Operation CHARM: Car repair manuals for everyone.

Part 1

AUXILIARY PARTS (I)
1. Remove the oil drain plug and drain the engine oil. After draining the engine oil, install the oil drain plug.

Tightening torque:
30 - 41 Nm (22 - 30 ft. lbs.)


Intake:





2. Disassemble in the order shown in the figure, referring to Disassembly Note.
3. Assemble in the reverse order of disassembly, referring to Assembly Note.

Disassembly Note
Oil Filter





Remove the oil filter by using the Special Service Tool (SST).

Dynamic Chamber Cover





1. Remove nuts (A).
2. Remove the dynamic chamber cover in the order shown.

Assembly Note
Charge Air Cooler, Air Intake Pipe Assembly
1. Hand tighten the nuts and bolts in the order shown until the air intake pipe No. 3 contacts the intake manifold.
2. Verify that the rubbers are not twisted or distorted.
3. Tighten the nuts and bolts to the specified torque in the order shown.





Tightening torque:
A: 7.9 - 10.7 Nm (70 - 95.4 inch lbs.)
Others: 19 - 25 Nm (14 - 18 ft. lbs.)


4. Hand tighten the nuts and bolts in the order shown until the charge air coolers and the air intake pipes No. 1 and No. 2 contact the intake manifold.
5. Verify that the rubbers are not twisted or distorted.
6. Tighten the nuts and bolts to the specified torque in the order shown.





Tightening torque:
A: 5.8 - 8.8 Nm (44 - 78 inch lbs.)
B: 7.9 - 10.7 Nm (70 - 95.4 inch lbs.)
Others: 19 - 25 Nm (14 - 18 ft. lbs.)


Oil Filter





1. Apply clean engine oil to the rubber seal of the oil filter.
2. Install the oil filter and tighten it by hand until the rubber seal contacts the oil cooler.
3. Tighten the oil filter 1 - 1/6 turns by using the SST.

Warm Up Three Way Catalytic Converter (LH)
1. Install a new gasket and the warm up three way catalytic converter (LH).





2. Tighten the bolts and new nuts in the order shown.

Tightening torque: 16 - 22 Nm (12 - 16 ft. lbs.)

AUXILIARY PARTS (II)

Intake:





1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly, referring to Assembly Note.

Assembly Note
Thermostat





1. Verify that the jiggle pin is aligned with the projection of thermostat gasket as shown.
2. Install the thermostat and gasket into the thermostat cover, aligning the projection to the cover as shown.

Lysholm Compressor





Before installation, temporarily fix the rubber onto the Lysholm compressor with two-side adhesive tape.

Intake Manifold Assembly





1. Install the intake manifold assembly with the new gaskets.
2. Tighten the bolts and nuts in the order shown.

Tightening torque:
19 - 25 Nm (14 - 18 ft. lbs.)


TIMING BELT





1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly Note

Disassembly Note
Crankshaft Pulley





1. Hold the drive plate by using the Special Service Tool (SST).
2. Remove the crankshaft pulley bolts.

CAUTION: The crankshaft position sensor rotor is on the rear of the pulley, and can be damaged easily.





3. Remove the crankshaft pulley.

Timing belt auto tensioner





1. Before removing the auto tensioner, temporarily install the timing belt pulley bolt.
2. Turn the crankshaft clockwise to align the timing marks of the pulleys.

CAUTION: When removing the bolt, hold the tensioner so that the bolt holes are aligned, otherwise the threads can be damaged.





3. Remove the auto tensioner bolts in five or six steps in the order shown.
4. Remove the auto tensioner.

Timing belt





1. Mark the timing belt rotation for proper reinstallation.

CAUTION: The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, bending it, or allowing oil or grease on it.

2. Remove the timing belt.

Timing belt pulley





1. Hold the drive plate by using the SST.





2. Loosen the timing belt pulley lock bolt 10 mm (0.39 inch).
3. Remove the timing belt pulley by using the SST.
4. Remove the crankshaft key.

Assembly Note
Timing belt pulley





1. Hold the drive plate by using the SST.
2. Apply clean engine oil to the timing belt pulley bolt threads.
3. Tighten the timing belt pulley bolt.

Tightening torque:
157 - 166 Nm (116 - 122 ft. lbs.)


Timing belt





1. Align the timing marks of the pulleys.





2. Install the timing belt on the pulleys in the order described below.
1) Timing belt pulley
2) No. 2 idler pulley
3) Camshaft pulley (LH)
4) No. 1 idler pulleys
5) Camshaft pulley (RH)
6) Tensioner pulley

Timing belt auto tensioner

CAUTION: Applying pressure of more than 9807 N (2200 lbf) can damage the tensioner.





1. Press in the tensioner rod slowly, using a press.
2. Insert a pin (1.6 mm (0.06 inch)) into the second hole in the body to hold the tensioner rod.
3. Reinstall the auto tensioner and hand tighten the auto tensioner bolts.





4. Push up the auto tensioner by using a screwdriver and tighten the auto tensioner bolts.

Tightening torque:
19 - 25 Nm (14 - 18 ft. lbs.)


5. Remove the pin from the auto tensioner, and apply tension to the belt.
6. Turn the crankshaft clockwise two turns, and align the timing marks.





7. Verify that all timing marks are correctly aligned. If not aligned, remove the timing belt and repeat the procedure from Timing belt.

Timing belt cover





1. Install the timing belt cover (Upper) and tighten the bolts in the order shown.

Tightening torque:
7.9 - 10.7 Nm (70 - 95.4 inch lbs.)






2. Install the No.3 engine mount bracket.

Tightening torque:
A: 44 - 60 Nm (32 - 44 ft. lbs.)
B: 19 - 25 Nm (14 - 18 ft. lbs.)






3. Install the timing belt covers (RH, LH) and tighten the bolts in the order shown.

Tightening torque:
7.9 - 10.7 Nm (70 - 95.4 inch lbs.)


Crankshaft pulley





1. Hold the drive plate by using the SST.

CAUTION: Install the crankshaft pulley carefully. The crankshaft position sensor rotor is on the rear of the pulley, and can be damaged easily.





2. Install the crankshaft pulley.
3. Hand tighten the crankshaft pulley bolts and tighten the bolts in the order shown.

Tightening torque:
26 - 30 Nm (19 - 22 ft. lbs.)


CYLINDER HEAD

Upper Engine:





1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly Note.

Disassembly Note
Camshaft pulley





1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft pulley lock bolts.
2. Remove the camshaft pulley lock bolts.
3. Remove the camshaft pulleys.

Camshaft Cap





1. Loosen the front camshaft cap bolts in five or six steps in the order shown.
2. Remove the front camshaft caps.

NOTE: Bolt (5) fits only the right cylinder head.

3. Loosen the camshaft cap bolts in five or six steps in the order shown.

CAUTION: Remove the thrust caps only after removing all camshaft caps. Otherwise, the thrust caps can be damaged.








4. Remove the camshaft caps.

Camshaft
Inspect the following when removing the camshafts.
1) Camshaft end play.
2) Camshaft journal oil clearance.

Cylinder head








1. Loosen the cylinder head bolts in two or three steps in the order shown.
2. Remove the cylinder head bolts.

CAUTION: Removing the LH cylinder head with the rubber insulator still installed can damage the knock sensor harness.

3. Remove the cylinder heads.

Valve keeper





1. Set the Special Service Tool (SST) against the upper valve spring seat as shown.
2. Compress the valve spring and remove the valve keepers.

Valve seal





Remove the valve seal by using the SST.

Assembly Note
Valve seal





CAUTION: The intake and exhaust valve seals are different as shown. The exhaust valve seal has ridges on the top for identification.





1. Assemble the SST so that depth L is as specified.

Depth L:
IN: 15.0 mm (0.591 inch)
EX: 13.5 mm (0.531 inch)


2. Slide the valve seal onto the valve guide with the SST.
3. Set the SST against the valve seal.

CAUTION: Using a hammer will damage the valve seal.





4. Using the SST, press the valve seal on by hand until the SST touches the cylinder head.

Valve spring





Install the valve spring with the closer pitch toward the cylinder head.

Valve keeper





1. Compress the valve spring with the SST, and install the valve keepers.
2. Remove the SST.
3. Tap the end of the valve stem lightly two or three times with a plastic hammer to verify that the keepers are fully seated.

Cylinder head gasket
1. Apply clean engine oil to new O-rings and install them to the oil control plugs.
2. Turn the crankshaft clockwise and apply clean engine oil to the cylinder walls.





3. Place a new cylinder head gasket on the left bank with the L mark.
4. Place a new cylinder head gasket on the right bank with the R mark.

Cylinder head





1. Install the cylinder heads to the cylinder block.
2. Tighten the cylinder head bolts as described below.
1) Before installation, measure the length of each bolt. Replace any that exceed the maximum length.

Length:
133.7 - 134.3 mm (5.264 - 5.287 inch)
Maximum:
135.0 mm (5.315 inch)


2) Apply clean engine oil to the threads and the seat face of each bolt and install them.

Torque Sequence:




Torque Sequence:





3) Tighten the bolts in two or three steps in the order shown.

Tightening torque:
23.1 - 25.9 Nm (17.0 - 19.1 ft. lbs.)






4) Put a paint mark on each bolt head.
5) Using the marks as a reference, tighten the bolts by turning each 85° - 95° in the sequence shown.
6) Further tighten each bolt by turning another 85° - 95°.





7) Fit the knock sensor harness into drill hole (A) on the cylinder block.
8) Pass the harness under the new rubber insulator on the LH cylinder head.

Camshaft





1. Apply clean engine oil to the camshaft journals and the supports.
2. Install the camshafts so that intake camshaft gear painted mark and exhaust camshaft gear painted mark align.

NOTE: If the painted timing marks are not visible see Camshaft Timing or TSB 01-016/02 for Camshaft Installation Procedure.

Camshaft cap





CAUTION:
- Camshaft caps must be assembled in the following procedure. Otherwise, camshaft can be broken or damaged because there is little camshaft thrust clearance.
- Install the thrust caps first. (Caps marked "4" and "8" for RH, and caps marked "A" and "E" for LH) Otherwise, camshaft can be broken or damaged.

1. Install the thrust caps onto the cylinder heads. Hand tighten the bolts in five or six steps in the order shown, until the thrust caps are fully seated on the cylinder heads.

CAUTION: Excessive silicone sealant will get into the cylinder head and cause the piston seizure.





2. Apply silicone sealant to the shaded areas as shown.

Thickness:
1.5 - 2.5 mm (0.06 - 0.09 inch)


3. Install the camshaft caps onto the cylinder heads.
Hand tighten the bolts in five or six steps in the order shown, until the camshaft caps are fully seated on the cylinder heads.








4. Tighten the bolts in the order shown.

Tightening torque:
11.3 - 14.2 Nm (99.9 - 125 inch lbs.)


5. Retighten the bolts in the order shown.

Tightening torque:
11.3 - 14.2 Nm (99.9 - 125 inch lbs.)


6. Apply clean engine oil to the new oil seal.





7. Push the oil seal slightly in by hand.
8. Tap the oil seal into the cylinder head by using a SST and hammer.

Protrusion:
0 - 0.5 mm (0 - 0.02 inch)






9. Tap in the new blind cap by using a plastic hammer.

Water temperature sender unit





1. Apply silicone sealant to the top two-thirds of the threads.
2. Install the water temperature sender unit.

Tightening torque:
6.4 - 9.3 Nm (57 - 82 inch lbs.)