TO INDEX

B ENGINE UNIT

1KR-FE --------------------------------------------- B - 1
ARTICLES TO BE PREPARED ----------- B - 1
SCHEMATIC DIAGRAM -------------------- B - 3
TIMING CHAIN COVER ----------------------- B - 4
DISASSEMBLING AND
ASSEMBLING --------------------------------- B - 4
TIMING CHAIN --------------------------------- B - 12
DISASSEMBLING AND
ASSEMBLING-------------------------------- B - 12
CAMSHAFT ASSEMBLY--------------------- B - 17
DISASSEMBLING AND
ASSEMBLING-------------------------------- B - 17
CYLINDER HEAD AY ------------------------- B - 26
DISASSEMBLING AND
ASSEMBLING-------------------------------- B - 26
CYLINDER BLOCK AY ----------------------- B - 35
DISASSEMBLING AND
ASSEMBLING-------------------------------- B - 35
B–1
1 1KR-FE
1-1 ARTICLES TO BE PREPARED
1-1-1 ARTICLES TO BE PREPARED LIST
SST
Shape Part No. Part name

09219-87101-000 Attachment,engine overhaul

09219-87202-000 Stand,engine overhaul

09278-87201-000 Tool,timing belt pulley holding

09223-87202-000 Replacer,crankshaft front oil seal

09043-97401-000 Wrench,double hexagon

09202-87002-100 Attachment,valve cotter

09202-87002-000
Remover & replacer,valve cotter
(09202-87001-000)

09201-87203-000 Remover & replacer,valve guide bush

09608-87302-000 Tool set,axle hub bearing & drive pinion bearing

09032-00100-000 Cutter,oil pan seal

 B–2

09221-B1010-000 Remover & replacer

09221-B1020-000 Remover & replacer

Tool
Scraper,Hexagonal rod wrench(Width across flats:2.5mm)

Instrument
Thickness gauge,Caliper gauge,Micrometer,Precision straightedge,Steel square,Dial gauge,Vernier calipers,Cylinder
gauge,Press gauge,Torque wrench

Lubricant,adhesive,others
Engine oil,Three Bond1104,Three Bond1207B,Three Bond1207C

1-1-2 INSTALLATION TO ENGINE OVERHAUL STAND

(1) Connecting procedure
1.Install the engine Ay to the SST.
(1) Make a 10 mm dia hole on the engine overhaul stand
attachment. 73mm

SST: 09219-87101-000
mm 50mm
43

T11E9264T10

(2) Install the partial engine to the engine stand.

SST: 09219-87202-000

T11E9266T16
B–3
1-2 SCHEMATIC DIAGRAM

T11E2001S48
 B–4
2 TIMING CHAIN COVER
2-1 DISASSEMBLING AND ASSEMBLING
2-1-1 DISASSEMBLING AND ASSEMBLING
(1) Components

B T:10.0&3.0 {102&31} T:7.7&1.5 {79&15} B

4

T:7.7&1.5 {79&15} N

1 2

~3

T:24.0&4.8 {245&48} B
~5

T:24.0&4.8 {245&48} B

14

T:24.0&4.8 {245&48}
~7
B
T:180.0&10.8 {1836&110}

6
~15
~9
8
~12

13
T:26.0&3.4 {265&34} B
11

T:26.0&3.4 {265&34} B B

T:8.5&1.7 {87&17} 10

T11E9102_1S40

k: Engin oil
Unit: N;m{kgf;cm}
~: Non-reusable parts
B–5
(2) Disassembling and assembling procedure
1 Gage S/A, oil level 9 Gasket, water pump
2 Guide S/A, oil level gage 10 Pan S/A, oil
3 Ring, O 11 Strainer S/A, oil
4 Cover Ay, cylinder head 12 Gasket, oil strainer
5 Gasket, cylinder head cover 13 Pulley, crankshaft
6 Bracket, oil filter 14 CoverAy, timing chain
7 Gasket, oil filter 15 Seal, type T oil
8 Pump Ay, water

2-1-2 POINTS OF DISASSEMBLY

1.Pull out the oil level gauge S/A. Remove the oil level gauge
guide S/A.

T11E9108T10

2.Remove the O ring from the Oil level gage guide S/A.

T11E9109T10

3.Remove the cylinder head cover Ay and cylinder head

7
cover gasket by removing the attaching bolts and nuts in
11 9 13
5
the sequence shown at the right figure.
4

14 15
1 2

6
3 12 8 10

T11E9107T10

4.Remove the oil filter gasket by removing the oil filter brack-
et.

T11E9110T10
 B–6
5.Remove the water pump gasket by removing the water
pump Ay.

T11E9111_1T10

6.Set the No.1 cylinder to the top dead center under the
compression stroke.
(1) Turn the crankshaft pulley in the normal direction, until
the timing mark (0 degrees) of the crankshaft pulley
is aligned with the timing point of the timing chain
cover Ay. Timing mark Timing mark
(2) Ensure that the timing mark of the camshaft timing
sprocket is at the top position.
If the timing mark is not at the top position, turn the T11E9276ET10

pulley one turn so that the timing mark comes at the

top.
7.Remove the oil pan S/A from the cylinder block Ay, using
the SST, by removing the attaching bolts and nuts of the
oil pan S/A.
SST: 09032-00100-000
CAUTION
• Be very careful not to deform the flange section of the SST
SST
oil pan S/A during the removal.

T11E9114T10

8.Remove the oil strainer gasket by removing the oil strainer

S/A.

T11E9115T10

9.While preventing rotation, using the SST, remove the

crankshaft pulley.
SST: 09278-87201-000
SST

T11E9116T10
B–7
10.Remove the timing chain cover Ay, using the SST, by
removing the attaching bolts and nuts.
SST: 09032-00100-000 SST
SST

T11E9117T10

11.With a flat screwdriver, remove the type T oil seal.

T11E9118T10

2-1-3 CLEANING
1.Clean the oil pan S/A and cylinder block Ay installation
surfaces of the timing chain cover Ay.

T11E9119T10

2.Clean the installation surface of the oil pan S/A.

T11E9254T10

2-1-4 POINTS OF ASSEMBLY

1.Install the type T oil seal to the timing chain cover Ay.
(1) Apply engine oil to the lip section of the type T oil seal.
LUBRICANT: Engine oil

S11K9975T10
 B–8
(2) Drive the type T oil seal vertically, using the SST. (0.5~'1.0
SPECIFIED VALUE: Press-fitting amount
from chain cover edge SST

Protruding amount: within 0.5 mm

Press-fitting depth: within 1 mm
SST: 09223-87202-000

T11E9120_1T10

2.Install the timing chain cover Ay.

(1) Remove oil and grease from the installation surface of the cylinder block Ay and timing chain cover
Ay.
(2) Apply liquid gasket at positions shown at the figure and perform the installation.
"A"figure
About 3mm Dia
3.5~4.5mm Dia
3.5~4.5mm Dia
About
"A"figure "B"figure 3mm Dia
3~3.5mm Dia "B"figure

Abo 3.5~
ut3.
5mm 4.5mm Dia
3.5~
4.5mm
3~3.5mm Dia Dia

"C"figure
50mm 40mm
"C"figure
Cover side Block side T11E9121_1ES16

ADHESIVE: Three Bond1207C / Apply to the points in the figure C at the cover side as shown in the

figure.
ADHESIVE: Three Bond1207B / Apply to the points in the figure A and B at the cover side as shown

in the figure and at the block side.

CAUTION
• Completely remove foreign matters, oil and grease 9 6
from the installation surface. 5

2 4
3 1
(3) Tighten the bolts in the sequence shown at the right
8
figure. 7

CAUTION !1

• Perform the assembling within three minutes after

application of the liquid gasket.
!0
(4) Wipe off any liquid gasket that has oozed out. T11E9255T10

SPECIFIED VALUE: Permissible oozing amount: within 1.5 mm

B–9
3.Install the oil strainer gasket to the oil strainer S/A and
install it to the timing chain cover Ay.

T11E9256T10

4.Installation of oil pan S/A.

(1) Ensure that no oil nor grease adheres to the oil pan S/A
39.5mm
installation surface of the cylinder block Ay and the
flange section of the oil pan S/A.
(2) Apply liquid gasket to the oil pan S/A and assemble it
to the cylinder block Ay. 39.5mm

ADHESIVE: Three Bond1207B

CAUTION 5mm
5
25.5mm
• Application of the liquid gasket should be started and 3.5&0.5mm Dia T11E9274_1ET10

finished at the seal surface with the cylinder block Ay.

6
(3) Tighten the bolts in the sequence shown at the right
2 4
figure.
As for other bolts, they can be tightened in any
sequence.
CAUTION
• Assembling should be started within three minutes
after application of the liquid gasket and the oil pan
S/A should be tightened within 15 minutes. 3
5 1 T11E8017T10

5.While preventing the crankshaft pulley with the SST, tight-

en the attaching bolt.
SST: 09278-87201-000

SST

T11E9257T10

6.Installation of water pump Ay.

(1) Assemble the new water pump gasket to the timing
chain cover Ay. Then, install the water pump Ay.

T11E9111_1T10
 B–10
(2) Tighten the bolts in the sequence shown at the right 3
3
figure. 55

22
1
1

44

T11E9258T10

7.Installation of oil filter bracket.

(1) Install the oil filter gasket to the timing chain cover Ay
and install the oil filter bracket.

T11E9110T10

(2) Tighten the bolts in the sequence shown at the right

figure.

2
3

T11E9259_1T10

8.Installation of cylinder head cover.

(1) Insert the cylinder head cover gasket to the gasket
groove and central boss of the coil Ay with ignitor.
SPECIFIED VALUE: Insert the gasket completely until it
contacts the end of the rib. (arrow
marked)

T11E9123T10

(2) Apply liquid gasket to the mating surface between the

cylinder head Ay and timing chain cover.
About3(4mm Dia
ADHESIVE: Three Bond1207B
CAUTION
• Assembling should be started within three minutes
after application of the liquid gasket and the cylinder
head cover should be tightened within 15 minutes. Liquid gasket

T11E9124ET10
B–11
(3) Tighten the attaching bolts in the sequence shown at
the right figure. After tightening all the bolts to the 9
11
5 7
9 13
3
specified torque, ensure again that the bolts 1 and 13

2 have been tightened to the specified torque. 4

12

2 1
15 14
2

10
11 4 8 6

T11E9125T10

9.Install the O-ring to the oil level gage guide S/A.

(1) Apply engine oil to the O-ring, and install it to the guide
S/A.
LUBRICANT: Engine oil

T11E9109T10

10.Install the oil level gauge guide S/A and insert the oil level
gauge S/A.

T11E9108T10
 B–12
3 TIMING CHAIN
3-1 DISASSEMBLING AND ASSEMBLING
3-1-1 DISASSEMBLING AND ASSEMBLING
(1) Components

T:10.5&2.5 {107&25}

T:19.0&3.8 {194&38}

B
T:9.0&1.8 {92&18}

6
5

T11E9103S40

Unit: N;m{kgf;cm}
B–13
(2) Disassembling and assembling procedure
1 Tensioner Ay, chain 6 Key, woodruff
2 Arm, timing chain tension
3 Chain, timing
4 Guide, timing chain
5 Sprocket, crankshaft timing

3-1-2 POINTS OF DISASSEMBLY

1.Remove the timing chain.
2.Ensure that the timing mark of the camshaft timing sprock-
Timing mark
et is at the top position.
If the timing mark is not at the top position, turn the pulley
one turn so that the timing mark comes at the top. (Set to
the top dead center under compression stroke of No.1
cylinder.)

T11E8104ET10

(1) Move the stopper plate of the chain tensioner Ay

clockwise. Under the unlocked state, push the
2
plunger as far as it will go.

T11E9128T10

(2) With the plunger pushed in, lock the plunger in this
pushed-in state by inserting an Allen wrench or the
like into the hole of the stopper plate.
TOOL: Hexagonal rod wrench(Width across flats:2.5mm)
(3) Remove the timing chain tensioner Ay by removing the
bolts.
(4) Remove the timing chain tensioner arm and timing
chain by removing the bolts.
T11E9129T10

3.Remove the timing chain guide and crankshaft timing

sprocket.

T11E9130T10
 B–14
4.Remove the woodruff key.

T11E9131T10

3-1-3 CHECK
(1) Check of chain, timing
1.Visually check the timing chain for wear, cracks, etc.
CAUTION
• If the timing chain exhibits any abnormality, check the
sprocket side, too.

T11E9132T10

2.Using vernier calipers or the like, measure the inner pitch 16Links
of the chain at any three points. Calculate the average
value.
SPECIFIED VALUE: 128mm (16Links)

T11E9278ET10

(2) Check of sprocket, crankshaft timing

1.Check to see if the crankshaft timing sprocket is dam-
aged.

T11E9133T10

(3) Check of guide, timing chain / Check of arm, timing

chain tension
1.Check the timing chain guide and the section (A) of the
timing chain tension arm for wear condition.
ALLOWABLE LIMIT: 0.5mm

T11E9260T10
B–15
(4) Check of tensioner Ay, timing chain
1.With the stopper plate of the timing chain tensioner Ay
held clockwise by your finger, ensure that the plunger
operates smoothly.
2.With your finger released from the stopper plate, push the
plunger while the stopper plate is locked. Ensure that the
plunger will not operate.

T11E9134T10

3-1-4 POINTS OF ASSEMBLY

1.Install the woodruff key into the groove of the crankshaft.

T11E9131T10

2.Install the crankshaft timing sprocket while aligning its

groove with the crankshaft woodruff key.
3.Install the timing chain guide.

T11E9135T10

4.During the installation, align the two orange mark plates of

the chain with the timing marks of the camshaft timing Orange paint mark
Orange paint mark plate plate
sprocket as shown in the figure.

Timing mark Timing mark

T11E8105ET10

5.During the installation, align the yellow mark plate of the

chain with the timing mark of the crankshaft timing sprock-
Yellow paint mark plate
et as shown in the figure.
6.Install the timing chain tension arm.

Timing mark
T11E9127ET10
 B–16
7.Install the chain tensioner Ay.
(1) Slightly turn the hexagonal section for servicing of the
camshaft (IN side) counterclockwise (reverse rota-
tion) so as to give a slack to the chain at the tension-
er side. Under this state, install the tensioner.

T11E9138T10

(2) Pull out the Allen wrench of the tensioner and turn the
crankshaft two turns to move the chain tensioner Ay.

T11E9139T10

(3) With the timing chain tensed, ensure that the timing
Timing mark
mark of the camshaft timing sprocket is at the top
position. (The cylinder No.1 is set to the top dead
center under the compression stroke.)

T11E8104ET10
B–17
4 CAMSHAFT ASSEMBLY
4-1 DISASSEMBLING AND ASSEMBLING
4-1-1 DISASSEMBLING AND ASSEMBLING
(1) Components

B T:15.0&1.0 {153&10}

B T:12.5&2.0 {128&20}

T:47.0&2.8 {479&28}

T11E9104_1S40

k: Engin oil
Unit: N;m{kgf;cm}
 B–18
(2) Disassembling and assembling procedure
1 Sprocket Ay, camshaft timing(DVVT Controller) 6 Camshaft S/A, No.2(Exhaust side)
2 Sprocket, camshaft timing No.2
3 Cap, camshaft bearing, No.1
4 Cap, camshaft bearing, No.2
5 Camshaft S/A, No.1(Intake side)

4-1-2 POINTS OF DISASSEMBLY

1.With the hexagonal section for servicing of the camshaft
Ay locked by means of a spanner or the like, loosen the
attaching bolts of the camshaft timing sprocket Ay (DVVT
controller) and camshaft timing No.2 sprocket. Remove
each sprocket.

T11E9140T10

2.Temporarily install the attaching bolt of the crankshaft pul-

ley. Turn the crankshaft 90 degrees (crank angle) in the
engine rotation direction from the top dead center under
the compression stroke of the cylinder No.1 so that the lift-
ed valve will not interfere with the piston during the 90$

removal of the camshaft Ay.

T11E9141T10

3.Remove the camshaft bearing No.1 and No.2 caps by

removing the bolts in the sequence shown at the right fig- w
!2 !4 !0
ure.

!3 !5 !1
e
u o t

q y i r

T11E9142T10

4.Remove the No.1/No.2 camshaft S/A.

T11E9143T10
B–19
4-1-3 CLEANING
1.Clean the installation surface of the camshaft bearing
No.1/No.2 caps.

T11E9144T10

4-1-4 CHECK
(1) Check of camshaft
1.Check the camshaft for bending.
(1) Measure the No.3 journal section for bending, using a
V-block and a dial gauge.
ALLOWABLE LIMIT: 0.03mm
NOTE
• The bend is a half of the gauge reading (runout) when
the camshaft is turned one turn. T11E9252T10

2.Check the height of the cam.

(1) Measure the cam height with a micrometer.
Camshaft specifications
Specified value IN 41.54(41.64
(mm) EX 40.97(41.07
Limit value IN 41.44
(mm) EX 40.87

Y11E9057T10

3.Check the thrust clearance of the camshaft.

(1) Using a dial gauge, measure the thrust clearance.
SPECIFIED VALUE: 0.100(0.225mm for both IN and EX
ALLOWABLE LIMIT: 0.24mm
Camshaft bearing cap/camshaft journal specifications
Detected item No.1 CAMCAP CAMSHAFT
JOURNAL(J1)
(Side width) (Thrust surface width)
IN
Specified value 33.175(33.200 33.3(33.4
T11E9145T10
(mm) (Side width) (Thrust surface width)
EX
23.175(23.200 23.3(23.4
 B–20
4.Check the oil clearance of the camshaft.
(1) Set a plastigage in the axial direction of the journal
section. Confirm the front mark of the camshaft bear-
ing No.1/No.2 cap and journal number. Tighten the
bolt to the specified torque.
(2) Remove the camshaft bearing cap. Measure the
widest part of the plastigage.
SPECIFIED VALUE: Camshaft oil clearances
Detected item Specified value T11E9253T10
Camshaft IN 1J 33.984(34.000
Journal diameter 2(4J 22.949(22.965
EX 1J 25.979(25.995
2(4J 22.949(22.965
Cylinder head IN 1J 34.025(34.045
Journal inner diame- 2(4J 23.000(23.021
ter EX 1J 26.032(26.052
2(4J 23.000(23.021
Camshaft IN 1J 0.025(0.061
oil clearances 2(4J 0.035(0.072
EX 1J 0.037(0.073
2(4J 0.035(0.072

ALLOWABLE LIMIT: Camshaft oil clearances

Detected item Limit value
Camshaft IN 1J 0.09
oil clearances 2(4J 0.1
EX 1J 0.1
2(4J 0.1

5.Check the camshaft timing sprocket Ay and camshaft tim-

ing No.2 sprocket for wear and damage.

T11E9147T10

(2) Check of sprocket Ay, camshaft timing

WARNING
• Do not disassemble the camshaft timing (DVVT controller) sprocket Ay.

1.Secure the hexagonal section provided for servicing the

camshaft to a vice.
2.Temporarily install the camshaft timing sprocket Ay by
means of the attaching bolt.

T11E9261T10
B–21
3.Hold one of the two advanced timing side ports at the
camshaft with your finger.
Advance port

Retard port

T11E8074ET10

4.Apply air pressure to the other advanced timing port by

means of an air tool.
CAUTION
• Care must be exercised as to splashing oil.
NOTE
• The most retard timing lock is disengaged.
5.At this time, ensure that the most retard timing angle lock
of the camshaft timing sprocket Ay is disengaged and the
sprocket can be freely moved by your hand without any T11E9149T10

binding in the range of about 30 degrees.

NOTE
• The camshaft timing sprocket Ay is locked when it 30$

comes at the most retard angle position.

6.After the inspection, lock the camshaft timing sprocket Ay
at the most retard timing position. Remove the sprocket.

T11E9262T10

4-1-5 POINTS OF ASSEMBLY

1.Install the No.1/No.2 camshaft.
(1) Turn the crankshaft about 90 degrees (crank angle) in
the engine rotation direction from the top dead center
of the cylinder No.1 so that the lifted valve will not 90$

interfere with the piston during the installation of the

camshaft.

T11E9141T10

(2) Apply engine oil to where the cam sections of the No.1
and No.2 camshafts contact with the journal sections.
LUBRICANT: Engine oil

T11E9150T10
 B–22
(3) Set the No.1 camshaft Ay so that the cam noses of the
No.1 and No.3 cylinders may hold the valve lifters. Camshaft S/A,No.1 Camshaft S/A,No.2
Also, set the No.2 camshaft Ay (exhaust side) so that Cylinder No.3 Cylinder No.1 Cylinder No.2
the cam noses of the No.1 and No.2 cylinders may
hold the valve lifters.

T11E9151ET10

(4) Set the camshaft bearing No.1/No.2 caps, respective-

I2

I3

I4
ly. Tighten the attaching bolts in the sequence shown !4
r w y
at the right figure.
CAUTION
e q t
• During the installation, make sure that the front marks !3
o u !1
(arrow marks) indicated on the top of each bearing cap
face the engine front side.
!5 !0 i !2
• As for the installation positions of the stamped num-

E2

E3

E4
ber's indicated on the top of the bearing caps, refer to T11E9152T10

the table below.

Installation positions of bearing cap No.2
Installation position
Stamping No.
Intake/exhaust Cylinder No.
I2 Cylinder No.1
I3 Intake side Cylinder No.2
I4 Cylinder No.3
E2 Cylinder No.1
E3 Exhaust side Cylinder No.2
E4 Cylinder No.3

2.Assemble the camshaft timing sprocket Ay (DVVT con-

troller) and camshaft timing No.2 sprocket.
(1) Apply engine oil to around the installation position of
the camshaft timing sprocket Ay of the camshaft.
LUBRICANT: Engine oil

T11E9153T10
B–23
(2) Insert the knock pin at the forward end of the camshaft
into the knock hole of the camshaft timing sprocket
Ay.
CAUTION
• After the insertion, lightly turn the sprocket to ensure
that the knock pin has been completely inserted.
• If the knock pin is not inserted in position and the
sprocket is strongly pushed and turned, the sprocket
end surface may be damaged. Therefore, utmost care T11E9154T10

must be exercised in this regard.

(3) Assemble in such a way that the knock pin at the for-
ward end of the camshaft may enter the groove of the
camshaft timing No.2 sprocket.
(4) By utilizing the hexagonal section provided for servic-
ing of the camshaft, tighten the attaching bolt for the
camshaft timing sprocket Ay and camshaft timing
No.2 sprocket.
3.Check the valve clearances.
Specified value
Valve clearance (mm)
IN During cold pe- 0.18'0.055
(0.035

EX riod 0.31'0.055
(0.035 T11E9155T10

(1) By utilizing the hexagonal section provided for servic-

ing of the camshaft, set the No.1 and No.2 camshafts
in such a way that the mating marks of the sprockets
face exactly upward.

T11E9156T10

(2) Using a thickness gauge, check the valve clearances

shown in the right figure.
Valves to be checked when cylinder No.1 is at the top dead
center under exhaust stroke
Cylinder No.1 Cylinder No.2 Cylinder No.3
IN EX IN EX IN EX
( ( < ( ( <

CAUTION T11E9157_1T10

• The thickness gauge should be inserted from the spark

plug side. (central side)
 B–24
(3) By utilizing the hexagonal section provided for servic-
ing the camshaft, turn the camshaft 180 degrees. Set
the No.1 and No.2 camshafts in such a way that the
mating mark of the timing sprocket may face exactly
downward.

T11E9158T10

(4) Using a thickness gauge, check the valve clearances

shown in the right figure.
Valves to be checked when cylinder No.1 is at the top dead
center under compression stroke
Cylinder No.1 Cylinder No.2 Cylinder No.3
IN EX IN EX IN EX
< < ( < < (

CAUTION T11E9159_1T10
• The thickness gauge should be inserted from the spark
plug side. (central side)
4.If the specified value is not obtained, remove the No.1 and No.2 camshafts. Replace the valve lifter as
follows, in order to obtain the specified value.
CAUTION
• Record the position of the valve where the clearance
deviates from the specification, as well as the their
Valve lifter thickness
measurement results.
Selection code
12 marking

J04E1018ET10

(1) Select the valve lifter, using the following formula given below, so that the valve clearance becomes
the specified value.
; Intake side
(Thickness of selected lifter) = (Thickness of removed lifter) ' [(Measurement clearance) ( 0.18mm]
;Exhaust side
(Thickness of selected lifter) = (Thickness of removed lifter) ' [(Measurement clearance) ( 0.31mm]
NOTE
• As for a new valve lifter, identification numbers have been written with indelible ink.
List of valve lifter
No. Lifter thickness (mm) No. Lifter thickness (mm) No. Lifter thickness (mm) No. Lifter thickness (mm)
12 5.12 28 5.28 44 5.44 60 5.6
14 5.14 30 5.3 46 5.46 62 5.62
16 5.16 32 5.32 48 5.48 64 5.64
18 5.18 34 5.34 50 5.5 66 5.66
20 5.2 36 5.36 52 5.52 68 5.68
22 5.22 38 5.38 54 5.54 ( (
24 5.24 40 5.4 56 5.56 ( (
26 5.26 42 5.42 58 5.58 ( (
B–25
5.Apply engine oil to the circumference of the selected valve
lifter. Insert the valve lifter straight into the lifter hole.
LUBRICANT: Engine oil
CAUTION
• After insertion, ensure that the valve lifter turns
smoothly.

T11E9160T10
 B–26
5 CYLINDER HEAD AY
5-1 DISASSEMBLING AND ASSEMBLING
5-1-1 DISASSEMBLING AND ASSEMBLING
(1) Components

5
1
6
5

7 6
2
Inside
7 T:32.0&3.2 {132&32}'180$& 100
~10 Inside
11
~10
11
9 ~12
~12
8

13

~4

T11E9105_1ES40

k: Engin oil
Unit: N;m{kgf;cm}
~: Non-reusable parts
B–27
(2) Disassembling and assembling procedure
1 Lifter, valve 8 Valve, exhaust
2 Bolt, cylinder head 9 Valve, intake
3 Head Ay, cylinder 10 Seal, valve stem oil
4 Gasket, cylinder head 11 Seat, valve spring
5 Lock, valve spring retainer 12 Bush, valve guide
6 Retainer, valve spring 13 Bolt, stud
7 Spring, compression

5-1-2 POINTS OF DISASSEMBLY

1.Remove the valve Lifter.
CAUTION
• When removing the valve lifters, record the stamped
numbers of the valve lifters for each valve.
• Place the valve lifters in order by the cylinder.

T11E9160T10

2.Evenly loosen the cylinder head bolts in the sequence

shown at the right figure over several stages and remove
them. 3 5 7 2

1 8 6 4

T11E9161T10

3.Remove the cylinder head Ay and cylinder head gasket

from the cylinder block Ay.

T11E9162T10

4.Using the SST, remove the valve spring retainer locks at

the intake side and exhaust side. Then, remove the valve SST
spring retainer and compression spring progressively.
SST: 09202-87002-000
CAUTION
• Place each part in order by the cylinder.

T11E9163T10
 B–28
5.Remove the intake valve and exhaust valve.
CAUTION
• Place each valve in order by the cylinder.

T11E9164T10

6.Remove the valve stem oil seal and valve spring seat.
7.Heat the cylinder head Ay in hot water or the like to
80(100Ç.

T11E9165T10

8.Using the SST, drive out the valve guide bush from the
combustion chamber side. SST

SST: 09201-87203-000
CAUTION
• The valve guide bush that has been once removed
cannot be used again.

T11E9166T10

9.Put a double nut to the stud bolt and remove the bolt.

T11E9167T10

5-1-3 CLEANING
(1) Cleaning of valves
1.Remove carbon which gets to each valve.
TOOL: Wire brush
WARNING
• Wear safety goggles during the cleaning so as to pro-
tect your eyes.

T11E9168T10
B–29
(2) Cleaning of head, cylinder
1.Using a scraper, clean the cylinder block surface and
manifold surface of the cylinder head.
TOOL: Scraper
WARNING
• Wear safety goggles during the cleaning so as to pro-
tect your eyes.
CAUTION
• Be very careful not to damage the cylinder head Ay T11E9169T10
during the cleaning.
• Be very careful not to allow the cylinder head gasket
debris, etc. to fall into the water jacket.
5-1-4 CHECK
(1) Check of head, cylinder
1.Using a straightedge and thickness gauge, perform measurement at sections shown at the figure
below.

IN side EX side

T11E9170ES10

ALLOWABLE LIMIT: 0.05mm

(2) Check of spring, compression

1.Using a straightedge, measure the squareness of the
valve spring.
ALLOWABLE LIMIT: 1.5mm

T01E9072T10

2.Measure the free length of the spring.

ALLOWABLE LIMIT: 51.63mm

T01E9073T10
 B–30
(3) Check of valve E
1 Unit check of valve
1.Check each valve for deformation and severe wear.
Unit check of valve
Detected item Specified value Limit value D
Stock thickness of valve IN 1.25&0.2 0.7
head section: A EX 1.30&0.2 0.7
(mm) B
'0.4
Contact width: B IN 1.30(0.1 ( A
(mm) EX 1.26'0.35
( C
(0.15 T11E9173T10

Valve specifications
Detected item Valve, intake Valve, exhaust
Valve head diameter: C 27.5&0.15 23.6&0.15
(mm)
Overall length: D (mm) 88.39 89.11
Diameter of stem end 4.2&0.3 4.2&0.3
section:E (mm)

2 Check of clearance between valve guide bush and Diameter point

valve stem
1.Using a caliper gauge, measure the inner diameter of the
valve guide bush. Using a micrometer, measure the outer
diameter of the valve stem.
CAUTION
• Perform the measurement at several sections.
Calculate the clearance at the section where the wear
T11E9174ET10
is the greatest.
2.Calculate the difference between the measured values to Diameter point
obtain the clearance.
Check of clearance between valve guide bush and valve stem
Detected item Specified value Limit value
Valve guide bush inner diame- 5.01(5.03 (
ter(mm)
Valve stem outer diame- IN 4.970(4.985 (
ter EX 4.965(4.980 (
(mm)
Clearance IN 0.025(0.060 0.08 T11E9175ET10

(mm) EX 0.030(0.065 0.1

3 Check of valve contact surface

1.Thinly apply read lead to the valve contact surface. Lightly Center of valve 70$
contact position
bring the valve into contact with the valve seat without 45$
20$
turning the valve. Check the contact and contact width.
Detected item Specified value
'0.4
Contact width: A IN 1.3(0.1
(mm) EX 1.26'0.35
(0.15
A

T11E9176ET10
B–31
(4) Correction of valve seat
1.With a 45 degrees cutter, grind the seat so that the contact
width can become greater than the specified value.
CAUTION
• Perform the seat correction, always checking the valve
contact position.
• Reduce the grinding force gradually as reaching to the
end of the grind so that no ridge may be formed at the
corrected surface. T11E9177T10

2.Check each valve for contact position. Perform grinding

with a 45 degrees cutter so that the contact position may
come to the center of the valve face.
3.Perform grinding with a 20 degrees or 70 degrees cutter in 70$

such a way that the valve contact position comes at the 45$
center throughout the circumference and the contact 20$

width becomes the specified value.

A

T11E9178T10

4.Rub the compound to the contact surface.

T11E9179T10

(5) Check of bolt, cylinder head

1.Measure the length of the cylinder head bolt.
ALLOWABLE LIMIT: Not to exceed 123.5mm
123.5mm or less

5-1-5 POINTS OF ASSEMBLY T11E9180ET10

1.Install the double nut to the stud bolt.

T11E9167T10
 B–32
2.With the SST, drive the new valve guide bush until the pro-
truding amount of it becomes the value indicated in the
A
table.
SST: 09201-87203-000
Driving valve guide bush into position
Bush-protruding amount IN 10.1&0.3
from the driven-in surface EX 9.7&0.3
(mm)

T11E9181T10

3.Polish the inner diameter with a reamer to bring the clear-

ance into the specified value. Inner diameter

SPECIFIED VALUE: IN : 0.025(0.06mm

EX : 0.03(0.065mm

T11E9182ET10

;;;
4.Install the valve spring seat and valve stem oil seal.

NOTE
shoulder section.

;;
(1) Apply engine oil to the inside of the new valve stem oil
seal. Install the valve stem oil seal by pushing its

• After press-fitting, ensure that the valve stem oil seal

has been press-fit to the specified dimension.
SPECIFIED VALUE: IN : 10.5&0.8mm

LUBRICANT: Engine oil

EX : 10.1&0.8mm
IN side EX side
T11E9183ET10

5.Install the exhaust valve and intake valve.

(1) Apply engine oil to the forward end of each valve over
the length of 30 mm or more. Then, install the valve. 30mm

LUBRICANT: Engine oil

T11E9184T10

(2) After installing each valve, apply engine oil to the valve
guide bush and the lip section of the valve stem oil
seal.
LUBRICANT: Engine oil

T11E9185T10
B–33
(3) Install the valve lifter.

T11E9187T10

(4) Using the SST, install the valve spring retainer lock.
SST: 09202-87002-000 SST
WARNING
• Wear safety goggles during the operation so as to pro-
tect your eyes.
• Be careful not to allow the compression spring, etc. to
jump out.

T11E9163T10

(5) After installing all the compression springs, apply

engine oil to the top surface of the valve lifter as
shown in the figure.
LUBRICANT: Engine oil

T11E9189T10

6.Install the cylinder head Ay to the cylinder block Ay.

(1) Set the cylinder head gasket and cylinder head Ay to
the cylinder block Ay.
(2) Assemble the plate washer to the cylinder head Ay.
Apply engine oil to the threaded portion of the bolt
and bolt side seat surface. Then, assemble the bolts.
LUBRICANT: Engine oil Apply engine oil

T11E9263ET10

(3) To assemble the cylinder head Ay, tighten the bolts over two or three stages in the sequence shown
at the right figure. Then, tighten them to the specified
torque.
6 4 2 7

8 1 3 5

T11E9191T10
 B–34
(4) After tightening to the specified torque, further tighten
each of them 180 degrees in the same sequence.
NOTE Paint mark
• Put a paint mark on the top of each cylinder head bolt
Tighten futher
in the same direction. After tightening the bolts 180 180$ degrees
degrees in the sequence above, ensure that all the
bolt marks have been turned 180 degrees.

Y11E9119ET10

7.Apply engine oil to the circumference of the valve lifter.

Insert the valve lifter straight into the lifter hole.
LUBRICANT: Engine oil
CAUTION
• Make sure that all the valves are assembled in position
with their numbers returned to their original positions.
• After assembling the valve lifter, ensure that the lifter
can turn lightly.
T11E9160T10
B–35
6 CYLINDER BLOCK AY
6-1 DISASSEMBLING AND ASSEMBLING
6-1-1 DISASSEMBLING AND ASSEMBLING
(1) Components

T:25.2&6.0 {257&61}

~11

B
~12

~13
T:25.2&6.0 {257&61}

15
~1

~14
~3
B

16 2
~1
T:10.0&3.0 {102&30}
10
9

5
8

4
~1

7
~1 B

T:15.0&0.9 {153&9}'90$&10$

T:59.0&6.0 {602&61}
T11E9106_1S40

k: Engin oil
m: Three Bond 1207B
Unit: N;m{kgf;cm}
~: Non-reusable parts
~1: Non-reusable parts during disassembling
 B–36
(2) Disassembling and assembling procedure
1 Plate, ventilation baffle 9 Washer, crankshaft thrust
2 Retainer, oil seal 10 Crankshaft
3 Seal, type T oil 11 Ring, compression, No.1
4 Cap, connecting rod bearing 12 Ring, compression, No.2
5 Bearing, connecting rod 13 Ring, oil
6 Rod, piston W/ connecting 14 Pin, piston
7 Cap, crankshaft bearing 15 Piston
8 Bearing, crankshaft 16 Rod, connecting

6-1-2 POINTS OF DISASSEMBLY

1.Remove the ventilation baffle plate.

T11E9194T10

2.Remove the oil seal retainer.

T1E9195T10

3.With a flat screwdriver, remove the type T oil seal.

T11E9196T10

4.Check the thrust clearance of the connecting rod.

SPECIFIED VALUE: Using a dial gauge or thickness
gauge, measure the thrust
clearance.
0.1(0.3mm
ALLOWABLE LIMIT: 0.35mm

T11E9197T10
B–37
5.Check the oil clearance of the connecting rod bearing.
(1) Remove the connecting rod bearing caps and con-
necting rod bearings.
CAUTION
• Place them in order by the cylinder.

T11E9198T10

(2) Clean the connecting rod bearing and crank pin.

T11E9199T10

(3) Set the plastigage in the axial direction of the crank

Plastigage
pin. Tighten the connecting rod bearing cap to the
specified torque.
CAUTION
• Do not turn the crankshaft.

T11E9200ET10

(4) Remove the connecting rod bearing cap. Measure the

plastigage at a point where the width is the greatest.
SPECIFIED VALUE: 0.016(0.042mm
ALLOWABLE LIMIT: 0.045mm

T11E9201T10

NOTE
• If the allowable limit is exceeded, install the bearing
which has the same number as that indicated on the
bearing back surface or connecting rod. (This bearing
is supplied together with the connecting rod.) If the
limit is still exceeded even after the bearing is
replaced, replace the crankshaft.

T11E9273T10
 B–38
Specified values
Fitting number Bore diameter of connecting Central thickness of bearing Crankshaft pin diameter (mm
rod big end (mm Dia) (mm) Dia)
1 43.000 or more 1.492(1.495
(43.008 or less
2 more than 43.009 1.495(1.498
39.992(40.000
(43.016 or less
3 more than 43.017 1.498(1.501
(43.024 or less

Measurement points for bore diameter of connecting rod big end and central thickness of bearing
Refer to Page B-44.

6.Remove the connecting rod bearing cap and connecting rod bearing.
7.Remove the piston Ay with the connecting rod by tapping
it by the holder of a hammer or the like, being careful not
to scratch the cylinder and crankshaft by the end of the
connecting rod.
CAUTION
• Place the pistons in order by the cylinder.

T11E9202T10

8.Check the thrust clearance of the crankshaft.

(1) With a thickness gauge, measure the thrust clearance.
SPECIFIED VALUE: 0.02(0.22mm
ALLOWABLE LIMIT: 0.30mm
NOTE
• If the thrust clearance exceeds the allowable limit,
replace the thrust washer.
If the clearance exceeds the limit even after the
replacement, replace the crankshaft. T11E9203T10

9.Check the oil clearance of the crankshaft.

(1) Remove the crankshaft bearing cap and crankshaft
bearing.
CAUTION
• Place the removed parts in the order of removal.
NOTE
• If any difficulty is encountered in removing the crank-
shaft bearing cap, remove it by tapping with a plastic
hammer.
CAUTION T11E9204T10

• Move the upper section of the crankshaft bearing cap

along the crankshaft.
B–39
(2) Clean the inside of the crankshaft bearing, inside of
the crankshaft bearing cap, journal section of the
cylinder block, and journal section of the crankshaft.
Check for severe wear or damage.

T11E9205T10

(3) Set the plastigage in the axial direction of the crank-

shaft journal. Tighten the crankshaft bearing cap to
the specified torque. Plastigage
CAUTION
• Do not turn the crankshaft.

T11E9206ET10

(4) Remove the crankshaft bearing cap. Measure the

plastigage at a point where the width is the greatest.
SPECIFIED VALUE: 0.021(0.046mm
ALLOWABLE LIMIT: 0.046mm

T11E9207T10
 B–40
NOTE
• If the oil clearance exceeds the allowable limit, install
the bearing which has the same number as that indi-
cated on the back surface of the bearing or crankshaft.

If the oil clearance still exceeds the limit even after the
bearing is replaced, replace the crankshaft.
No.1 No.4
• The following indicates the relationship between the No.2 No.3
crankshaft bearing number, crank journal number and T11E9271T10

cylinder block journal number.

Crankshaft bearing number 6 Crank journal number
' Cylinder block journal number
Cylinder block journal hole diameter
No.4
Cylinder block journal hole diameter (mm Dia)
No.3
No. 48 tolerance
0 or more No.2
1
'0.006 or less No.1
More than '0.006
2
'0.012 or less
T11E9272T10
More than '0.012
3
'0.018 or less

Crankshaft journal diameter

Crankshaft journal diameter (mm Dia)
No. 44 tolerance
(0.012 or more
2
(0.006 or less
More than (0.006 4
1
0 or less

Crankshaft bearing thickness Y11E9168T10

Crankshaft bearing thickness (mm Dia)

No. 2.0 tolerance
More than (0.008
2
(0.005 or less
More than (0.005
3
(0.002 or less
More than (0.002
4
'0.001 or less
More than '0.001
5
'0.004 or less

10.Remove the crankshaft bearing cap. Remove the crank-

shaft bearing, crankshaft thrust washer and crankshaft.
CAUTION
• Loosen the bolts of the crankshaft bearing cap over 8
4
3
two or three stages in the sequence shown at the right 6 7
figure. 2
5
1

T11E9208T10
B–41
11.Disassemble the piston and connecting rod.
(1) By using the piston ring tool, No.1 compression ring,
No.2 compression ring and oil ring.
CAUTION
• Never reuse the removed piston ring.

Y11E9170T10

6-1-3 CLEANING
(1) Cleaning of block, cylinder
1.With an oil stone or the like, clean the chain cover surface
of the cylinder block, cylinder head surface, oil pan S/A
and ventilation baffle plate surface.
WARNING
• Wear safety goggles during the cleaning so as to pro-
tect your eyes.
T11E9211T10
CAUTION
• Be careful not to scratch the cylinder block during the
cleaning.
• Be very careful not to allow the cylinder head gasket
debris, etc. to fall into the water jacket.
(2) Cleaning of piston
1.Using an old piston ring or the like, remove carbon.
WARNING
• Wear safety goggles during the cleaning so as to pro-
tect your eyes.
CAUTION
• Be careful not to scratch the piston during the clean-
ing.
T11E9212T10
2.Remove carbon from various parts using cleaning fluid,
etc.
6-1-4 CHECK
(1) Check of block, cylinder
1.Using a straightedge and thickness gauge, perform mea-
surement at sections shown at the right figure.
ALLOWABLE LIMIT: 0.05mm

T11E9217T10

2.With the cylinder gauge, measure the points shown at the Thrust derection
right figure and record them. Crankshaft axial
derection
SPECIFIED VALUE: Specified inner diameter of cylinder
block
71.000(71.013mm
10mm
ALLOWABLE LIMIT: 71.013mm
Center
10mm
T11E9268ET10
 B–42
3.Calculate the degree of ellipse and degree of taper.
ALLOWABLE LIMIT: 0.02mm A
NOTE B
• Degree of ellipse: A(B or a(b
• Degree of taper: A(a or B(b

a
b

T01E9146T10

(2) Check of piston

1.Measure the outer diameter of the piston.
(1) At a point 10 mm from the lower end of the piston skirt
section, measure the outer diameter in a direction
vertical to the pin bore.
22.7mm
SPECIFIED VALUE: 70.921(70.931mm
ALLOWABLE LIMIT: 70.921mm

T11E9222T10

2.Check the piston ring groove.

(1) With the thickness gauge and piston ring, check the
piston clearance over the entire circumference.
Ring groove clearance
Detected item Specified value Limit value
No.1 0.02(0.07 0.07
No.2 0.02(0.06 0.06
Oil 0.020(0.065 0.065

T11E9223T10
B–43
3.Check the clearance between the mating ends of the pis-
ton ring.
(1) Using the piston, push in the piston ring up to the posi-
tion about 45 mm from the top surface of the cylinder
block. With the thickness gauge, measure the clear- A
ance between the mating ends.
Clearance between mating ends of ring
Detected item Specified value Limit value
No.1 0.2(0.3 0.79
T11E9224T10
No.2 0.4(0.6 0.75
Oil 0.1(0.4 0.69

4.Measure the oil clearance between the cylinder and the

piston.
(1) Measure the piston outer diameter and cylinder inner
diameter to obtain the oil clearance. If the limit is
exceeded, replace the piston or replace the cylinder
block.
SPECIFIED VALUE: 0.080(0.103mm
ALLOWABLE LIMIT: 0.103mm
NOTE
• The oil clearance between the piston and the cylinder
block is the difference between the minimum inner
diameter of the cylinder in the thrust direction and the
piston maximum outer diameter. (basic diameter)
• Since there is ridged wear at the upper end of the slid-
ing range of the piston ring, be sure to measure the
point with greater wear.
Specified values for cylinder block inner diameter and piston
outer diameter
Cylinder block inner daimeter (mm 71'0.013
(0

Dia)
Piston outer daimeter (mm Dia) 70.915&0.05

(2) If the piston or cylinder block has been replaced,

check the oil clearance once again after the replace-
ment.
(3) Check of crankshaft
1.Check the crankshaft for bending.
(1) With a dial gauge, measure the bend of 2J.
ALLOWABLE LIMIT: 0.03mm
CAUTION
• The bend is a half of the gauge reading (runout) when
the crankshaft is turned one turn.

T11E9226T10
 B–44
2.Check the crankshaft for wear. 10.4 (B)
5.5 (A)
(1) Calculate the degree of ellipse and degree of taper for
the points on the journal shown at the right figure,
using a micrometer.
ALLOWABLE LIMIT: Crank journal outer diameter
0.03mm
Degree of ellipse and degree of
taper 0.03mm
NOTE Y11E9189T10
• Degree of ellipse: A(B or a(b
• Degree of taper: A(a or B(b
(2) Calculate the degree of ellipse and degree of taper for A
the points on the pin shown at the right figure, by B

measuring the outer diameter with a micrometer.

ALLOWABLE LIMIT: Crank pin outer diameter 0.03mm a
b
Degree of ellipse and degree of
taper 0.03mm
NOTE
• Degree of ellipse: A(B or a(b 4 12 4 12

• Degree of taper: A(a or B(b T11E9228T10

3.Measure the thickness of the crankshaft thrust washer.

SPECIFIED VALUE: 1.94(1.99mm

T11E9214T10

(4) Check of rod, connecting

1.Check of oil level.
SPECIFIED VALUE: 43.000(43.024mm

T11E9215T10

2.Measure the stock thickness of the connecting rod bear-

ing.
SPECIFIED VALUE: 1.492(1.501mm

T11E9216T10
B–45
(5) Check of bolt, connecting rod
Forward end of End of screw
1.Measure the outer diameter (A) of the connecting rod bolt thread
tapered section
at several points.
ALLOWABLE LIMIT: Outer diameter: 6.4 mm
A

T11E9229ET10

6-1-5 POINTS OF ASSEMBLY

1.Assemble the piston, connecting rod and piston pin.
(1) Apply engine oil to the pin hole of the connecting rod.
Temporarily assemble the piston and connecting rod
with their front marks aligned with each other.
LUBRICANT: Engine oil
Front mark

T11E9231ET10

(2) Assemble the SST to the piston pin as shown at the

right figure.
SST: 09221-B1010-000 SST

T11E9232T10

(3) Insert the piston pin assembled with the SST to the pis-
ton and connecting rod. Then, set them to the SST.
SST
SST: 09221-B1020-000

SST

T11E9210T10
 B–46
(4) Heat the piston side of the connecting rod. (Approx.
80(220Ç)
CAUTION
• If the temperature will not rise above 190 Ç, apply oil. Fromt mark
SPECIFIED VALUE: 1.8&0.6mm
(5) Using a press, assemble the piston pin into the piston
and connecting rod.
CAUTION
1.8&0.6
• Press fit the piston pin from the front mark side of the T11E9234ET10
piston.
• During press-fitting, the piston pin should be pushed
from exactly above. Never apply the force diagonally.
2.Assemble the oil ring, compression ring No.2 and com-
pression ring No.1. NO.1
(1) The compression ring No.2 and compression ring No.1
should be installed using the piston ring tool with the
identification mark T facing upward.
NO.2

Cross-sectiom Distinction mark

T11E9235ET10

(2) Assemble the rings in such a way that the mating ends
of each ring face in the direction indicated in the fig-
ure.

Oil ring

Compression Compression
ring No.1 ring No.2

Front mark
Coil expander

T11E9236ET16

3.Assemble the crankshaft, crankshaft bearing cap, crank-

shaft bearing and crankshaft thrust washer.
(1) With the crankshaft (lower) bearing positioned correct-
ly, assemble it to the crankshaft bearing cap. A
NOTE
• Assemble in such a way that the difference between A B

and B does not exceed 0.8 mm.

T11E9239T10
B–47
(2) Assemble the crankshaft (upper) bearing, while align-
ing with the oil hole of the cylinder block.

T11E9237T10

(3) Insert and install the crankshaft thrust washer into the
No.3 journal at the block side in such a way that the Oil groove
oil groove faces toward the outside. (crank side)
CAUTION
• Before assembling, apply engine oil to the oil groove
side.
LUBRICANT: Engine oil
(4) After applying engine oil to the crankshaft sliding sur-
face of the crankshaft (upper) bearing, assemble the T01E9165ET10
crankshaft.
LUBRICANT: Engine oil
(5) After applying engine oil to the crankshaft sliding sur-
face of the crankshaft (lower) bearing, assemble the
crankshaft bearing cap with its front mark facing to
the front.
LUBRICANT: Engine oil

T11E9240T10

(6) After applying engine oil to the crankshaft bolt, tighten

the bolts over two or three stages in the sequence
shown at the right figure.
LUBRICANT: Engine oil 5
1
(7) After assembling, ensure that the crankshaft turns 6
3 2
smoothly. 7
4
8

T11E9241T10

4.Assemble the piston Ay with connecting rod, connecting

rod bearing and connecting rod bearing cap.
(1) Confirm the directions of the mating marks of the com-
pression rings and oil ring.
(2) Apply engine oil to the sliding surface of the piston and
connecting rod.
LUBRICANT: Engine oil

T11E9242T10
 B–48
(3) With the front mark of the piston facing to the front,
insert the piston into the cylinder block using the pis-
ton ring tool.
CAUTION Front mark

• Assemble the piston and cylinder in the same combi-

nation as that before disassembling.

T11E9243ET10

(4) Assemble the connecting rod bearing to the connect- 2.3&0.2mm

ing rod bearing cap at the position shown at the fig-
ure. Apply engine oil to the sliding surface of the con-
necting rod bearing.
LUBRICANT: Engine oil

T11E9275T10

(5) Assemble the connecting rod to the front mark of the Front mark
connecting rod bearing cap.
CAUTION
• Assemble in such a way that the front mark of the con-
necting rod bearing cap comes at the front direction.
Ensure that the knock pin is aligned with the knock
hole.
• Assemble the connecting rod and connecting rod bear-
ing cap in the same combination as that before disas- T11E9245ET10

sembling.
(6) Apply a thin film of engine oil to the seat surface and
threaded portion of the connecting rod bolt and
assemble it.
LUBRICANT: Engine oil

Apply engine oil

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(7) Tighten the connecting rod bolts alternately over two

or three stages. Also, retighten each of the bolts Paint mark
about 90 degrees in the same sequence.
NOTE Tighten futher
• Put a paint mark on the top of each connecting rod 90$degrees
bolt in the same direction. After tightening the bolts 90
degrees in the sequence above, ensure that all the
paint marks have been turned 90 degrees.
Y11E9211ET10
B–49
5.Install the type T oil seal to the oil seal retainer.
(1) Apply engine oil to the lip section of the type T oil seal.
LUBRICANT: Engine oil

T11E9249T10

(2) Using the SST, assemble the type T oil seal vertically.
SPECIFIED VALUE: Press-fitting amount
from oil seal retainer
Protruding amount: within 0.5 mm
SST A
Press-fitting depth: within 1 mm
SST: 09608-87302-000

T11E9270T10

6.Apply liquid gasket to the oil seal retainer. Then, assemble

it to the cylinder block Ay.
CAUTION 3(4mm Dia
• Perform the assembling within three minutes after
application of the liquid gasket.
ADHESIVE: Three Bond1207B

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7.Clean the ventilation baffle plate and installation surface. Apply liquid gasket to the ventilation baffle
plate.
CAUTION
3(4mm Dia
• Assemble the ventilation baffle plate within three min-
utes after application of the liquid gasket.
ADHESIVE: Three Bond1207B

T11E9279ET10

8.Perform tightening in the sequence shown at the figure.

7 6 8

1 2

5 4

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