Apply liquid gasket to the mating surface of
cylinder block and ladder frame.
| •
|
When assembling ladder frame, the
liquid sealant Loctite 5900H, Threebond 1217H or
equivalent should be applied ladder
frame. |
| •
|
The part must be assembled within
5 minutes after sealant was
applied. |
| •
|
Apply sealant to the inner threads
of the bolt
holes. | |
|
| 13. |
Install ladder frame (A) with 10 bolts, in
several passes, in sequence shown.
Tightening
torque
Step 1 : 8.8 ~ 9.8N.m (0.9 ~ 1.0kgf.m,
6.5 ~ 7.2lb-ft)
Step 2 : 17.7 ~20.6N.m (1.8 ~ 2.1kgf.m,
13.0 ~ 15.2lb-ft)
Step 3 : 27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m,
20.3 ~ 23.1lb-ft)
|
| (1) |
Tighten the bolts in order number as
shown with the 3 steps. |
| (2) |
Loosen the bolts as reverse tightening
order. |
| (3) |
Tighten the bolts in order number as
shown with the 3 steps. |
|
| 14. |
Install rear oil seal.
| (1) |
Apply engine oil to a new oil seal
lip. |
| (2) |
Using SST (09231-H1100, 09214-3K100) (B)
and a hammer, tap in the oil seal (A) until its surface is
flush with the rear oil seal retainer edge.
| |
| 15. |
Install CKPS (Crankshaft position sensor) (A)
and sensor cover.
Tightening
torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~
8.7lb-ft)
|
|
| 16. |
Install oil pressure switch.
| (1) |
Apply adhesive to 2 or 3
threads.
Adhesive : MS 721-39 (B) or
equivalent. |
| (2) |
Install the oil pressure switch
(A).
Tightening torque
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8
~ 8.7lb-ft)
|
| |
| 17. |
Install knock sensor (A).
Tightening
torque
18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m, 13.7 ~
17.4lb-ft)
|
|
| 18. |
Install oil level gauge assembly.
| (1) |
Install a new O-ring on the oil level
gauge. |
| (2) |
Apply engine oil on the
O-ring. |
| (3) |
Install the oil level gauge assembly (A)
with the bolt.
Tightening torque
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m,
5.8 ~ 8.7 lb-ft)
|
| |
| 19. |
Install tensioner assembly integrated bracket
(A).
Tightening
torque
39.2 ~ 44.1 N.m (4.0 ~ 4.5 kgf.m, 28.9 ~
32.5 lb-ft)
|
|
| 20. |
Install the water pump.
(Refer to Cooling system in this
group) |
| 21. |
Install the alternator.
(Refer to EE
group) |
| 22. |
Install the balance shaft & oil pump
assembly.
(Refer to Lubrication system in this
group) |
| 23. |
Install the cylinder head
assembly.
(Refer to Cylinder head in this group)
|
| 24. |
Install the timing chain.
(Refer to Timing system in this group)
|
| 25. |
Install the intake manifold and exhaust
manifold.
(Refer to Intake and exhaust system in this
group) |
| 26. |
Remove the engine from the engine
stand. |
| 27. |
AT : Install the drive plate (A) and the
adapter plate (B) (AT).
Tightening
torque :
117.7 ~ 127.5 N.m (12.0 ~ 13.0 kgf.m,
86.8 ~ 93.9 lb-ft)
|
MT : Install the flywheel.
Tightening
torque :
117.7 ~ 127.5 N.m (12.0 ~ 13.0 kgf.m,
86.8 ~ 93.9 lb-ft)
|
| •
|
Always use new drive plate (or
flywheel) bolts. |
| •
|
Apply sealant to the screw part
(10mm from the end of the bolt) when reusing the drive
plate bolts.
Sealant : Three
bond 2403, Loctite 200 or 204
| |
| •
|
Install and uniformly tighten the
7 bolts, in several
passes. | | |
| 28. |
Install the engine assembly on the
vehicle.
(Refer to Engine and transaxle assembly in
this group)
Add all fluids to their normal operating
levels. | |
