Engine Overhaul Iriz-Min

WORKSHOP MANUAL
ENGINE OVERHAUL
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S4P
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Model YR 2014
English Edition RDCE-140S4P020-05
Destination: ALL
September 2014 Published in Malaysia
Copyright ©
Perusahaan Otomobil
Nasional Sdn. Bhd.
(Company No.: 100995-U)
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Published in Malaysia 9 September 2014 Eng

WORKSHOP MANUAL ALL
Group Index /I
00 GENERAL ................................................................................... 00/1 - 00/16

11A ENGINE <S4P-VVT> .............................................................. 11A/1 - 11A/117
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All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

ALL WORKSHOP MANUAL
/ II Group Index
NOTE
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GENERAL 00
Content /1
00 GENERAL
OUTLINE OF CHANGES ............................................................... 00/2
DESCRIPTION ......................................................................... 00/2
TABLE OF CHANGE ITEMS & REFERENCE MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
OUTLINE OF CHANGE ITEMS ..................................................... 00/5
AIR BAG SYSTEM INFORMATION .................................................. 00/6

WARNING ............................................................................ 00/6
HOW TO USE THIS MANUAL ....................................................... 00/7

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS .... 00/7
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ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
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DEFINITION OF TERMS ............................................................ 00/7
STANDARD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
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REFERENCE VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
INDICATION OF TIGHTENING TORQUE ......................................... 00/8
EXPLANATION OF MANUAL CONTENTS ........................................ 00/9
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ENGINE MODEL AND SERIAL NUMBER LOCATION ............................. 00/12
TIGHTENING TORQUE ................................................................ 00/12

STANDARD PARTS TIGHTENING TORQUE ...................................... 00/12
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TIGHTENING TORQUE OF FLANGE BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/12
TIGHTENING TORQUE OF BOLT (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/13
TIGHTENING TORQUE OF FLANGE NUT (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/13
TIGHTENING TORQUE SCREW (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/14
TIGHTENING TORQUE STUD (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/14
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PRECAUTION BEFORE SERVICE ..................................................... 00/14

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00 GENERAL
/2 OUTLINE OF CHANGES
OUTLINE OF CHANGES WEO000OLINE14001
DESCRIPTION
This bulletin updates information on VVT engine and is additional supplement to WORKSHOP
MANUAL ENGINE OVERHAUL Pub. No: RDCE-080S4P020–00 (CamPro Basic) and RDCE-080S4P020–04
(CamPro-CFE) which contains changes/modifications/updates/additional information due to the intro-
duction of Variable Valve Timing (VVT) fitted on CamPro engine.
TABLE OF CHANGE ITEMS & REFERENCE MANUALS
This table indicates those changes and/or addition, etc. have been made; the change items are listed
in the sequence in which they are presented in this bulletin. Please use this table for reference when
performing repair or overhaul procedures which related to CamPro-CFE engine.
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LEGEND :
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: The symbol indicates a system which is no changes has been made and the information is
not in this supplement manual. The respective item/system should be referred to the pre-
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vious supplement or/and basic manual.
: The symbol indicates a system which a changes and/or addition has been made and the
information is presented in this supplement manual.
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: The symbol indicates a system is not equipped in the vehicle of the respective manual
(Basic or Supplement).
PUB. NO: RDCE-080S4P020 –
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CHANGE CLASSIFICATION BASIC BULLETIN
00 01 02 03 04 05 (NEW)
GRP 00 – GENERAL
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CamPro
CamPro-CPS
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CamPro - IAFM
Engine & Trans-
mission Model
CamPro-IAFM+
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CamPro-CFE
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VVT
Engine Model &
Serial Number –
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Location
GRP 11A- ENGINE <S4P>
CamPro
CamPro-CPS
CamPro-IAFM
Specifications
CamPro-IAFM+
CamPro-CFE
VVT

GENERAL 00
OUTLINE OF CHANGES /3

00 01 02 03 04 05 (NEW)
CamPro
CamPro-CPS
CamPro-IAFM
Special tools
CamPro-IAFM+
CamPro-CFE
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VVT
CamPro
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CamPro-CPS
CamPro-IAFM
Alternator and
ignition system
CamPro-IAFM+
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CamPro-CFE
VVT
CamPro
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CamPro-CPS
CamPro-IAFM
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Timing belt
CamPro-IAFM+
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CamPro-CFE
VVT
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CamPro
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CamPro-CPS
Fuel and emis- CamPro-IAFM

sion control sys-
tem CamPro-IAFM+
CamPro-CFE
VVT

00 GENERAL
/4 OUTLINE OF CHANGES

00 01 02 03 04 05 (NEW)
CamPro
CamPro-CPS
CamPro-IAFM
Water pump and
water hose
CamPro-IAFM+
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CamPro-CFE
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VVT
CamPro
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CamPro-CPS
CamPro-IAFM
Intake and ex-
haust manifold
CamPro-IAFM+
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CamPro-CFE
VVT
CamPro
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CamPro-CPS
CamPro-IAFM
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Camshaft and
tappet
CamPro-IAFM+
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CamPro-CFE
VVT
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CamPro
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CamPro-CPS
CamPro-IAFM
Cylinder head
and valve
CamPro-IAFM+
CamPro-CFE
VVT

GENERAL 00
OUTLINE OF CHANGES /5

00 01 02 03 04 05 (NEW)
CamPro
CamPro-CPS
CamPro-IAFM
Oil pump and oil
pan
CamPro-IAFM+
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CamPro-CFE
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VVT
CamPro
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CamPro-CPS
CamPro-IAFM
Piston and con-
necting rods
CamPro-IAFM+
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CamPro-CFE
VVT
CamPro
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CamPro-CPS
CamPro-IAFM
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Crankshaft and
cylinder block
CamPro-IAFM+
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CamPro-CFE
VVT
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OUTLINE OF CHANGE ITEMS

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GRP 11A–ENGINE <S4P-CFE>

Change Items Reference Page Description of Changes
Engine and Transmission Model 00/12 • Add information for 1.3L
11A/4 • New specifications for VVT.
11A/4
Specifications 11A/6
11A/10
11A/11
Special Tools 11A/12 • New special tools procedure.

00 GENERAL
/6 AIR BAG SYSTEM INFORMATION
Change Items Reference Page Description of Changes

Alternator and Ignition System • New spark plug for VVT.
11A/16
• Introduction of idler assy to replace
11A/18
power steering pump.
11A/19
• Introduction of smart alternator.
Fuel and Emission Control System 11A/26
• New throttle body design.
11A/27
Intake Manifold 11A/29
• New intake manifold design.
11A/30
Maniverter • Introduction of maniverter to replace
11A/31
exhaust manifold and catalytic convert-
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11A/32
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Timing Belt 11A/35
11A/36 • Update service procedure.
11A/39
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Water Pump and Water Hose 11A/48
• New thermostat design and specifica-
11A/49
tions.
11A/50
Camshaft and Tappet
11A/52
11A/54
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• Add camshaft bent limit specifica-
tions.
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Cylinder Head and Valves 11A/69 • New specifications related to VVT.
11A/71
Oil Pump and Oil Pan 11A/79
• Update service procedure.
11A/81
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Piston and Connecting Rods 11A/87

11A/89
• New piston design and specifications.
11A/91
11A/92
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Crankshaft and Cylinder Block 11A/101 • Update specifications.

11A/103 • Add crankshaft bent limit specifica-
11A/104 tions
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11A/106
11A/115
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AIR BAG SYSTEM INFORMATION WEO000BSERV14001
This vehicle has an air bag system which will supplement the seat belt in certain frontal collisions. The
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air bag is not a substitute for the seat belt in any type of collision. The drivers and all other occupants
should wear seat belts at all times. Warning if the “SRS” warning light does not illuminate for several
seconds when the ignition key is turned to “ON” or the engine is started or if the warning light stays
on while driving, take the vehicle to your nearest authorized dealer immediately. Also if the vehicle's
front end is damaged or if the airbag has deployed, take the vehicle for service immediately. The air
bag system must be inspected by an authorized dealer ten years after the date of vehicle registration.
Read the “SRS” section of your owner's manual before driving for important information about op-
eration and service of the air bag system. When you are going to discard your gas generator or vehicle,
please see your dealer.
WARNING

GENERAL 00
HOW TO USE THIS MANUAL /7
(1) Improper service or maintenance of any component of the SRS or any SRS —related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative.)
(2) SRS components should not be subjected to heat over 85 °C (185 °F) , so remove the SRS-ECU, air
bag module and clock spring before drying or baking the vehicle after painting.
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized dealer.
(4) Dealer personnel must thoroughly review Chassis Manual, and especially its GROUP 52B - Supple-
mental Restraint System (SRS), before beginning any service or maintenance of any component
of the SRS or any SRS-related component.
NOTE :
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring
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warnings.
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HOW TO USE THIS MANUAL WEO000READS14001
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SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however, that for engine and transmission-related component
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parts, this manual covers only on-vehicle inspections, adjustments and the removal and installation
procedures for major components. For detailed information concerning the inspection, checking, ad-
justment, disassembly and reassembly of the engine, transmission and major components after they
have been removed from the vehicle, please refer to separate manuals covering the engine and the
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transmission.
ON-VEHICLE SERVICE
“On-Vehicle Service” is a procedure for performing inspections and adjustments of particularly import-
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ant locations with regard to the construction and for maintenance and servicing, but other inspections
(for looseness, play, cracking, damage and etc.) must also be performed.
INSPECTION
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Under this title are presented inspection and checking procedures to be performed by using special
tools and measuring instruments and by feeling but for actual maintenance and servicing procedures,
visual inspections should always be performed as well.
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DEFINITION OF TERMS
STANDARD VALUE
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Indicates the value as the standard for judging the quality of a part of assembly on inspection or the
value to which the part or assembly is corrected and adjusted. It is given by tolerance.
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LIMIT
Shown the standard for judging the quality of a part or assembly on inspection and means the max-
imum or minimum value within which the part or assembly must be kept functionally or in strength.
It is a value established outside the range of standard value.
REFERENCE VALUE
Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly
and adjustment procedures, and so they can be completed in a shorter time).
CAUTION :
Indicates the presentation of information particularly vital to the worker during the performance of
maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or
damage to component parts, or a reduction of component or vehicle function or performance, etc.

00 GENERAL
/8 HOW TO USE THIS MANUAL
INDICATION OF TIGHTENING TORQUE

The tightening torque shown in this manual is a basic value with a tolerance of ±10% except the fol-
lowing cases when the upper and lower limits of tightening torques are given.
1. The tolerance of the basic value is within ±10%
2. Special bolts or nuts are in use.
3. Special tightening methods are used.
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GENERAL 00
HOW TO USE THIS MANUAL /9
EXPLANATION OF MANUAL CONTENTS WEO000READS14002
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DOIIC000R9001

00 GENERAL
/ 10 HOW TO USE THIS MANUAL
SYMBOL DESCRIPTION
A Indicates the group title
B Indicates the section title
C Indicates the group number
D Indicates the page number
E Component Diagram
A diagram of the component parts is provided near the front of each section in order
to give a reader a better understanding of the installed condition of the component
parts.
F Denotes non reusable part
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G Denotes tightening torque.
For bolts and nuts which do not have a tightening torque listed, refer to the “Tighten-
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ing torque”
H Symbol for lubrication sealants and adhesives.
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Information concerning the locations for lubrication and for application of sealants
and adhesives is provided, by using symbols, in the diagrams of component parts or
on the page following the component parts page, and explained.
DOIIC000R9058
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Grease (multipurpose grease unless there is a brand
or type specified)
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Sealant or adhesive
DOIIC000R9059
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Brake fluid or automatic transmission fluid

DOIIC000R9060
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Engine oil, gear oil or air condition compressor oil

DOIIC000R9061
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Adhesive tape or butyl rubber tape.

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DOIIC000R9062
Indicates procedures to be performed before the work in that section is started, and
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procedures to be performed after the work in that section is finished.
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Maintenance and servicing Procedures

The number provided within the diagram individual the sequence for maintenance
and servicing procedures.
1. A diagram of the components part is provided near the front of each section in
K order to give the reader a better understanding of the installed condition of
component parts.
2. The number provided within the diagram indicate the sequence for maintenance
and servicing procedures; the symbol N indicates a non reusable part; the tightening
torque is provided where applicable.
Removal steps:
The part designation number correspond to the number in the illustration to indicate
removal steps.

GENERAL 00
HOW TO USE THIS MANUAL / 11
SYMBOL DESCRIPTION
Disassembly steps:
The part designation number correspond to the number in the illustration to indicate
disassembly steps.
Installation steps:
Specified in case installation is impossible in reverse order of removal steps
Reassembly steps:
Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted
if reassembly is possible in reverse order of disassembly steps.
Classifications of major maintenance/service points
When there are major points relative to maintenance and serving procedures (such as
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L essential maintenance and service points, maintenance and service standard values,
information regarding the use of special tools, etc.) these are arranges together as
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major maintenance and service points and explained in detail.
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Indicates that there are essentials point for removal
or disassembly.
DOIIC000R9052
DOIIC000R9051
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Indicates that there are essential point for installation
or reassembly
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Indicates that there are essential points for both
DOIIC000R9053
M Operating procedures, caution etc. on removal, installation disassembly and reassembly

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and reassembly are described.

N Table for graphic explaination
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00 GENERAL
/ 12 ENGINE MODEL AND SERIAL NUMBER LOCATION
ENGINE MODEL AND SERIAL

NUMBER LOCATION WEO000GINFO14001
1. The engine model number is stamped at the

cylinder block as shown in the following.
Engine Model Engine Displacement

S4PE 1332 cm³ (81.28 cu.in)
S4PH 1597 cm³ (97.45 cu.in)
Symbol Description
A Engine model / code system
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B Engine serial number
2. The engine serial number is stamped near
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the engine model number.
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Engine serial number [Example]
AA0201 to YY9999
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DOIRC000R13002
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TIGHTENING TORQUE WEO000TTORQ14001
General tightening torque is as shown in the following table.

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The specified part tightening torque is shown at the beginning of each group.
STANDARD PARTS TIGHTENING TORQUE
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TIGHTENING TORQUE OF FLANGE BOLT

Classification
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Flange bolt (Dia.) Thread size (Pitch x length) Specified torque

M5 0.6 mm (0.024 in) ± 0.1 kgm (1 Nm, 0.72
0.8 x 30 mm (0.031 x 1.18 in)
ft.lbs)
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1.0 x 10 mm (0.039 x 0.39 in)

1.0 x 12 mm (0.039 x 0.47 in)
1.0 x 18 mm (0.039 x 0.71 in)
1.0 mm (0.039 in) ± 0.1 kgm (1 Nm, 0.72
M6 1.0 x 20 mm (0.039 x 0.79 in)
ft.lbs)
1.0 x 25 mm (0.039 x 0.98 in)
1.0 x 35 mm (0.039 x 1.38 in)
1.0 x 50 mm (0.039 x 1.97 in)

GENERAL 00
TIGHTENING TORQUE / 13
Classification
Flange bolt (Dia.) Thread size (Pitch x length) Specified torque
1.25 x 16 mm (0.049 x 0.63 in)
1.25 x 25 mm (0.049 x 0.98 in) 2.4 mm (0.094 in) ± 0.2 kgm (2 Nm, 1.45
1.25 x 30 mm (0.049 x 1.18 in) ft.lbs)
M8
1.25 x 40 mm (0.049 x 1.57 in)
1.25 x 70 mm (0.049 x 2.76 in) 1.2 kgm (12 Nm, 8.68 ft.lbs) ± 0.1 kgm (1
1.25 x 100 mm (0.049 x 3.94 in) Nm, 0.72 ft.lbs)
4.85 mm (0.19 in) ± 0.35 kgm (3.5 Nm, 2.53
1.25 x 18 mm (0.049 x 0.71 in) SP
ft.lbs)
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1.0 mm (0.039 in) ± 0.1 kgm (1 Nm, 0.72
1.25 x 25 mm (0.049 x 0.98 in)
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ft.lbs)
M10 3.5 mm (0.14 in) ± 0.2 kgm (2 Nm, 1.45
1.25 x 35 mm (0.049 x 1.38 in)
ft.lbs)
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3.0 mm (0.12 in) ± 0.2 kgm (2 Nm, 1.45
1.25 x 50 mm (0.049 x 1.97 in)
ft.lbs)
1.25 x 90 mm (0.049 x 3.54 in) 5.0 mm (0.2 in) ± 0.2 kgm (2 Nm, 1.45 ft.lbs)
TIGHTENING TORQUE OF BOLT (SPECIAL)
Classification se
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Bolt (Dia.) Thread size (Pitch x length) Specified torque
M8 43 mm (1.69 in) 2.0 kgm (20 Nm, 14.47 ft.lbs) + 60°
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs) + 4.0 kgm (40 Nm, 28.93
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ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 5.0

M9 160 mm (6.3 in) ± 0.35 mm (0.014 in)
kgm (50 Nm, 36.16 ft.lbs) ± 0.2 kgm (2 Nm,
1.45 ft.lbs) + 60°(min), 64° (max) and
60°(min), 64° (max).
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1.25 x 55 mm (0.049 x 2.17 in) 5.0 mm (0.2 in) ± 0.2 kgm (2 Nm, 1.45 ft.lbs)
3.5 mm (0.14 in) ± 0.2 kgm (2 Nm, 1.45
1.25 x 105 mm (0.049 x 4.13 in)
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M10 ft.lbs)
5.15 mm (0.2 in) ± 0.24 kgm (2.4 Nm, 1.74
69 mm (2.72 in)
ft.lbs)
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17.5 mm (0.69 in) 5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.2 kgm (2
26 mm (1.02 in) Nm, 1.45 ft.lbs) + 60°± 2°
M12
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3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 mm

30 mm (1.18 in)
(0.008 in) + 40 ± 2°
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2
M14 70 mm (2.76 in)
Nm, 1.45 ft.lbs) +120° ± 4°
TIGHTENING TORQUE OF FLANGE NUT (SPECIAL)
Classification
Flange nut (Dia.) Thread size (Pitch) Specified torque
M6 1.0 mm (0.039 in) ± 0.1 kgm (1 Nm, 0.72
1.0 mm (0.039 in)
ft.lbs)
2.4 mm (0.094 in) ± 0.2 kgm (2 Nm, 1.45
M8 1.25 mm (0.049 in)
ft.lbs)

00 GENERAL
/ 14 PRECAUTION BEFORE SERVICE
Classification
Flange nut (Dia.) Thread size (Pitch) Specified torque
M10 3.5 mm (0.14 in) ± 0.2 kgm (2 Nm, 1.45
1.25 mm (0.049 in)
ft.lbs)
TIGHTENING TORQUE SCREW (SPECIAL)
Classification
Screw (Dia.) Thread size (Pitch) Specified torque
0.25 mm (0.01 in) ± 0.05 kgm (0.5 Nm, 0.36
M4 0.7 x 16 mm (0.028 x 0.63 in)
ft.lbs)
1.0 mm (0.039 in) ± 0.1 kgm (1 Nm, 0.72
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1.0 x 16 mm (0.039 x 0.63 in)
ft.lbs)
M6
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1.0 mm (0.039 in) ± 0.1 kgm (1 Nm, 0.72
1.0 x 25 mm (0.039 x 0.98 in)
ft.lbs)
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TIGHTENING TORQUE STUD (SPECIAL)
Classification
Stud (Dia.) Thread size (Pitch x length) Specified torque
M6
M8
1.0 x 50 mm (0.039 x 1.97 in)
1.25 x 27 mm (0.049 x 1.06 in) se 0.5 kgm (5 Nm, 3.62 ft.lbs)

0.85 mm (0.033 in) ± 0.25 kgm (2.5 Nm, 1.81
ft.lbs)
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1.25 x 40 mm (0.049 x 1.57 in)
1.2 mm (0.047 in) ± 0.1 kgm (1 Nm, 0.72
M10 1.25 x 60 mm (0.049 x 2.36 in)
ft.lbs)
1.25 x 65 mm (0.049 x 2.56 in)
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PRECAUTION BEFORE SERVICE WEO000BSERV14002
When the engine or transmission is disassembled and reassembled, pay attention to the following.
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Removal and Disassembly For prevention of wrong installation or reas-

sembly and for ease of operation, put mating
mark (A) to the parts where no function is ad-
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versely affected.
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DOIIE00AR9001

GENERAL 00
PRECAUTION BEFORE SERVICE / 15
Tightening Torque Tighten the part properly to specified torque.
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DOIIE00AR9002
Replacement Part When oil seal, O-ring, packing and gasket have
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been removed, be sure to replace them with
new parts.
However, rocker cover gasket may be reused if
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it is not damaged.
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DOIIE00AR9003
Oil and Grease Before reassembly, apply specified oil to the

rotating and sliding parts.
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DOIIE00AR9004
Special Tool Be sure to use Special Tools when their use is

specified for the operation. Use of substitute
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tools will resulting malfunction of the part or

damage it.
DOIIE00AR9005

00 GENERAL
/ 16 PRECAUTION BEFORE SERVICE
Sealant Use specified brand of sealant.

Use of sealant other than specified sealant may
cause water or oil leaks.
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DOIIE00AR9006
Rubber Part Do not stain timing belt and V-belt with oil or
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water.
Therefore, do not cleaned the pulley and
sprocket with detergent.
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DOIIE00AR9007
Genuine Part When the part is replace, be sure to use Proton

genuine part.
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For selection of appropriate part, refer to the

Parts Catalog.
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DOIIE00AR9008
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ENGINE <S4P-VVT> 11A
Content /1
11A ENGINE <S4P-VVT>

SPECIFICATIONS ....................................................................... 11A/4
GENERAL SPECIFICATIONS ........................................................ 11A/4
SERVICE SPECIFICATIONS .......................................................... 11A/4
TORQUE SPECIFICATIONS ......................................................... 11A/6
NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING 11A/10
BOLTS ..................................................................................
SEALANTS ............................................................................ 11A/11
FORM-IN-PLACE GASKET(FIPG) ................................................... 11A/11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/11
Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/11
y
From-in-Place Gasket Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/11
nl
SPECIAL TOOLS ........................................................................ 11A/12
ALTERNATOR AND IGNITION SYSTEM ............................................ 11A/16
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REMOVAL AND INSTALLATION ................................................... 11A/16
FEAD BELT ROUTE .................................................................. 11A/18
REMOVAL SERVICE POINTS ....................................................... 11A/19
INSTALLATION SERVICE POINTS .................................................. 11A/20
FUEL AND EMISSION CONTROL SYSTEM ........................................

REMOVAL AND INSTALLATION ................................................... se 11A/26
11A/26
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INTAKE MANIFOLD ................................................................... 11A/29

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MANIVERTER ........................................................................... 11A/31

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TIMING BELT ........................................................................... 11A/35

REMOVAL AND INSTALLATION .................................................. 11A/35
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WATER PUMP AND WATER HOSE ................................................. 11A/48

CAMSHAFT AND TAPPET ........................................................... 11A/52

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/54
INSPECTION .......................................................................... 11A/68
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/68
CAMSHAFT BENT LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/68

/2 Content
CYLINDER HEAD AND VALVES ..................................................... 11A/69

INSPECTION .......................................................................... 11A/76
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/76
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/77
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/77
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/78
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/78
OIL PUMP AND OIL PAN ............................................................. 11A/79

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REMOVAL SERVICE POINT ......................................................... 11A/81
nl
INSPECTION .......................................................................... 11A/85
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/85
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PISTON AND CONNECTING RODS ................................................. 11A/87
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INSPECTION .......................................................................... 11A/91
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/91
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) . . . . . . . . . . . . . . . . . . . . . . 11A/91
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CRANKSHAFT AND CYLINDER BLOCK ............................................ 11A/101
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INSPECTION .......................................................................... 11A/104

CRANKSHAFT OIL CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/104
CRANKSHAFT BENT LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/104
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/105
er
REMOVAL AND INSTALLATION SERVICE POINTS ............................. 11A/115

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Content /3
NOTE
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nl
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se
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/4 SPECIFICATIONS
SPECIFICATIONS WEO11ASPECS14001
GENERAL SPECIFICATIONS
Specifications
Items
S4PE-1.3 L S4PH-1.6 L
Total displacement 1332 cm³ (81.28 cu.in) 1597 cm³ (97.45 cu.in)
Bore x stroke 76.0 mm (2.99 in) x 73.4 mm 76.0 mm (2.99 in) x 88.0 mm
(2.89 in) (3.46 in)
Direction of Rotation Clockwise (From front : SAE)
Number of cylinders 4
y
Orientation East-West
Valve train DOHC 16V
nl
Combustion chamber Pentroof type
Firing order 1–3–4–2
O
Compression ratio 10.0 : 1
Intake 8
Number of valve
Exhaust 8
Lubrication system
Oil pump type
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Pressure feed, full-flow filtration
Trochoid type
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Cooling system Water-cooled forced circulation
Water pump type Centrifugal impeller type
Tappet Mechanical
na
SERVICE SPECIFICATIONS WEO11ASPECS13006
Items Standard Limit / Tolerance

Camshaft
er
Intake 43.92 mm (1.73 in) ±

(1.3) 0.10 mm (0.004 in)
nt
Intake 44.35 mm (1.75 in) ±

Camshaft cam height
(1.6) 0.10 mm (0.004 in)
Exhaust 43.92 mm (1.73 in) ±
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0.10 mm (0.004 in)

Camshaft journal diameter 28.000 mm (1.1 in) – 0.040 mm (0.002
in), – 0.061 mm
Fo
(0.002 in)
Camshaft bent limit — 0.05 mm (0.002 in)
Cylinder head and valves
Flatness of cylinder head gasket surface 0.1 mm (0.004 in) or less —
Cylinder head gasket surface grinding limit (includ- 0.2 mm (0.008 in)
—
ing grinding of cylinder block gasket surface)
Cylinder head overall height 134.70 mm (5.3 in) ±
0.25 mm (0.01 in)
Cylinder head bolt nominal length 160.00 mm (6.3 in) ±
0.35 mm (0.014 in)

SPECIFICATIONS /5

Intake 1.50 mm (0.059 in) ±
0.15 mm (0.006 in)
Valve margin
Exhaust 1.95 mm (0.077 in) ±
0.15 mm (0.006 in)
Intake 4.973 mm (0.2 in) ±
0.009 mm (0 in)
Valve stem diameter
Exhaust 4.963 mm (0.2 in) ±
0.009 mm (0 in)
Intake 0.0335 mm (0.001 in) ±
0.0150 mm (0.001
y
in)
Valve stem-to-guide clearance
nl
Exhaust 0.0435 mm (0.002 in) ±
0.0150 mm (0.001
in)
O
Valve face angle 45° ± 0.25°
Intake 54.90 mm (2.16 in) ±
0.35 mm (0.014 in)
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Valve stem projection
Exhaust 54.90 mm (2.16 in) ±
0.35 mm (0.014 in)
Intake 115.43 mm (4.54 in) ±
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0.30 mm (0.012 in)
Overall valve length
Exhaust 114.63 mm (4.51 in) ±
0.30 mm (0.012 in)
Intake 48.362 mm (1.9 in) —
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Valve spring free height

Exhaust 48.362 mm (1.9 in) —
Intake 17.2 kgm (172 Nm, 124.41 ±
ft.lbs) / 40.5 mm (1.59 in) 0.1 kgm (1 Nm, 0.72
er
ft.lbs) / —
Valve spring load / installed height
Exhaust 17.2 kgm (172 Nm, 124.41 ±
ft.lbs) / 40.5 mm (1.59 in) 0.1 kgm (1 Nm, 0.72
nt
ft.lbs) / —
Valve spring squareness 2.72° —
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Valve seat contact width Intake 1.15 mm (0.045 in) + 0.29 mm (0.011
in), – 0.28 mm
(0.011 in)
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Exhaust 1.33 mm (0.052 in) + 0.28 mm (0.011

in), – 0.29 mm
(0.011 in)
Valve guide internal diameter 5.0 mm (0.2 in) —
Valve guide projection Intake 12.00 mm (0.47 in) ±
0.15 mm (0.006 in)
Exhaust 8.50 mm (0.33 in) ±
0.15 mm (0.006 in)
Oil pump and oil pan
Oil pump tip clearance 0.06 - 0.18 mm (0.002 -
—
0.007 in)

/6 SPECIFICATIONS

Oil pump side clearance 0.03 - 0.10 mm (0.001 -
—
0.004 in)
Oil pump body clearance 0.04 - 0.10 mm (0.002 - 0.35 mm (0.014 in)
0.004 in)
Pistons and connecting rods
Piston outside diameter 75.975 mm (2.99 in) Refer 11A/92
No. 1 ring 0.03 - 0.05 mm (0.001 -
—
0.002 in)
Piston ring side clearance
No. 2 ring 0.02 - 0.04 mm (0.001 -
—
y
0.002 in)
No. 1 ring 0.2 - 0.35 mm (0.008 - 0.014
nl
—
in)
Piston ring and gap clearance No. 2 ring 0.37 - 0.57 mm (0.015 -
—
O
0.022 in)
Oil ring 0.2 - 0.5 mm (0.008 - 0.02 in) —
Piston pin O.D. 19.000 mm (0.75 in) + 0.000 mm (0 in), –
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0.005 mm (0 in)
Crankshaft pin oil clearance 0.02 - 0.044 mm (0.001 - 0.1 mm (0.004 in)
0.002 in)
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Connecting rod big end side clearance 0.1 - 0.25 mm (0.004 - 0.01 0.4 mm (0.016 in)
in)
Crankshaft and cylinder block
Crankshaft end play 0.05 - 0.18 mm (0.002 - 0.25 mm (0.01 in)
na
0.007 in)
Crankshaft journal diameter 48.0 mm (1.89 in) —
Crankshaft bent limit — 0.03 mm (0.001 in)
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Crankshaft pin diameter 46.0 mm (1.81 in) —

Crankshaft journal oil clearance 0.02 - 0.044 mm (0.001 - 0.1 mm (0.004 in)
0.002 in)
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Cylinder block gasket surface flatness 0.03 mm (0.001 in) —

Cylinder block gasket surface grinding limit (includ- 0.2 mm (0.008 in)
—
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ing grinding of cylinder head gasket surface)

Cylinder block overall height 256 mm (10.08 in) ±
0.15 mm (0.006 in)
Fo
Cylinder block cylindricity 0.025 mm (0.001 in) —

Cylinder block I.D. (Bore) 76.0 mm (2.99 in) Refer 11A/104
Piston to cylinder clearance 0.02 - 0.05 mm (0.001 -
—
0.002 in)
TORQUE SPECIFICATIONS WEO11ASPECS13007
Items Value
Alternator, power steering pump, air-cond compressor and ignition system
1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
Water pump pulley bolt
ft.lbs)

SPECIFICATIONS /7
Items Value
2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.2 kgm (2 Nm,
Alternator bolt (alternator side)
1.45 ft.lbs)
Alternator pivot nut
1.45 ft.lbs)
M8
Fead belt tensioner 1.45 ft.lbs)
bolt 5.2 kgm (52 Nm, 37.61 ft.lbs) ± 0.2 kgm (2 Nm,
M10
1.45 ft.lbs)
Oil level gauge guide bolt
ft.lbs)
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TV damper bolt
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ft.lbs) + 120°± 4°
1.75 kgm (17.5 Nm, 12.66 ft.lbs) ± 0.25 kgm (2.5
Spark plug
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Nm, 1.81 ft.lbs)
Plug top coil bolt
ft.lbs)
Cam shaft sensor bolt
Oil control valve bolt se

ft.lbs)
ft.lbs)
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Idler assy bolt
1.45 ft.lbs)
Air-cond compressor bolt
1.45 ft.lbs)
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Fuel system and emission system

Bracket harness fuel rail
ft.lbs)
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Throttle body bolt and bracket 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
ft.lbs)
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Fuel rail bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
ft.lbs)
Intake manifold
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MAP sensor bolt
ft.lbs)
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Intake manifold bolt and nut

1.45 ft.lbs)
Lifting eye bolt
1.45 ft.lbs)
Maniverter
Oxygen (Lambda) sensor
7.23 ft.lbs)
Maniverter heatshield bolt
ft.lbs)
Bolt
Bracket catalytic con- 1.45 ft.lbs)
verter 2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.2 kgm (2 Nm,
Nut
1.45 ft.lbs)

/8 SPECIFICATIONS
Items Value
Step Remark Value
(Nut no.1 to no. 8
1 in ascending or-
1.45 ft.lbs)
der)
Maniverter nut (Nut no.1 to no. 8
2 in ascending or-
1.45 ft.lbs)
der)
(Nut no.1 to no. 8
3 (If re- 2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2 Nm,
in ascending or-
quired) 1.45 ft.lbs)
der)
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Timing belt
nl
Upper
ft.lbs)
Timing belt cover bolt
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Lower
ft.lbs)
Timing belt tensioner bolt
1.45 ft.lbs)
Engine mounting
Bolt M8
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0.72 ft.lbs)
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Bolt M10
bracket (left) 1.45 ft.lbs)
Nut
ft.lbs)
Back plate bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
na
ft.lbs)
Intake
3.62 ft.lbs)
er
Camshaft sprocket bolt

15.0 kgm (150 Nm, 108.49 ft.lbs) ± 2.5 kgm (25
Exhaust
Nm, 18.08 ft.lbs)
VVT bolt cap 3.2 kgm (32 Nm, 23.15 ft.lbs) ± 0.2 kgm (2 Nm,
nt
1.45 ft.lbs)
Water pump
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Thermostat pipe assembly bolt 2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.2 kgm (2 Nm,
1.45 ft.lbs)
Coolant temperature sensor 2.7 kgm (27 Nm, 19.53 ft.lbs) ± 0.2 kgm (2 Nm,
Fo
1.45 ft.lbs)
0.820 kgm (8.2 Nm, 5.93 ft.lbs) ± 0.246 kgm (2.46
Water pump bolt
Nm, 1.78 ft.lbs)
Camshaft and Tappet
Cam cover bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
ft.lbs)
Bearing cap bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
ft.lbs)
Cylinder head and valves

SPECIFICATIONS /9
Items Value
Step Remark Value
One bolt at a
time. Follow se- 2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2 kgm (2 Nm,
A
quence no. 1 to 1.45 ft.lbs)
no. 10
One bolt at a
time. Follow se- 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45
B
quence no. 1 to ft.lbs)
Cylinder head bolt no. 10
One bolt at a
y
time. Follow se-
C 90° ~ 94°
quence no. 1 to
nl
no. 10
One bolt at a
O
time. Follow se-
D 90° ~ 94°
quence no. 1 to
no. 10
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Oil pump and oil pan
Oil pan bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
ft.lbs)
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Drain plug
3.62 ft.lbs)
Oil pan windage tray
ft.lbs)
na
Oil pan baffle bolt
ft.lbs)
Oil pick up pipe bolt
ft.lbs)
er
Front case bolt
ft.lbs)
nt
Oil filter 1.4 kgm (14 Nm, 10.13 ft.lbs) ± 0.2 kgm (2 Nm,
1.45 ft.lbs)
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Relief valve
3.62 ft.lbs)
Oil pump backplate screw
Fo
ft.lbs)
Crank sensor 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
ft.lbs)
Stud (Special) 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.2 kgm (2 Nm, 1.45
ft.lbs)
Pistons and connecting rods
2.2 kgm (22 Nm, 15.91 ft.lbs) ±0.2 kgm (2 Nm,
Connecting rod bolt
1.45 ft.lbs) + 90° ± 5°
Crankshaft and cylinder block
Direct damper flywheel bolt (DDF) 12.5 kgm (125 Nm, 90.41 ft.lbs) ± 0.5 kgm (5 Nm,
3.62 ft.lbs)

/ 10 SPECIFICATIONS
Items Value
Rear plate bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
ft.lbs)
Rear oil seal case bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
ft.lbs)
Bearing cap bolt 5.15 kgm (51.5 Nm, 37.25 ft.lbs) ± 0.24 kgm (2.4
Nm, 1.74 ft.lbs)
Oil pressure switch
ft.lbs)
Knock sensor bolt 2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.5 kgm (5 Nm,
3.62 ft.lbs)
y
Target wheel (Patch lock screw) 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
nl
ft.lbs)
Plug tapper PT 3/8 Side 4.0 kgm (40 Nm, 28.93 ft.lbs) ± 0.5 kgm (5 Nm,
O
3.62 ft.lbs)
Rear 6.4 kgm (64 Nm, 46.29 ft.lbs) ± 1.0 kgm (10 Nm,
7.23 ft.lbs)
NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTS

se WEO11ASPECS14002
Part of the engine use plastic region tightening bolts. The tightening procedure for these is different
from that of conventional bolts and is described in relevant parts of this manual. Note that plastic
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region tightening bolts have fixed service limits. These are indicated in relevant parts of this manual
and must be strictly observed.
• Plastic region tightening bolts are used for the following applications:
1. Cylinder head bolts
na
• The tightening procedure is basically as follows:

After tightening a bolt to the specified torque, tighten the bolt with 2 times additional torque
angle.
The fist torque angle must within 60° (min) and 64° (max). It will be followed by second torque
er
angle with also within 60° (min) and 64° (max).

The exact tightening procedure differs depending on the bolt and is described in relevant parts
of this manual.
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Fo

SPECIFICATIONS / 11
SEALANTS
Items Specified sealant Quantity
Oil pan
Threebond 1207F
Oil seal rear
Bushing knock
Threebond
Pin dowel
Plug tapper
TB 2403
Backplate cover bolt
Cylinder head (Cam bearing cap) TB 1110B
As required
y
Intake manifold bracket bolt TB 2440B
TB 1130
nl
Oil pressure switch
3M ATD Part No.8660 or equivalent
Direct damper flywheel bolt
O
3M Nut Locking Part No.4171 or equivalent
Engine coolant temperature sensor
Piston – Connecting rod Yugen Kugyo Standards DS-711 or equival-
ent
FORM-IN-PLACE GASKET(FIPG)
se WEO11ASPECS14003
The engine has several areas where the form-in place gasket (FIPG) is in use. To ensure that the gasket
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fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too
thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing
of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore , it is absolutely ne-
na
cessary to apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanization (RTV) type and is supplied in a
100–gram tube (Part No. MD970389, MD997110 or PC111001). Since the RTV hardens as it reacts with
the moisture in the atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No.
er
MD970389, can be used for sealing both engine oil and coolant, while Part No. MD970389, MD997110
or PC111001 can only be used for engine oil sealing.
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Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly
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striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in
between the joined surfaces. In this case, however, care must be taken to prevent damage to the
joined surfaces. For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available.
Fo
Be sure to use the special tool to remove the oil pan. <Except aluminium die-cast oil pans>
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
From-in-Place Gasket Application
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. also be sure to encircle the bolt
hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When

/ 12 SPECIAL TOOLS
the parts are mounted, make sure that the gasket is applied to the required area only. In addition,
do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of
time (about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
SPECIAL TOOLS WEO11ASTOOL14001
Tool Number Name Use
y
Crankshaft rear oil Installation of crankshaft
EZT 0011
seal installer rear oil seal
nl
DOIHC11AR04045
O
Oil pressure switch Removal and installation of
MD998054
se
wrench oil pressure switch
DOIIE11AR9004
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Crankshaft front oil Installation of crankshaft
MD998304
na
seal installer front oil seal
DOIIE11AR9005
er
Crankshaft front oil Guide for installation of

nt
MD998305
seal guide crankshaft front oil seal
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DOIIE11AR9006
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Cylinder head bolt Removal and installation of

MB991653
wrench (10) cylinder head bolt
DOIIE11AR9016
Removal and installation of

engine oil filter (When us-
MB991396 Oil filter wrench
ing the oil filter of
MD135737)
DOIIC012R9001

SPECIAL TOOLS / 13
Removal and installation of

Oxygen (Lambda) Oxygen (Lambda) sensor
MD998770
sensor wrench and coolant temperature
sensor
DOIIC015R9001
To get accurate angle dur-

Mot. 59104
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Angle gauge ing installing cylinder head
00 00 059 104
bolt and TV damper bolt
nl
DOIGE11AR03136
O
To insert valve collet into
EZT 0001 Valve collet installer
se
valve groove accurately
DOIGE11AR03132
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EZT 0002 Valve collet remover To remove valve collet
na
DOIGE11AR03162
er
To lock TV damper from

nt
EZT 0003 TV damper stopper

turning
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DOIGE11AR03105
Fo
To install and remove valve

EZT 0005 Valve stem seal plier stem seal and spring seat
from valve
DOIGE11AR03104
Camshaft oil seal in- Installation of camshaft oil

EZT 0006
staller seal
DOIGE11AR03155

/ 14 SPECIAL TOOLS
TV damper bolt To turn crankshaft sprocket

EZT 0007
dummy during aligning timing belt
DOIGE11AR03146
To guide connecting rod
y
EZT 0008 Con rod jig and connecting rod bearing
during installation
nl
DOIGE11AR03160
O
To prevent camshaft
Camshaft Sprocket
EZT 0004 sprocket from turning dur-
se
Stopper
ing installing timing belt
DOIGE11AR03134
lU
EZT 0044 Flywheel Stopper To lock flywheel
na
DOIME11AR11051
er
To support valve during re-

Cylinder Head Valve
nt
EZT 0046 moving and installing valve

Jig
collet
rI
DOIME11AR11053
Fo
Holding camshaft sprocket

MB990767 End Yoke holder when loosening or tighten-
ing bolt (used MD998715)
DOIIE11AR9002
Holding camshaft sprocket

MD998715 Pin (2–off) when loosening or tighten-
ing bolt (used MD990767)
DOIIE11AR9008

SPECIAL TOOLS / 15
To lock VVT camshaft be-

VVT Camshaft Stop-
EZT 0043 fore loosening or tightening
per
VVT camshaft sprocket.
DOINE11AR12013
y
MB990938 Handle Use with adapter installer
nl
DOIIT22AR9007
O
MB991203 Adapter installer For core plug installation
DOIGE11AR03146 se
lU
Base
1
plate
2 Holder
Press
na
3
unit EZT One way valve In- To install a new one way
4 Plunger 0058 staller valve into cylinder block
DOINE11AR13001
One
er
way
5
valve
bolt
nt
rI
Fo

/ 16 ALTERNATOR AND IGNITION SYSTEM
ALTERNATOR AND IGNITION SYSTEM WEO11ASASSY13003
REMOVAL AND INSTALLATION
y
nl
O
se
lU
na
er
nt
rI
Fo
DOIRE11AR14036

ALTERNATOR AND IGNITION SYSTEM / 17
: Non-reusable parts
Removal steps :
1. Plug top coil
2. Spark plug
3. Cam shaft sensor
4. Oil control valve
5. Fead belt
6. Fead belt tensioner
7. Alternator
y
8. Water pump pulley
9. Idler assy
nl
10. Air-cond compressor
11. TV damper pulley
O
12. Oil level gauge
13. Oil level gauge guide
T1 : 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T2 : 1.75 kgm (17.5 Nm, 12.66 ft.lbs) ± 0.25 kgm (2.5 Nm, 1.81 ft.lbs)
se
T5 : 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 120° ± 4°
lU
na
er
nt
rI
Fo

FEAD BELT ROUTE WEO11ASASSY13004
y
nl
O
se
lU
na
DOIRE11AR14013
er
Symbol Description
1 Fead belt tensioner
nt
2 TV damper
3 Air-cond compressor pulley
4 Idler assy
rI
5 Water pump upper pulley

6 Alternator pulley
Fo
7 Water pump lower pulley

T3 2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs)
T6 5.2 kgm (52 Nm, 37.61 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs)

REMOVAL SERVICE POINTS WEO11ASPROC13009
FEAD BELT REMOVAL

1. Insert ratchet into square hole on tensioner
arm.
2. Push the ratchet towards engine intake side
and pull out the fead belt from the alternat-
or.
3. Loosen the fead belt tensioner half way.
4. Remove the fead belt between the slot of
the loosed tensioner.
y
DOIRE11AR14005
nl
WATER PUMP PULLEY REMOVAL
1. Before removing fead belt, loose 3 pieces
O
water pump pulley bolts.
Symbol Description
A Ratchet
se B Water pump pulley bolts

lU
DOIRE11AR14001
na
TV DAMPER BOLT AND TV DAMPER

REMOVAL
1. Use the special tool (EZT 0003) to hold the
er
TV damper in order to loose the TV damper

bolt.
Symbol Description
nt
A TV damper bolt
B TV damper pulley
rI
C Dowel
D Crankshaft
Fo
E Sprocket crankshaft
DOIRE11AR14029

INSTALLATION SERVICE POINTS

TV DAMPER BOLT AND TV DAMPER
INSTALLATION
1. Hold TV damper by using special tool (EZT
0003).
Symbol Description
A TV damper bolt
B TV damper pulley
C Dowel
y
D Crankshaft
nl
E Sprocket crankshaft
O
se
lU
DOIRE11AR14029
na
2. Tighten TV damper bolt to the specified

torque.
Specified torque (T5):
er
Steps Specified torque

3.0 kgm (30 Nm, 21.7 ft.lbs) ±
1
0.2 kgm (2 Nm, 1.45 ft.lbs)
nt
2 120° ± 4°
Symbol Description
rI
A MOT 591-04
DOIRE11AR14002
B EZT 0003
Fo

WATER PUMP PULLEY INSTALLATION

1. Locate water pump pulley on the front case.
The “FRONT” marking on the water pump
pulley is facing towards the mechanic.
NOTE :
Make sure the ‘FRONT’ making must be the
same direction with water pump ‘DOT’ mark.
2. Install and tighten the bolts to the specified
torque.
Specified torque :
y
0.72 ft.lbs)
nl
Symbol Description
O
A Water pump pulley
B Water pump
C Bolt
se
D “FRONT” marking
lU
DOIGE11AR03003
na
ALTERNATOR INSTALLATION
1. Install alternator lower bolt and nut to the
front case assy. Pre-tighten 2 to 3 times the
er
alternator lower nut and lift up the alternat-

or to the correct position.
nt
Symbol Description
A Alternator lower bolt
B Alternator lower nut
rI
DOIRE11AR14014
Fo
2. Tighten the alternator upper bolt to the

specified torque.
Specified torque :
2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
Symbol Description
C Alternator upper bolt
DOIRE11AR14003

3. Tighten alternator lower nut to the specified

torque.
Specified torque :
3.5 kgm (35 Nm, 25.32 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
Symbol Description
B Alternator lower nut
y
DOIRE11AR14004
nl
FEAD BELT INSTALLATION
1. Install fead belt tensioner assy to the front
O
case as shown in the illustration. Tighten
fead belt tensioner bolt to the specified
torque.
se
Standard value torque :
2.2 - 2.6 kgm (22 - 26 Nm, 15.91

T3
- 18.81 ft.lbs)
lU
5.0 - 5.4 kgm (50 - 54 Nm, 36.16
T6
- 39.06 ft.lbs)
DOIRE11AR14026
2. Wrap the fead belt around the tensioner

na
roller nicely.
NOTE :
Make sure the word “MITSUBOSHI” on the
er
fead belt is facing outward.

nt
rI
DOIRE11AR14006
Fo
3. Insert ratchet into square hole on tensioner

arm. Wrap the fead belt around the pulleys
anticlockwise in the sequence of 1 → 2 → 3 →
4
Symbol Description
A Ratchet
1 TV damper
2 Air-cond compressor pulley
3 Power steering pulley
4 Water pump pulley
DOIRE11AR14027

4. While ensuring no slack, push the ratchet

(A) toward engine to replace the fead belt
and then complete the belt installation
around alternator pulley and water pump
pulley.
Symbol Description
A Ratchet
5 Alternator pulley
6 Water pump pulley
Release the tensioner in position. Check and
y
DOIRE11AR14028
adjust to ensure fead belt in correct and
good position.
nl
OIL CONTROL VALVE INSTALLATION
O
1. Before installing the oil control valve to the
cylinder head, make sure the filter element
and o-ring are fixed properly in the oil con-
trol valve.
se Insert the oil control valve into the cylinder

head and tighten the bolt to the specified
torque.
lU
Specified torque :
0.72 ft.lbs)
na
CAUTION :
Ensure the filter element installed correctly
in order to prevent wrong installation and
er
cause engine operation failure.
Symbol Description
nt
A Oil control valve

B O-ring
C Filter element
rI
Fo
DOINE11AR11047

CAM SHAFT SENSOR INSTALLATION

1. Tighten the cam shaft sensor bolt to the
specified torque.
Specified torque :
0.72 ft.lbs)
Symbol Description
A Cam position sensor
B Bolt
y
nl
O
se
lU
DOINE11AR11042
na
SPARK PLUG INSTALLATION

1. Install spark plug to cylinder head assy to the
specified torque.
er
Specified torque :
1.75 kgm (17.5 Nm, 12.66 ft.lbs) ± 0.25 kgm
(2.5 Nm, 1.81 ft.lbs)
nt
Spark plug gap :

0.8 ~ 0.9 mm (0.031 ~ 0.035 in)
rI
Symbol Description
A Spark plug
Fo
B Spark plug gap
DOIRE11AR14030

PLUG TOP COIL INSTALLATION

1. Ensure the plug top coil rubber shoulder
should seat properly on cam cover lip.
2. Tighten plug top coil to the specified torque.
Specified torque :
0.72 ft.lbs)
Symbol Description
A Section view
y
B Plug top coil rubber shoulder
nl
O
se
lU
DOINE11AR11045
na
er
nt
rI
Fo

/ 26 FUEL AND EMISSION CONTROL SYSTEM
FUEL AND EMISSION CONTROL SYSTEM WEO11ASASSY13005
y
nl
O
se
lU
na
er
DOIRE11AR14037
— Lubricate all o-rings injector with engine oil during reassembly

nt
: Non–reusable parts
rI
Removal steps :
1. Solenoid valve 6. O-ring
2. Solenoid valve hose 7. Injector
Fo
3. Bracket harness fuel rail 8. Bracket harness throttle body

4. Fuel rail assy 9. Throttle body
5. Injector clip 10. Throttle body gasket

FUEL AND EMISSION CONTROL SYSTEM / 27
INJECTORS REMOVAL
1. Remove the injector clip by using screw
driver.
2. Pull out the injector from fuel rail. Make sure
not to drop the injectors.
Symbol Description
A Injector clip
B Fuel rail
y
DOINE11AR11037 C Injector
D Screw driver
nl
O
INJECTORS INSTALLATION
1. Fit a new o-ring on the injector.
se Symbol
A O-ring
Description
2. Coat the o-ring with oil.

lU
CAUTION :
(1) Make sure not to let oil get into the fuel
rail.
DOIME13BR07004 (2) Make sure not to insert injector slant-
na
ingly.
3. Insert the injector top end onto the fuel rail
while turning the injector in both directions.
er
Make sure the injector turns smoothly. If the

injector does not turn smoothly, probable
cause is the O-ring which can bind in the fuel
nt
rail.
Symbol Description
rI
B Injector
C Fuel rail
Fo
DOINE11AR11039

/ 28 FUEL AND EMISSION CONTROL SYSTEM
4. Install a new injector clip by sliding the open

end onto the fuel rail and the injector slot.
Make sure that the injector clip is in close
contact with the fuel rail and the injector
slot.
Symbol Description
D Injector clip
E Injector slot
y
DOIME13BR07006
nl
THROTTLE BODY INSTALLATION
1. Install the throttle body gasket into the in-
O
take manifold groove.
se
lU
DOIRE11AR14016
2. Fix the throttle body to the intake manifold.

na
3. Tighten the 4 pcs throttle body bolt to the

specified torque.
Specified torque :
er
0.72 ft.lbs)
nt
rI
DOIRE11AR14015
Fo

INTAKE MANIFOLD / 29
INTAKE MANIFOLD WEO11ASASSY13006
y
nl
O
se
lU
na
er
DOIRE11AR14038
Removal steps :
nt
1. Map sensor 4. Intake manifold

2. Clip 5. Intake manifold gasket
3. Breather hose (Part load 6. Lifting eye
rI
Fo

/ 30 INTAKE MANIFOLD

WEO11ASPROC13011
MAP SENSOR INSTALLATION

Install MAP sensor to intake manifold and tight-
en to the specified torque.
Specified torque (T1) :
ft.lbs)
Symbol Description
y
DOIRE11AR14017
A MAP sensor
nl
INTAKE MANIFOLD INSTALLATION
1. Install intake manifold gasket into the intake
O
manifold groove as shown in the illustration.
Symbol Description
A Intake manifold gasket
se B Intake manifold groove

lU
DOIRE11AR14011
2. Install intake manifold to the cylinder head

na
and then tighten bolt flange and nut to the

specified torque.
Specified torque (C and D) :
2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.2 kgm (2
er
Nm, 1.45 ft.lbs)

nt
Symbol Description
C Bolts
D Nuts
rI
DOIRE11AR14012
Fo

MANIVERTER / 31
MANIVERTER WEO11ASASSY14001
y
nl
O
se
lU
na
er
DOIRE11AR14039
nt
Removal steps :
1. Oxygen (Lambda) sensor 4. Maniverter gasket
rI
2. Maniverter heatshield 5. Bracket catalytic converter

3. Maniverter
Fo
T1 :5.0 kgm (50 Nm, 36.16 ft.lbs) ± 1.0 kgm (10 Nm, 7.23 ft.lbs)
T4 : Tightening torque procedures for exhaust manifold
Steps Torque Bolt numbers
2.8 kgm (28 Nm, 20.25 ft.lbs) ±
A
0.2 kgm (2 Nm, 1.45 ft.lbs) Bolt no. 1 to no.8
2.8 kgm (28 Nm, 20.25 ft.lbs) ± In ascending order
B
0.2 kgm (2 Nm, 1.45 ft.lbs)
2.8 kgm (28 Nm, 20.25 ft.lbs) ± Bolt no. 1 to no.8
C (if required)
0.2 kgm (2 Nm, 1.45 ft.lbs) In ascending order

/ 32 MANIVERTER
OXYGEN SENSOR REMOVAL

1. By using the special tool, remove the oxygen
(lambda sensor).
Symbol Description
A Special tool (MD998770)
y
DOIRE11AR14019
nl
MANIVERTER HEATSHIELD REMOVAL
1. Remove maniverter heatshield bolts (5pcs).
O
Symbol Description
A Maniverter heatshield
se
B Bolt position
lU
DOIRE11AR14020
na
MANIVERTER REMOVAL
1. Remove maniverter nuts (8pcs).
er
nt
rI
DOIRE11AR14022
Fo

MANIVERTER INSTALLATION
1. Install maniverter gasket to cylinder head
studs as shown in the illustration.
NOTE :
Ensure the ‘702’ marking at maniverter gas-
ket is facing to the maniverter side.
Symbol Description
A Maniverter gasket
DOIRE11AR14031 B ‘702’ marking

MANIVERTER / 33
2. Install maniverter to cylinder head studs.

According to the tightening sequence as
shown in the illustration, tighten the nuts to
the specified torque.
Step Torque Sequence proced-
ure
2.8 kgm (28
Nm, 20.25
1 ft.lbs) ± 0.2
kgm (2 Nm, Bolt no. 1 to no.
1.45 ft.lbs)
y
8
2.8 kgm (28 (In ascending or-
nl
Nm, 20.25 der)
2 ft.lbs) ± 0.2
kgm (2 Nm,
O
1.45 ft.lbs)
2.8 kgm (28
Bolt no. 1 to no.
Nm, 20.25
se
3 (If re- 8
ft.lbs) ± 0.2
quired) (In ascending or-
kgm (2 Nm,
der)
1.45 ft.lbs)
lU
DOIRE11AR14032
na
BRACKET CATALYTIC CONVERTER

INSTALLATION
1. Install bracket catalytic converter at cylinder
er
block.
2. Tighten the bolt to the specified tightening
torque.
nt
Specified torque:
2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
rI
Symbol Description
A Bolt
Fo
B Bracket catalytic converter
DOIRE11AR14052

/ 34 MANIVERTER
MANIVERTER HEATSHIELD INSTALLATION

1. Install maniverter heatshield onto cylinder
head and then tighten to the specified
torque.
Specified torque:
0.72 ft.lbs)
Symbol Description
A Maniverter heatshield
y
DOIRE11AR14020
B Bolt position
nl
OXYGEN SENSOR INSTALLATION
1. By using the special tool tighten the oxygen
O
(lambda sensor) according to the specified
torque.
Specified torque:
se
5.0 kgm (50 Nm, 36.16 ft.lbs) ± 1.0 kgm (10
Nm, 7.23 ft.lbs)
Symbol Description
lU
A Special tool (MD998770)
DOIRE11AR14019
na
er
nt
rI
Fo

TIMING BELT / 35
TIMING BELT WEO11ASASSY13007
y
nl
O
se
lU
na
er
DOIRE11AR14040
Pre-removal and post-installation.

nt
• Cam cover (Refer 11A/52 )

Removal steps :
rI
1. Timing belt upper cover 6. Crankshaft sprocket

2. Timing belt lower cover 7. VVT bolt cap
3. Engine mounting bracket 8. Camshaft VVT sprocket
Fo
4. Timing belt tensioner 9. Camshaft exhaust sprocket

5. Timing belt 10. Backplate cover

/ 36 TIMING BELT
TIMING BELT AND TIMING BELT TENSIONER

REMOVAL
1. Remove the timing belt upper cover stud bolt
from cylinder head by using standard tool.
Symbol Description
Timing belt upper cover stud
A
bolt
y
DOINE11AR11159
nl
2. Align camshaft sprocket timing marks “A”
with cam cover marks “B”.
O
NOTE :
Ensure that crankshaft is safe position (90°
ATDC) for cylinder no. 1
se
Symbol Description
A Camshaft sprocket timing marks
B Cam cover marks
lU
DOINE11AR11020
3. By using the special tool (EZT 0007), align the

na
crankshaft sprocket dowel pin to the front

case marking at one o’clock position.
Symbol Description
er
C Crankshaft sprocket dowel pin

D Front case marking
nt
E TV damper bolt
rI
DOIGE11AR03141
Fo
4. Insert the special tool in between two cam-

shaft sprockets in order to ensure the cam-
shaft sprockets “STOP” from turning.
Symbol Description
A Special tool (EZT 0004)
DOINE11AR11155

TIMING BELT / 37
5. If the timing belt is to be reuse, draw an ar-

row on the belt to indicate the rotation dir-
ection before removing the belt. This will
ensure the timing belt is fitted correctly
when it is reused.
y
DOINE11AR11023
nl
6. Loosen the timing belt tensioner bolt by us-
ing ratchet. Then, remove the timing belt
tensioner and timing belt together.
O
CAUTION :
To remove the tensioner bolt, make sure to
use the correct socket in order to prevent
se tensioner head bolt from damage and wear.
Symbol
A
Description
Single type socket box
lU
B Ratchet
DOINE11AR11021 C Timing belt tensioner
na
CAMSHAFT VVT SPROCKET REMOVAL

1. Turn camshaft intake (VVT) and camshaft
exhaust until both sprockets marks located
er
at 5 o’clock position.
NOTE :
The position of the camshaft VVT locator
nt
suppose to be at the top of the camshaft and

the exhaust locator suppose to be at the
bottom of the camshaft. At this position,
rI
both camshafts are at rest condition without

any pressure from the valves.
Fo
DOINE11AR12001

/ 38 TIMING BELT
2. Prepare a piece of clean cloth with an approx-

imate dimension as shown in the illustration.
Place the clean cloth on the cylinder head at
the special tool placement area. Then, posi-
tion the special tool (EZT 0043) on top of the
clean cloth. The camshaft VVT locator posi-
tion now suppose to be align with the special
tool grooves. The special tool will lock the
camshaft VVT locator from turning during
loosening the sprocket bolt.
NOTE :
The purpose of using the clean cloth is to
y
DOINE11AR12002
avoid scratches on the cylinder head surface.
nl
3. By using 2 pieces of cam cover bolts, fix the
special tool (EZT 0043) to the cylinder head
O
by pre-tightening the 2 pieces of bolts.
CAUTION :
Do not apply any torque on the 2 pieces cam
cover bolts. It might damage the camshafts.
se
lU
DOINE11AR12003
na
4. Loosen the camshaft VVT sprocket bolt.

er
nt
rI
DOINE11AR12004
Fo
5. Remove the camshaft VVT sprocket from

engine.
DOINE11AR12005

TIMING BELT / 39
CAMSHAFT EXHAUST SPROCKET REMOVAL

1. By using special tool as shown in the illustra-
tion, lock the camshaft exhaust sprocket.
2. Loosen the camshaft exhaust bolt.
Symbol Description
A Ring spanner
B Special tool (MB990767)
C Special tool (MD998715)
3. Remove the camshaft exhaust sprocket from
y
DOINE11AR11184
engine.
nl
WEO11ASPROC13013
O
CAMSHAFT VVT SPROCKET INSTALLATION
1. Install the camshaft VVT sprocket into the
engine and pre-tighten the camshaft VVT
se sprocket bolt accordingly.

NOTE :
The position of the camshaft VVT locator
lU
suppose to be at the top of the camshaft and
the exhaust locator suppose to be at the
DOINE11AR12006
bottom of the camshaft. At this position,
both camshafts are at rest condition without
na
any pressure from the valves.

2. Prepare a piece of cloth with an approximate
dimension as shown in the illustration. Place
er
the clean cloth on the cylinder head at the

special tool placement area. Then, position
the special tool (EZT 0043) on top of the
nt
clean cloth. The camshaft VVT locator posi-

tion now suppose to be align with the special
tool grooves. The special tool will lock the
rI
camshaft VVT locator from turning during

loosening the sprocket bolt.
NOTE :
Fo
The purpose of using the clean cloth is to

DOINE11AR12002
avoid scratches on the cylinder head surface.

/ 40 TIMING BELT
3. By using 2 pieces of cam cover bolts, fix the

special tool (EZT 0043) to the cylinder head
by pre-tightening the 2 pieces of bolts.
CAUTION :
Do not apply any torque on the 2 pieces cam
cover bolts. It might damage the camshafts.
4. Tighten the camshaft VVT sprocket according
to the specified tightening torque.
Specified torque :
3.62 ft.lbs)
y
DOINE11AR12003
nl
VVT BOLT CAP INSTALLATION
1. By using special tool (EZT 0043), lock the
O
camshaft VVT sprocket as shown in the illus-
tration.
2. Tighten the VVT bolt cap to the specified
se
torque.
Specified torque :
3.2 kgm (32 Nm, 23.15 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
lU
Symbol Description
DOINE11AR12008
A Ratchet
na
B Socket
C Camshaft inlet (VVT) sprocket
D Special tool (EZT 0043)
er
nt
rI
Fo

TIMING BELT / 41
CAMSHAFT EXHAUST SPROCKET BOLT

INSTALLATION
1. Place the camshaft exhaust sprocket on the
camshaft exhaust dowel pin as shown in the
illustration.
Symbol Description
A Camshaft exhaust dowel pin
y
nl
O
se
lU
DOINE11AR11104
na
2. By using special tool (MD998715), lock the

camshaft exhaust sprocket and tighten the
camshaft exhaust sprocket bolt to the spe-
cified torque.
er
Specified torque :
15.0 kgm (150 Nm, 108.49 ft.lbs) ± 2.5 kgm
(25 Nm, 18.08 ft.lbs)
nt
Symbol Description
A Special tool (MB990767)
rI
B Special tool (MD998715)

DOINE11AR11185 C Torque wrench
Fo
TIMING BELT AND TIMING BELT TENSIONER

INSTALLATION
1. Align camshaft sprocket timing marks “B”
with cam cover marks “ A” and lock the
sprocket by using special tool as shown in il-
lustration.
NOTE :
Ensure that crankshaft is in a safe position
(90° ATDC) for cylinder no.1.
Symbol Description
DOINE11AR11027
A Cam cover marks

/ 42 TIMING BELT
Symbol Description
B Camshaft sprocket timing
marks
C Special tool (EZT 0004)
2. By using the special tool (EZT 0007) align the
crankshaft sprocket dowel pin to the front
case marking at one o’clock position.
Symbol Description
D Front case marking
y
E TV damper bolt
nl
O
DOIGE11AR03024
3. Fit timing belt tensioner bearing by putting

the timing belt tensioner foot into the core
seplug and ensure the allen key hole is posi-

tioned opposite to the foot as shown in illus-
tration.
lU
Symbol Description
A Timing belt tensioner
B Timing belt tensioner foot
na
C Core plug
D Allen key hole
DOINE11AR11058 E Timing belt tensioner bolt
er
4. Pre-tighten the timing belt tensioner bolt by

hand.
5. Before installing the reused timing belt,
nt
make sure the arrow mark on top of the

timing belt is facing to the right direction.
rI
Fo
DOIGE11AR03177

TIMING BELT / 43
6. Firstly, fit timing belt halfway on to crank-

shaft sprocket and camshaft sprockets. Then,
fit timing belt around timing belt tensioner
pulley and push fully the timing belt onto all
sprockets and pulley as shown in the illustra-
tion.
Caution:
Ensure no slack along span 1 [S1] and span
2 [S2] area.
y
nl
O
se
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DOINE11AR11051
na
7. Turn the timing belt tensioner clockwise until

timing belt tensioner pointer indicator is ex-
actly over the right hand side edge of indic-
ator notch (refer view A). Then, tighten the
er
tensioner bolt whilst holding the Allen key

in place.
Specified torque :
nt
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2

Nm, 1.45 ft.lbs)
rI
Symbol Description
A Timing belt tensioner
Fo
Timing belt tensioner

B
pointer indicator
C Indicator notch
D Allen key
E Ratchet
DOINE11AR11053

/ 44 TIMING BELT
8. By using the special tool (EZT 0007) with TV

damper bolt, rotate the engine twice (720º
crankshaft rotation). Ensure the crankshaft
dowel pin marking is align back to the front
case.
CAUTION :
Remove special tool (EZT 0004) from it posi-
tion before rotating the crankshaft sprocket.
Symbol Description
E TV damper bolt
y
DOINE11AR11161
nl
9. When the indicator stops within the nominal
position at the centre of the indicator notch,
the timing belt is in the required timing belt
O
tension specification as shown in the illustra-
tion.
se
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na
er
nt
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DOINE11AR11052
Fo

TIMING BELT / 45
10. If the indicator does not stops within the

nominal position, insert the Allen key and
retain the installation shaft’s position while
loosening the tensioner bolt with torque
wrench. Then using the Allen key, slowly ro-
tate the installation shaft anti-clockwise until
the indicator moves to the free arm position
as shown. (View D)
Symbol Description
A Allen key
B Torque wrench
y
nl
O
se
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DOINE11AR11055
na
11. Rotate tensioner bearing clockwise until the

pointer is positioned in the centre of the
notch scale as shown. (View C)
12. Retighten tensioner bolt whilst holding the
er
Allen key in place.

Specified torque :
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2
nt
Nm, 1.45 ft.lbs)
Symbol Description
rI
A Allen key
B Torque wrench
Fo
DOINE11AR11056

/ 46 TIMING BELT
13. By using the special tool (EZT 0007) with TV

damper bolt, rotate the engine twice (720º
crankshaft rotation). Ensure the crankshaft
dowel pin marking is align back to the front
case.
CAUTION :
Remove special tool (EZT 0004) from it posi-
tion before rotating the crankshaft sprocket.
Symbol Description
A Camshaft sprocket timing marks
y
B Cam cover marks
nl
D Front case marks
O
se
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DOINE11AR11057
na
14. If the indicator stops within the nominal po-

sition at the centre of the indicator notch,
the timing belt is in the required timing belt
tension specification. If the indicator still
er
does not stops in the middle of the indicator

notch, repeat procedures no.1 until no.14.
nt
rI
Fo
DOINE11AR11052

TIMING BELT / 47
16. After checking the timing belt tension, insert

again the special tool in between the two
camshaft sprockets in order to make sure the
camshaft sprockets “STOP” from turning.
Symbol Description
y
DOINE11AR11155
nl
17. Then, turn TV damper bolt anti-clockwise to
loosen TV damper bolt and special tool.
Remove TV damper bolt and special tool be-
O
fore installing timing belt cover.
Symbol Description
A TV damper bolt
se B Special tool (EZT 0007)

lU
DOINE11AR11162
na
TIMING BELT LOWER COVER AND UPPER

COVER INSTALLATION
1. Install timing belt lower cover (B) assy to en-
gine front cover lower side and tighten the
er
bolt flange.
nt
0.72 ft.lbs)
rI
2. Install timing belt upper cover (A) assy to

cylinder head front side and tighten the bolt
DOINE11AR11032 flange.
Fo

0.72 ft.lbs)

/ 48 WATER PUMP AND WATER HOSE
WATER PUMP AND WATER HOSE WEO11ASASSY13008
y
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O
se
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er
DOIRE11AR14041
— Sealant
nt
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Removal steps :
1. Coolant temperature sensor 7. Clip
2. Retainer clip 8. Return hose
Fo
3. Washer 9. Seal
4. Thermostat 10. Water pump
5. Thermostat seal 11. Water pump gasket
6. Thermostat pipe assy

WATER PUMP AND WATER HOSE / 49
COOLANT TEMPERATURE SENSOR

REMOVAL
Use ratchet with long socket to remove the en-
gine coolant temperature sensor.
Symbol Description
A Ratchet
B Long socket
y
DOIRE11AR14035
nl
THERMOSTAT REMOVAL
1. Use circlip plier to remove retainer clip.
O
2. Then, use a screw driver to pry out the
washer.
3. The thermostat can be removed by using
se
plier.
Symbol Description
A Circlip plier
lU
B Retainer clip
C Thermostat pipe
DOINE11AR11009
D Washer
na
E Thermostat
THERMOSTAT PIPE ASSY REMOVAL

1. Release coolant return hose clamp from cyl-
er
inder head.
2. Remove bolts bracket thermostat pipe.
nt
Symbol Description
Bolt thermostat pipe at cylinder
A
rI
block
Coolant return hose from cylinder
B
block
Fo
DOINE11AR11013

/ 50 WATER PUMP AND WATER HOSE

WEO11ASPROC13015
THERMOSTAT INSTALLATION
1. Fit the thermostat seal to the thermostat se-
curely.
2. Fit the thermostat into thermostat pipe assy
as shown in illustration.
NOTE :
Ensure the bleed hole is at the top position
30 ° ± 5 °.
y
DOIRE11AR14057
nl
3. Fit securely the washer and insert retainer
clip using circlip plier into thermostat pipe
assy securely.
O
Symbol Description
A Bleed hole
se
B Thermostat
C Retainer clip
D Washer
lU
NOTE :
(1) Make sure the retainer clip holes is in
lower position.
(2) Ensure the thermostat washer and retain-
na
er clip are properly inserted in the groove

(F).
er
nt
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DOIRE11AR14058
Fo

WATER PUMP AND WATER HOSE / 51
THERMOSTAT PIPE ASSY INSTALLATION

1. Apply a small amount of soap water to the
thermostat seal at the thermostat pipe as-
sembly. Press the water pump case assembly
while twist it left and right . Careful to not
damage the thermostat seal.
2. If the seal does not turn smoothly, the seal
is probably being clamped. Disconnect the
thermostat pipe assembly and check the seal
for any damage. Then, re-insert the new
thermostat pipe assembly seal and repeat
y
procedure no.1.
3. Tighten the thermostat pipe bolt to the spe-
nl
cified torque.
Specified torque :
O
2.4 kgm (24 Nm, 17.36 ft.lbs) ±0.2 kgm (2
Nm, 1.45 ft.lbs)
Symbol Description
se A
B
C
Thermostat seal
Thermostat pipe
Return hose
lU
D Thermostat pipe assy bolt
DOINE11AR11016
E Front case
na
COOLANT TEMPERATURE SENSOR

INSTALLATION
1. If reused the engine coolant temperature
er
sensor, apply the specified sealant to the

thread.
Specified sealant :
nt
3M Nut Locking Part No. 4171 or equivalent.

rI
DOIGE11AR03039
Fo
2. Use ratchet with long socket to tighten the

engine coolant temperature sensor to the
specified torque.
Specified torque :
2.7 kgm (27 Nm, 19.53 ft.lbs) ±0.2 kgm (2
Nm, 1.45 ft.lbs)
Symbol Description
A Ratchet
B Long socket
DOIRE11AR14035

/ 52 CAMSHAFT AND TAPPET
CAMSHAFT AND TAPPET WEO11ASASSY13009
y
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er
nt
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DOIRE11AR14045

CAMSHAFT AND TAPPET / 53
— Sealant
— Lubricate all internal parts with engine oil during reassembly
Pre-removal and post-installation.
• Camshaft VVT sprocket (Refer 11A/35 )
• Camshaft exhaust sprocket (Refer 11A/35 )
Removal steps :
1. Front lambda sensor bracket
2. Breather hose (Full load)
3. Breather hose (Part load)
4. Oil filler cap
y
5. Cam cover
6. Cam cover seal
nl
7. Camshaft cap
8. Camshaft oil seal
O
9. VVT camshaft
10. Trigger wheel
11. Exhaust camshaft
12. Tappet
se
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er
nt
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Fo

INSPECTION
TAPPET SELECTION PROCEDURE
CAUTION :
(1) The tappet clearance measurements should only be done after a minimum of 2 hours of soaking.
(2) Ensure that cam sprocket timing mark in line with cam cover timing mark (crank is 90° ATDC).
(3) Cylinder head must be clamped with cylinder block to get precise tappet clearance measurement.
(4) Rotate cam sprocket clockwise direction as below sequence and measure the clearance using
thickness gauge.
Side Cam rotation Cam lobe number measurement
y
0° 1&2
nl
90° 5&6
Inlet
180° 7&8
O
270° 3&4
0° 5&6
90° 7&8
Exhaust
se
180° 3&4
270° 1&2
(5) Measure clearances X and Y (16 places) using a thickness gauge.
lU
X = 0.2 ± 0.05
Y = 0.3 ± 0.05
(6) If incorrect, select new tappets for correct clearance by using formula below.
Intake grade = Z + ( X – 0.2 )
na
Exhaust grade = Z + ( Y – 0.3 )
Symbol Description
X Tappet clearance for intake
er
Y Tappet clearance for exhaust

Z Tappet grade dimension
(7) Remove camshafts and known tappets, lubricate selected grade of tappets with oil and locate
nt
in cylinder head assy.

(8) Install camshafts and caps without using sealant on front caps.
rI
(9) Verify clearance X and Y (16 places) using a thickness gauge.

(10) Apply sealant as shown and install front caps.
(11) The sequence to secure camshaft front cap and camshaft intermediate cap as below :
Fo
Sequence 1st 2nd 3rd 4th 5th

Cam cap inlet I1 I5 I2 I4 I3
Cam cap exhaust E1 E5 E2 E4 E3

y
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O
se
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DOINE11AR11116
Symbol Description
er
A Intake camshaft
B Exhaust camshaft
C Tappets
nt
D Cylinder head assy

X Tappet clearance for intake
rI

Fo

y
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O
se
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DOINE11AR10012
1. STEP 1
1.1 Align markings (A) at VVT sprocket and exhaust camshaft sprocket to the cam cover top
er
marking as shown in the illustration.
Symbol Description
nt
A Camshaft sprockets marking

I Intake side
rI
E Exhaust side
1.2 Measure tappet clearance using thickness gauge (View B) between tappet top surface and
camshaft lobe :
Fo
Camshaft lobe number for tappet clearance

Camshaft sprocket angle
Intake side Exhaust side
0°
No.1 and No.2 No.5 and No.6
(12 o’clock)

y
nl
O
se
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DOINE11AR11163
2. STEP 2
2.1 Set markings (A) of VVT sprocket and exhaust camshaft sprocket at 90°( 3 o’clock ) as shown
er
in the illustration.
Symbol Description
nt

I Intake side
rI
E Exhaust side
camshaft lobe as below :
Fo

90°
(3 o’clock)

y
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O
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DOINE11AR11004
3. STEP 3
er
Symbol Description
nt

I Intake side
rI
E Exhaust side
Fo

180°
(6 o’clock)

y
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O
se
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DOINE11AR11005
4. STEP 4
er
Symbol Description
nt

I Intake side
rI
E Exhaust side
Fo

270°
(9 o’clock)
5. Note all 16 pieces tappet clearance as shown in table below.
Tappet No. Tappet clearance measurement, X (intake)

1 X1
2 X2
3 X3
4 X4

Tappet No. Tappet clearance measurement, X (intake)

5 X5
6 X6
7 X7
8 X8
Tappet No. Tappet clearance measurement, Y (exhaust)
1 Y1
2 Y2
3 Y3
y
4 Y4
5 Y5
nl
6 Y6
7 Y7
O
8 Y8
CAMSHAFT CAP REMOVAL
se
1. Loosen all bearing caps bolts based on the
loosening sequence as shown in the illustra-
tion.
lU
Symbol Description
I Intake side
E Exhaust side
na
DOINE11AR11064
er
TAPPET REMOVAL
1. Remove tappets using a magnetic tool (A).
nt
CAUTION :
Do not mix the original tappet position.
rI
Fo
DOIGE11AR03052

2. Refer tappet grade at all tappets as shown

in the illustration (inside the tappet).
3. Note all tappets grade in table below.
y
DOINE11AR11063
nl
Tappet No. Tappet grade dimension Z (intake)
1 Z1
O
2 Z2
3 Z3
4 Z4
se
5 Z5
6 Z6
7 Z7
lU
8 Z8
Tappet No. Tappet grade dimension Z (exhaust)
1 Z1
na
2 Z2
3 Z3
4 Z4
er
5 Z5
6 Z6
7 Z7
nt
8 Z8

rI
TAPPET INSTALLATION
Fo
1. Refer table below for tappet clearance spe-

cification.
DOIGE11AR03122
Type Tappet clearance specification ( in mm )

Intake X = 0.2 mm ± 0.05 mm
Exhaust Y = 0.3 mm ± 0.05 mm

Tappet clearance meas-

Clearance specification ( in mm ) Description
urement
X1 0.25 mm Reuse old tappet
X1 < 0.15 mm Replace with new tappet
X1 > 0.25 mm Replace with new tappet
Tappet clearance meas-
Clearance specification ( in mm ) Description
urement
Y1 0.35 mm Reuse old tappet
Y1 < 0.25 mm Replace with new tappet
Y1 > 0.35 mm Replace with new tappet
y
2. Refer formula below for intake and exhaust
nl
tappet grade identification.
Intake Grade :
Z + ( X – 0.2 mm )
O
Exhaust Grade :
Z + ( Y – 0.3 mm )
Symbol
X
se
Description ( in mm )
Tappet clearance for intake
lU
Z Tappet grade dimension
FOR EXAMPLE, THE CALCULATION BELOW
SHOWS THE INTAKE TAPPET GRADE SELECTION.
na
Z + (X – 0.2mm) : 3.000 + (0.3 – 0.2)

: 3.000 + (0.1)
: 3.100 mm
er
Due to 3.100 mm is very close to 3.105 mm, select

tappet grade 08
nt
Mechanical tappet grade Dimension (A) ( in mm )

01 3.000
rI
02 3.015
03 3.030
04 3.045
Fo
05 3.060
06 3.075
07 3.090
08 3.105
09 3.120
10 3.135
11 3.150
12 3.165
13 3.180
14 3.195
15 3.210

Mechanical tappet grade Dimension (A) ( in mm )

16 3.225
17 3.240
18 3.255
19 3.270
20 3.285
21 3.300
22 3.315
23 3.330
24 3.345
y
25 3.360
nl
26 3.375
27 3.390
O
28 3.405
29 3.420
30 3.435
31
32
33 se 3.450
3.465
3.480
lU
34 3.495
35 3.510
36 3.525
na
37 3.540
38 3.555
39 3.570
er
40 3.585
41 3.600
42 3.615
nt
43 3.630
44 3.645
rI
45 3.660
46 3.675
Fo
47 3.690
3. Apply minimum sufficient amount of engine
oil on the tappet and insert all tappets inside
cylinder head assy.
DOINE11AR11066

CAMSHAFT INSTALLATION
1. Make sure that the cam trigger tab is prop-
erly inserted in the camshaft slot.
2. Tighten the bolt according to the specified
torque.
Specified torque:
0.72 ft.lbs)
3. Apply engine oil to the camshafts.

4. Install the camshafts on the cylinder head.
y
Be careful not to confuse the VVT camshaft
with the exhaust camshaft.
nl
Symbol Description
O
C VVT camshaft
D Cam trigger wheel
E Cam trigger tab
se
F Camshaft slot
G Bolt
lU
DOIRE11AR14055
na
CAMSHAFT CAP INSTALLATION

1. Surface should be clean, dry and free from
grease and debris.
er
2. Apply sealant on front camshaft bearing cap

as shown in the illustration.
Specified sealant :
nt
TB1110B
Sealant bead diameter size:

rI
3 mm (0.12 in) ± 1 mm (0.039 in)
DOIRE11AR14056
Symbol Description
Fo
A Sealant

3. Before installing the other bearing caps, ar-

range the bearing caps by referring the
stamped identification marking on each the
bearing caps.
Identifica-
tion mark- Description
ing
A I (Intake side), E (exhaust side)
B Bearing caps number
C Arrow facing to timing belt
side
y
DOIGE11AR03056
nl
4. Tighten bearing caps bolt using the following
tightening sequence order.
O
Sequence 1st 2nd 3rd 4th 5th
VVT cam-
I3 I4 I2 I5 I1
shaft cap
se
Exhaust
camshaft E3 E4 E2 E5 E1
cap
lU
Steps Operation
Tighten camshaft caps in se-
quence using minimum force
S1
leaving an even gap between
na
cam caps and cylinder head.

Tighten camshaft cap evenly in
S2
sequence until the gap is closed
Tighten camshaft cap in se-
er
quence order to the specified

S3 torque :
nt
1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1

kgm (1 Nm, 0.72 ft.lbs)
Symbol Description
rI
A Front camshaft bearing cap

DOIRE11AR14053
B Leave even gap
Fo
C Bearing cap intermediate

I Intake side
E Exhaust side
NOTE :
Do not splash engine oil on the VVT camshaft
and exhaust camshaft cap cylinder head area.

5. Verify again all 16 pieces tappets clearance

using thickness gauge.
Symbol Description
A Thickness gauge
B Camshaft lobe
6. If the tappets clearance is not within tappet
clearance specification , remove again all
camshaft bearing caps and select the correct
new tappet.
y
DOINE11AR10013
nl
VVT CAMSHAFT OIL SEAL INSTALLATION
O
oil to oil seal housing and oil seal lip.
2. Securely insert new oil seal inside oil seal
housing.
3. Slowly and carefully knock the oil seal by
seusing special tool (outer) until it properly

fitted at oil seal housing.
lU
Symbol Description
A Oil seal
DOINE11AR11178 B Special tool EZT 0006 (outer)
C Mallet
na
er
nt
rI
Fo

EXHAUST CAMSHAFT OIL SEAL

INSTALLATION
oil to oil seal housing and oil seal lip.
2. Insert oil seal into the special tool (inner) and
then by using another part of the special tool
(outer), knock in the oil seal carefully using
mallet as shown in the illustration.
Symbol Description
A Oil seal housing
y
B Special tool EZT 0006 (inner)
nl
C Special tool EZT 0006 (outer)
D Mallet
E Oil seal
O
CAUTION :
Do not damage the oil seal during installa-
tion.
se
lU
DOINE11AR11179
na
OIL FILLER CAP INSTALLATION

Clean oil cap and cam cover sealing face from oil
trace/debris using soft cloth during oil change
er
or oil top-up.
nt
rI
DOINE11AR11065
Fo

INSPECTION
CAMSHAFT
Measure the cam heights and replace the cam-
shaft when the height exceeds the specified
limit.
Identification mark Standard value

43.92 mm (1.73
1.3 in) ± 0.10 mm
(0.004 in)
Intake
44.35 mm (1.75
y
1.6 in) ± 0.10 mm
(0.004 in)
nl
43.92 mm (1.73
Exhaust All in) ± 0.10 mm
O
(0.004 in)
Symbol Description
A Cam lobes heights measurement
se B
C
D
Micro meter
Cam position lobes measurement
Camshaft
lU
DOIGE11AR06170
na
CAMSHAFT BENT LIMIT

Measure the cam journal at 3 positions (A) to
check the bent limit. If the measurement exceeds
the specified limit, replace the camshaft.
er
Limit :
0.05 mm (0.002 in)
nt
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DOIRE11AR14059
Fo

CYLINDER HEAD AND VALVES / 69
CYLINDER HEAD AND VALVES WEO11ASASSY13010
y
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O
se
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er
nt
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Fo
DOIRE11AR14051

/ 70 CYLINDER HEAD AND VALVES
— Lubricate all internal parts with engine oil during reassembly

Removal steps :
1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
4. Core plug 35 mm
5. Intake valve collet
6. Intake valve spring retainer
7. Intake valve spring
y
8. Intake valve
nl
9. Exhaust valve collet
10. Exhaust valve spring retainer
11. Exhaust valve spring
O
12. Exhaust valve
13. Intake valve stem seal and spring seat
14. Exhaust valve stem seal and spring seat
15.
16.
17.
Intake valve guide
Exhaust valve guide
Intake valve seat se
lU
18. Exhaust valve seat
19. Cylinder head
T1:
Steps Value Remarks
na
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2 kgm (2 • One bolt at a time
A
Nm, 1.45 ft.lbs) • Follow sequence No.1 to 10
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 for step A, B C and D.
er
B • Repeat each step until all

Nm, 1.45 ft.lbs)
bolts achieve specification.
C 90° ~ 94° (Min)
nt
D 90° ~ 94° (Min)

rI
Fo

CYLINDER HEAD BOLT REMOVAL

1. Use special tool to loose the bolts in se-
quence order and then use hand to untight-
en completely the bolts as shown in the illus-
tration.
2. After loosening all bolts engine, remove the
cylinder head assy from engine.
CAUTION :
The plug guides cannot be replaced or change,
y
be careful not to damage or deform the plug
guides when removing the cylinder head bolts.
nl
Symbol Description
O
TBS Timing belt side
se
lU
DOIGE11AR03143
na
VALVE COLLET REMOVAL

1. Locate cylinder head assy on top of the spe-
cial tool as shown in the illustration.
er
Symbol Description
A Cylinder head assy
nt
B Special tool (EZT 0046)

rI
DOIME11AR11024
Fo
2. Before using special tool, ensure the special

tool stopper is located at the shown location.
Symbol Description
B Special tool (EZT 0002) stopper
DOINE11AR11164

3. Knock the valve spring retainer with mallet

in order to remove valve collet.
Symbol Description
A Cylinder head assy
y
DOIME11AR11025
nl
4. Remove valve collet from special tool at the
shown location.
O
Symbol Description
A Valve collet
B EZT 0002
se
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DOIME11AR11026
na
VALVE STEM SEAL AND SPRING SEAT

REMOVAL
1. Use special tool to remove valve steam seal
and spring seat.
er
Symbol Description
nt
rI
DOINE11AR11165
Fo


VALVE STEM SEAL AND SPRING SEAT
INSTALLATION
1. Use special tool to install the valve stem seal
and spring seat into the intake and exhaust
valve guide.
Symbol Description
A Valve stem seal and spring
seat
y
B Valve guide
nl
CAUTION :
Do not reuse the removed valve stem seals.
O
se
lU
DOINE11AR11166
na
INTAKE VALVE AND EXHAUST VALVE

INSTALLATION
1. Apply engine oil to the intake valve and ex-
er
haust valve.
2. Install the intake valve and exhaust valve to
the cylinder head side.
nt
Symbol Description
C Intake or exhaust valve
rI
Fo
DOIGE11AR03125

VALVE SPRING INSTALLATION

1. Install intake valve and exhaust valve into
cylinder head, then locate on the special tool
Symbol Description
Intake valve and exhaust
B
valve
C Cylinder head
y
nl
O
se
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DOINE11AR11167
na
2. Locate valve spring on intake valve or ex-

haust valve.
3. Align and locate valve spring retainer over
intake valve or exhaust valve.
er
Symbol Description
nt
D Valve spring
E Valve spring retainer
rI
DOIGE11AR03126
Fo
VALVE COLLET INSTALLATION

1. Insert the valve collet to the special tool as
shown in the illustration.
Symbol Description
1 Bigger semi circumference
2 Smaller semi circumference
CAUTION:
Make sure the smaller semi circumference
facing outward when inserting the collet
DOIGE11AR03063
into the special tool.

2. Be careful to press down the special tool (EZT

0001) until ‘click’ sound is heard.
Remove special tool and check the valve col-
lets position. Make sure the valve collets are
fix securely into it's position.
Symbol Description
F Valve collets
y
nl
O
se
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DOIME11AR11030
na
3. Put out the special tool (EZT 0046), then

knock the valve use roll bar to make sure
valve collets is properly fixed in it’s position.
er
nt
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DOIME11AR11031
Fo
CYLINDER HEAD BOLT INSTALLATION

1. When installing the cylinder head bolts,
check that the shank length (A) of each bolt
meets the limit. If the limit is exceeded, re-
place the bolt.
Specification :
160 mm (6.3 in) ± 0.35 mm (0.014 in)
2. Install the washers as illustrated.

3. Apply engine oil to the bolt threads and
washers.
DOIGE11AR03065

4. According to the tightening sequence as

shown in the illustration, tighten the bolts
to the specified torque.
Symbol Description
TBS Timing belt side
y
DOIGE11AR03066
nl
TIGHTENING PROCEDURES (SERVICE) :
Steps Value Remarks
O
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2 kgm
A • One bolt at time.
(2 Nm, 1.45 ft.lbs)
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm • Follow sequence No. 1 to 10 for steps
B A, B, C & D.
(2 Nm, 1.45 ft.lbs)
C
D
90° ~ 94°
90° ~ 94° se • Repeat each step until all bolts achieve
specification.
lU
5. By using special tool (Mot.591.04), tighten
all bolts to the specified torque.
Symbol Description
A Special tool (Mot.591.04)
na
er
nt
DOINE11AR11168
INSPECTION
rI
CYLINDER HEAD
1. Check the cylinder head gasket surface for
Fo
flatness by using a straightedge and thickness

gauge.
Standard value :
0.1 mm (0.004 in)
2. If the service limit is exceeded, correct to

meet the specification.
Grinding limit :
DOIIE11AR9066 * 0.2 mm (0.008 in)
*Includes / combined with cylinder block

grinding

Cylinder head height (Specification when

new) :
134.7 mm (5.3 in)
VALVE
1. Check the valve face for correct contact. If
incorrect, reface using a valve refacer. Valve
should make a uniform contact with the seat
at the centre of valve face.
2. If the margin (B) is smaller than the service
limit, replace the valve.
y
Standard value :
Intake : 1.5 mm (0.059 in) ± 0.15 mm (0.006
nl
in)
Exhaust : 1.95 mm (0.077 in) ± 0.15 mm
(0.006 in)
O
DOIIE11AR9067
3. Measure the valve total length. If the meas-

urement is less than the specified valve, re-
se place the valve.
Items
Intake
Standard
115.43 mm (4.54 in)
lU
Exhaust 114.63 mm (4.51 in)
VALVE SPRING
1. Measure the valve spring free height. If the
na
height is less than the limit value, replace the

valve spring.
Standard specification :
er
Items Standard
Intake 48.362 mm (1.9 in)
Exhaust 48.362 mm (1.9 in)
nt
Symbol Description
rI
A Valve spring
DOIGE11AR06173
B Vernier caliper
2. Place the spring on a flat surface next to a
Fo
steel square. Rotate the spring while check-

ing for a gap between the side of the spring
and the steel square.
3. Measure the squareness of the valve spring
and if the limit is exceeding the limit value,
replace the valve spring.
Standard value :
1 mm or less
Limit :
2 mm
DOIGE11AR06172

Symbol Description
C Squareness
D Valve spring
E Steel square
VALVE GUIDE
1. Measure the clearance between the valve
guide (A) and valve stem. If the limit is ex-
ceeded, replace the valve guide or valve, or
both.
y
Items Standard
0.0335 mm (0.001 in)
nl
Intake
± 0.015 mm (0.001 in)
0.0435 mm (0.002 in)
Exhaust
O
± 0.015 mm (0.001 in)
DOIIE11AR9069
VALVE SEATS
se
1. Assemble the valve, then measure the valve
stem projection (A) between the end (B)of
the valve stem and the spring seating surface
lU
(C). If the measurement exceeds the specified
limit, replace the valve seat.
Items Standard
na
Intake 54.9 mm (2.16 in) ± 0.35

mm (0.014 in)
Exhaust 54.9 mm (2.16 in) ± 0.35
mm (0.014 in)
er
DOIIE11AR01120
nt
rI
Fo

OIL PUMP AND OIL PAN / 79
OIL PUMP AND OIL PAN WEO11ASASSY13011
y
nl
O
se
lU
na
er
nt
rI
Fo
DOIRE11AR14042

/ 80 OIL PUMP AND OIL PAN
— Sealant
— Apply engine oil to all moving parts before installation
Removal steps :
1. Oil filter 11. Relief valve seal
2. Oil drain plug 12. Relief valve spring
3. Gasket 13. Relief valve piston
4. Crank angle sensor 14. Front oil seal
5. 15. Front case
Oil pan
y
6. 16. Front case seal
Windage tray
7. 17. Oil pump backplate
Baffle
nl
8. 18. Oil pump inner rotor
Oil pick up pipe
9. 19. Oil pump outer rotor
Oil seal
20. Stud (Special)
O
10.
Relief valve plug
se
lU
na
er
nt
rI
Fo

REMOVAL SERVICE POINT WEO11ASPROC13018
OIL PAN REMOVAL

1. Remove 19 pieces oil pan bolts.
y
DOIME11AR11034
nl
2. Remove the hidden oil pan bolt at the
transmission side (A).
O
Symbol Description
A Two bolts hidden at the loc-
ations shown.
se
B Oil pan
lU
na
er
nt
rI
DOIME11AR11033
Fo
3. Pry out the oil pan by using the flat screw

driver as shown in illustration.
CAUTION :
Slowly perform to avoid deformation of the
oil pan flange.
DOIME11AR11035


FRONT CASE INSTALLATION
1. Clean the surfaces on the cylinder block and
front case surfaces.
2. Locate front case seal in front case groove.
Symbol Description
A Front case seal
3. Align the oil pump rotor back plate to the
crankshaft.
y
DOINE11AR11130 4. Align dowel holes to the dowels at cylinder
block.
nl
5. Fix the front case to cylinder block properly.
FRONT OIL SEAL INSTALLATION
O
1. Place the special tool on the crankshaft's
front end and apply engine oil to its outer
circumference.
se
lU
na
DOIGE11AR03099
2. Apply engine oil to the oil seal lip, then push

the oil seal along the guide by hand until it
touches the front case. Tap the oil seal into
er
place by using the special tool.

nt
rI
Fo
DOIGE11AR03100

OIL PICKUP PIPE INSTALLATION

1. Slowly insert the oil pick up pipe oil seal to
the oil pan hole. Carefully do not damage
the oil seal during installation. After installa-
tion, check condition the pipe fitting.
2. If the oil seal does not turn smoothly, the oil
seal is probably being clamped. Remove the
oil seal and check for any damage. If the oil
seal is damage, install a new oil seal by re-
peating step no.1.
3. Tighten the oil pick up pipe bolts to the
y
DOIGE11AR03112 specified torque.
Specified torque :
nl
1.45 ft.lbs)
O
4. Tighten the baffle bolts in the sequence or-
der to the specified torque.
Specified torque :
se 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm,

0.72 ft.lbs)
lU
Symbol Description
A Baffle
na
DOINE11AR11088
5. Tighten the windage tray bolts in the se-

er
quence order to the specified torque.

Specified torque :
nt
0.72 ft.lbs)
rI
Symbol Description
A Windage tray
Fo
DOINE11AR11089

OIL PAN INSTALLATION

1. Clean the mating surfaces of the cylinder
block and oil pan from sealant. Wipe off the
pre-lubrication oil using isoprophyl alcohol.
2. Apply a 3 mm (0.12 in) ± 1 mm (0.039 in)
bead of form-in-place gasket to the outer
circumference of the oil pan flange.
Symbol Description
A Bolt hole
Specified sealant :
y
DOIGE11AR03070 Part No. MD970389 (Sealant – Threebond
TB1207F).
nl
3. Tighten the bolts in the sequence order
O
shown in the illustration.
Specified torque :
0.72 ft.lbs)
se
lU
na
DOINE11AR11087
OIL FILTER INSTALLATION

1. Clean the oil filter mounting surface on the
er
front case.
2. Apply a small amount of engine oil to the o-
ring at the new oil filter.
nt
Symbol Description
A Oil filter o-ring
rI
Fo
DOIGE11AR03111

3. Attach oil filter to housing thread and rotate

until oil filter seal is seated against seal face.
4. Use the special tool (MB991396) to tighten
the oil filter to the specified torque.
Specified torque :
1.4 kgm (14 Nm, 10.13 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
y
DOIGE11AR03071
nl
CRANK ANGLE SENSOR INSTALLATION
1. Apply soap water to crank angle sensor and
O
tighten the crank sensor screw by using torx
to the specified torque.
se
0.72 ft.lbs)
Symbol Description
lU
A Crank angle sensor
DOIGE11AR03072
B Target wheel
C Screw special
na
INSPECTION
OIL PUMP
er
1. Fit the oil pump rotors into the front case.

2. Check the tip clearance using a thickness
gauge.
nt
Standard value :
0.06 - 0.18 mm (0.002 - 0.007 in)
rI
Symbol Description
A Oil pump rotors
Fo
DOINE11AR11169
B Front case
C Thickness gauge

3. Check the side clearance using a straight

edge and thickness gauge.
Standard value :
0.03 - 0.10 mm (0.001 - 0.004 in)
Symbol Description
A Oil pump rotors
B Straight edge
C Thickness gauge
y
DOINE11AR11170
nl
4. Check the body clearance using a thickness
gauge.
Standard value :
O
0.04 - 0.10 mm (0.002 - 0.004 in)
Limit :
se
0.35 mm (0.014 in)
Symbol Description
A Oil pump rotors
lU
B Front case
DOINE11AR11171 C Thickness gauge
na
er
nt
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Fo

PISTON AND CONNECTING RODS / 87
PISTON AND CONNECTING RODS WEO11ASASSY13012
y
nl
O
se
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na
er
nt
rI
Fo
DOIRE11AR14043

/ 88 PISTON AND CONNECTING RODS
— Apply engine oil to all moving parts before installation

Removal steps :
1. Connecting rod bolt
2. Connecting rod cap
3. Connecting rod bearing
4. Piston and connecting rod assembly
5. Connecting rod bearing
6. Piston ring No.1
7. Piston ring No.2
y
8. Oil ring
nl
9.Piston pin circlip
10.
Piston pin
O
11.
Piston
12.
Connecting rod
T1 : 2.2 kgm (22 Nm, 15.91 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 90° ± 5°
se
lU
na
er
nt
rI
Fo

CONNECTING ROD CAP REMOVAL

1. Indicate a marking at the side of the connect-
ing rod big end as shown in the illustration.
CAUTION :
To facilitate reassembly, please do not punch
the connecting rod.
y
DOIME11AR11056
nl
2. Remove the connecting rod caps bolts and
then remove the connecting rod cap.
O
Symbol Description
A Crankshaft
B Connecting rod cap
se
lU
DOIME11AR11057
na
CONNECTING ROD, PISTON PIN AND PISTON

REMOVAL
1. Insert special tool into the connecting rod
and then remove the connecting rod prop-
er
erly from cylinder block.

CAUTION :
nt
Do not scratch the crankshaft surface.
Symbol Description
rI
A EZT 0008
DOIME11AR11058
Fo
2. NOTE :
1) Due to piston pin circlip position is differ-
ent for ‘FRONT’ and ‘REAR’ side, only remove
the ‘FRONT’ side piston pin circlip as shown
2) If reused the piston and piston pin, the
piston pin circlip at ‘REAR’ side must be re-
moved . In order to remove the circlip, care-
fully push the circlip open end to 12 o’clock
or 6 o’clock before removing the circlip using
small screw driver.
DOIRE11AR14046

Symbol Description
A Piston pin circlip
B Piston ‘FRONT’ side mark
By using small screw driver, carefully pry-out
the piston pin circlip from connecting rod
pin oil groove as shown in the illustration.
CAUTION :
Do not scratch the piston circlip housing
surface.
Symbol Description
y
A Connecting rod
nl
B Piston pin circlip
C Small screw driver
O
DOINE11AR11173 D Pin oil groove
3. Pull out piston pin from piston and connect-
ing rod.
se Symbol
A
B
Piston pin
Piston
Description
lU
C Connecting rod
na
DOINE11AR11102
4. If the part is in good condition, keep the

er
piston, piston pin, and connecting rod togeth-

er. Do not mix-up pistons, piston pins, and
connecting rods from different cylinders.
nt
rI
Fo
DOINE11AR11100

INSPECTION WEO11ASPROC13020
PISTON RINGS
1. Check the piston ring side clearance. If the
clearance exceeds the specified limit, replace
the ring or piston, or booth.
Standard value :
No. 1 ring : 0.03-0.05 mm (0.001-0.002 in)
No. 2 ring : 0.02-0.04 mm (0.001-0.002 in)
y
DOIIE11AR9087
nl
2. Insert the piston ring into the cylinder bore
and push it down with a piston (A). Ensure
that the piston's crown is in contact with the
O
ring such that the ring is at 90° to the cylin-
der wall. Then, measure the end gap (C) with
a thickness gauge. If the gap is too large,
se
replace the piston ring (B).
Standard values :
No. 1 ring : 0.20-0.35 mm (0.008-0.014 in)
No. 2 ring : 0.37-0.57 mm (0.015-0.022 in)
lU
Oil ring : 0.2-0.5 mm (0.008-0.02 in)
DOIGE11AR03076
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC

na
GAUGE METHOD)
1. Wipe all oil off the crankshaft pin and con-
necting rod bearing.
er
2. On the pin, place a plastic gauge that is cut

to the same length as the bearing's width.
The plastic gauge must be centered on the
nt
pin in parallel with the pin's axis.

3. Gently place the connecting rod cap in posi-
tion and tighten the bolts to the specified
rI
torque.
4. Remove the bolts and gently remove the
DOIIE11AR9089
connecting rod cap.
Fo
5. Measure the compressed part of the plastic

gauge at its widest point using the scale
printed on the plastic gauge bag.
Standard value :
0.02-0.044 mm (0.001-0.002 in)
Limit :
0.1 mm (0.004 in)


WEO11ASPROC13021
PISTON / PISTON PIN AND CONNECTING

ROD INSTALLATION
1. Refer cylinder bore identification marks at
cylinder block top surface as shown in the il-
lustration.
2. Select correct piston size according to the
cylinder bore identification mark. The piston
size outer diameter identification mark is
painted on top of piston surface. Ensure that
y
marks are same as cylinder bore identifica-
tion mark.
nl
For example,
Cylinder
O
bore identi-
A B A A
fication
mark
se Piston size
outer dia-
meter identi- A B A A
lU
fication
mark
DOINE11AR11111
na
Piston Grade A B C
Outer Diameter Limit 75.965 mm (2.99 in) ± 75.975 mm (2.99 in) ± 75.985 mm (2.99 in) ±
0.005 mm (0 in) 0.0075 mm (0 in) 0.005 mm (0 in)
Assembly Clearance 0.035 mm (0.001 in) ± 0.035 mm (0.001 in) ± 0.035 mm (0.001 in) ±
er
(before coating) 0.010 mm (0 in) 0.0125 mm (0 in) 0.010 mm (0 in)

3. CAUTION :
nt
By using air gun, clean piston, piston pin and

piston pin circlip groove in order to remove
all dust and chips.
rI
Before installing the piston to the connecting

rod, ensure the ‘DOT’ marking at piston and
connecting rod are facing in same direction
Fo
Symbol Description
A ‘ DOT’ marking
B Piston
DOIRE11AR14047
C Connecting rod

4. Prior to the installation of piston pin, apply

a sufficient amount of lubrication to the
outer surface pin and small end bore of the
connecting rod.
Lubrication type : Engine oil or non-water
soluble press oil (Yugen Kugyo Standards
DS-711 or equivalent)
y
DOINE11AR11106
nl
5. Press the piston pin through the connecting
rod small end bore until it is stopped by
circlip located at the other side of piston
O
bore.
se
lU
DOINE11AR11107
6. Insert piston pin circlip into piston pin groove

na
by positioning the open end circlip as shown

Symbol Description
er
A Piston pin circlip

B Piston ‘FRONT’ mark
nt
CAUTION :
(1) The circlip can only be reused until 3
times removal only.
rI
(2) Do not use the piston and connecting

DOIRE11AR14046
rod assy if additional load is required to
insert pin into the piston.
Fo
(3) When installing the piston pin, be sure

to keep the piston pin square with the
small end bore of the connecting rod.
(4) When reinstalling the piston pin, make
sure that the clearance fit is within the
specification as shown in the table be-
low.

Connect-
Piston Pin ing rod Clearance
Lenght of
outside small end (calcu-
Pin
diameter inside dia- lated)
meter
Ø19 ( 0, - 19.012 ± 0.007 – 54 ( 0, -
0.005 ) 0.005 0.022 0.3 )
7. Carefully, press-in the piston pin circlip by
hand and then push-in the circlip by using
small screw driver.
Symbol Description
y
A Connecting rod
nl
B Piston pin circlip
C Small screw driver
O
D Pin oil groove
CAUTION :
Use cloth to cover the circlip during installa-
se
DOINE11AR11182 tion in order to avoid the circlip missing.
OIL CONTROL RING INSTALLATION

lU
1. Fit the oil control ring spacer into the piston
ring groove. Then, fit the upper and lower
side rails.
na
Symbol Description
A Upper and lower side rails
B Oil control ring spacer
1 Groove ring compression top
er
2 Groove ring compression

second
nt
3 Groove ring oil control

NOTE :
rI
(1) Apply minimum engine oil at the groove.

(2) The spacer and side rails are reversible.
Spacer and side rail sizes are color-coded as
Fo
follows :
Part Colour
Gap clearance
name mark
0.2 kgm (2 Nm, 1.45
Side rails None ft.lbs) ± 0.005 kgm (0.05
Nm, 0.036 ft.lbs)
DOIRE11AR14048 0.02 - 0.05 kgm (0.2 - 0.5
Spacer White
Nm, 0.14 - 0.36 ft.lbs)

2. To install a side rail, fit one end of the rail

(C) into the groove then press the rest of the
rail into position by hand as shown in the il-
lustration.
CAUTION :
Do not fit side rails using a piston ring ex-
pander as they may break.
3. After installing 3 pieces of oil ring, check the
upper and lower side rails condition and en-
sure it can be turned smoothly.
y
DOIIE11AR9094
nl
COMPRESSION TOP RING (1R) /
COMPRESSION SECOND RING (2R) INSTALLATION
O
1. Using a ring expander, fit the piston ring No.
2 and ring No. 1 with their identification
marks facing upward (on the piston crown
side).
se Symbol
A
Description
Ring expander
lU
DOIIE11AR9095
2. Refer table below for identification paint

na
marks on piston rings.
Symbol Part name Color paint

Compression
er
A Yellow
top ring
Compression
B Blue
nt
second ring
rI
DOINE11AR11110
Fo
3. Refer table below for identification stamping

marks on piston rings.
I.D mark Part name Gap clearance

Compres-
0.2 - 0.35 mm
1R sion top
(0.008 - 0.014 in)
ring
Compres-
0.37 - 0.57 mm
2R sion second
(0.015 - 0.022 in)
ring
DOINE11AR11113

PISTON AND CONNECTING ROD ASSEMBLY

INSTALLATION
1. Remove connecting rod cap.
2. Select and install the proper connecting rod
bearing.
3. Set special tool for the piston insertion on
reamer bolt of the connecting rod.
Symbol Description
4. Apply engine oil to the piston rings, oil ring,
y
DOIGE11AR03161 connecting rod bearing, and cylinder bore.
nl
CAUTION :
Ensure the cylinder bore is flawless. Else,
rebore it to the following specifications.
O
5. Align the gaps of the piston rings and oil ring
(side rails and spacer) as shown in the illustra-
tion.
se Symbol
A
Description
Side rail (ring - oil - control)
lU
B Ring - compression - top
C Ring - compression - second and
spacer (ring - oil - control)
D Piston pin
na
DOIIE11AR9097
er
nt
rI
Fo

6. Ensure all arrow marking on top of the pis-

tons are facing to timing belt side as shown
Symbol Description
Arrow marking facing timing
A
belt side
y
nl
O
se
lU
DOINE11AR11174
na
7. Compress the piston rings tightly with a

suitable ring compression tool, then press
the piston and connecting rod assembly fully
into the cylinder bore. Do not strike the pis-
er
ton hard since the piston rings may break

and the crank pin may be nicked.
NOTE :
nt
(1) Ensure that the identification marks on

the piston crown coincide with those on
the cylinder block top surface.
rI
(2) Ensure the ‘←’ mark is facing to timing

belt side.
DOIIE11AR9098
(3) Ensure to make the notch by the locking
Fo
around the bearing on the same time

8. Remove the special tool ( EZT0008 ) from
connecting rod.
9. Install and pre-tighten bolt connecting rod
by hand. Then, tighten to the specified
torque.
Specified torque :
2.2 kgm (22 Nm, 15.91 ft.lbs) + 90°

CONNECTING ROD BEARING INSTALLATION

1. Select bearings according to the crankshaft
and connecting rod identification marks or
color codes.
y
nl
O
se
lU
DOIRE11AR14054
na
BEARING SELECTION TABLE

CRANKSHAFT & CON ROD COMBINATION
Crankshaft identific- Con rod / bore identifica- Bearing selected Oil clearance (mm)
er
ation mark tion mark

A 1 0.020 – 0.036
1 B 1 0.024 – 0.044
nt
C 2 0.024 – 0.040
A 1 0.024 – 0.044
rI
2 B 2 0.020 – 0.044
C 3 0.020 – 0.040
A 2 0.024 – 0.040
Fo
3 B 3 0.020 – 0.040
C 3 0.028 – 0.044

2. The connecting rod identification mark is

stamped at big end bore portion as shown
Symbol Description
A Big end bore identification mark
y
DOIME11AR11040
nl
3. The connecting rod bearing identification
mark is painted on the bearing top surface
O
Symbol Description
A Identification mark
se
4. The example to select the correct connecting
rod bearing is shown in table below.
Crankshaft identific-
lU
ation mark (pin no.1 2 1 1 2
until pin no.4)
DOINE11AR11175 Connecting rod
identification mark A C B B
na
(example)
Select correct con-
necting rod bearing 1 2 1 2
number
er
CONNECTING ROD CAP INSTALLATION

nt
1. Aligning the marks made during disassembly,

fit the bearing cap onto the connecting rod.
If the connecting rod is new and has no index
rI
mark, ensure that the front marks on the

connecting rod and connecting rod cap are
on the same side.
Fo
Symbol Description
A Front marks
DOIRE11AR14050

2. Check that the connecting rod big end side

clearance confirms with specifications.
Standard value :
0.10 - 0.25 mm (0.004 - 0.01 in)
Limit:
0.4 mm (0.016 in)
y
DOIGE11AR03085
nl
CONNECTING ROD BOLT INSTALLATION
O
CAUTION :
To fit the connecting rod bolts with the cylinder
head in place, the spark plugs must be removed
beforehand.
se
1. Pre-tighten all the connecting rod cap bolts.
2. Tighten the bolts to the specified torque.
Specified torque :
lU
2.2 kgm (22 Nm, 15.91 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
DOIGE11AR03086
3. Then, using the special tool ( Mot.59104 ),
na
tighten the connecting rod bolts according

to the specified torque angle.
Torque angle :
90° ± 5°
er
nt
rI
Fo

CRANKSHAFT AND CYLINDER BLOCK / 101
CRANKSHAFT AND CYLINDER BLOCK WEO11ASASSY13013
y
nl
O
se
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na
er
nt
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Fo
DOIRE11AR14044

/ 102 CRANKSHAFT AND CYLINDER BLOCK
— Sealant
— Patch Lock Screw (TB1300)
— Apply engine oil to all moving parts before installation.
Removal steps :
1. Direct damper flywheel (DDF) 12. Core plug 35 mm
2. Rear plate 13. Plug tapper PT 3/8
3. Rear oil seal case 14. Pin dowel
y
4. Rear oil seal 15. Bushing knock OD 11X9
5. Crankshaft bushing 16. Bushing knock OD 14X16
nl
6. Target wheel 17. Front mounting stud
7. Knock sensor 18. Bearing cap ( lower )
O
8. 19. Crankshaft bearing ( upper )
Oil pressure switch
9. Cylinder block 20. Crankshaft bearing ( lower )
10. One way valve 21. Crankshaft assy
se
11. Bushing knock OD 14X19.3
lU
na
er
nt
rI
Fo

OIL PRESSURE SWITCH REMOVAL

1. Disconnect the oil pressure switch terminals.
2. By using the special tool (MD998054), remove
the oil pressure switch (A).
CAUTION :
Take care not to damage the oil pressure
switch when removing it.
y
nl
O
se
lU
DOINE11AR11153
na
DIRECT DAMPER FLYWHEEL (DDF)

REMOVAL
1. Lock the Direct Damper Flywheel (A) by using
er
special tool (B).

2. Then, loosen the 5 pieces bolts (C) as shown
nt
Symbol Description
Direct Damper Flywheel
A
rI
(DDF)
DOINE11AR11132
C Direct Damper Flywheel bolts
Fo

INSPECTION WEO11ASPROC13023
CRANKSHAFT OIL CLEARANCE

The crankshaft oil clearance can be measured
easily using a plastic gauge (A).
To check the crankshaft oil clearance with a
plastic gauge, carry out the following procedure:
1. Wipe all oil off the crankshaft journal and
the bearing's inside surface.
2. Install the crankshaft.
3. Cut the plastic gauge such that its length
y
DOIIE11AR9105 matches the width of the bearing, then place
it on the journal along the journal's axis.
nl
4. Gently fit the crankshaft bearing cap and
tighten the bolt to the specified torque.
O
5. Remove the bolts and gently remove the
crankshaft bearing cap.
6. Using the scale printed on the plastic gauge
bag, measure the plastic gauge's crushed
se section at its widest point.

Standard value :
0.018 - 0.036 mm (0.001 - 0.001 in)
lU
Limit :
0.1 mm (0.004 in)
DOIIE11AR9106
na
NOTE :
The crankshaft pins and journals are fillet-rolled
(B) and must not be machined to undersize di-
mensions.
er
nt
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Fo
DOIIE11AR9107
CRANKSHAFT BENT LIMIT

Measure the main journal at 3 positions (A) to
check the bent limit. If the measurement exceeds
the specified limit, replace the crankshaft.
Limit :
0.03 mm (0.001 in)
DOIRE11AR14060

CYLINDER BLOCK
1. Visually check for cracks, rust, and corrosion,
and inspect the cylinder block using a flaw
detecting agent. Rectify defects where pos-
sible or replace the cylinder block.
2. Ensure that the top surface is free of gasket
chips and other foreign material. Check the
cylinder block's top surface for distortion
using a straight edge and thickness gauge.
Standard value :
0.03 mm (0.001 in)
y
DOIIE11AR9108
Limit :
nl
0.1 mm (0.004 in)
3. Check the cylinder walls for cracks and
O
seizure marks. If defects are evident, bore all
the cylinders to oversize or replace the cylin-
der block.
se
4. Using a cylinder gauge, measure each cylin-
der's bore and cylindricity. If any cylinder is
severely worn, bore all the cylinders to over-
size and replace the piston and piston rings
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accordingly. Take measurements at the
points shown.
Standard value :
Cylinder bore : 76.0 mm (2.99 in)
na
Cylinder stroke : 86.0 mm (3.39 in)

Cylindricity : 0.025 mm (0.001 in) or less
er
DOIIE11AR06001
Cylinder Bore Inner Diameter (ID)

nt
Bore Grade A B C
Bore Diameter + 0.005 mm (0 in) + 0.015 mm (0.001 in) + 0.025 mm (0.001 in)
rI
Limit - 0.005 mm (0 in) + 0.005 mm (0 in) + 0.015 mm (0.001 in)

Fo


WEO11ASPROC13025
CRANKSHAFT JOURNAL BEARING

INSTALLATION
1. Select bearings according to the crankshaft
identification marks. If they are not identifi-
able, measure the crankshaft journals and
choose bearings to match the measurements.
Example : Shaft 1 + Bore 2 = Bearing 3.
y
nl
O
se
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DOIRE11AR14054
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BEARING SELECTION TABLE

CRANKSHAFT JOURNAL CYLINDER BLOCK BEARING SELECTED
Crankshaft Bearing iden- OIL CLEAR-
Outer diamet- Bore identi- Inner diamet- Bearing thick- ANCE (mm)
er
identifica- tification
er (mm) fication mark er (mm) ness (mm)
tion mark mark
0 52.000- 1 1.988-1.991 0.018 – 0.036
nt
52.006
1 52.006- 2 1.991-1.994 0.018 – 0.036
1 47.994-48.000
52.012
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2 52.012- 3 1.994-1.997 0.018 – 0.036

52.018
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0 52.000- 2 1.991-1.994 0.018 – 0.036

52.006
1 52.006- 3 1.994-1.997 0.018 – 0.036
2 47.988-47.994
52.012
2 52.012- 4 1.997-2.000 0.018 – 0.036
52.018
0 52.000- 3 1.994-1.997 0.018 – 0.036
52.006
1 52.006- 4 1.997-2.000 0.018 – 0.036
3 47.982-47.988
52.012
2 52.012- 5 2.000-2.003 0.018 – 0.036
52.018

2. Identification marks showing the cylinder

block bearing bore diameter are stamped in
the position shown. Bearings must be selec-
ted and installed in accordance with these
identification marks.
Symbol Description
A First reading start from right
side to left side
B Timing belt side
C Cylinder block top surface
y
DOINE11AR11019
3. In order to select correct crankshaft main
bearing , refer the main bearing identifica-
nl
tion mark at crankshaft and cylinder block.
For example,
O
At crankshaft
(journal no.1
2 3 3 2 2
until journal
no.5)
se At cylinder
block (right side 1
to left side)
2 0 2 2
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Select main
bearing identific- 3 5 3 4 4
ation number
4. The main bearing identification number is
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painted on the main bearing outer surface

Symbol Description
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B Painted identification mark

nt
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DOIGE11AR03083
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5. Except for the center bearing, all the upper

bearings are grooved. The center bearings
have flanges and no groove. The center
bearings are the same at the top and bottom.
Symbol Description
E No groove
F Grooved
Lower bearing (No. 1, 2, 3, 4
G
and 5)
Upper bearing (No. 1, 2, 4 and
H
DOINE11AR11183
5)

Symbol Description
I Center upper bearing (No. 3)
6. The lower bearing are all grooveless.
BEARING CAP INSTALLATION

1. On the bottom surface of each bearing cap
is the cap's number and an arrow . Starting
at the timing belt side, fit the bearing caps
in numerical order. Ensure that the arrows
point towards the timing belt side.
2. Apply engine oil to the threaded portion and
y
bearing surface.
nl
O
DOIGE11AR03093
3. Tighten the bearing cap bolts according to

tightening order as illustration.
se
Specified torque :
5.15 kgm (51.5 Nm, 37.25 ft.lbs) ± 0.24 kgm
(2.4 Nm, 1.74 ft.lbs)
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na
DOIGE11AR03094
er
nt
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Fo

4. After fitting the bearing caps, measure the

end play at the crankshaft. If the measure-
ment exceeds the specified limit, replace the
crankshaft bearings.
Standard value :
0.07 - 0.195 mm (0.003 - 0.008 in)
Limit :
0.25 mm (0.01 in)
y
nl
O
se
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DOIGE11AR03116
na
TAPPER PLUG PT 3/8 INSTALLATION

1. Apply a small amount of screw lock patch
(TB1300) at the tapper plug thread the as
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shown in the picture.
Symbol Description
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A Screw lock patch (TB1300)

B Tapper plug PT 3/8
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DOINE11AR13018
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2. Tighten the tapper plug PT 3/8 to the spe-

cified torque.
4.0 kgm (40 Nm, 28.93 ft.lbs) ± 0.5 kgm (5
Nm, 3.62 ft.lbs)

6.4 kgm (64 Nm, 46.29 ft.lbs) ± 0.5 kgm (5
Nm, 3.62 ft.lbs)
Symbol Description
A Allen key
DOIRE11AR14033

Symbol Description
B Torque wrench
CORE PLUG (35 MM) INSTALLATION

1. Apply a small amount of screw lock patch
(TREEBOND 1386D) at the core plug surface
as shown in the picture.
Symbol Description
Screw lock patch (TREEBOND
A
1386D)
y
B Core plug
nl
C Special tool ( MB991203)
DOINE11AR13020
D Special tool ( MB990938)
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2. Carefully knock using mallet until the groove
line align.
Symbol Description
se A
B
Special tool ( MB991203)
Special tool ( MB990938)
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DOIRE11AR14034
ONE WAY VALVE INSTALLATION

er
1. Align the special tool (EZT 0058–1) locator

into the cylinder block hole as shown in the
nt
picture.
Symbol Description
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A Special tool (EZT 0058–1) locator

B Cylinder block hole
Special tool (EZT 0058–1) base
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C
plate
DOINE11AR13002
D Cylinder block

2. Tighten the (EZT 0058–5) special bolt on the

(EZT 0058–1) base plate.
Symbol Description
Special tool (EZT 0058–1) base
A
plate
B Cylinder block
Special tool (EZT 0058–5) special
C
bolt
y
DOINE11AR13003
nl
3. Apply a small amount of engine oil into the
cylinder block one way valve hole through
the special tool (EZT 0058–2) holder as shown
O
in the picture.
Symbol Description
A Lubricant (Engine oil)
se B Special tool (EZT 0058–2) holder.

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DOINE11AR13004
4. Insert one way valve into the special tool (EZT

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0058–2) holder.
Symbol Description
A One way valve
er
B Special tool (EZT 0058–2) holder

nt
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DOINE11AR13006
Fo
5. Insert special tool (EZT 0058–4) plunger into

the special tool (EZT 0058–2) holder.
Symbol Description
Special tool (EZT 0058–4) Plun-
A
ger
DOINE11AR13007

6. Tighten the special tool (EZT 0058–3) press

unit by hand. Make sure the special tool (EZT
0058–3) press unit turns smoothly.
Symbol Description
Special tool (EZT 0058–3) press
A
unit
y
DOINE11AR13008
nl
7. Fully tighten the special tool (EZT 0058–3)
press unit.
O
Symbol Description
A Special tool (EZT 0058–2) holder
Special tool (EZT 0058–3) press
B
se
unit
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DOINE11AR13009
8. Remove the special tool (EZT 0058) and make

na
sure one way valve is fully allocated as shown

in the picture.
Symbol Description
er
A One way valve

nt
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DOINE11AR13010
Fo

OIL PRESSURE SWITCH INSTALLATION

1. Apply the specified sealant to the thread of
oil pressure switch.
Specified sealant :
TB 1130
2. Use the special tool (MD998054) to tighten

the oil pressure switch to the specified
torque.
Specified torque :
y
1.45 ft.lbs)
nl
3. Install the oil pressure switch terminal.
CAUTION :
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• Apply sealant such that none is squeezed out
past end of the thread.
• Do not over-tighten the oil pressure switch.
se
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DOIGE11AR03119
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KNOCK SENSOR INSTALLATION

1. Install the knock sensor to cylinder block and
tighten the bolt flange
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Specified torque :
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.5 kgm (5
Nm, 3.62 ft.lbs)
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Symbol Description
A Knock sensor
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NOTE :
DOIGE11AR03089 The knock sensor terminal shall facing out-
Fo
ward 90°.

REAR OIL SEAL INSTALLATION

1. Apply a small mount of engine oil to the en-
tire circumference of the oil seal lip.
2. Tap in the oil seal with the mallet as show in
the illustration.
Symbol Description
B Rear oil seal
C Crankshaft rear oil seal housing
y
D Mallet
nl
O
se
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DOIHC11AR04048
na
REAR OIL SEAL CASE INSTALLATION

1. Apply liquid gasket to the rear oil seal case
at the illustrated position (if it has no pre-
er
formed gasket attached)

Specified sealant :
Part No. MD970389 or equivalent (RTV seal-
nt
ant, TREEBOND TB1207F).
CAUTION :
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Squeeze the liquid gasket uniformly so that

there is no break in the gasket nor is there
DOIGE11AR03097 too much gasket.
Fo
2. Apply a suitable amount of engine oil to the

entire periphery of the oil seal lip and install
the oil seal on the cylinder block.

DIRECT DAMPER FLYWHEEL (DDF)

INSTALLATION
1. Clean off sealant, oil and deposits from the
threaded portion, tightening bolts and from
the threaded holes on the crankshaft.
2. Apply engine oil to the bolt flange and to
the threaded holes on the crankshaft.
3. Apply sealant to the threaded portion of the
bolt ( if the bolt is reused ).
Specified sealant :
3M Nut Locking Part No. 4171 or equivalent
y
DOINE11AR11134
4. Install direct dual flywheel to the crankshaft
nl
rear end as illustration and fit the bolt.
Symbol Description
O
A Cylinder block
B Direct damper flywheel (DDF)
C Direct damper flywheel bolt
se
1. Using the flywheel stopper to secure direct
damper flywheel and then tighten the direct
damper flywheel bolts to the specified
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torque.
Service tightening torque :
12.5 kgm (125 Nm, 90.41 ft.lbs) ± 0.5 kgm (5
Nm, 3.62 ft.lbs)
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Symbol Description
A Direct damper flywheel (DDF)
er

DOINE11AR11132 C Direct damper flywheel bolt
2. Lock the Direct Damper Flywheel (A) by using
nt
special tool (B).

3. Then, loosen the 5 pieces bolts (C) as shown
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REMOVAL AND INSTALLATION SERVICE

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POINTS WEO11ASPROC13027
TARGET WHEEL REMOVAL

1. Insert an equivalent size of rubber pad into
the vice to avoid the crankshaft journal from
scratch as shown in the illustration.
Symbol Description
A Vice
B Rubber pad
DOIGE11AR09002

2. During fixing the crankshaft at vice, make

sure the rubber pad is firmly hold at the
crankshaft.
Symbol Description
A Vice
B Rubber pad
C Target wheel
D Crankshaft
y
DOIGE11AR09003
nl
3. Clean the target wheel surface and patch
lock screw properly.
O
Steps Description
Spray an anti-rust to remove
A
any rust or dirt on the surface.
se
Use compress air to blow and
B
clean the surface.
Wipe with cloth to ensure the
C patch lock allen key head is
lU
free from any rust or dirt.
na
er
nt
rI
DOIGE11AR09010
Fo
4. Use a ratchet together with an allen key to

remove 3 pieces of patch lock screws from
the target wheel.
CAUTION :
• It is highly recomended to use socket type
allen key to prevent any damage on the
patch lock allen key head.
• Ensure patch lock allen key head is clean
before removal.
Symbol Description
C Target wheel
DOIGE11AR09007

Symbol Description
D Crankshaft
E Socket with allen key
F Patch lock screw
G Ratchet
TARGET WHEEL INSTALLATION

Install new patch lock screw into target wheel
with the specified torque as shown in the illustra-
tion.
y
Specified torque :
nl
0.72 ft.lbs)
O
Symbol Description
C Target wheel
DOIGE11AR09007
D Crankshaft
se
E Socket with allen key
F Patch lock screw
G Ratchet
lU
na
er
nt
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Fo

NOTE
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nl
O
se
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na
er
nt
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Fo

Fo
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nt
er
na
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se
O
nl
S4P Model YR 2014 English Edition RDCE-140S4P020-05
y
September 2014 Published in Malaysia

Engine Overhaul Iriz-Min

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WORKSHOP MANUAL

Published in Malaysia 9 September 2014 Eng

00 GENERAL ................................................................................... 00/1 - 00/16

Published in Malaysia 9 September 2014 Eng

Published in Malaysia 9 September 2014 Eng

AIR BAG SYSTEM INFORMATION .................................................. 00/6

HOW TO USE THIS MANUAL ....................................................... 00/7

TIGHTENING TORQUE ................................................................ 00/12

PRECAUTION BEFORE SERVICE ..................................................... 00/14

Published in Malaysia 9 September 2014 Eng

OUTLINE OF CHANGES WEO000OLINE14001

Published in Malaysia 9 September 2014 Eng

PUB. NO: RDCE-080S4P020 –

Fuel and emis- CamPro-IAFM

Published in Malaysia 9 September 2014 Eng

PUB. NO: RDCE-080S4P020 –

Published in Malaysia 9 September 2014 Eng

PUB. NO: RDCE-080S4P020 –

OUTLINE OF CHANGE ITEMS

GRP 11A–ENGINE <S4P-CFE>

Published in Malaysia 9 September 2014 Eng

Change Items Reference Page Description of Changes

Piston and Connecting Rods 11A/87

Crankshaft and Cylinder Block 11A/101 • Update specifications.

AIR BAG SYSTEM INFORMATION WEO000BSERV14001

Published in Malaysia 9 September 2014 Eng

Published in Malaysia 9 September 2014 Eng

INDICATION OF TIGHTENING TORQUE

Published in Malaysia 9 September 2014 Eng

EXPLANATION OF MANUAL CONTENTS WEO000READS14002

Published in Malaysia 9 September 2014 Eng

Brake fluid or automatic transmission fluid

Engine oil, gear oil or air condition compressor oil

Adhesive tape or butyl rubber tape.

Maintenance and servicing Procedures

Published in Malaysia 9 September 2014 Eng

M Operating procedures, caution etc. on removal, installation disassembly and reassembly

and reassembly are described.

Published in Malaysia 9 September 2014 Eng

ENGINE MODEL AND SERIAL

1. The engine model number is stamped at the

Engine Model Engine Displacement

TIGHTENING TORQUE WEO000TTORQ14001

General tightening torque is as shown in the following table.

TIGHTENING TORQUE OF FLANGE BOLT

Flange bolt (Dia.) Thread size (Pitch x length) Specified torque

1.0 x 10 mm (0.039 x 0.39 in)

Published in Malaysia 9 September 2014 Eng

ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 5.0

3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 mm

Published in Malaysia 9 September 2014 Eng

1.25 x 27 mm (0.049 x 1.06 in) se 0.5 kgm (5 Nm, 3.62 ft.lbs)

PRECAUTION BEFORE SERVICE WEO000BSERV14002

Removal and Disassembly For prevention of wrong installation or reas-

Published in Malaysia 9 September 2014 Eng

Tightening Torque Tighten the part properly to specified torque.

Oil and Grease Before reassembly, apply specified oil to the

Special Tool Be sure to use Special Tools when their use is

tools will resulting malfunction of the part or

Published in Malaysia 9 September 2014 Eng

Sealant Use specified brand of sealant.

Genuine Part When the part is replace, be sure to use Proton

For selection of appropriate part, refer to the