Engine: Service Precautions

Precautions for Drain Engine Coolant
Drain engine coolant when engine is cooled.

Precautions for Disconnecting Fuel Piping
^ Before starting work, make sure no fire or spark producing items are in the work area.
^ Release fuel pressure before disconnecting and disassembly
^ After disconnecting pipes, plug openings to stop fuel leakage.

Precautions for Removal and Disassembly
^ When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations.
^ Exercise maximum care to avoid damage to mating or sliding surfaces.
^ Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
^ Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly
^ When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used where noted in the step.

Precautions for Inspection, Repair and Replacement
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary

Precautions for Assembly and Installation
^ Use torque wrench to tighten bolts or nuts to specification.
^ When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.
^ Replace with new gasket, packing, oil seal or O-ring.
^ Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage.
^ Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.
^ Release air within route when refilling after draining engine coolant.
^ Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure that there are no leaks at fuel line connections.
^ After repairing, start engine and increase engine speed to check engine coolant, fuel, oil, and exhaust systems for leakage.

Parts Requiring Angular Tightening
^ For final tightening of the following engine parts use Tool:
Tool number: KV10112100 (BT-8653-A)
- Cylinder head bolts
- Main bearing cap bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle tightening)
^ Do not use a torque value for final tightening.
^ The torque value for these parts are for a preliminary step.
^ Ensure thread and seat surfaces are clean and lightly coated with engine oil.