Engine Removal/lnstallation

Installation
Bracket Bolts Torque Specifications: P/S PUMP
BRACKET

SIDEEIIGII{E
t t 1.25m.D i'OUT{T BRACKET
2a 'tn (2,4 kgt ft,
17 tbtftl

10 x 1.25mm
54 t$m 15.5tgfm,
iO lbflrl

ALTERI{ATOR
10 x 125 mm BNACKET
il,a t*m {4.5 tgt'm,
d, tbtft) A/C @MPRESSOR
BRACIGT

t0 r 125 ]nm
a,l t+Jnll.5 lgf-rn,
3 tbf{tl

8 r 1.25mm
24 N.m 12.4kg{.m; 10 x 1.25mrn
17tbtfrl ,L il.tn {1.5 tgt m, :|:l lbf'ft}

5- 12
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 EngineInstallation: 2. Installthe upper bracket,then tightenthe nuts in the
numberedseauence.
lnstallthe enginein the reverseorderof removal.
Reinstallthe mount bolts/nutsin the followingsequence
Failureto follow these proceduresmay causeexcessrve
noiseand vibration.and reducebushinglife.
O 12 x 1.25mm A 12r1.25mm
7a N.m {7.5kgf'm, 7il N.m 17.5kgl'm,
1 . I n s t a l lt h e t r a n s m i s s i o nm o u n t a n d b r a c k e t t. h e n 54 tbf.trl 5,r lbt.ft)
tighten the bolts on the frame side. Do not tighten
the bolts/nutson the transmissionside.

A/T:
12x 1.25mm
TM'{SMISSION 6,aN.m16.5kgtr.m,
MOUNT 47 tbt f0

R
R

3. Installthe rear mount bracketmountingbolt. Do not

tightenthe bolt.

TRANSMISSION
MOUNT BRACKEY

M/T: TRANSMISSION
MOUNT

12x 1.25mm
64 N.m {6.5kgt.m,
47 tbl.ft)

MOUNN G BOLT
!, m, Replace.

(cont'd)

www.emanualpro.com 5-13
 EngineRemovaUlnstallation
(cont'd)
Installation
4. T i g h t e nt h e b o l t / n u t so n t h e t r a n s m i s s i o nm o u n t 5. Tightenthe rear mount bracketmountingbolt.
bracketin the numberedsequence.

AIT:

@ 12 x 1.25mm O 12x 1.25mm

?4 N.m {t.5 kgt.h, 6l .m (6.5kgtm,
5,4lbf.ftl 47 tbt{r} 12 x 1.25mm
59 N.m {6.0 lgl'm, ait lbf.ftl
Replace.

M/T:

i?. 12 x 1.25mm
74 N.m {7.5kgf'm.
s/rtbr.ftl

,,.....\.L}
@'...,'..4:

a1l12 x 1.25mm
64 N.m {6.5kgf.m,
47 lbf.ft)

5 - 14
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 Mount and Brackst Bolts/Nuts Torqus Value Specitications:

A: '10x 1.25mm
64 N.m 16.5kgI.m, 47 lb{.ftl
B: 12 x 1.25mm
59 N.m 16.0kgf.m, 43 lblft)
Replace.
C : 1 4x 1 . 5m m
8:l N.m (8.5kgt.m, 6r lbl'ft)
Replace.
D: 10x 1,25mm
,t4 N.m (4.5 kgf'm,33 lbIft)
Er 12x 1.25mm
83 N.m 18.5kgf.m, 61 lbl.ftl

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5-17
 ValveClearance
Adiustment
Adjustthe valvesonly when the cylinderheadtempera- Adjustthe valveson No. 1 cylinder.
ture is lessthan 100"F(38"C).
Intake: 0.08- 0.12mm (0.003- 0.005inl
1. Removethe cylinderheadcover. Exhaust:0.16- 0.20 mm (0.006- 0.008in)

Removethe middlecover(seepage6-11). Loosenthe locknut,and turn the adiustmentscrew

until the feeler gauge slides back and forth with a
"UP" mark on the slightamountof drag.
Set the No. 1 pistonat TDC.The
pulleysshouldbe at the top, and the TDC markson
the pulleysshouldalignwith the pointerson the back
LOCI(NUT
9 x 0.75m.n
25 N.m 12.5kgf.m, 18lbf.ft)

POINTER POINTER
Adiusting Screw Locations:

INTAKE

No.4 No.3 No.2 No. 1

EXHAUST

(cont'd)

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 ValveClearance v
Adjustment(cont'dl
6. Tightenthe locknut,and checkthe clearanceagajn. 8. Rotatethe crankshaft180"counterclockwise
to brinq
Repeatthe adjustmentif necessary. No. 4 pistonto TDC.
The "UP" marksshould be pointingstraightdown.
Adjustthe valveson No. 4 cylinder.

"UP" MARKS

GAUGE

7. (camshaft
Rotatethe crankshaft180"counterclockwise Rotatethe crankshaft180'counterclockwise
to brino
pulleyturns90'). No.2 pistonto TDC.
The "UP" marksshouldbe on the exhaustside.Adjust The "UP" marksshouldbe on the intakeside.Adiust
the valveson No.3 cylinder. the valveson No. 2 cylinder.

"UP" MARKS
.UP" MARKS

1 0 . Installthe cylinderheadcover(seepage6-32).

1 1 . Retorquethe crankshaftpulleybolt (seepage6-7).

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 CrankshaftPulleyand PulleyBolt
Replacement
When installingand tighteningthe pulley,follow the procedurebelow.

Clean,removeany oil, and lubricatepointsshown below.

C: Clean
x I Removeany oil
a: Lubricate
CRANKSHAFT
PULLEY

WASHER CRANKSHAFT

o
X X oooo o
X o o
X - oooo o
6r.
R
o".
X
X
^ oooo o
X X o
o
o

Crankshaftpulley bolt size and torque value:

14 x 1.25mm
177N'm (18.0kgf.m,130lbt.ftl

NOTE:Do not use an impactwrenchwhen installing.

HOLDERATTACHMENT.
50 mm, OFFSET
OTMAB- PY3OlOA
SOCKET,19 mm
07JAA- 001020A
{or Commercially
available}

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 TimingBelt
lllustratedIndex

CYLINDER HEAD
COVER
Referto page6-32
kgf.m, 7.2 tbtft) when installing.
HEADCOVERGASKET
\ Replacewhen leaking,
@ damagedor deteriorated.
WASHER Cl Apply liquidgasketat
Replaceif damaged the eightcornersof the
or deteriorated, k6
TIMING BELT
Inspection,page6-9
Adjustment,page6-9
Removal,page6-10
page6-11
Installation,

RUEBER SEAL
Replaceil damaged 8 x 1.25mm
ot detetiorated. 37 N.m (3.8kst.m,27lbf ftl

MIDOLECOVER

6x1.0mm
9.8N.m {1.0kgf.m,
1.2lbt.ftl

RUBBER SEALS
Replacewhen damaged
or deteriorated,

LOWERCOVER

ADJUSTINGBOLT
10 x 1.25mm
TIMINGBELT 54 N.m (5.5kgl.m, 40 lbf.ft)
ORIVEPULLEY
R e p l a c e m e n t ,p a g e 6 ' 7 CNANKSHAFT PULLEY
page6-7
neplacement,

lnstallwith concave
surfacefacingout,
Removeany oaland clean,
BOLT
14 x 1.25mm
CRANKSHAFTSPEEO 6x1.0mm 177N.m (18.0kgf'm,
FLUCTUATIONICKF} 9.8Nm(1.0kgl.m, 130 tbf.fr)
SENSOR 7.2 tbl.ft)
6x1.0mfi Replacement, Page6-7
1 1N . m{ 1 . 1k g t m , Do not usean impact
8.0 rbtft) wrenchwhen installing.

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 Timing Belt
Removal
Replacethe timing belt at 105,000miles (168,000km) 5. Loosenthe mountingnut and locknut,then remove
accordingto the maintenanceschedule{normalcondi- the altefnatorbelt.
tions/severe conditions).lf the vehicleis regularlydriven LOCKNUT
in eitherof the following conditions,replacethe timing I x 1.25mm
belt at 60,000miles(U.S.A.l100.000km (Canada). 2a N.m 12.4kgt m, 17 lblftl
- ln very high temperatures(over 110'F,43"C).
- In very low temperatures(under-20"F.-29"C).

1 . Turn the crankshaftpu\ley so the No. 1 piston is at

top deadcenter(TDC).

2. Removethe guard bar and splashshield (seepage

5-7).

,l
Loosenthe mountingbolt and lockbolt.then remove
the power steering(P/S)pump belt.
MOUNNNGBOLT
8 x 1.25rnm
24 N.m {2.4 kgt.m, 17 lbf.ftl
10 x 1,25mm
4,1N.m (,1.5kgt m, 33 lbtftl
AELT

6. Removethe cruisecontrolactuator(seesection4).

7. S u p p o r tt h e e n g i n ew i t h a j a c k ,t h e n r e m o v et h e
u p p e r b r a c k e t .M a k e s u r e t o p l a c e a c u s h i o n
betweenthe oil Danand the iack.

12 x 1.25mm
74 N.m (7.5kgf m, 54 lbtftl

24 N.m 12.4kgf.m, lt lbf.ftl

BRACKET
4. Loosenthe idler pulley bracketbolt and adjusting
bolt,then removethe air conditioning(lVC)compres
sor belt(seepage5-4).

6-10
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8. Removethe cylinderheadcover.
NOTE:Referto page6-32when installingthe cylin-
der headcover.
9 . Removethe crankshaftpulley(seepage6-7).
Installation
Installthe timing belt in the reverseorderof removal;
Only key pointsare describedhere,
1. Setthetiming beltdrivepulleyso thatthe No. 1 piston
is at top dead center (TDC).Align the groove on the
timingbeltdrivepulleyto the pointeron the oil pump.

1 0 . Removethe middle cover and lower cover. Do not POINTER GROOVE

usethesecoversto storeremoveditems.
MTDDLE 6x1.0mm
COVER 9.8N.m {1.0kgt m,

DRIVEPULLEY
Clean.
LOWER
COVER 2. Set the camshaftpulleysso that the No. I piston is at
TDC.Alignthe TDCmarkson the camshaftpulleysto
9.8N.m(1.0kgt.m,7.2lbf.ftl
the pointerson the backcover.

1 1 . Markthe directionof rotationon the timing belt.

CAMSHAFT
12. Loosenthe adjustingbolt 180'.Pushthe tensionerto PULLEY
Clean.
removetensionfrom the timing belt, then retighten
the adiustingbolt.

r-t

AINUSTING BOLT POINTER

54 N.m (5,5 kgt m,
.(} tbf.rrl

1 3 . R e m o v et h e t i m i n gb e l t . (cont'd)

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 GylinderHead
lllustratedIndex
To avoiddamage,wait until the enginecoolanttemperaturedropsbelow 100'F(38'C)beforeremovingthe cylinderhead.

6x1.0mm
9.8 N.m (1.0kgI.m, 7.2 lbf.ft)
WASHER
Replace when damaged
or deteriorated, CYLINDERHEAD
COVEB
Reterto page6 32 when
installingcylinderheadcover.

RUBEER
SEAL HEAOCOVERGASKET
R e p l a c ei f Beplacewhen leaking,
or deteriorated, damagedor deteriorated.
Apply liquidgasketat
the eightcornersof the

8 x 1.25mm
24 N.m (2.4
17 tbtft)

6x1.0mm
9.8N.m (1.0kgf.m.
7.2 tbf.fo
Applyengineoil to the
threads.

Seesection4. CAMSHAFT
HOLDER
CYLINDEB
HEADPLUG ---..-@ 0+---.."...- DOWEL
Replace- s<-- KEY PIN
OIL SEAL
Replace.

CAMSHAFT
PULLEY

8 x 1.25mm
37 N.m {3.8kgf.m,
27 tbtft)
OILSEAL
Replace.

6x1.0mm
9.8 N.m (1.0kgl.m,7.2lbtftl

6-1 4
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 gasket.
takecarenot to fold it or damagethe contactsurface.
-?Ehandling a metal

cleanall the partsin solvent,dry them and apply lubricantto any contactparts.
Priorto reassembling,

CYLINDERHEADBOLT
1 1x 1 . 5m m
85 N.m {8.7kgf.m,6:} lbf.ft)
Tightening,page6'30.
Applyengineoilto the threads.
VALVEKEEPERS END PIVOTBOLT
63 N.m 16.4kgl m, 46 lbf.ft)

\ SPRINGBETAINER
EXHAUSTVALVE
SPRING INTAKEVALVE
SPRING

INTAKEVALVESEAL
Replace.
EXHAUSYVALVE
SEAL
Replace. VALVESPRING
SEAT
EXHAUSTVALVE INTAKEVALVE
GUIDE GUIDE
page6-25
Inspection,
Replacem6nt,page6-25 HEAD
Reaming,page6-27 Removal,page6-16
Warpage,page6 27
Valveseatreconditioning,
page6 28
page6-30
Installation,

EXHAUST
VALVE

INTAKEVALVE
Removal,page6-23
page6-29
Installation,

CYLINDERHEAO
GASKET
Replace.

OIL CONTROL
10x 1.25mm ORIFICE
4,0N.m {i1.5kgf.m. Clean.
33 rbf.ft)
O.RING
Replace.

DOWELPIN

8 x 1.25mm
24 N.m (2.4kgf.m,
17 tbf.ft)

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 GylinderHead
Removal
for thisprocedure.
Engineremovalis not required 6. Loosenthe locknutand mountingnut, then remove
the alternatorbelt.
l!@ Make sure iacks and safety stands are
placed properly, and hoist blackels ale attachgd to the LOCKNUT
correctposition on the engine. 8 x 1.25mm
24 N.m (2.4 kgf.m, 17 lbt.ftl

NOTE:
o U s e f e n d e rc o v e r st o a v o i d d a m a g i n gp a i n t e ds u r -
faces.
o To avoid damage,unplugthe wiring connectorscare-
fully while holdingthe connectorportion.
. To avoid damagingthe cylinderhead,wait until the
enginecoolanttemperaturedrops below 100"F(38'C)
beforelooseningthe retainingbolts.
. Markall wiring and hosesto avoid misconnection.
Also, be surethat they do not contactother wiring or
hoses,or interferewith other parts.

1 . Disconnect
the negativeterminalfrom the battery.

2. Drain the engine coolant (see page 10-5).Remove 10x 1.25mm

the radiatorcapto speeddraining. 44 N.m (4.5kgt.m. 33 lbf.ft)
BELT
Removethe intakeair duct and air cleanerhousing
(seepage5-2).

4. R e m o v et h e m o u n t i n gb o l t a n d l o c k b o l t , t h e n 7. Removethe P/SOUmobracket.
r e m o v et h e p o w e r s t e e r i n g( P / S )p u m p b e l t a n d
pump (seepage5-4).

5. Loosenthe idler pulley bracketbolt and adjusting

bolt, then remove the air conditioning(A,/C)com,
pressorbelt.

ADJUSTINGBOLT
ADJUSTING LOCKNUT
BOLT 8 x 1 . 2 5m m
24 N m {2.4ksf.m, 17 lbttt}

l0 x 1.25mm
44 N.m (4.5kgf.m,
33 rbf.ft)

IOLERPULLEYBBACKETBOLT
10 x 1.25mm
44 N.m {4.5 kgtm, 33 lbf ft)

tt\ aA
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o-Io