UNIT REPAIR
Accessory Parts
Tools Required
DW100-030 Stand-Engine Overhaul
Removal Procedure
- Remove the flywheel(Manual transmission) or flexible plate(Auto transmission) from the engine assembly.
- Install the engine overhaul stand(DW100-030) to the engine.
- Remove the cylinder head cover. Refer to "Cylinder Head Cover"
in this section.
- Remove the accessory belt. Refer to "Accessory Belt"
in this section.
- Remove the power steering pump. Refer to Section 6B, Power Steering Pump.
- Remove the A/C compressor. Refer to Section 7B, A/C compressor.
- Remove the generator. Refer to Section 1E, Engine Electrical.
- Remove the accessory belt tensioner. Refer to "Accessory Belt"
in this section.
- Remove the water pump. Refer to Section 1D, Engine Cooling.
- Remove the intake manifold. Refer to "Intake Manifold"
in this section.
- Remove the exhaust manifold. Refer to "Exhaust Manifold"
in this section.
- Remove the engine oil stick gauge guide pipe.
- Remove the power steering pump, A/C compressor bracket.
Installation Procedure
- Install the power steering pump, A/C compressor bracket.
Tighten
- Power Steering Pump Bracket Mounting Bolts: 20 N•m (14.7 lb-ft).
- A/C Compressor Mounting Bracket Bolts: 30 N•m (22.1 lb-ft).
- Install the engine oil stick gauge guide pipe.
Tighten
Oil Level Gage Tube Retaining Bolt: 10.5 N•m (7.7 lb-ft).
- Install the water pump. Refer to Section 1D, Engine Cooling.
- Install the exhaust manifold. Refer to "Exhaust Manifold"
in this section.
- Install the intake manifold. Refer to "Intake Manifold"
in this section.
- Install the accessory belt tensioner. Refer to "Accessory Belt"
in this section.
- Install the generator. Refer to Section 1E, Engine Electrical.
- Install the A/C compressor. Refer to Section 7B, A/C Compressor.
- Install the power steering pump. Refer to Section 6B, Power Steering Pump.
- Install the accessory belt. Refer to "Accessory Belt"
in this section.
- Install the cylinder head cover. Refer to "Cylinder Head Cover"
in this section.
- Remove the engine from the engine overhual stand(DW100-030).
- Install the flywheel(Manual transmission) or flexible plate(Auto transmission) to the engine assembly.
Tighten
Flywheel/Flexible Plate Bolts: 45 N•m (33.2 lb-ft).
Cylinder Head
Removal Procedure
- Remove the accessory parts. Refer to "Accessory Parts"
in this section.
- Remove the oil pan. Refer to "Oil Pan"
in this section.
- Remove the timing chain. Refer to "Timing Chain System"
in this section.
- Remove the camshaft. Refer to "Unit Repair-Camshaft"
in this section.
- Remove the cylinder head bolts.
- Remove the cylinder head with the gasket.
Cylinder Head Inspection
Caution : Take extreme care to prevent any scratches, nicks or damage to the Cylinder Head Surface. If scratched, damage may happen to engine.
- Clean the sealing surfaces.
- Inspect the cylinder head for the following.
- Cracks, damage or pitting in the combustion chambers.
- Debris in the oil galleries. Continue to clean the galleries until all debris is removed.
- Coolant leaks or damage to the deck face sealing surface.
- Damage to any gasket surfaces.
- Damage to any threaded bolt holes.
- Burnt or eroded areas in the combustion chamber.
- Cracks in the exhaust ports and combustion chambers.
- External cracks in the water passages.
- Restrictions in the intake or exhaust passages.
- Restrictions in the cooling system passages.
- Rusted, damaged or leaking core plugs.
- If the cylinder head is cracked or damaged, it must be replaced. No welding or patching of the cylinder head is recommended.
- Measure the clearance between the straight–edge and the cylinder head deck face using a feeler gauge at four points along the straight–edge.
- Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be flat within the spec. (Refer to the Engine Spec. in the Section)
- Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder head height should be in specifications, replace the cylinder head. If the cylinder head height is out of specifications, replace the cylinder head.
Installation Procedure
- Install the cylinder head with the NEW gasket.
- Install the cylinder head bolts.
Tighten
Cylinder Head Bolts: 22 N•m + 82° (16.2 lb-ft + 82°)
- Install the camshaft. Refer to "Unit Repair-Camshaft"
in this section.
- Install the timing chain. Refer to "Timing Chain System"
in this section.
- Install the oil pan. Refer to "Oil Pan"
in this section.
- Install the accessory parts. Refer to "Accessory Parts"
in this section.
Camshaft
Removal Procedure
Caution : Take extreme care to prevent any scratches, nicks or damage to the camshaft bearing. If scratched, damage may happen to engine.
- Remove the accessory parts. Refer to "Accessory Parts"
in this section.
- Remove the cylinder head. Refer to "Unit Repair-Cylinder Head"
in this section.
Notice : Intake Sprocket of the Camshaft is the same as Exhaust Sprocket.
Caution : Make sure that camshaft caps have to be set on the original position and direction. If mixed, damage may happen to engine.
- Remove the camshaft sprocket.
- Remove the camshaft bearing cap.
Measuring and Inspection
- Measure the camshaft lift. If it is out of specification, replace it. Refer to "Engine Specification"
in this section.
- Measure the camshaft journal outer diameter. If it is out of specification, replace it. Refer to "Engine Specification"
in this section.
- Install the camshaft bearing cap to the cylinder head.
Tighten
Camshaft Cap Bolts: 10 N•m (7.4 lb-ft)
- Measure the camshaft journal inner diameter. If it is out of specification, replace it. Refer to "Engine Specification"
in this section.
Installation Procedure
Caution : Take extreme care to prevent any scratches, nicks or damage to the camshaft bearing. If scratched, damage may happen to engine.
- Lubricate the camshaft surface with the clean engine oil.
- Install the camshaft bearing cap.
- Install the camshaft bearing cap bolts.
Tighten
Camshaft Cap Bolts: 10 N•m (7.4 lb-ft).
- Install the camshaft sprocket.
- Install the camshaft sprocket bolts.
Tighten
Camshaft Sprocket Retaining Bolts: 60 N•m (44.2 lb-ft).
- Install the cylinder head. Refer to "Unit Repair-Cylinder Head"
in this section.
- Install the accessory parts. Refer to "Unit Repair-Accessory Parts"
in this section.
Valve Train Components
Tools Required
EN-49074 Compressor-Universal Valve Spring
EN-49075 Adapter-Valve Spring Compressing
Removal Procedure
- Remove the camshaft. Refer to "UNIT REPAIR–Camshaft"
in this section.
Caution : Do not scratch on the valve tappet. And must not use gloves or tools.
- Remove the valve tappet.
- Install the universal valve spring compressor(EN-49074) and adapter(EN-49075).
- Remove the valve key.
- Remove the valve spring, retainer, and seal.
Valve Inspection
- Inspect the valve for damage from the head to tip for the following conditions.
- pitting in the valve seat area (1)
- lack of valve margin (2)
- bending in the valve stem (3)
- pitting or excessive wear in the stem (4)
- worn valve key grooves (5)
- worn valve tip (6)
- Replace the valve if any of these conditions exist.
- Inspect the valve springs. If the valve spring ends are not parallel, replace the valve spring.
- Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as required.
Notice : Valve guide is not movable. Replace the cylinder head if it is out of specification.
- Measure the valve stem diameter and valve guide inside diameter. If it is out of specification, replace it. Refer to "Engine Specification"
in this section.
- Measure the valve spring free length. If it is out of specification, replace it. Refer to "Engine Specification"
in this section.
Installation Procedure
- Install the valve spring, retainer, and seal.
- Install the universal valve spring compressor(EN-49074) and adapter(EN-49075) to cylinder head.
- Install the valve key.
Caution : Do not scratch on the valve tappet. And must not use gloves or tools.
- Install the valve tappet.
- Install the camshaft. Refer to "Unit Repair-Camshaft"
in this section.
Piston / Ring / Connecting Rod
Tools Required
Removal Procedure
Caution : Take extreme care to prevent any scratches or damage to the inner side of the cylinder, piston, and connecting rod cap bearings.
- Remove the cylinder head. Refer to "Unit Repair- Cylinder Head"
in this section.
Important : Check and confirm the piston assembly sequence and the connecting rod bearing sequence, not to confuse.
- Remove the piston assembly with the connecting rod bearing.
- Separate the piston pin from the piston.
- Separate the piston ring from the piston.
Inspection
- Clean the inner of the cylinder with a clean cloth.
- Inspect the inner of the cylinder if it is damaged.
- Measure the inner diameter of the cylinder. If it is out of specification, replace it. Refer to "Engine Specification"
in this section.
- Clean the piston with a clean cloth.
- Measure the outer diameter of the piston at the 15mm up from the bottom. If it is out of specification, replace it. Refer to "Engine Specification"
in this section.
- Measure the inner diameter of the cylinder at the 50mm below from the surface of the cylinder head and the clearance of the piston at the 15mm up from the end of the piston skirt. If it is out of specification, replace it. Refer to "Engine Specification"
in this section.
- Measure the piston ring groove clearance. If the piston ring groove clearance is out of specification, replace the piston and rings. Refer to "Engine Specification"
in this section.
- Measure the piston ring gap. If the piston ring gap is out of specification, replace the piston ring. Refer to "Engine Specification"
in this section.
- Measure the piston pin. If it is out of specification, replace it. Refer to "Engine Specification"
in this section.
- Cut the plastic gauge(a) as the same length of the bearing width and put it on the crankshaft bearing. It should be parallel with crankshaft.
- Install the connecting rod bearing and caps. Tighten it.
Tighten
Connecting Rod Bearing Cap Nuts : 33 N•m (24.3 lb-ft)
- Remove the connecting rod bearing and caps again.
- Measure the clearance of the connecting rod bearing oil as the scale of the plastic gauge.
Installation Procedure
Caution : Take extreme care to prevent any scratches or damage to the inner side of the cylinder, piston, and connecting rod cap bearings.
- Install the piston ring from the piston.
- Assemble the connecting rod with the pin to the piston.
- Install the piston assembly to the cylinder using the piston installer(EN-49078).
- Install the piston assembly and connecting rod bearing caps with the bearing.
- Tighten the connecting rod bearing cap nuts.
Tighten
Connecting Rod Bearing Cap Nuts : 33 N•m (24.3 lb-ft).
- Install the cylinder head. Refer to "Unit Repair-Cylinder Head"
in this section.
Engine Block
Tools Required
EN-49071 Installr-Crankshaft Rear Seal
Romoval Procedure
Caution : Take extreme care to prevent any scratches, nicks or damage to inner side of the cylinder and bearings. If scratched, damage may happen to engine.
- Remove the piston assembly. Refer to "Unit Repair-Piston/Ring/Connecting Rod"
in this section.
- Remove the crankshaft rear oil seal cover with the gasket.
Caution : Check and confirm the crankshaft bearing sequence not to confuse. If mixed, damage may happen to engine.
- Remove the crankshaft journal bearing cap.
- Remove the crankshaft.
Inspection Procedure
- Measure the crankshaft out-of-round (bending). If it is out of specification, replace it. Refer to "Engine Specification"
in this section.
- Cut the plastic gauge(a) as the same length of the bearing width and put it on the crankshaft bearing. It should be parallel with crankshaft.
- Install the crankshaft journal bearing and cap.
- Remove the connecting rod bearing and cap again.
- Measure the clearance of the connecting rod bearing oil as the scale of the plastic gauge. If it is out of specification, replace it as a new one. Refer to "Engine Specification"
in this section.
- Inspect the crankshaft rear oil seal cover and oil seal. If damaged or leaked, replace it.
Installation Procedure
Caution : Check and confirm the crankshaft journal bearing cap sequence not to confuse. If mixed, damage may happen to engine.
- Assemble the crankshaft journal bearing cap.
- Tighten the crankshaft journal bearing cap bolt.
Tighten
Crankshaft Bearing Cap Bolts : 57.5 N•m (42.4 lb-ft).
- Install the crankshaft rear oil seal using crankshaft rear oil seal installer(EN-49071).
- Install the crankshaft rear oil seal cover.
- Install the crankshaft rear oil seal cover bolts.
Tighten
Crankshaft Rear Oil Seal Cover Bolts (M6 x 1.0): 10.5 N•m (7.7 lb-ft).
- Remove the piston assembly. Refer to "Unit Repair-Piston/Ring/Connecting Rod"
in this section.
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