And CB-80 engines which are mounted on the DAIHATSU CHARADE. The contents. I Moun:ed underneath rear seat flwr / Mounted urderneath rear seat:loor. ENGINE COMPONENTS AND TIGHTENING TORQUE. Want to know the tightening sequence for 1992 cuore cylinder head bolt - 1992 dihatsu cuore cylinder head bolt tightening sequence torque.
EMTO INDEXENGINE MECHANICALTIMING CHAIN. EM–-0 2 COMPONENTS. EM–-0 2 REMOVAL.
EM–-0 3 INSPECTION. EM–-0 6 INSTALLATION. EM–-0 7 CYLINDER HEAD. EM–-012 COMPONENTS. EM–-012 REMOVAL.
EM–-013 DISASSEMBLY. EM–-016 INSPECTION. EM–-017 ASSEMBLY. EM–-022 INSTALLATION. EM–-024 CYLINDER BLOCK.
EM–-032 COMPONENTS. EM–-032 CYLINDER BLOCK (S221). EM–32-1 COMPONENTS (S221). EM–32-1 DISASSEMBLY. EM–-033 INSPECTION. EM–-040 ASSEMBLY.
EM–48 ENGINE TUNE-UP. EM–56 ENGINE COOLANT. EM–56 RADIATOR CAP. EM–56 DRIVE BELT. EM–56 ENGINE OIL. EM–56 SPARK PLUG. EM–56 VALVE CLEARANCE.
EM–56 IGNITION TIMING. EM–56 BATTERY. EM–56 CHARCOAL CANISTER. EM–56 FUEL LINE & CONNECTION.
EM–56 COMPRESSION CHECK. EM–56 CHECKING OF A/F (Air/Fuel) CONTROL SYSTEM. EM–58 SERVICE SPECIFICATIONS.
EM–59 SSTs. EM–62 TIGHTENING TORQUE. EM–63JEM0EM–2TIMING CHAINCOMPONENTS: Tightening torque #: Non-reusable Unit: Nm B 6.0 - 9.0 B B 5.3 - 9.8 q B N e 7.2 - 10.8 B B wB 8.8 - 13.2 r t# 14.4 - 21.6 (M8 × 1.25) 7.5 - 10.8 (M6 × 1.0) 5.3 - 9.8!0 B!1!2#!4 5.9 - 11.1 u y B o B i B 15.2 - 22.8 @6 @1 @8 B B 8.1 - 13.8!7# 120 - 140!6 B!8 5.3 - 9.8!9 @0 5.3 - 9.8 B 5.3 - 9.8 B!5 @2 B @4 @7 7.2 - 10.8!3 @5 @3q w e r t y u i o!0!1!2!3!4Oil filler cap Ignition coil Igniter assy Cylinder head cover Cylinder head cover gasket Water pump pulley Water pump Water pump gasket Timing chain cover No. 2 Oil control valve Timing chain cover Timing chain cover gasket Timing chain tensioner Tensioner arm!5!6!7!8!9 @0 @1 @2 @3 @4 @5 @6 @7 @8Timing chain Crankshaft pulley Type T oil seal Crank angle sensor Crank angle sensor plate Timing chain guide No. 2 Timing chain guide Valve timing controller Camshaft No. 1 Camshaft No.
2 sprocket Camshaft No. 2 Camshaft sprocket key CrankshaftJEM1EM–3REMOVAL1. Remove the drive belt.
(Refer to the CH section.) 2. Remove the ignitor assembly.
(European specifications only)JEM23. Remove the ignition coil from the cylinder head cover.JEM34. Remove the cylinder head cover and gasket by removing the retaining bolts and nuts in the sequence shown in the right figure.y!2w!0qir eto!1!3uJEM45. Remove the alternator bracket.JEM56. Remove the oil control valve from the timing chain cover.JEM6EM–47.
Remove the idler pulley bracket.JEM78. Remove the crank angle sensor from the timing chain cover.JEM89.
Remove the water pump pulley. Remove the idler pulley.Water pump pulleyIdler pulleyJEM911. Turn the crankshaft in the engine rotating direction, until the timing mark on the crankshaft pulley is aligned with the indicator on the timing chain cover.
NOTE:. At this point, the No.
1 cylinder assumes the top dead center.JEM012. Ensure that the mate mark on the camshaft timing sprocket points upward. If the mate mark does not point upward, turn the crankshaft another one turn. And ensure that now the mark points upward.
NOTE:. Now, the No. 1 cylinder assumes the top dead center under the compression stroke.Mate markJEM1EM–513. Remove the crankshaft pulley by removing the pulley bolt, while preventing the crankshaft pulley from being turned, using the following SST.
SST: 1-000JEM214. Removal of oil pan. (1) Loosen the attaching bolts and nuts of the oil pan over two or three stages. Pull out the bolts and nuts. (2) Separate the oil pan from the cylinder block by driving the following SST into between the cylinder block and the oil pan. SST: 0-000JEM515.
Remove the timing chain cover by removing the retaining bolts and nuts.JEM316. Remove the crank angle sensor plate.FJEM417. Move the chain tensioner stopper plate downward. Under this unlocked state, push in the plunger deeply.Stopper plateJEM5EM–618. With the plunger in a pushed-in state, align the holes of the stopper plate and chain tensioner.
Insert a hexagonal rod wrench into place to lock it. NOTE:. For this operation, use a hexagonal rod wrench whose width across flats is 2.5 mm.JEM619. Remove the chain tensioner under a condition in which the plunger is locked with the hexagonal rod wrench inserted.JEM720. Remove the timing chain by removing the timing chain guide No. Remove the crankshaft timing sprocket.JEM822.
Remove the timing chain guide and timing chain arm.JEM9INSPECTIONChain Guide and Chain Arm Measure the wear of the chain guide and arm. Allowable Wear Limit: 0.5 mm If the wear exceeds the allowable wear limit, replace the chain guide and/or chain arm.WearJEM0EM–7Chain Tensioner 1. Depress the stopper plate with your finger. Ensure that the plunger moves smoothly. When your finger is released from the stopper plate, ensure that the stopper plate is locked. Under this state, the plunger will not move, even if the plunger is moved with your finger.MoveRaise LockJEM1INSTALLATION1.
Install the timing chain guide. Tightening Torque: 5.3 - 9.8 NmJEM22. Assemble the crankshaft timing sprocket. Align the mate mark of the timing chain mark plate (golden color) with the mate mark of the crankshaft timing sprocket. Proceed to install the timing chain.Golden colorMate markJEM34.
Install the timing chain guide No. Tightening Torque: 5.3 - 9.8 Nm NOTE:. After the timing chain guide No. 2 has been installed in place, the chain teeth of the crankshaft timing sprocket section will not jump up.JEM45. Align the mate mark of the timing chain mark plate (golden color) with the mate mark of the camshaft timing sprocket. Proceed to install the timing chain.Golden colorMate markJEM5EM–86.
Install the timing chain arm. Tightening Torque: 15.2 - 22.8 NmJEM67. Slightly turn the camshaft counterclockwise, using the hexagonal section of the camshaft so that the chain at the tensioner side may be slackened.
Under this state, proceed to install the tensioner. Tightening Torque: 7.2 - 10.8 NmJEM78. Pull out the hexagonal rod wrench from the chain tensioner. NOTE:.
Ensure that a tension is applied to the timing chain.JEM89. Install the crank angle sensor plate in such a direction that the “F” mark comes at the front side.FJEM910. Assemble a new timing chain cover gasket on the timing chain cover.JEM0EM–911. Apply liquid gasket at those points shown in the figure below. Install the timing chain cover.
Tightening Torque: 14.4 - 21.6 Nm (M8 × 1.25) 7.2 - 10.8 Nm (M6 × 1.0) Liquid Gasket: Three Bond TB 1280E or equivalent NOTE:. Make sure to completely remove all foreign substance and oil, etc.
From the gasket surface. The assembling should be carried out within three minutes after the application of liquid gasket.: Application points of liquid gasketC C C C A A B B3 4 mm3 4 mmA-A cross-section 03 4 mm B-B cross-section 03 mm C-C cross-section 06 mmJEM112.
Install the oil pan (For the installation procedure, refer to EM–53.) 13. Assemble the crankshaft pulley. Install the pulley bolt, using the following SST.
SST: 1-000 Tightening Torque: 120 - 140 NmJEM214. Install the idler pulley.
Tightening Torque:35.2 - 52.8 Nm15. Install the water pump pulley. Tightening Torque: 8.1 - 15.0 NmWater pump pulleyIdler pulleyJEM3EM–1016. Install the crank angle sensor.
Tightening Torque: 5.3 - 9.8 Nm NOTE:. Prior to the installation, apply oil to the O-ring section of the sensor.JEM417. Install the oil control valve. Tightening Torque: 5.3 - 9.8 Nm NOTE:.
Be sure to completely remove any foreign matter that may lodge at the installation hole or oil control valve. Apply engine oil to the O-ring section.JEM518. Install the alternator bracket and idler pulley bracket.JEM619.
Set the cylinder head cover gasket to the gasket groove of the head cover. Insert the gasket into the boss at the central section. Insertion Amount: 1 to 7 mmGasket 1 - 7 mmJEM7EM–1120. Apply liquid gasket to those points indicated in the right figure. Liquid Gasket: Three Bond TB 1280E or equivalent NOTE:. Guide to application amount: 5 mm in diameter and 2 mm in height. The assembling should be carried out within three minutes after the application of liquid gasket.JEM8Liquid gasket21.
Assemble the head cover retaining bolts in the sequence specified in the right figure. Tightening Torque: 7.2 - 10.8 Nm (Cap nut) 8.8 - 13.2 Nm (Nut) NOTE:. Before the two cap nuts are installed on the central section of the cylinder head cover, install the washer seal in place.iw!2r!3y!0!1otequJEM922. Install the ignition coil. Tightening Torque:6.0 - 9.0 NmJEM023. Install the ignitor assembly. (European specifications only) Tightening Torque: 5.3 - 9.8 Nm 24.
Install the drive belt. (Refer to the CH section.)JEM1EM–12CYLINDER HEADCOMPONENTSB: Tightening torque #: Non-reusable Unit: Nm B B B 14.4 - 21.6 e q t 15.2 - 22.8 B B B i# o 10.5 - 14.5!1!0!2!5 u y#!6!7!8!9# @0 @1 r B w40 - 54 17.1 - 31.9 @2 B B @3 @4 6.4 - 9.6 B!3 B!4 @5 @6 B42.3 - 47.75.3 - 9.8 @7 #0 @8# B @9B B B B B #1# 20 - 30 BB 5.3 - 9.8q w e r t y u i o!0!1Oil filler cap Ignition coil Spark plug Igniter assy Cylinder head cover Cylinder head cover gasket Intake manifold Intake manifold gasket Camshaft bearing cap No. 1 Camshaft bearing cap No. 2 Valve timing controller!2!3!4!5!6!7!8!9 @0 @1 @2 @3Camshaft No. 1 Camshaft No.
2 sprocket Camshaft No. 2 Valve lifter Valve spring retainer lock Valve spring retainer Valve spring Valve stem oil seal Valve seat Valve Straight screw plug Gasket@4 @5 @6 @7 @8 @9 #0Oil control valve filter Valve guide Cam angle sensor Cylinder head Exhaust manifold gasket Exhaust manifold Exhaust manifold heat insulator #1 Cylinder head gasketJEM2EM–13REMOVAL1. Remove the timing chain. (Refer to the Timing Chain section.) 2. Remove the throttle body.JEM33. Remove the throttle body bracket.JEM44. Remove the oil level gauge and oil level gauge bracket.
NOTE:. The oil level gauge bracket has been provided only on the J102 series.JEM55. Remove the pulsation damper.JEM66.
Remove the fuel delivery pipes and injectors.JEM7EM–147. Remove the intake manifold.JEM88. Remove the air valve pipe. (J102 series only) 9. Remove the DVVT oil filter.JEM910.
Remove the exhaust manifold cover.JEM011. Remove the oxygen sensor.JEM112. Remove the exhaust manifold and gasket.JEM2Revision 1EM–1513. Remove the cam angle sensor.sEM814. Remove the radiator thermo control switch.
(M101, J102 series) 15. Remove the water inlet. Remove the thermostat. (M101, J102 series) 16.
Remove the engine coolant temperature sensor. (M101, J102 series)sEM916-1. Remove the water outlet and thermostat. (S221 series) 16-2. Remove the water outlet housing and water inlet pipe subassembly. (S221 series)sEM516-3. Remove the radiator thermo control switch.
(S221 series) 16-4. Remove the engine coolant temperature sensor and water bypass outlet subassembly. (S221 series)sEM617.
Remove the spark plugs.sEM0EM–15-118. Remove the camshaft bolt, while preventing the camshaft No.
1 from turning, using the hexagonal section of the camshaft No. Remove the DVVT controller from the camshaft No. 1.Revision 1sEM119. Turn the crankshaft 90 degrees in the engine rotating direction. NOTE:. When the camshaft is turned in the following Step (20), care must be exercised to ensure that the valves will not interfere with the piston.sEM2EM–1620. Turn the cams, as indicated in the right figure, using the hexagonal sections of the camshafts No.
NOTE:. The cam should be turned to such a position where the valve lifter pushes up least the camshaft.Camshaft No. 1 (IN side) No.
4 Camshaft No. 2 (EX side) No.
Remove the camshaft bearing caps No. 2 in the sequence specified in the right figure.!0 w r e qo!2!1yituJEM922. Remove the camshafts No.
Remove the cylinder head retaining bolts in the sequence specified in the right figure. Remove the cylinder head and gasket from the cylinder block.et!0iwquoyrJEM1DISASSEMBLYCylinder head 1. Remove the valve lifters from the cylinder head.JEM2EM–172. Remove the valve spring retainer locks, using the following SSTs. SST: 2-000 2-0A0JEM33. 6.Remove the valve spring retainers, and valve springs.
Remove the valves from the cylinder head. Remove the valve stem oil seals, using pliers or the like. Remove the valve spring seats from the cylinder head.
WARNING:. Make sure to protect your eyes with safety goggles during this operation. Be very careful not to allow the spring, etc. To jump out.JEM4Camshaft No. Secure the camshaft by clamping it in a vise.
CAUTION:. Be very careful not to scratch the cam journal section. Remove the camshaft drive gear from the camshaft.JEM5INSPECTIONCylinder head NOTE:. Clean the cylinder head by removing the remaining gasket materials, carbon deposits, and so forth.
Check the cylinder head for cracks, using a dye penetration or like.JEM0EM–181. Check of cylinder head for flatness Using a precision straight edge and a feeler gauge, check the gasket surfaces contacting the cylinder head and manifolds for warpage.
Maximum Surface Warpage: Cylinder Block Side: 0.04 mm Intake Manifold Side: 0.10 mm Exhaust Manifold Side: 0.05 mm If surface warpage of the cylinder block side exceeds the maximum limit, reface or replace the cylinder head. If surface warpage of the intake manifold and/or exhaust manifold side exceeds the maximum limit, replace the cylinder head. If the cylinder head surface warpage at the cylinder block side exceeds the maximum warpage, reface the cylinder head within the minimum thickness limit. Cylinder Head Height Limit: 112.7 mmJEM72. Check of camshaft oil clearance NOTE:. Prior to this oil clearance check, the camshaft should be checked for bend in advance.
(See page EM–20.) (1) Measure the oil clearance between the camshaft and the camshaft bearing cap. NOTE:. For the tightening method of the camshaft bearing cap, refer to page EM–25. Oil Clearance: IN: No. 1: 0.025 - 0.061 No. 5: 0.037 - 0.073 EX: No. 5: 0.037 - 0.073 If the oil clearance does not conform to the specification, measure the camshaft journals, camshaft bearing cap bore diameter.
Replace the any part which will not conform to the specifications. NOTE:. As for the replacement of the camshaft bearing cap, it should be replaced as a set with the cylinder head.Camshaft journal outer diameter Intake side No. 5 33.984 - 34.000 22.979 - 22.995 25.979 - 25.995 22.979 - 22.995 Camshaft bearing cap bore diameter 34.025 - 34.045 23.032 - 23.052 26.032 - 26.052 23.032 - 23.052JEM8Exhaust sideJEM9EM–193. Check of camshaft thrust clearance Assemble the camshaft, referring to the assembling procedure of the camshaft in EM–25. Measure the thrust clearance.
Specified Thrust Clearance: Intake Side 0.10 - 0.24 mm Exhaust Side 0.10 - 0.24 mmJEM04. Check and grinding of valves (1) Visually inspect the valve stem for seizure or damage. NOTE:. If seizure or damage is found, replace the valve and valve guide bush as a set. However, this replacement should be performed only after the checks for the valve seat, valve stem and valve guide bush have been finished.
The valve guide bush hole must be used for refacing the valve seat. Hence, if the valve guide bush hole exhibits any roughness due to seizure, etc., rectify the hole with an adjustable reamer. (2) Visually inspect the valve head for melting or damage. If the valve head exhibits any melting or damage, replace the valve.
If the roughness on the contact surface can be corrected, grind the valve seat contact surface with a valve refacer. (3) Grind the valves only enough to obtain a smooth contact surface with the valve seat.
Valve Face Angle: 45.5° NOTE:. Make sure the valves are ground to the correct valve face angle. (4) Visually inspect the valve stem end for abnormal wear.
If the valve stem end exhibits abnormal wear, correct the stem end with a valve refacer. However, this correction should be made within a limit of 0.2 mm from the standard length. Reference Intake Valve: 79.4 mm Exhaust Valve: 79.8 mm NOTE:. Be very careful not to allow the valve to be overheated during grinding. Standard Length: Intake Valve: 88.15 mm (Unleaded) 88.35 mm (Leaded) Exhaust Valve: 89.1 mmJEM1JEM2JEM3JEM4EM–20Revision 1sEM3(5) Inspect the valve head for its stock thickness. Minimum Stock Thickness: Intake Valve: 0.8 ± 0.2 mm (Unleaded) 1.0 ± 0.2 mm (Leaded) Exhaust Valve: 1.0 ± 0.2 mm If the stock thickness of the valve head is less than the minimum stock thickness, replace it with a new one.sEM45.
Refacing of valve seat NOTE:. Be sure to always check the valve contact position when refacing the seat. Be sure to gradually reduce your force at the end of grinding so that no difference in height may be formed in the refacing surface.sEM7(1) Using a 45-degree cutter, perform grinding to a contact width slightly greater than the specified value.
(2) Check the valve contact position. It is satisfactory if the contact position comes at the center of the valve face. If the contact position will not come at the center, perform grinding further, using a 45-degree cutter. (3) Grind the valve seat, using a 20-degree cutter or a 70degree cutter, so that the valve contact position comes at the center all around the circumference of the valve and the contacting width conforms to the specified value. (4) Carry out hand lapping, using compound.70° 45° 20°1.4 ± 0.5 mmsEM8sEM9Revision 1EM–20-1Measuring point6. Check of clearance between valve guide bush and stem (1) Measure the inner diameter of the valve guide, using a caliper gauge, as well as the outer diameter of the valve stem, using a micrometer, respectively. (2) Determine the difference between the respective measured values and calculate the clearance.
If the calculated clearance exceeds the allowable limit, replace the valve or bush. NOTE:. The measurement should be conducted at several points, as indicated in the figure on the right. Then, calculate the clearance at the maximum wear section. Table showing specified values and allowable limit values Check of valve guide bush-to-valve stem clearanceItems Guide bush inner diameter (mm) Valve stem outer diameter (mm) Clearance (mm) IN EX IN EX Specified value 05.0 05.0 05.0+0.022 +0.010 –0.010 –0.025 –0.020 –0.035Valve guide bush measuring sectionsEM2Measuring pointAllowable limit — — —sEM30.020 - 0.047 0.030 - 0.0570.070 0.0807.
Replacement of valve guide bush (1) Warm up the cylinder head to 80 to 100°C, using hot water or the like. (2) Drive out the valve guide bush from the combustion chamber side, using a suitable tool. NOTE:. Never reuse the bush that has been driven out once. (3) Drive a new valve guide bush into position, until the projection height becomes the specified value, using a suitable tool. NOTE:. Be very careful not to excessively drive the bush.
Be sure to confirm the dimension during the operation. Specified Value of Projection Height: 14.5 ± 0.3 (Both intake side and exhaust side)sEM4sEM5(4) Using an adjustable reamer, ream the valve guide bush to remove any burr or the like. NOTE:. This reaming should be made only enough to remove the burr or the like. (5) Check of oil clearance Ensure that the oil clearance meets the specifications.sEM5EM–20-28. Check of manifold Check the cylinder head attaching surface of the intake manifold and exhaust manifold for warpage, using a straight edge and a thickness gauge.
Maximum Warpage: 0.7 mmRevision 1sEM6Camshaft 1. Check of gear Visually inspect the teeth for wear. Check of shaft (1) Checking camshaft for runout Support the camshaft at its both ends with V-shaped blocks.
Set a dial gauge to the mid-point of the center journal section of the camshaft. Turn the camshaft one turn, making sure that the camshaft will not move in the axial direction.
Take a reading on the dial gauge during the turning. Calculate the maximum runout, i.e. The difference between the maximum and minimum readings.
Maximum Runout: 0.03 mm If the runout exceeds the maximum limit, replace the camshaft.sEM7sEM8EM–21(2) Checking of cam lobe height Measure the cam lobe height, using a micrometer. Specified Cam Lobe Height:K3-VE IN EX 40.45 mm 39.96 mm K3-VE2 40.75 mm 40.69 mmJEM03. Check of DVVT controller (1) Clamp the hexagonal section for servicing of the camshaft assembly No. 1 in a vice, etc. (2) Temporarily tighten the attaching bolt at the DVVT controller attaching bolt hole so as to plug the oil passage at the timing advance side.JEM6(3) Wind a vinyl tape, as indicated in the right figure.
Then, make a hole at either of the two advance ports.Advance portJEM7(4) Apply compressed air to the advance port where the hole has been made, using a pneumatic tool. CAUTION:. Care must be exercised, for oil will splash. NOTE:.
The most retarded angle lock will be unlocked.JEM8(5) At this time, ensure that the most retarded angle lock of the DVVT controller becomes unlocked and the DVVT controller can be moved by your hand without binding within a range of approximately 30°. NOTE:.
The DVVT controller will be locked when it comes to the most retarded angle position.JEM9EM–22(6) After completion of the check, lock the DVVT controller at the most retarded angle position. Then, remove the timing pulley attaching bolt.
NOTE:. After the bolt has been removed, be sure to wipe off any residual sealing material lodged at the screw hole of the camshaft.
(Failure to perform this operation may result in malfunction of the DVVT after assembling.)JEM0Thermostat For checking and replacement procedures, refer to the CO section. Radiator thermo control switch For checking procedure, refer to the CO section. Crank angle sensor For checking and replacement procedures, refer to the IG section.
Cam angle sensor For checking and replacement procedures, refer to the IG section. Spark plug For checking and replacement procedures, refer to the IG section.JEM0ASSEMBLYCylinder head NOTE:. Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones. CAUTION:.
It should be noted that the valves for unleaded gasoline specifications differ from those for leaded gasoline specifications. Identification marks: Unleaded Gasoline: IN=I1, EX=E1 Leaded Gasoline: IN=I9, EX=E9Unleaded gasoline Exhaust valve Intake valve Leaded gasoline Exhaust valve Intake valveE1I1E9I9JEM2EM–231. Install the valve spring seat 2.
Installation of valve stem oil seal (1) Apply engine oil to the inner surface of the metal ring of the stem oil seal. (2) Drive the valve stem oil seal into position. NOTE:. Make sure that the stem oil seals will not tilt against the stem.15.8JEM33. Dip the long portion of the valve stem end at least 20 mm into engine oil. Install the valve to the cylinder head.
NOTE:. Care must be exercised as to the installing position. Do not pull out the valve once it has been inserted. If the inserted valve should be pulled out, replace the valve stem oil seal with a new one.At least 20 mmDip this portion into engine oil.JEM45.
Assembly of valve springs, valve spring retainers and valve spring retainer locks (1) Install the valve spring to the valve lifter inserting hole. (2) Install the valve spring retainer to the valve spring. Install the valve spring retainer locks while compressing the valve spring retainer, using the following SST.
SST: 2-000 2-0A0JEM5(3) After installing the valve spring retainer lock, lightly tap the valve spring retainer with a plastic hammer or the like so as to ensure that the valve spring retainer locks are installed securely. WARNING:. During this operation, care must be exercised to ensure that the valve spring retainer or retainer locks may not jump out. Protect your eyes with safety goggles during this operation. Never tap the hole into which the valve lifter is inserted.
Secure the camshaft by clamping it in a vise. CAUTION:. Be very careful not to scratch the cam journal section. Install the camshaft drive gear to the camshaft.JEM6JEM7EM–24INSTALLATION1. Clean the gasket attaching surfaces of the cylinder block and cylinder head with a scraper. Remove all foreign substance and oil, etc. Completely from the gasket surface.
NOTE:. Be very careful not to drop scrapping debris of the gasket into the holes of the water jacket and oil holes.JEM8NOTE:. The assembling should be carried out within three minutes after the application of liquid gasket. Care must be exercised to ensure that no valve lifter may drop from the cylinder head.3.
Install the plate washer on each cylinder head bolt. Apply engine oil to the threaded portion of each bolt and the seat surface of each plate washer. NOTE: The washer plate can be installed in either way. The washer does not have the front side nor the back side.4. Tighten the cylinder head over two to three stages in the sequence specified in the right figure. Tightening Torque: 32.0 - 34.0 Nm5. Put a paint mark on the head section of each bolt at the engine front side.
Tighten the attaching bolts further 90 degrees, using the mark as a guide.;;;;;IN side EX side 6 mm 20 ± 3 mm 18 ± 3mm 2 mmJEM92. Apply liquid gasket, following the procedure shown in the right figure. Set the cylinder head gasket and cylinder head. Liquid Gasket: Three Bond TB 1280E or equivalentCylinder head Cylinder head gasket Liquid gasket Cylinder block Application points of liquid gasket Approx.
2.5 mmApplication of engine oilJEM0iyqeo!0rwtuJEM1Paint mark Tighten further 90 degrees.JEM2EM–25NOTE:. Using a micrometer, measure the diameter of the shaded, threaded ridge portion of the cylinder head bolt, as indicated in the right figure. This measurement should be conducted at several points. If the diameter has worn exceeding the allowable limit, replace the cylinder head bolt. Allowable Limit: Diameter of threaded ridge diameter:25208.75 mmJEM37. Turn the crankshaft 90 degrees in the engine rotating direction from the top dead center of No. NOTE:.
Utmost attention must be paid so that a lifting valve will not interfere with the piston when assembling the camshaft.JEM48. Apply engine oil to the cam lobe sections of the camshafts No. 2, the cylinder head journal sections and the top sections of the lifters.JEM59.
With the cam position aligned as shown in the right figure, set the camshaft to the cylinder head.Camshaft No. 1 (IN side) No. 4Camshaft No. 2 (EX side) No. Install the camshaft bearing caps No.
2 in the sequence specified in the right figure. Tightening Torque: 10.5 - 14.5 Nm NOTE:.
Make sure that the camshaft bearing cap is assembled in such a direction that the arrow-headed mark points toward the front of the engine.e!1 o!0!2rqwutiyJEM7EM–2611. Insert the knocking pin at the forward end of the camshaft No. 1 into the knocking pin hole of the DVVT controller.
Proceed to assemble the DVVT controller. NOTE:.
After completion of the insertion, lightly turn the DVVT controller by your hand. Ensure that the knocking pin has been inserted securely in place.Revision 1PinsEM2912. Tighten the camshaft bolt, while preventing the camshaft No. 1 from turning, using the hexagonal section of the intake camshaft. Tightening Torque: 40 - 54 NmsEM3013.
Install the spark plugs. Tightening Torque: 14.4 - 21.6 NmsEM3114.
With the jiggle pin of the thermostat aligned with the protruded section for locating the water inlet, install the water inlet in the cylinder head. (M101, J102 series) Tightening Torque: 7.2 - 10.8 NmsEM3215. Install the radiator thermo control switch to the water inlet. (M101, J102 series) Tightening Torque: 30 - 40 Nm 16.
Install the engine coolant temperature sensor. (M101, J102 series) Tightening Torque: 16 - 24 NmsEM33Revision 1EM–27Projected section Cut-out section16-1. Assemble the water outlet, while facing the jiggle pin of the thermostat upward. (S221 series) Tightening Torque: 11.2 - 16.8 NmJiggle pinsEM916-2. Install the engine coolant temperature sensor and water bypass outlet. (S221 series) Tightening Torque: 16 - 24 Nm 16-3.
Install the radiator thermo control switch. (S221 series) Tightening Torque: 19.6 - 29.4 NmsEM017.
Install the cam angle sensor to the cylinder head. Tightening Torque: 5.3 - 9.8 Nm NOTE:.
Prior to the installation of the sensor, be sure to apply oil to the O-ring of the sensor.sEM418. Install the exhaust manifold and gasket in the sequence specified in the right figure. (M101, J102 series) Tightening Torque: 21 - 29 Nmwe rtqsEM519. Install the exhaust manifold and gasket in the sequence specified in the right figure. (S221 series) Tightening Torque: 23.2 - 34.8 Nm (Bolt) 32.0 - 48.0 Nm (Nut)r yw qet usEM2EM–27-120.
Install the oxygen sensor to the exhaust manifold. Tightening Torque: 29.0 - 39.0 Nm NOTE:. Never use an impact wrench when assembling the oxygen sensor.
Care must be exercised not to give damage to the harness during the assembling operation.Revision 1sEM621. Install the exhaust manifold cover.
(M101, J102 series) Tightening Torque: 5.3 - 9.8 NmsEM722. Install the DVVT oil filter, using a new gasket. Tightening Torque: 17.1 - 31.9 Nm NOTE:. Make sure that no foreign substance gets to the filter hole and filter plug of the cylinder head. The gasket is a non-resuable part. Install the air valve pipe. (J102 series only)sEM8EM–2823.
Install the intake manifold. Tightening Torque: 15.2 - 22.8 NmJEM924. Install the fuel delivery pipes and injectors. Tightening Torque: 16.8 - 25.2 NmJEM025. Install the pulsation damper.JEM126. Install the oil level gauge and insert the oil level gauge in place. Tightening Torque: 6.0 - 11.1 NmJEM227.
Install the throttle body bracket. Tightening Torque: 16.8 - 25.2 Nm 28. Install the throttle body. Tightening Torque: 5.3 - 9.8 Nm 29. Install the timing chain. (Refer to the Timing Chain section.)JEM3EM–2930. Adjustment of valve clearance (1) Turn the crankshaft in the engine rotating direction so that the crankshaft key groove may point upward.
NOTE:. Set the No. 1 cylinder to the top dead center.JEM0(2) Ensure that the mate mark on the camshaft timing sprocket points upward.
If the mate mark does not point upward, turn the crankshaft another one turn. And ensure that now the mark points upward. NOTE:. Now, the No. 1 cylinder assumes the top dead center under the compression stroke.Mate marksJEM5(3) Check the valve clearances at those points specified in the right figure, using a thickness gauge. Valves to be checked at top dead center of No. 1 cylinder under compression strokeNo.
1 cylinder IN EX No. 2 cylinder IN EX — No. 3 cylinder IN — EX No. 4 cylinder IN — EX —JEM6(4) Turn the crankshaft another one turn so that the No. 1 cylinder assumes the top dead center under the exhaust stroke.
Check the valve clearances at those points specified in the right figure. Valves to be checked at top dead center of No. 1 cylinder under exhaust strokeNo.
1 cylinder IN — EX — No. 2 cylinder IN — EX No.
3 cylinder IN EX — No. 4 cylinder IN EXJEM7EM–30(5) If the valve clearances will not come within the specified values, remove the timing chain and camshaft. Specified Valve Clearances: Intake (cold): 0.145 - 0.235 Exhaust (cold): 0.275 - 0.365 (6) Select proper valve lifters, using the formula given below, so that the valve clearances may fall within the specified values. Intake (Thickness of lifter to be selected) = (Thickness of removed lifter) + (Measured clearance) – 0.18 mm Exhaust (Thickness of lifter to be selected) = (Thickness of removed lifter) + (Measured clearance) – 0.31 mmJEM0NOTE:.
The thickness of the lifter to be assembled must be measured at the center of the lifter. Each valve lifter bears a mark that identifies its lifter thickness.Viewed from direction A16Viewed from direction AJEM9Code 12 14 16 18 20 22 24 26Lifter thickness (mm) 5.120 5.140 5.160 5.180 5.200 5.220 5.240 5.260Code 28 30 32 34 36 38 40Lifter thickness (mm) 5.280 5.300 5.320 5.340 5.360 5.380 5.400Code 42 44 46 48 50 52 54Lifter thickness (mm) 5.420 5.440 5.460 5.480 5.500 5.520 5.540Code 56 58 60 62 64 66 68Lifter thickness (mm) 5.560 5.580 5.600 5.620 5.640 5.660 5.680JEM0EM–31(7) Apply engine oil to the outer periphery of each selected valve lifter. Proceed to insert the valve lifters into the lifter holes.
Assemble the camshafts No. (Refer to EM–25.) (8) Install the timing chain and chain cover. (Refer to the Timing Chain section.) (9) Install the cylinder head cover and gasket on the cylinder head. (Refer to the Timing Chain section.)JEM0EM–32CYLINDER BLOCKCOMPONENTS: Tightening torque #: Non-reusable parts Unit: Nm i u y B q# w 6.8 - 10.2 B e B r t 5.3 - 9.7B 7.2 - 11.7 5.3 - 9.7!0 7.2 - 10.8 35.0 - 45.0!1!7!8 @6!9 @5 @4 @8 # B 120 - 140 @9 53.0 - 65.0 #0 6.0 - 11.0 B #1 #2# q w e r t y u i o!0!1!2!3!4!5!6!7!8!9 @0 Cylinder head gasket Cylinder block Rear oil seal retainer Rear oil seal Rear end plate Water pump pulley Water pump Water pump gasket Timing chain oil nozzle Oil pump Oil relief valve Piston ring No.
1 Piston ring No.