Beruflich Dokumente
Kultur Dokumente
GROUP 11B
ENGINE OVERHAUL
CONTENTS
GENERAL SPECIFICATIONS . . . . . . 11B-2 OIL PAN AND TIMING CHAIN CASE 11B-26
REMOVAL AND INSTALLATION . . . . . . . . 11B-26
SERVICE SPECIFICATIONS. . . . . . . 11B-2
TIMING CHAIN . . . . . . . . . . . . . . . . . . 11B-32
FASTENER TIGHTENING REMOVAL AND INSTALLATION . . . . . . . . 11B-32
SPECIFICATIONS . . . . . . . . . . . . . . . 11B-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-37
GENERAL SPECIFICATIONS
M1113000201501
Descriptions Specifications
Engine type 4B11
Bore × stroke mm (in) 86 (3.39) × 86 (3.39)
Total displacement cm3 (cu in) 1,998 (121.9)
Combustion chamber Pent-roof type
Number of cylinders 4
Valve mechanism Type DOHC
Intake valve 8
Exhaust valve 8
Compression ratio 10.0
Valve timing Intake valve Opens (BTDC) 25° −0° <CALIFORNIA>,
28° −3° <Except CALIFORNIA>
Closes (ABDC) 48° −23° <CALIFORNIA>,
45° −20° <Except CALIFORNIA>
Exhaust valve Opens (BBDC) 24° −44° <CALIFORNIA>,
21° −41° <Except CALIFORNIA>
Closes (ATDC) 0° −20° <CALIFORNIA>,
3° −23° <Except CALIFORNIA>
Fuel injection system type Electronic control MPI
Ignition system type Electronic spark-advance control type (4-coil
type)
Generator type Alternating current system (with built-in IC
regulator)
Starter motor type Reduction drive type
SERVICE SPECIFICATIONS
M1113000301627
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ENGINE OVERHAUL
SERVICE SPECIFICATIONS
11B-3
Item Standard value Limit
Overall length of valve mm (in) Intake 113.18 (4.456) 112.68 (4.436)
Exhaust 105.89 (4.169) 105.39 (4.149)
Valve margin mm (in) Intake 1.022 (0.0402) 0.522 (0.0206)
Exhaust 1.094 (0.0431) 0.594 (0.0234)
Free height of valve spring mm (in) 47.44 (1.868) 46.44 (1.828)
Squareness of valve spring 2° or less 4°
Clearance between valve guide Intake 0.020 −0.047 0.10 (0.004)
and valve stem mm (in) (0.0008 −0.0019)
Exhaust 0.030 −0.054 0.15 (0.006)
(0.0012 −0.0021)
Valve seat contact width mm Intake 1.16 −1.46 (0.046 −0.058) −
(in) Exhaust 1.35 −1.65 (0.053 −0.065) −
Oversize rework dimensions of 0.25 oversize 11.23 −11.25 −
valve guide hole mm (in) diameter (0.442 −0.443)
Intake oversize rework 0.3 oversize 36.22 −36.24 −
dimensions of valve seat hole diameter (1.426 −1.427)
mm (in)
Exhaust oversize rework 0.3 oversize 30.22 −30.24 −
dimensions of valve seat hole diameter (1.190 −1.191)
mm (in)
Piston and connecting rod
Piston pin press-fit load N (pound) 7,500 −17,500 −
(1,686 −3,934)
Clearance between piston ring No.1 0.03 −0.07 (0.001 −0.003) 0.1 (0.004)
and ring groove mm (in) No.2 0.03 −0.07 (0.001 −0.003) 0.1 (0.004)
Piston ring end gap mm (in) No.1 0.15 −0.28 (0.006 −0.011) 0.8 (0.03)
No.2 0.30 −0.45 (0.012 −0.018) 0.8 (0.03)
Oil 0.10 −0.35 (0.004 −0.014) 1.0 (0.004)
Clearance of connecting rod big end thrust mm (in) 0.10 −0.25 (0.004 −0.010) 0.4 (0.016)
Outside diameter of connecting rod bolt mm (in) − 0.1 (0.004)
Connecting rod bearing oil clearance mm (in) 0.018 −0.045 0.1 (0.004)
(0.0007 −0.0018)
Crankshaft and cylinder block
Underhead length of bearing cap bolt mm (in) 75.3 (2.96) −
Crankshaft end play mm (in) 0.05 −0.25 (0.002 −0.010) 0.4 (0.016)
Crankshaft journal oil clearance mm (in) 0.012 −0.030 0.1 (0.004)
(0.0005 −0.0012)
Distortion of cylinder block top surface mm (in) 0.05 (0.002) 0.02 (0.0008)
Grinding limit of cylinder block top surface mm (in) − 0.2 (0.008)
Cylinder block cylinder bore mm (in) 86 (3.4) −
Cylindricity of cylinder block mm (in) 0.15 (0.006) −
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11B-4 ENGINE OVERHAUL
FASTENER TIGHTENING SPECIFICATIONS
Item Specification
Generator and ignition system
Idler pulley bolt 48 ± 7 N⋅ m (36 ± 4 ft-lb)
Auto tensioner 22 ± 4 N⋅ m (17 ± 2 ft-lb)
Crankshaft bolt 210 N⋅ m (155 ft-lb)
Generator nut 44 ± 10 N⋅ m (32 ± 7 ft-lb)
Generator bolt 44 ± 10 N⋅ m (32 ± 7 ft-lb)
Ignition coil bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
Spark plug 25 ± 5 N⋅ m (19 ± 3 ft-lb)
Power steering pump bracket bolt (M8) 23 ± 2 N⋅ m (17 ± 1 ft-lb)
Power steering pump bracket bolt (M10) 44 ± 8 N⋅ m (33 ± 5 ft-lb)
Throttle body and EGR system
Vacuum pump assembly bolt (M6) 11 ± 1 N⋅ m (98 ± 8 in-lb)
Vacuum pump assembly bolt (M8) 24 ± 3 N⋅ m (18 ± 1 ft-lb)
Throttle body bolt 9.5 ± 2.5 N⋅ m (84 ± 22 in-lb)
Throttle body stay bolt 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Exhaust gas recirculation valve support bolt 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Exhaust gas recirculation pipe bolt 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Exhaust gas recirculation support stay A bolt 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Exhaust gas recirculation support stay B bolt 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Exhaust gas recirculation valve bolt 24 ± 3 N⋅ m (18 ± 1 ft-lb)
Manifold absolute pressure (MAP) sensor screw 4.0 ± 1.0 N⋅ m (36 ± 8 in-lb)
Solenoid valve screw 4.0 ± 1.0 N⋅ m (36 ± 8 in-lb)
Intake manifold and fuel system
Oil dipstick guide bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
Injector protector rear bolt 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Fuel rail bolt 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Intake manifold nut 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Intake manifold assembly bolt washer 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Intake manifold stay bolt 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Injector protector front bolt 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Generator bracket bolt 44 ± 8 N⋅ m (33 ± 5 ft-lb)
Knock sensor bolt 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Engine oil pressure switch 10 ± 2 N⋅ m (89 ± 17 in-lb)
Exhaust manifold
Exhaust manifold upper cover bolt 14 ± 1 N⋅ m (124 ± 8 in-lb)
Exhaust manifold lower cover bolt 14 ± 1 N⋅ m (124 ± 8 in-lb)
Exhaust manifold nut 49 ± 5 N⋅ m (36 ± 3 ft-lb)
Exhaust manifold bracket D bolt 20 ± 5 N⋅ m (15 ± 3 ft-lb)
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ENGINE OVERHAUL
FASTENER TIGHTENING SPECIFICATIONS
11B-5
Item Specification
Exhaust manifold bracket bolt 41 ± 10 N⋅ m (30 ± 7 ft-lb)
Exhaust manifold bracket A, B bolt 41 ± 10 N⋅ m (30 ± 7 ft-lb)
Crankshaft position sensor bolt 11 ± 1 N⋅ m (98 ± 8 in-lb)
Crankshaft position sensor cover bolt (M6) 11 ± 1 N⋅ m (98 ± 8 in-lb)
Crankshaft position sensor cover bolt (M10) 49 ± 6 N⋅ m (36 ± 4 ft-lb)
Water hose and pipe
Water inlet fitting bolt 24 ± 3 N⋅ m (18 ± 1 ft-lb)
Water outlet fitting bolt 24 ± 3 N⋅ m (18 ± 1 ft-lb)
Thermostat housing bolt 24 ± 3 N⋅ m (18 ± 1 ft-lb)
Engine hanger bolt 28 ± 8 N⋅ m (21 ± 5 ft-lb)
Engine coolant temperature sensor 30 ± 9 N⋅ m (22 ± 6 ft-lb)
Water pump bolt 24 ± 3 N⋅ m (18 ± 1 ft-lb)
Water pipe nut 24 ± 3 N⋅ m (18 ± 1 ft-lb)
Camshaft position sensor 11 ± 1 N⋅ m (98 ± 8 in-lb)
Oil pan and timing chain case
Cylinder head cover bolt 3.0 ± 1.0 N⋅ m (27 ± 8 in-lb)
→5.5 ± 0.5 N⋅ m (49 ± 8 in-lb)
Timing chain case bolt (M6) 10 ± 2 N⋅ m (89 ± 17 in-lb)
Timing chain case bolt (M8 × 10) 13 ± 1 N⋅ m (115 ± 8 in-lb)
Timing chain case bolt (M8 × 28) 24 ± 4 N⋅ m (18 ± 2 ft-lb)
Oil pan bolt (M6) 10 ± 2 N⋅ m (89 ± 17 in-lb)
Oil pan bolt (M8) 29 ± 2 N⋅ m (21 ± 1 ft-lb)
Air compressor bracket bolt 23 ± 6 N⋅ m (17 ± 4 ft-lb)
Oil drain plug 39 ± 5 N⋅ m (29 ± 3 ft-lb)
Oil filter 14 ± 2 N⋅ m (124 ± 17 in-lb)
PCV valve 2.5 ± 0.4 N⋅ m (22 ± 3 in-lb)
Engine support bracket assembly washer bolt 45 ± 5 N⋅ m (33 ± 3 ft-lb)
Timing chain
Chain upper guide bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
Oil jet bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
V.V.T. intake sprocket bolt 59 ± 5 N⋅ m (44 ± 3 ft-lb)
V.V.T. exhaust sprocket bolt 59 ± 5 N⋅ m (44 ± 3 ft-lb)
Timing chain tensioner bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
Tensioner lever bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
Timing chain guide bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
Camshaft
Engine oil control valve (OCV) bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
Camshaft bearing cap bolt (M6) 12 ± 1 N⋅ m (107 ± 8 in-lb)
Front camshaft bearing cap bolt (M8) 17 ± 3 N⋅ m (14 ± 2 ft-lb)
→30 ± 2 N⋅ m (22 ± 1 ft-lb)
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11B-6 ENGINE OVERHAUL
FASTENER TIGHTENING SPECIFICATIONS
Item Specification
Cylinder head and valves
Cylinder head bolt 35 ± 2 N⋅ m (26 ± 1 ft-lb) →+180°
Oil pump chain
Drive plate bolt 40 ± 2 N⋅ m (29 ± 1 ft-lb) →+30°
Flywheel bolt 40 N⋅ m (30 ft-lb) →130 N⋅ m (96 ft-lb)
Oil pump case bolt 26 ± 2 N⋅ m (19 ± 1 ft-lb)
Oil pump sprocket bolt 23 ± 2 N⋅ m (17 ± 1 ft-lb)
Oil pump tensioner lever bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
Oil pump chain guide bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
Ladder frame bolt 26 ± 1 N⋅ m (19 ± 1 ft-lb)
Piston and connecting rod
Connecting rod cap bolt 5.0 N⋅ m (44 in-lb) →20 N⋅ m (15 ft-lb) →+90°
Crankshaft and cylinder block
Crankshaft sensing ring bolt 11 ± 1 N⋅ m (98 ± 8 in-lb)
Bearing cap bolt 26.5 ± 2.0 N⋅ m (20 ± 1 ft-lb) →+45°
NEW TIGHTENING METHOD BY USING PLASTIC REGION TIGHTENING BOLT
2. Bearing cap bolt
.
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ENGINE OVERHAUL
SEALANTS AND ADHESIVES
11B-7
SEALANTS AND ADHESIVES
M1113000501494
SPECIAL TOOLS
M1113000601899
MB991883
B991396
D998727
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11B-8 ENGINE OVERHAUL
SPECIAL TOOLS
MB992089 MB992089-01
Retainer holder C
MB991659 −
Guide D
MB991614
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ENGINE OVERHAUL
SPECIAL TOOLS
11B-9
Tool Tool number and Supersession Application
name
MB991367 − Removal and installation of oil
Special spanner pump sprocket
B991367
MB991385 −
Pin
B991385
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11B-10 ENGINE OVERHAUL
GENERATOR AND IGNITION SYSTEM
10 ± 2 N·m
89 ± 17 in-lb
9
25 ± 5 N·m
19 ± 3 ft-lb
10
23 ± 2 N·m
17 ± 1 ft-lb
44 ± 8 N·m
33 ± 5 ft-lb
5
8 4
2
48 ± 7 N·m
36 ± 4 ft-lb
22 ± 4 N·m
17 ± 2 ft-lb
7 1
44 ± 10 N·m
6 48 ± 7 N·m 32 ± 7 ft-lb
36 ± 4 ft-lb 44 ± 10 N·m
210 N·m 32 ± 7 ft-lb
155 ft-lb
AK600613AD
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ENGINE OVERHAUL
GENERATOR AND IGNITION SYSTEM
11B-11
REMOVAL SERVICE POINT
.
AK502869 AD
MB991398
Spark plug
AK600875AC
Spark plug
AK600875AC
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11B-12 ENGINE OVERHAUL
GENERATOR AND IGNITION SYSTEM
AK503335 AD
: Wipe clean with a rag. 2. Wipe off the dirt on the washer and on the thread hole of the
: Wipe clean with a rag and degrease. crankshaft using a rag.
: Wipe clean with a rag, degrease and 3. Wipe off the dirt on the crankshaft pulley and the crankshaft
apply a small amount of engine oil.
sprocket using a rag, and then remove the grease from the
portion shown in the illustration.
NOTE: Remove grease to prevent the coefficient of friction
of the pressing portion from declining due to adhesion of oil.
Washer Crankshaft 4. Install the crankshaft pulley.
sprocket
5. Apply an appropriate and minimum amount of engine oil to
the threaded portion of the crankshaft and lower part of the
flange.
6. With off the chamfered side on the inside of the washer
facing the bolt top, install the washer to the crankshaft pulley
bolt.
Crankshaft Crankshaft 7. Tighten the crankshaft pulley bolt to the specified torque.
pulley bolt
Specified torque: 210 N⋅ m (155 ft-lb)
Crankshaft pulley
Engine front
AK602911AD
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ENGINE OVERHAUL
GENERATOR AND IGNITION SYSTEM
11B-13
>>C<< GENERATOR / POWER STEERING PUMP
BRACKET INSTALLATION
Power steering 1. Temporarily tighten power steering pump bracket bolts.
pump bracket 2. Temporarily tighten generator bolts.
1 3. Tighten them to the specified torque according to the order
as illustrated.
Specified torque
Power steering pump bracket:
M8 23 ± 2 N⋅ m (17 ± 1 ft-lb)
M10 44 ± 8 N⋅ m (33 ± 5 ft-lb)
Generator: 44 ± 10 N⋅ m (32 ± 7 ft-lb)
Generator
5 75 mm
2 (2.95 in)
80 mm
3 (3.15 in)
4
AK503383AD
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11B-14 ENGINE OVERHAUL
THROTTLE BODY AND EGR SYSTEM
2
3
11 ± 1 N·m
4 98 ± 8 in-lb
1
24 ± 3 N·m
18 ± 1 ft-lb
9.5 ± 2.5 N·m
84 ± 22 in-lb
6 20 ± 2 N·m
15 ± 1 ft-lb
7 12
11 20 ± 2 N·m
8 15 ± 1 ft-lb
13
16 20 ± 2 N·m 24 ± 3 N·m
14 15 ± 1 ft-lb 18 ± 1 ft-lb
18
9
10
17
20 ± 2 N·m 15
15 ± 1 ft-lb
20 20 ± 2 N·m
19 15 ± 1 ft-lb
5
4.0 ± 1.0 N·m
36 ± 8 in-lb
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ENGINE OVERHAUL
THROTTLE BODY AND EGR SYSTEM
11B-15
Removal steps (Continued)
19.Solenoid valve
20.O-ring
>>A<< 21.Manifold absolute pressure (MAP)
sensor
22.O-ring
Exhaust gas
recirculation valve AK503321AD
Protrusion AK503320AD
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11B-16 ENGINE OVERHAUL
THROTTLE BODY AND EGR SYSTEM
6 3
4 5
7
1
10 2
9 AK503289AD
Shaded position
AK503319AE
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ENGINE OVERHAUL
INTAKE MANIFOLD AND FUEL SYSTEM
11B-17
INTAKE MANIFOLD AND FUEL SYSTEM
REMOVAL AND INSTALLATION
M1113032500144
6
20 ± 2 N·m
11 15 ± 1 ft-lb
8 3
9
10 20 ± 2 N·m
7 15 ± 1 ft-lb
5
4 20 ± 2 N·m
15 ± 1 ft-lb
17
20 ± 2 N·m
15 ± 1 ft-lb
20 ± 2 N·m
21 15 ± 1 ft-lb
16
15
20 ± 2 N·m
22 15 ± 1 ft-lb 14
10 ± 2 N·m 20 ± 2 N·m
89 ± 17 in-lb 15 ± 1 ft-lb
13 20 ± 2 N·m
1 15 ± 1 ft-lb
20 12 20 ± 2 N·m
2 15 ± 1 ft-lb
44 ± 8 N·m
33 ± 5 ft-lb
18
10 ± 2 N·m
89 ± 17 in-lb
19 AK603507 AB
A A AK503595AC
AK502727AD
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ENGINE OVERHAUL
INTAKE MANIFOLD AND FUEL SYSTEM
11B-19
>>E<< O-RING INSTALLATION
CAUTION
Do not allow engine oil to enter the fuel rail.
When inserting an O-ring into the injector on the injection noz-
zle side, use special tool MB992106 to gradually expand the
O-ring, and fit it in place.
MB992106
AK502784AD
AK502744
AK502745
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11B-20 ENGINE OVERHAUL
INTAKE MANIFOLD AND FUEL SYSTEM
AK603524 AB
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ENGINE OVERHAUL
EXHAUST MANIFOLD
11B-21
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
M1113004901320
49 ± 5 N·m 3
36 ± 3 ft-lb
11 ± 1 N·m
98 ± 8 in-lb
49 ± 6 N·m 11 ± 1 N·m
36 ± 4 ft-lb 98 ± 8 in-lb
20 ± 5 N·m 4 5
15 ± 3 ft-lb 9
6
8
41 ± 10 N·m
30 ± 7 ft-lb 14 ± 1 N·m
10
124 ± 8 in-lb
2
AK603508 AB
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11B-22 ENGINE OVERHAUL
EXHAUST MANIFOLD
<For CALIFORNIA>
14 ± 1 N·m
124 ± 8 in-lb 5
49 ± 5 N·m
36 ± 3 ft-lb 7 11 ± 1 N·m
98 ± 8 in-lb
49 ± 6 N·m 11 ± 1 N·m
36 ± 4 ft-lb 98 ± 8 in-lb
2 3
1
4
41 ± 10 N·m
30 ± 7 ft-lb
6 8
14 ± 1 N·m
124 ± 8 in-lb
AK603581 AB
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ENGINE OVERHAUL
EXHAUST MANIFOLD
11B-23
INSTALLATION SERVICE POINTS
.
Exhaust manifold
bracket A AK502376 AD
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11B-24 ENGINE OVERHAUL
WATER HOSE AND PIPE
24 ± 3 N·m
10 18 ± 1 ft-lb
30 ± 9 N·m
11 12 22 ± 6 ft-lb 4
24 ± 3 N·m
5 18 ± 1 ft-lb
3
28 ± 8 N·m 24 ± 3 N·m 1
21 ± 5 ft-lb 15 18 ± 1 ft-lb
16 6
17 7
24 ± 3 N·m
18 ± 1 ft-lb
11 ± 1 N·m 2
98 ± 8 in-lb 8
9
18
19
11 ± 1 N·m
98 ± 8 in-lb
13
14
AK502857AD
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ENGINE OVERHAUL
WATER HOSE AND PIPE
11B-25
INSTALLATION SERVICE POINTS
.
Jiggle valve
AK304916 AC
AK502544 AD
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11B-26 ENGINE OVERHAUL
OIL PAN AND TIMING CHAIN CASE
1
11
10
4
2.5 ± 0.4 N·m
3 22 ± 3 in-lb
16
10 ± 2 N·m 2
89 ± 17 in-lb
13 ± 1 N·m
115 ± 8 in-lb
45 ± 5 N·m 10 ± 2 N·m
33 ± 3 ft-lb 89 ± 17 in-lb 14 ± 2 N·m
9 124 ± 17 in-lb
8
14 15 13
24 ± 4 N·m
18 ± 2 ft-lb 10 ± 2 N·m
7 89 ± 17 in-lb
39 ± 5 N·m 29 ± 2 N·m
29 ± 3 ft-lb 21 ± 1 ft-lb
12 23 ± 6 N·m
17 ± 4 ft-lb
AK603510AB
Removal steps Removal steps (Continued)
1. Breather hose <<A>> >>E<< 9. Oil filter
2. PCV hose >>D<< 10. Cylinder head cover
3. PCV valve 11. Cylinder head cover gasket
4. O-ring 12. Air compressor bracket
5. Oil filler cap <<B>> >>C<< 13. Oil pan
6. O-ring 14. Engine support bracket
7. Oil drain plug >>B<< 15. Front oil seal
8. Oil drain plug gasket <<C>> >>A<< 16. Timing chain case
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ENGINE OVERHAUL
OIL PAN AND TIMING CHAIN CASE
11B-27
REMOVAL SERVICE POINTS
.
MB991396
AK502733AD
Groove AK502874AD
AK502732AD
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11B-28 ENGINE OVERHAUL
OIL PAN AND TIMING CHAIN CASE
Hammer
AK502907AD
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ENGINE OVERHAUL
OIL PAN AND TIMING CHAIN CASE
11B-29
CAUTION
Install the timing chain case within three minutes after
applying liquid gasket.
4.5 ± 0.5 mm 3. Apply liquid gasket (Three bond 1217G, LOCTITE 5900,
(0.18 ± 0.02 in) 5970, 5971 or equivalent) of 2.5 ± 0.5 mm (0.10 ± 0.02 inch)
in thickness to the timing chain case. For illustrated A
A locations, however, apply liquid gasket of 4.5 ± 0.5 mm (0.18
A A
± 0.02 inch) in diameter or liquid gasket of 2.5 ± 0.5 mm
A Ø4.5 ± 0.5 mm (0.10 ± 0.02 inch) by putting one on top of another as shown
(0.18 ± 0.02 in)
in the illustration.
B BA 3 ± 0.5 mm
A
(0.118 ± 0.02 in) 4. Install the timing chain case.
2.5 mm NOTE: Be careful when install mounting bolts as they are
(0.098 in)
different in length.
Ø2.5 ± 0.5 mm
(0.10 ± 0.02 in)
3 ± 0.5 mm 1 ± 0.5 mm
(0.118 ± 0.02 in) (0.04 ± 0.02 in) Ø2.5 ± 0.5 mm
(0.10 ± 0.02 in)
Ø2.5 ± 0.5 mm
(0.10 ± 0.02 in)
B
C B
D
B B
A
A
A: M8 × 28 mm (1.1 in)
B: M6 × 25 mm (1.0 in)
C: M6 × 25 mm (1.0 in)
D: M8 × 10 mm (0.4 in) AK502378 AD
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11B-30 ENGINE OVERHAUL
OIL PAN AND TIMING CHAIN CASE
MB991448
AK502802AD
AK502734AH
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ENGINE OVERHAUL
OIL PAN AND TIMING CHAIN CASE
11B-31
13
4. Tighten the cylinder head cover to the tightening torque of
1 6 7 8 14 3.0 ± 1.0 N⋅ m (27 ± 8 in-lb) in the order shown in the
illustration.
5. Then, tighten it to the specified torque in the same order.
18 5 2 9 Specified torque: 5.5 ± 0.5 N⋅ m (49 ± 4 in-lb)
12 15
4 3 10 16
17 11
AK502760AF
AK305422 AD
CAUTION
Use special tool MB991396 to install the oil filter. Tighten-
ing it by hand causes oil leakage due to lack of torque.
3. Screw in the oil filter. When the O-ring contacts the mounting
MB991396 surface, use a filter wrench to tighten it
Specified torque: 3/4 turn (14 ± 2 N⋅ m [124 ± 17 in-lb]).
AK502733AD
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11B-32 ENGINE OVERHAUL
TIMING CHAIN
TIMING CHAIN
REMOVAL AND INSTALLATION
M1113026600261
59 ± 5 N·m 8
44 ± 3 ft-lb
10
7
10 ± 2 N·m
89 ± 17 in-lb
1
10 ± 2 N·m
89 ± 17 in-lb
10 ± 2 N·m
89 ± 17 in-lb 9
59 ± 5 N·m 6
44 ± 3 ft-lb
3 5
10 ± 2 N·m 10 ± 2 N·m
89 ± 17 in-lb 89 ± 17 in-lb
AK502933 AD
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ENGINE OVERHAUL
TIMING CHAIN
11B-33
REMOVAL SERVICE POINTS
.
AK502737
AK502736
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11B-34 ENGINE OVERHAUL
TIMING CHAIN
AK502739
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ENGINE OVERHAUL
TIMING CHAIN
11B-35
4. Hold the hexagonal portion of the camshaft with a wrench
and tighten the camshaft sprocket bolt to the specified
torque.
Specified torque: 59 ± 5 N⋅ m (44 ± 3 ft-lb)
AK502738
Crankshaft key
AK502924 AD
AK502910AD
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11B-36 ENGINE OVERHAUL
TIMING CHAIN
4. Align the link plate (orange) with the timing mark of the
Timing mark Link plate
(orange)
intake V.V.T. sprocket to loop the timing chain.
Rotate the intake V.V.T. sprocket by one or two teeth to
align with the timing mark.
AK502757AD
5. Align the timing mark of the crankshaft sprocket with the link
plate (orange) to loop the timing chain. Because of timing
chain slacks, hold it to prevent the timing mark from coming
off the link plate (orange).
Link plate
(orange)
Timing mark
AK603512AB
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ENGINE OVERHAUL
TIMING CHAIN
11B-37
>>D<< TIMING CHAIN TENSIONER
INSTALLATION
1. Install the timing chain tensioner on the cylinder block and
Ratchet release hole
tighten it to the specified torque.
Wire Specified torque: 11 ± 1 N⋅ m (98 ± 8 in-lb)
2. Remove the hard wire (piano wire or the like) of φ1.5 or
hexagonal bar wrench (1.5 mm [0.05 inch]) from the timing
chain tensioner. This enables the plunger of the timing chain
tensioner to push the tensioner lever to keep the timing
Plunger fixed
chain tight.
hole
AK502854 AG
INSPECTION
M1113026700213
.
AK502968AE
Exhaust valve side 2. Valve clearance can be measured at the illustrated location
No.1 No.3 in this condition.
7
5
1
3
9
1 1
6
4
8
8
6
2
4
1 2
1 0
5
1
No.1 No.2
Intake valve side AK502387AG
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11B-38 ENGINE OVERHAUL
TIMING CHAIN
AK502758
AK502545AG
Exhaust valve side 6. Valve clearance can be measured at the illustrated location
No.2 No.4 in this condition.
7. If measured values are out of the standard value, record
7
5
1
3
measured values.
9
1 1
6
4
8
6
2
4
5
1
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ENGINE OVERHAUL
CAMSHAFT
11B-39
CAMSHAFT
REMOVAL AND INSTALLATION
M1113026900176
7
17 ± 3 N·m → 30 ± 2 N·m 8
14 ± 2 ft-lb 22 ± 1 ft-lb 7 12 ± 1 N·m
107 ± 8 in-lb
7
8
6
7
5 6 11
9 10
12
10 ± 2 N·m
89 ± 17 in-lb
1
2
4
3
10 ± 2 N·m
89 ± 17 in-lb
AK502934 AD
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11B-40 ENGINE OVERHAUL
CAMSHAFT
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ENGINE OVERHAUL
CAMSHAFT
11B-41
3. The identification color of the camshaft bearing is painted at
the illustrated position.
Identification
color
AK502970 AD
AK502390 AD
8 4 2 6
8 4 2 6
7 3 1 5
AK503813 AD
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11B-42 ENGINE OVERHAUL
CAMSHAFT
Timing chain side 7. Tighten each front camshaft bearing cap mounting bolt to
(1) (2) the temporarily torque of 17 ± 3 N⋅ m (14 ± 2 ft-lb) in the
order shown (1).
4 1
8. Tighten each front camshaft bearing cap mounting bolt to
3 3 the specified torque in the order shown (2).
Specified torque: 30 ± 2 N⋅ m (22 ± 1 ft-lb)
2 4
1 2
AK503814AD
AK303651AF
INSPECTION
M1113027000154
.
CAMSHAFT
Measure camshaft height (camshaft major axis). If the height is
less than the limit, replace the camshaft.
Standard value:
Intake: 43.25 mm (1.703 inches)
Exhaust: 45.00 mm (1.772 inches)
Limit:
Intake: 42.75 mm (1.683 inches)
Exhaust: 44.50 mm (1.752 inches)
AK503020AD
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ENGINE OVERHAUL
CAMSHAFT
11B-43
CAMSHAFT OIL CLEARANCE (PLASTIGAGE
METHOD)
1. Thoroughly wipe oil on the outside diameter of the camshaft
and the inside diameter of the bearing.
2. Install the bearing to the camshaft.
3. Put straightly the plastigage having the length of the bearing
width on the journal axis, centering the axis.
Plastigage 4. Carefully install the bearing cap.Tighten the bolt as
instructed in >>B<< Bolt Installation Point.
5. Remove the bolt and the bearing cap carefully.
AK503390 AD
VALVE TAPPET
Wall thickness 1. Measure the valve tappet at the illustrated position. If the
measured value is not in agreement with the value in the
table corresponding to the identification mark, replace the
valve tappet.
AK304938 AE
Identification mark
AK502867AD
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11B-44 ENGINE OVERHAUL
CAMSHAFT
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ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-45
CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION
M1113006901597
35 ± 2 N·m
26 ± 1 ft-lb → +180˚
3
35 ± 2 N·m
26 ± 1 ft-lb → +180˚
1 4
2
8 7
11 12
21
13 15 9
16
18 17
19
10
20
14
AK604561 AB
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11B-46 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
AK502741AD
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ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-47
INSTALLATION SERVICE POINTS
.
AK503378AE
2. Use special tool MD998737 to press fit the valve stem seal
into the valve guide with the valve stem used as a guide.
MD998737
AK502742AD
MD998735
AK502741AD
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11B-48 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
Degreasing
AK602942AD
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ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-49
>>D<< CYLINDER HEAD BOLT INSTALLATION
1. Install new cylinder head bolts and washers in the following
procedure.
NOTE: Cylinder head bolts and washers must not be
reused.
2. Apply an appropriate amount of engine oil to top and bottom
surfaces of washers and threaded portion of bolts.
3. Install cylinder head bolts to the cylinder head.
NOTE: Bolts and washers are different parts for bolts on the
timing chain side.
4. Tighten cylinder head bolts in several steps to the specified
Timing chain side
torque according to the assembly order shown.
Specified torque: 35 ± 2 N⋅ m (26 ± 1 ft-lb)
8 6 1 3 9
10 4 2 5 7
AK502392 AD
INSPECTION
M1113007001371
.
CYLINDER HEAD
1. Check the cylinder head for water leakage, gas leakage,
damage or cracks before cleaning.
2. Completely remove oil, scale, sealant, carbon, etc. After
cleaning oil passages, blow air to make sure that they are
not clogged.
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11B-50 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
CAUTION
The grinding limit shall be within 0.2 mm (0.008 inch) in
combination with the cylinder block to be assembled.
3. For the flatness on the cylinder head bottom, measure
distortion using a straight edge and thickness gauge. If the
distortion exceeds the limit, grind and repair it.
Distortion on bottom
Standard value: Within 0.05 mm (0.002 inch)
Limit: 0.02 mm (0.0008 inch)
Grinding limit: 0.2 mm (0.008 inch)
AK502740 Cylinder head height: 128.5 mm (5.06 inches)
.
VALVE
1. Repair the valve seat if contact with the valve seat is poor,
uneven or broken.
2. Measure the margin.
If the limit is exceeded, replace the valve.
The bottom of valve
seat contact facet Standard value:
Intake 1.022 mm (0.0402 inch)
Exhaust 1.094 mm (0.0431 inch)
Margin
Limit:
Intake 0.522 mm (0.0206 inch)
AK305408AD
Exhaust 0.594 mm (0.0234 inch)
3. Measure overall length of the valve.
If the limit is exceeded, replace the valve.
Standard value:
Intake 113.18 mm (4.456 inches)
Exhaust 105.89 mm (4.169 inches)
Limit:
Length Intake 112.68 mm (4.436 inches)
Exhaust 105.39 mm (4.149 inches)
AK305409AD
VALVE SPRING
1. Measure free height of the spring.
Squareness
If the limit is exceeded, replace the spring.
Standard value: 47.44 mm (1.868 inch)
Limit: 46.44 mm (1.828 inch)
2. Measure squareness of the spring.
Free height If the inclination exceeds the limit, replace the spring.
Standard value: 2° or less
Limit: 4°
AK305410AD
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ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-51
VALVE GUIDE
Measure clearance between the valve guide and valve stem. If
the clearance exceeds the limit, replace the valve guide or
valve, or both.
Standard value:
Intake 0.020 −0.047 mm (0.0008 −0.0019 inch)
Valve
guide Exhaust 0.030 −0.054 mm (0.0012 −0.0021 inch)
Limit:
Intake 0.10 mm (0.004 inch)
Stem diameter Exhaust 0.15 mm (0.006 inch)
Guide inside diameter AK300168 AF
VALVE SEAT
Assemble the valve, then measure the contact width. If the
measurement exceeds the specified limit, replace the valve
seat.
Valve seat
Standard value
Contact width Intake: 1.16 −1.46 mm (0.046 −0.058 inch)
Exhaust: 1.35 −1.65 mm (0.053 −0.065 inch)
CAUTION
If the variation in the width exceeds 0.2 mm (0.008 inch)
even if the contact width is within the standard value,
AK601281AD
replace or correct the valve seat.
45˚ 45˚
60˚
AK503333AD
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11B-52 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
Cut
0.5 – 1 mm
(0.02 – 0.04 in)
AK300719AE
AK603511AB
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ENGINE OVERHAUL
OIL PUMP CHAIN
11B-53
OIL PUMP CHAIN
REMOVAL AND INSTALLATION
M1113033700011
3 2
40 ± 2 N·m
29 ± 1 ft-lb → +30˚
12
13
7
10 ± 2 N·m 26 ± 1 N·m
89 ± 17 in-lb 10 ± 2 N·m
89 ± 17 in-lb 19 ± 1 ft-lb
11
Apply engine oil to
all moving parts
before installation.
23 ± 2 N·m
10 26 ± 2 N·m
19 ± 1 ft-lb
17 ± 1 ft-lb
AK603506 AB
Removal steps Removal steps (Continued)
<<A>> >>F<< 1. Drive plate bolt <CVT> >>C<< 8. Oil pump tensioner lever
2. Adapter plate <CVT> >>C<< 9. Oil pump chain
3. Drive plate <CVT> <<B>> >>C<< 10. Oil pump sprocket
<<A>> >>E<< 4. Flywheel bolt <M/T> 11. Oil pump case
5. Flywheel <M/T> >>B<< 12. Crankshaft sprocket
>>D<< 6. Rear oil seal <<C>> >>A<< 13. Ladder frame
>>C<< 7. Oil pump chain guide
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11B-54 ENGINE OVERHAUL
OIL PUMP CHAIN
AK502869 AD
AK604583AB
AK502755AD
AK502756
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ENGINE OVERHAUL
OIL PUMP CHAIN
11B-55
INSTALLATION SERVICE POINTS
.
3 mm (0.12 in)
8.5 mm
3 mm (0.33 in)
(0.12 in)
AK502868AD
1 4
12
10 9 5 7
AK603522AB
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11B-56 ENGINE OVERHAUL
OIL PUMP CHAIN
AK604583AB
MD998718
AK502871AD
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ENGINE OVERHAUL
OIL PUMP CHAIN
11B-57
>>E<< FLYWHEEL BOLT INSTALLATION
1. Clean off sealant and oil of thread of crankshaft and flywheel
bolt.
2. Use special tool MB991883 to secure the flywheel.
MB991883
AK603577 AB
AK600847AC
6 5
3 AK603576 AB
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11B-58 ENGINE OVERHAUL
OIL PUMP CHAIN
AK503335 AD
CAUTION
• If the tightening angle is less than 30° , tightening per-
formance may not be secured. Use caution to the tight-
ening angle during tightening.
MB991614
• If the tightening angle becomes more than 30° , com-
pletely loosen bolts and start tightening over again
according to the procedure.
4. Use special tool MB991614 to tighten bolts 30° according to
30˚ the tightening order.
AK603584AB
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ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-59
PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
M1113008401811
6 7
5
10
11
9
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11B-60 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
Cylinder No.
AK502531AE
Guide A: 18.9 mm
(0.74 in)
Guide C
Guide A: 20.9 mm
(0.82 in)
Guide D
Base (MB991659)
Guide A: 21.9 mm
(0.86 in)
AK305415AE
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ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-61
1. Insert the push rod into the piston pin from the front mark
Front mark side of the piston top surface, and attach special tool
MB991659.
2. Set the piston and connecting rod assembly on the base so
A
20
that the front mark of the piston faces upward.
Push rod 3. Use a press to push the push rod and pull out the piston pin.
NOTE: After pulling out the piston pin, organize pistons, pis-
Pinston pin ton pins and connecting rods by cylinder No.
Front mark
Guide D
Base
AK603502 AB
J 1
J 2
J 3
J 4
J 5
AK503237AD
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11B-62 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
20
A
3. Align the front mark of the piston with that of the connecting
rod to assemble.
4. Apply engine oil to the circumference of the piston pin.
5. Insert the guide A side of the piston pin assembled in
section 1 into the pin hole from the front mark side of the
piston.
AK603503 AB
AK304891
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ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-63
>>C<< PISTON RING NO. 2 / PISTON RING NO. 1
INSTALLATION
Use a piston ring expander to assemble piston rings with their
identification marks facing upward. Piston rings can be assem-
bled by hand without using the piston ring expander.
Piston ring
expander
AK304892AD
Identification mark
Identification mark
No. 1 ring: 1T
No. 2 ring: 2T
No.1
No.2
AK502529 AE
AK502730
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11B-64 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
No.1
No.2
No.3
No.4
AK502527AD
Identification
Identification mark
color
AK502521 AD
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ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-65
If the outside of the cap is directly struck, the lateral force is
added to the broken-out section. Thus, pay attention to the bro-
ken-out section that might be difficult to be separated or might
fall.
Clean the broken-out section before the installation to the
engine, using compression air.
1. Assemble the bearing cap on the connecting rod by aligning
it with the mark put during removal. If a new connecting rod
without a mating mark is used, assemble so that the detent
notch of the bearing is on the same side as illustrated.
Cylinder No.
Notch 2
Front mark
AK503157AE
AK502752
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11B-66 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
INSPECTION
M1113008501368
.
PISTON RINGS
1. Check clearance between piston rings and ring grooves. If
the limit is exceeded, replace piston rings or piston, or both.
Standard value:
No. 1 ring: 0.03 −0.07 mm (0.001 −0.003 inch)
No. 2 ring: 0.03 −0.07 mm (0.001 −0.003 inch)
Limit: 0.1 mm (0.004 inch)
AK502751
2. Put piston rings into the cylinder bore, press them against
Please down ring the piston top face, and push them in. After achieving
with piston
squareness, measure the end gap with a thickness gauge. If
the end gap is excessive, replace piston rings.
Standard value:
No. 1 ring: 0.15 −0.28 mm (0.006 −0.011 inch)
No. 2 ring: 0.30 −0.45 mm (0.012 −0.018 inch)
Oil ring: 0.10 −0.35 mm (0.004 −0.014 inch)
Piston ring
End cap Limit:
AK603466 AB
No. 1 ring: 0.8 mm (0.03 inch)
No. 2 ring: 0.8 mm (0.03 inch)
Oil ring: 1.0 mm (0.04 inch)
.
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ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-67
3. Carefully install the connecting rod cap and tighten bolts to
the specified torque of 5.0 N⋅ m (44 in-lb) →20 N⋅ m (15
ft-lb) →+90° .
4. Remove bolts and gently remove the connecting rod cap.
Plastigage
AK503373 AD
Plastigage
AK503374AD
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11B-68 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
6 5
11 ± 1 N·m
98 ± 8 in-lb
4 3
AK604556AB
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ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-69
NOTE: If a tooth bends, be sure to replace the crankshaft sens-
ing ring with a new one.
4 3
2
Crankshaft sensing ring AK502865AD
Groove
AK502394 AE
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11B-70 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
No.3
No.4
No.5
J 1
J 2
J 3
J 4
J 5
AK502530 AD
Identification
Identification mark
color
AK502396 AD
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ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-71
>>D<< CRANKSHAFT BEARING LOWER
INSTALLATION
1. When replacing the crankshaft bearing lower, select a
Journal identification mark position
bearing with the size corresponding to the crankshaft journal
diameter in the table below.
No.1
No.2
No.3
No.4
No.5
AK502528AD
Identification
Identification mark
color
AK502418 AD
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11B-72 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
10 6 2 3 7
9 5 1 4 8
AK502395 AD
AK502750AD
AK503375
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ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-73
INSPECTION
M1113008801381
.
AK502747
AK502748
CYLINDER BLOCK
1. Visually check the cylinder block for scratch, rust and
corrosion. Use a flaw detecting agent to check for cracks. If
it is found faulty, repair or replace it.
2. Measure distortion on the top surface of the cylinder block
using a straight edge and thickness gauge.
If distortion exceeds the limit, grind and repair it.
A gasket or the like must not be adhered to the top surface
of the cylinder block during measurement.
Distortion on bottom
Standard value: Within 0.05 mm (0.0020 inch)
Limit: 0.02 mm (0.0008 inch)
Grinding limit: 0.2 mm (0.008 inch)
AK502746
3. Check the cylinder wall for scratch or seizure. If there is any
defect, replace the cylinder block.
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11B-74 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
AK503371AD
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