11B-1

GROUP 11B

ENGINE OVERHAUL
CONTENTS

GENERAL SPECIFICATIONS . . . . . . 11B-2 OIL PAN AND TIMING CHAIN CASE 11B-21
REMOVAL AND INSTALLATION . . . . . . . . 11B-21
SERVICE SPECIFICATIONS. . . . . . . 11B-2
TIMING CHAIN . . . . . . . . . . . . . . . . . . 11B-26
REWORK DIMENSIONS . . . . . . . . . . 11B-3 REMOVAL AND INSTALLATION . . . . . . . . 11B-26
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-29
TORQUE SPECIFICATIONS . . . . . . . 11B-3
CAMSHAFT . . . . . . . . . . . . . . . . . . . . 11B-32
SEALANTS . . . . . . . . . . . . . . . . . . . . 11B-6 REMOVAL AND INSTALLATION . . . . . . . . 11B-32
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-35
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B-7
CYLINDER HEAD AND VALVES. . . . 11B-37
ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION . . . . . . . . 11B-37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-10 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-40
REMOVAL AND INSTALLATION . . . . . . . . 11B-10
OIL PUMP CHAIN <4B11> . . . . . . . . . 11B-43
THROTTLE BODY . . . . . . . . . . . . . . . 11B-13 REMOVAL AND INSTALLATION . . . . . . . . 11B-43
REMOVAL AND INSTALLATION . . . . . . . . 11B-13
BALANCER CHAIN <4B12> . . . . . . . 11B-47
INLET MANIFOLD AND FUEL SYSTEM REMOVAL AND INSTALLATION . . . . . . . . 11B-47
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-14
REMOVAL AND INSTALLATION . . . . . . . . 11B-14 PISTON AND CONNECTING ROD . . 11B-53
REMOVAL AND INSTALLATION . . . . . . . . 11B-53
EXHAUST MANIFOLD. . . . . . . . . . . . 11B-17 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-58
REMOVAL AND INSTALLATION . . . . . . . . 11B-17
CRANKSHAFT AND CYLINDER BLOCK
WATER HOSE AND PIPE . . . . . . . . . 11B-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-59
REMOVAL AND INSTALLATION . . . . . . . . 11B-19 REMOVAL AND INSTALLATION . . . . . . . . 11B-59
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-62
11B-2 ENGINE OVERHAUL
GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS
M1113000203154

Item Specification
Engine model 4B11 4B12
Type In-line DOHC
Number of cylinders 4
Combustion chamber Pentroof type
Total displacement mL 1,998 2,360
Cylinder bore mm 86 88
Piston stroke mm 86 97
Compression ratio 10 10.5
Auto lash adjuster Non-equipped

SERVICE SPECIFICATIONS
M1113000303645

Item Standard value Limit

Timing chain
Valve clearance mm Inlet 0.20 ± 0.03 −
Exhaust 0.30 ± 0.03 −
Camshaft
Cam height of camshaft mm Inlet 43.25 42.75
Exhaust 45.00 44.50
Camshaft bearing (metal) oil clearance mm 0 − 0.032 −
Cylinder head and valve
Distortion of cylinder head bottom mm Within 0.05 0.2
Grinding limit of cylinder head bottom mm − 0.2
Overall height of cylinder head mm 128.5 −
Overall length of valve mm Inlet 113.18 112.68
Exhaust 105.89 105.39
Valve margin mm Inlet 1.022 0.522
Exhaust 1.094 0.594
Free height of valve spring mm 49.4 48.4
Squareness of valve spring 2° or less 4°
Clearance between valve guide and Inlet 0.020 − 0.047 0.10
valve stem mm Exhaust 0.030 − 0.057 0.15
Valve seat contact width mm Inlet 1.16 − 1.46 −
Exhaust 1.35 − 1.65 −
Valve guide projection from cylinder head upper surface mm 14.6 − 15.2 −
Piston and connecting rod
 ENGINE OVERHAUL 11B-3
REWORK DIMENSIONS

Item Standard value Limit

Piston pin press-fit load N 7,500 − 17,500 −
Clearance between piston ring and No.1 0.03 − 0.07 0.1
ring groove mm No.2 0.03 − 0.07 0.1
Piston ring end gap mm No.1<4B11> 0.15 − 0.28 0.8
No.1<4B12> 0.15 − 0.25 0.8
Piston ring end gap mm No.2<4B11> 0.30 − 0.45 0.8
No.2<4B12> 0.25 − 0.40 0.8
Oil 0.10 − 0.35 1.0
Clearance of connecting rod big end thrust mm 0.10 − 0.25 0.4
Outside diameter of connecting rod bolt mm − 0.1
Connecting rod bearing oil clearance mm 0.018 − 0.045 0.1
Crankshaft and cylinder block
Underhead length of crankshaft bearing cap bolt mm 75.5 − 76.5 −
Crankshaft axial play mm 0.05 − 0.25 0.4
Crankshaft journal oil clearance mm 0.012 − 0.030 0.1
Distortion of cylinder block top surface mm 0.05 0.2
Grinding limit of cylinder block top surface mm − 0.2
Cylinder block cylinder bore mm 4B11 86 −
4B12 88 −
Cylindricity of cylinder block mm 0.15 −

REWORK DIMENSIONS
M1113024301784

Item Standard value

Cylinder head and valve
Cylinder head oversize valve seat bore diameter mm Intake 0.30 O.S. 36.22 − 36.24
Exhaust 0.30 O.S. 30.22 − 30.24
Cylinder head oversize valve guide bore diameter mm 0.25 O.S. 11.23 − 11.25

TORQUE SPECIFICATIONS
M1113023405371

Item N⋅m
Alternator and ignition system
Idler pulley bolt 44 ± 8
Auto tensioner 22 ± 4
Crankshaft pulley centre bolt 210
Alternator nut 44 ± 10
11B-4 ENGINE OVERHAUL
TORQUE SPECIFICATIONS

Item N⋅m
Alternator bolt 44 ± 10
Ignition coil bolt 10 ± 2
Spark plug 25 ± 5
Accessory bracket bolt 44 ± 8
Throttle body
Vacuum pipe assembly bolt 11 ± 1
Throttle body bolt 9.5 ± 2.5
Manifold absolute pressure (MAP) sensor screw 4.0 ± 1.0
Solenoid valve screw 4.0 ± 1.0
Water pipe bolt 10 ± 2
Inlet manifold and fuel system
Oil level gauge guide bolt 10 ± 2
Injector protector rear bolt 3.5 ± 1.5 → 20 ± 2
Delivery pipe bolt 3.5 ± 1.5 → 20 ± 2
Inlet manifold bolt and nut 3.5 ± 1.5 → 20 ± 2
Inlet manifold stay bolt 20 ± 2
Inlet manifold stay B bolt 20 ± 2
Inlet manifold stay C bolt 20 ± 2
Injector protector front bolt 3.5 ± 1.5 → 20 ± 2
Detonation sensor bolt 20 ± 2
Oil pressure switch 10 ± 2
Exhaust manifold
Exhaust manifold cover bolt 8.0 ± 2.0
Exhaust manifold nut 49 ± 5
Exhaust manifold bracket bolt (Exhaust manifold side) 56 ± 8
Exhaust manifold bracket bolt (Cylinder block side) 41 ± 10
Crank angle sensor bolt 11 ± 1
Crank angle sensor cover bolt 11 ± 1
Oxygen sensor 44 ± 5
Water hose and pipe
Water inlet fitting bolt 24 ± 3
Water outlet fitting bolt 24 ± 3
Thermostat housing bolt 24 ± 3
Engine hanger bolt 28 ± 8
Coolant temperature sensor 30 ± 9
Water pump bolt 24 ± 3
Water pipe nut 24 ± 3
Camshaft position sensor 11 ± 1
Oil pan and timing chain case
Cylinder head cover bolt 3.0 ± 1.0 → 5.5 ± 0.5
 ENGINE OVERHAUL 11B-5
TORQUE SPECIFICATIONS

Item N⋅m
Timing chain case bolt <M6> 10 ± 2
Timing chain case bolt <M8 × 10> 13 ± 1
Timing chain case bolt <M8 × 30> 24 ± 4
Oil pan bolt <M6> 10 ± 2
Oil pan bolt <M8> 31 ± 2
Air compressor bracket bolt 23 ± 6
Oil drain plug 39 ± 5
Oil filter 14 ± 2
PCV valve 2.5 ± 0.4
Engine support bracket assembly washer bolt 48 ± 6
Timing chain
Inlet V.V.T. sprocket bolt 59 ± 5
Exhaust camshaft sprocket bolt 59 ± 5
Timing chain tensioner bolt 10 ± 2
Tensioner lever bolt 10 ± 2
Timing chain guide bolt 10 ± 2
Camshaft
Oil feeder control valve (OCV) bolt 10 ± 2
Camshaft bearing cap bolt 12 ± 1
Front camshaft bearing cap bolt 17 ± 3 → 30 ± 2
Cylinder head and valves
Cylinder head bolt 35 ± 2 → +90°+90°
Oil pump chain
Drive plate bolt 40 → 130
Oil pump case bolt 26 ± 2
Oil pump sprocket bolt 23 ± 2
Oil pump tensioner lever bolt 10 ± 2
Oil pump chain guide bolt 10 ± 2
Ladder frame bolt 24 ± 2
Balancer chain
Drive plate bolt 40 → 130
Balancer shaft module bolt 20 → 44 → 0 → 20 → +135°
Balancer shaft chain tensioner bolt 10 ± 2
Lever tensioner bolt 10 ± 2
Balancer shaft chain guide bolt 10 ± 2
Ladder frame bolt 24 ± 2
Piston and connecting rod
Connecting rod cap bolt 5.0 → 20 → +90°
Crankshaft and cylinder block
Crankshaft sensing ring bolt 11 ± 1
11B-6 ENGINE OVERHAUL
SEALANTS

Item N⋅m
Bearing cap bolt 26.5 ± 2.0 → +45°

SEALANTS
M1113000503605

Item Specified sealant

Drive plate bolt ThreeBond 1324 or equivalent
Oil pan ThreeBond 1227D, ThreeBond 1217G (MITSUBISHI MOTORS
GENUINE Part No,1000A923), ThreeBond 1207F
(MITSUBISHI MOTORS GENUINE Part No,MD970389),
LOCTITE 5970, LOCTITE 5900 or equivalent
Cylinder head cover (matching area of the ThreeBond 1227D, ThreeBond 1217G (MITSUBISHI MOTORS
cylinder head and the timing chain case GENUINE Part No.1000A923), LOCTITE 5900 or equivalent
assembly)
Ladder frame ThreeBond 1227D, ThreeBond 1217G (MITSUBISHI MOTORS
GENUINE Part No.1000A923), LOCTITE 5970 or equivalent
Cylinder head gasket (matching area of ThreeBond 1217G (MITSUBISHI MOTORS GENUINE Part
the cylinder block and the cylinder head) No.1000A923), LOCTITE 5900 or equivalent
Timing chain case ThreeBond 1227D, ThreeBond 1217G (MITSUBISHI MOTORS
GENUINE Part No.1000A923), LOCTITE 5900 or equivalent
Coolant temperature sensor ThreeBond 1324N, LOCTITE 262 or equivalent
Oil pressure switch ThreeBond 1212D, ThreeBond 1215 or equivalent
NOTE: The number in brackets shows the genuine DISASSEMBLY
part number. Parts assembled with FIPG can be easily disassem-
LIQUID GASKET (FIPG) bled without using a special method. In some cases,
FIPG is used for some parts in the engine. It is nec- however, it is necessary to lightly tap parts with a
essary to pay attention to an application amount, wooden hammer or similar tool to break sealant
application procedure and applied surface condition between mating surfaces. Or lightly driving a smooth
for this gasket to fully achieve its purpose. and thin gasket scraper in mating surfaces is useful,
Too small amount causes leakage while too much but full care must be exercised not to damage mating
amount squeezes out to block or narrow water and surfaces. As special tool Oil pan FIPG cutter
oil passages. Therefore, it is absolutely essential to (MD998727) is set, use this tool.
apply a correct amount of liquid sealant continuously
without break to eliminate leakage from joints. CLEANING OF GASKET SURFACE
FIPG used for engine parts hardens reacting with Completely remove all deposits from the gasket sur-
moisture in the air, and is usually used for metal face with a gasket scraper or wire brush. Make sure
flanges. that the surface to which FIPG is applied is smooth.
The gasket surface must be free from grease and
CAUTION foreign substances. Be sure to remove old FIPG that
Reapply the FIPG with care to the followings. has entered mounting holes and screw holes.
1. Completely remove the old FIPG including the
residue in gaps of parts.
APPLICATION PROCEDURE
Apply FIPG in a determined diameter and continu-
2. Using MITSUBISHI MOTORS GENUINE parts
ously without break. Completely enclose the periph-
cleaner (MZ100387) or equivalent, degrease
ery of mounting holes. FIPG can be wiped off if it is
the FIPG application surface carefully.
not hardened. Install parts in place while FIPG is still
3. According to the FIPG application proce-
wet. Take care not to allow FIPG to adhere to other
dures, apply it accurately.
locations than necessary locations during installa-
 ENGINE OVERHAUL 11B-7
SPECIAL TOOLS

tion. Do not pour oil or water on applied locations or

do not start the engine until sufficient time (approxi-
mately one hour) passes. The application procedure
of FIPG may differ depending on areas. Follow the
procedure in the body of the manual to apply FIPG.

SPECIAL TOOLS
M1113000603516

Tool Part No. Tool name Application

MB991883 Flywheel stopper Securing of drive plate

MB991883

MB991398 Spark plug wrench Removal and installation of spark

plug

MB992106 O-ring installer Installation of O-ring on injector

injection nozzle side

B992106

MB991396 Oil filter wrench Removal and installation of oil

filter

B991396

MD998727 Oil pan FIPG cutter Removal of oil pan

D998727

MB991448 Bushing remover and Press fit of front oil seal

installer base
11B-8 ENGINE OVERHAUL
SPECIAL TOOLS

Tool Part No. Tool name Application

MD998735 Valve spring Compression of valve spring
compressor

MB992089 Retainer holder C

MB992085 Valve stem seal pliers Extraction of valve stem seal

MD998737 Valve stem seal Installation of valve stem seal

installer

MD998780 Piston pin setting tool Extraction and press fit of piston
pin

MB991659 Guide D

MB991614 Angle gauge Installation of crankshaft bearing

cap bolt

MB991614

MD998718 Rear oil seal installer Press fit of rear oil seal
 ENGINE OVERHAUL 11B-9
SPECIAL TOOLS

Tool Part No. Tool name Application

MB991346 Top cover wrench Removal and installation of oil
pump sprocket(4B11)

B991346
11B-10 ENGINE OVERHAUL
ALTERNATOR AND IGNITION SYSTEM

ALTERNATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION
M1113001002718

10 ± 2 N·m
9

10
25 ± 5 N·m

8
4

5 2
1
7 22 ± 4 N·m
6
210 N·m
44 ± 8 N·m
44 ± 8 N·m

44 ± 10 N·m
44 ± 8 N·m
44 ± 10 N·m

3
AKB00725AB

Removal sequence Removal sequence (Continued)

1. Idler pulley <<A>> >>B<< 6. Crankshaft pulley centre bolt
2. Idler pulley >>B<< 7. Crankshaft pulley washer
>>C<< 3. Alternator >>B<< 8. Crankshaft pulley
>>C<< 4. Accessory bracket 9. Ignition coil
5. Auto tensioner <<B>> >>A<< 10. Spark plug
 ENGINE OVERHAUL 11B-11
ALTERNATOR AND IGNITION SYSTEM

REMOVAL SERVICE POINTS >>B<< CRANKSHAFT PULLEY /

<<A>> CRANKSHAFT PULLEY CENTRE CRANKSHAFT PULLEY WASHER /
BOLT REMOVAL CRANKSHAFT PULLEY CENTRE BOLT
INSTALLATION

MB991883
MB991883

AK502869 AC

AK503335 AC
1. Use special tool Flywheel stopper (MB991883) to
secure the drive plate. 1. Use special tool Flywheel stopper (MB991883) to
2. Remove the crankshaft pulley centre bolt. secure the drive plate.
: Wipe clean with a rag.
<<B>> SPARK PLUG REMOVAL : Wipe clean with a rag and degrease.
: Wipe clean with a rag, degrease and
apply a small amount of engine oil.

MB991398

Spark plug
Washer Crankshaft
sprocket

AK600875AB

Using special tool Spark plug wrench (MB991398),

remove the spark plug.
Crankshaft Crankshaft
INSTALLATION SERVICE POINTS pulley bolt
Crankshaft pulley
>>A<< SPARK PLUG INSTALLATION

Engine front
AK602911AJ

MB991398
2. Wipe off the dirt on the crankshaft pulley washer
and on the thread hole of the crankshaft using a
Spark plug rag.
3. Wipe off the dirt on the crankshaft pulley and the
crankshaft sprocket using a rag, and then remove
the grease from the portion shown in the
AK600875AB illustration.
Use special tool Spark plug wrench (MB991398), NOTE: Remove grease to prevent the coefficient
tighten the spark plug to specified torque of 25 ± 5 of friction of the pressing portion from declining
N⋅m. due to adhesion of oil.
4. Install the crankshaft pulley.
11B-12 ENGINE OVERHAUL
ALTERNATOR AND IGNITION SYSTEM

5. Apply an appropriate and minimum amount of >>C<< ALTERNATOR INSTALLATION

engine oil to the threaded portion of the crankshaft
and lower part of the flange.
6. With the chamfered side on the inside of the 1
washer facing the bolt top, install the crankshaft
pulley washer to the crankshaft pulley centre bolt.
7. Tighten the crankshaft pulley centre bolt to the
specified torque of 210 N⋅m.

2
AKC00006 AB

1. Temporarily tighten alternator bolt and nut.

2. First tighten the upper mounting bolt to the
specified torque, and then tighten the lower nut.
Specified torque: 44 ± 10 N⋅m
 ENGINE OVERHAUL 11B-13
THROTTLE BODY

THROTTLE BODY
REMOVAL AND INSTALLATION
M1113009800347

11 ± 1 N·m

9.5 ± 2.5 N·m

5
6

8
7

4.0 ± 1.0 N·m

4.0 ± 1.0 N·m

10 9 AKC00007AB

Removal steps INSTALLATION SERVICE POINTS

1. Vacuum pipe and hose
>>A<< MANIFOLD ABSOLUTE PRES-
2. Purge hose
3. Chamber SURE (MAP) SENSOR INSTALLATION
4. Throttle body stay CAUTION
5. Throttle body • Install the manifold absolute pressure (MAP)
6. Throttle body gasket
sensor, taking care not to give a shock to it.
7. Solenoid valve
8. O-ring • Do not use a manifold absolute pressure
>>A<< 9. Manifold absolute pressure (MAP) (MAP) sensor that has fallen down.
sensor
10. O-ring
11B-14 ENGINE OVERHAUL
INLET MANIFOLD AND FUEL SYSTEM

INLET MANIFOLD AND FUEL SYSTEM

REMOVAL AND INSTALLATION
M1113032501169

3.5 ± 1.5
20 ± 2 N·m

6 11
8 3
9
10
7 3.5 ± 1.5
20 ± 2 N·m
5
4 3.5 ± 1.5
20 ± 2 N·m
18

3.5 ± 1.5
20 ± 2 N·m

20 ± 2 N·m
21 14

16 17 13
3.5 ± 1.5
20 ± 2 N·m
10 ± 2 N·m
22
1 20 ± 2 N·m 15
2
20 ± 2 N·m
19
12 20 ± 2 N·m
10 ± 2 N·m

20

AKB00727 AB

Removal sequence Removal sequence (Continued)

1. Oil level gauge rod >>D<< 12. Inlet manifold stay
2. O-ring 13. Inlet manifold stay B
>>G<< 3. Injector protector rear 14. Inlet manifold stay C
>>G<< 4. Bracket 15. EGR gasket
>>G<< 5. Bracket 16. Injector protector front
>>G<< 6. Delivery pipe assembly >>C<< 17. Inlet manifold
>>F<< 7. Injection support 18. Inlet manifold gasket
8. O-ring 19. Oil level gauge guide
>>F<< 9. Injector 20. O-ring
>>E<< 10. O-ring >>B<< 21. Detonation sensor
11. Delivery pipe >>A<< 22. Oil pressure switch
 ENGINE OVERHAUL 11B-15
INLET MANIFOLD AND FUEL SYSTEM

INSTALLATION SERVICE POINTS >>C<< INLET MANIFOLD INSTALLATION

>>A<< OIL PRESSURE SWITCH INSTAL- CAUTION
LATION Temporarily tighten the inlet manifold because
there is a bolt tightening procedure for the inlet
manifold, delivery pipe and injector protector.
1 mm 5 mm Install the inlet manifold and temporarily tighten bolts.

>>D<< INLET MANIFOLD STAY

INSTALLATION

AK600888AB

CAUTION
• Do not allow sealant to squeeze out to the
screw tip.
• Do not tighten, exceeding the specified
torque. AK502727AC
1. Completely remove sealant adhering to the oil
pressure switch and cylinder block threaded Make sure that the inlet manifold stay is in intimate
holes. contact with the inlet manifold and cylinder block
boss before tightening it to the specified torque of 20
2. Apply sealant of 5 mm to the threaded portion of
± 2 N⋅m.
the oil pressure switch shown in the illustration.
Specified sealant:
ThreeBond 1212D, ThreeBond 1215 or equiva-
>>E<< O-RING INSTALLATION
lent CAUTION
3. Tighten the oil pressure switch to the cylinder Do not allow engine oil to enter the delivery pipe.
block to the specified torque of 10 ± 2 N⋅m.
O-ring
>>B<< DETONATION SENSOR
INSTALLATION
MB992106
Detonation sensor

AK600790 AB

When inserting an O-ring into the injector on the

45˚
injection nozzle side, use special tool O-ring installer
(MB992106) to gradually expand the O-ring, and fit it
in place.
AC807670 AD

Align the detonation sensor connector with the posi- >>F<< INJECTOR AND INJECTOR
tion shown in the illustration, and then tighten it to the SUPPORT INSTALLATION
specified torque of 20 ± 2 N⋅m.
1. Apply spindle oil or gasoline to the O-ring of the
injector.
2. Insert the injector into the delivery pipe while
rotating the injector from side to side, taking care
not to damage the O-ring.
11B-16 ENGINE OVERHAUL
INLET MANIFOLD AND FUEL SYSTEM

3. Check that the injector rotates smoothly. If it does 5. Securely assemble the injector to the injector
not rotate smoothly, the O-ring may be caught. groove and delivery pipe collar.
Remove the injector and check the O-ring for
damage. Then, insert it again into the delivery >>G<< DELIVERY PIPE ASSEMBLY /
pipe and check.
BRACKET / INJECTOR PROTECTOR
REAR INSTALLATION

8 6 7
4 5
11
2 3
AK502744 9 10
1
4. Make sure that the protrusion of the injector is at AK700818AC
the centre as shown in the illustration.
1. Install the delivery pipe assembly, bracket and
injector protector on the cylinder head.
2. Tighten mounting bolts together with temporarily
tightened inlet manifold mounting bolts in the
order shown in the illustration.
3. Tighten the delivery pipe assembly, bracket,
injector protector rear and inlet manifold in the
order shown in the illustration.
Temporarily torque: 3.5 ± 1.5 N⋅m
AK800066 Specified torque: 20 ± 2 N⋅m
 ENGINE OVERHAUL 11B-17
EXHAUST MANIFOLD

EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
M1113011901247

5
44 ± 5 N·m

8.0 ± 2.0 N·m 8.0 ± 2.0 N·m

11 ± 1 N·m
2
11 ± 1 N·m
49 ± 5 N·m
3
41 ± 10 N·m 4

56 ± 8 N·m
41 ± 10 N·m

1
8

AKB00728AB

Removal steps Removal steps (Continued)

>>D<< 1. Exhaust manifold bracket <<A>> >>B<< 5. Oxygen sensor
2. Crank angle sensor cover 6. Exhaust manifold cover
>>C<< 3. Crank angle sensor >>A<< 7. Exhaust manifold
>>C<< 4. O-ring 8. Exhaust manifold gasket
11B-18 ENGINE OVERHAUL
EXHAUST MANIFOLD

REMOVAL SERVICE POINTS Tighten the oxygen sensor to the specified torque by
using special tool oxygen sensor wrench
<<A>> OXYGEN SENSOR REMOVAL
(MB991953).
Tightening torque: 44 ± 5 N⋅m
Oxygen sensor

>>C<< CRANK ANGLE SENSOR / O-RING

INSTALLATION
MB991953
CAUTION
• Do not apply a force such as torsion or twist
to the O-ring during assembly of the sensor.
• Assemble the sensor, taking care not to give a
AC301966AB
shock to it.
Remove the connection and clamp of oxygen sensor • Do not use a sensor that has fallen down.
connector, and then use special tool oxygen sensor Tighten the crank angle sensor to the specified
wrench (MB991953) to remove the oxygen sensor. torque of 11 ± 1 N⋅m.

INSTALLATION SERVICE POINTS >>D<< EXHAUST MANIFOLD BRACKET

>>A<< EXHAUST MANIFOLD INSTALLA- INSTALLATION
TION
CAUTION
The exhaust manifold gasket, washers and nuts
must not be reused.
1. After temporarily tightening the exhaust manifold
2 1 bracket with the installation bolts, check the
exhaust manifold fastens securely to the cylinder
block.
4 5 3 2. Tighten the cylinder block side bolt to the
specified tightening torque.
Tightening torque: 41 ± 10 N⋅m
AKB00880 AB

1. Tighten the exhaust manifold nut to the specified Crank angle sensor cover
torque of 49 ± 5 N⋅m in the order shown in the
illustration.

>>B<< OXYGEN SENSOR INSTALLATION

CAUTION
• Do not use a sensor that has fallen down.
Exhaust manifold bracket
AKC00009 AB

Oxygen sensor
3. Tighten the exhaust manifold side bolt to the
specified tightening torque.
Tightening torque: 56 ± 8 N⋅m
MB991953

AC301966AB
 ENGINE OVERHAUL 11B-19
WATER HOSE AND PIPE

WATER HOSE AND PIPE

REMOVAL AND INSTALLATION
M1113032900722

9 24 ± 3 N·m

30 ± 9 N·m
10 11 3
4 24 ± 3 N·m
2

24 ± 3 N·m 1
28 ± 8 N·m 14
5
6
24 ± 3 N·m

24 ± 3 N·m
8 7

15
16
11 ± 1 N·m

12
13

AKC00005 AB

Removal steps Removal steps (Continued)

1. Water hose 15. Camshaft position sensor
>>C<< 2. Coolant temperature sensor 16. O-ring
3. Water outlet fitting
4. Outlet fitting gasket INSTALLATION SERVICE POINTS
5. Water inlet fitting
>>A<< THERMOSTAT HOUSING / WATER
>>B<< 6. Thermostat
>>A<< 7. Thermostat housing PIPE ASSEMBLY INSTALLATION
8. Thermostat housing gasket Assemble the thermostat housing and water pipe,
>>A<< 9. Water pipe assembly and temporarily tighten them to the cylinder head
10. Water pipe gasket and water pump. Then tighten them to the specified
11. O-ring torque of 24 ± 3 N⋅m.
12. Water pump assembly
13. Water pump gasket
14. Engine hanger
11B-20 ENGINE OVERHAUL
WATER HOSE AND PIPE

>>B<< THERMOSTAT INSTALLATION >>C<< COOLANT TEMPERATURE

SENSOR INSTALLATION
CAUTION
Be careful not to give a shock, twist and the like
to the resin mould with a tool during installation.

Jiggle Valve

AK304916 AB

Install the thermostat with the jiggle-valve facing

almost straight upwards.

AK502544 AC

1. Apply an appropriate and minimum amount of

sealant to the coolant temperature sensor, taking
care not to allow sealant to squeeze out.
Specified sealant:
ThreeBond 1324N, Loctite 262 or equivalent
2. Tighten the coolant temperature sensor to the
cylinder block to the specified torque of 30 ± 9
N⋅m.
 ENGINE OVERHAUL 11B-21
OIL PAN AND TIMING CHAIN CASE

OIL PAN AND TIMING CHAIN CASE

REMOVAL AND INSTALLATION
M1113026301520

6
3.0 ± 1.0 N·m 5.5 ± 0.5 N·m

1
11
10

2.5 ± 0.4 N·m

4
3

2
10 ± 2 N·m

13 ± 1 N·m

10 ± 2 N·m
48 ± 6 N·m
16 14 ± 2 N·m
9

14 15
13
24 ± 4 N·m
7 8
10 ± 2 N·m
39 ± 5 N·m
31 ± 2 N·m
12
23 ± 6 N·m
AKB00212 AC

Removal steps Removal steps (Continued)

1. Breather hose <<A>> >>E<< 9. Oil filter
2. PCV hose >>D<< 10. Cylinder head cover
3. PCV valve 11. Cylinder head cover gasket
4. O-ring 12. Air compressor bracket
5. Oil filler cap <<B>> >>C<< 13. Oil pan
6. O-ring 14. Engine support bracket
7. Oil drain plug >>B<< 15. Front oil seal
8. Oil drain plug gasket <<C>> >>A<< 16. Timing chain case
11B-22 ENGINE OVERHAUL
OIL PAN AND TIMING CHAIN CASE

REMOVAL SERVICE POINTS 3. Lightly tap and slide special tool Oil pan FIPG
<<A>> OIL FILTER REMOVAL cutter (MD998727) to remove the oil pan.

<<C>> TIMING CHAIN CASE REMOVAL

MB991396
Hammer

AK502733AC

Use special tool Oil filter wrench (MB991396) to

remove the oil filter. AK901126AC

If the timing chain case is difficult to remove, insert a

<<B>> OIL PAN REMOVAL hammer handle as shown in the illustration and
1. Remove oil pan tightening bolts. lightly pry it.

CAUTION
INSTALLATION SERVICE POINTS
Lightly tap the oil pan FIPG cutter to drive in, tak-
ing care not to damage the ladder frame and oil >>A<< TIMING CHAIN CASE INSTALLA-
pan sealed area. TION
CAUTION
Groove
• Completely remove all the old liquid gasket,
which might be remaining in the installation
hole, the O-ring groove or among the compo-
nents such as the cylinder head gasket.
• Sufficiently check that there is no residual oil
on the place where degreasing is performed.
If fingerprints are left, do not touch it with
bare hands after the degreasing, since the
Groove AK502874AC oils from your fingers will harm the seal abil-
ity.
2. Lightly tap special tool Oil pan FIPG cutter
(MD998727) to drive in the illustrated groove of 1. Completely remove liquid gasket adhering to the
the oil pan and ladder frame. timing chain case, cylinder block and cylinder
head.
2. Degrease the surface where the liquid gasket is
MD998727 applied and the contact surface between the
cylinder block and the cylinder head.

AK502732AC
 ENGINE OVERHAUL 11B-23
OIL PAN AND TIMING CHAIN CASE

7.5 ± 0.5 mm Ø2.5 ± 0.5 mm

Ø2.5 ± 0.5 mm 1 ± 0.5 mm

A A C-C view

C
G C

A-A view D
B B A A

3 ± 0.5 mm
Ø2.5 ± 0.5 mm 4.5 ± 0.5 mm 3 ± 0.5 mm

2.5 mm

B-B view
Ø4.5 ± 0.5 mm Ø2.5 ± 0.5 mm

AK703733AE

CAUTION
Install the timing chain case within three minutes
after applying the liquid gasket.
3. Apply liquid gasket of 2.5 ± 0.5 mm in thickness to
the timing chain case. For the place "D" shown in
the illustration, however, apply the liquid gasket
whose diameter is 4.5 ± 0.5 mm or pile up the
liquid gasket of 2.5 ± 0.5 mm as shown in the
illustration.
Specified sealant:
ThreeBond 1217G or equivalent

AK703734AC

4. The engine oil staying at the cylinder gasket

oozes to the 3-plane contact surface described in
Step 2 and 3. Swiftly apply the liquid gasket to this
area after degreasing.
Specified sealant:
ThreeBond 1217G or equivalent
11B-24 ENGINE OVERHAUL
OIL PAN AND TIMING CHAIN CASE

CAUTION
A A The front oil seal must not be a strong press fit.
The strong press fit can possibly cause the oil
leakage, damaging the front oil seal.
A A 2. Use special tool Bush remover and installer base
(MB991448) in order to press-fit the front oil seal
into the timing chain case as shown in the
illustration.
B
B
>>C<< OIL PAN INSTALLATION
B 1. Completely remove liquid gasket adhering to the
C B
cylinder block and oil pan.
D
B B CAUTION
Install the oil pan within three minutes after liquid
gasket is applied.
A
A
1 mm
A: M8 × 30 C: M6 × 25
B: M6 × 25 D: M8 × 10

AK502378 AI

5. Tighten timing chain case mounting bolts to the

specified torque.
Ø 2.5 ± 0.5 mm
Tightening torque
A: 24 ± 4 N⋅m AK502377AC
B: 10 ± 2 N⋅m
2. Apply liquid gasket of φ2.5 ± 0.5 mm of thickness
C: 10 ± 2 N⋅m
in diameter to the illustrated area of the oil pan.
D: 13 ± 1 N⋅m
Specified sealant:
ThreeBond 1217G or equivalent
>>B<< FRONT OIL SEAL INSTALLATION
3. Tighten the oil pan to the specified torque of 10 ±
1. Apply a small amount of engine oil to the entire 2 N⋅m (M6) and 29 ± 2 N⋅m (M8).
inner diameter of the front oil seal lip.

MB991448 Chain case >>D<< CYLINDER HEAD COVER

INSTALLATION
Oil seal
1. Completely remove liquid gasket adhering to the
cylinder head cover, timing chain case and
cylinder head.
1.5 – 2.5 mm 2. Degrease the surface where the liquid gasket is
applied and the contact.

MB991448

AK800005 AB
 ENGINE OVERHAUL 11B-25
OIL PAN AND TIMING CHAIN CASE

4. Tighten the cylinder head cover to the tightening

4 mm torque of 3.0 ± 1.0 N⋅m in the order shown in the
illustration.
5. Then, tighten it to the specified torque of 5.5 ± 0.5
2 mm 2 mm N⋅m in the same order.
Cylinder head

>>E<< OIL FILTER INSTALLATION

1. Clean the oil filter mounting surface of the ladder
4 mm frame.

Timing chain case AK901127 AC

CAUTION
Install the cylinder head cover immediately after
liquid gasket is applied. AK305422AB
3. Appropriately use a minimum amount of sealant.
Besides, be careful not to allow sealant to 2. Apply engine oil to the O-ring of the oil filter.
squeeze out from the application area.
Apply liquid gasket of 4 mm of thickness in
diameter.
MB991396
Specified sealant:
ThreeBond 1217G or equivalent

11
1 5 6 12

AK502733AC

4 2 7 CAUTION
16 13
10
Use special tool Filter wrench (MB991396) to
install the oil filter. Tightening it by hand causes
14 oil leakage due to lack of torque.
15 9 3 8
AKB00057AB
3. Screw in the oil filter. When the O-ring contacts
the mounting surface, use a filter wrench to
tighten it 1 turns (14 ± 2 N⋅m).
11B-26 ENGINE OVERHAUL
TIMING CHAIN

TIMING CHAIN
REMOVAL AND INSTALLATION
M1113026601253

Apply engine oil to

all moving parts
before installation.

59 ± 5 N·m
8
5

7
10 ± 2 N·m
59 ± 5 N·m

2 4

10 ± 2 N·m
10 ± 2 N·m
AKB00096 AC

Removal steps REMOVAL SERVICE POINTS

<<A>> >>D<< 1. Timing chain tensioner
<<A>> TIMING CHAIN TENSIONER
2. Tensioner lever
3. Timing chain guide REMOVAL
>>C<< 4. Timing chain
<<B>> >>B<< 5. Exhaust camshaft sprocket bolt
6. Exhaust camshaft sprocket
Wire
assembly
<<C>> >>A<< 7. Inlet V.V.T. sprocket bolt
8. Inlet V.V.T. sprocket assembly
Ratchet release hole

Plunger fixed hole

AK502854 AE

1. Insert a flatblade screwdriver into the release hole

of the timing chain tensioner to release the latch.
 ENGINE OVERHAUL 11B-27
TIMING CHAIN

2. Push the tensioner lever by hand and push in the INSTALLATION SERVICE POINTS
plunger of the timing chain tensioner until it hits >>A<< INLET V.V.T. SPROCKET BOLT
the bottom. Then, insert a hard wire (piano wire or
the like) of φ1.5 or hexagonal bar wrench (1.5 INSTALLATION
mm) into the fixing hole of the plunger.
V.V.T. sprocket
3. Remove the timing chain tensioner.

<<B>> EXHAUST CAMSHAFT SPROCKET

BOLT REMOVAL

V.V.T. sprocket bolt Camshaft

AK503070AC

1. Assemble the inlet V.V.T. sprocket assembly in the

following procedure.
• Make sure that the knock pin of the inlet camshaft
assembly is positioned facing straight upward.
AK502737 • Apply an appropriate and minimum amount of
engine oil to the circumference of the tip of the
Hold the hexagonal portion of the exhaust camshaft
inlet V.V.T. sprocket assembly and the entire cir-
with a wrench and loosen the exhaust camshaft
cumference of the area into which the inlet V.V.T.
sprocket bolt.
sprocket assembly is inserted.
• Slowly insert the inlet V.V.T. sprocket assembly
<<C>> INLET V.V.T. SPROCKET BOLT into the normal position of the inlet camshaft
REMOVAL assembly with its knock pin hole facing straight
upward.
2. Install the V.V.T. sprocket.
3. Make sure that the V.V.T. sprocket is securely
inserted into the bottom and that the V.V.T.
sprocket does not rotate with the hexagonal
portion of the camshaft secured with a wrench.

AK502736

Hold the hexagonal portion of the inlet camshaft with

a wrench and loosen the inlet V.V.T. sprocket bolt.

AK502739

4. Hold the hexagonal portion of the camshaft with a

wrench and tighten the inlet V.V.T. sprocket bolt to
the specified torque of 59 ± 5 N⋅m.

>>B<< EXHAUST CAMSHAFT SPROCKET

BOLT INSTALLATION
1. Assemble the exhaust camshaft sprocket
assembly in the following procedure.
11B-28 ENGINE OVERHAUL
TIMING CHAIN

• Make sure that the knock pin of the exhaust cam- 1. Align the timing mark of the inlet V.V.T. sprocket
shaft assembly is positioned facing straight and the exhaust camshaft sprocket.
upward. 2. Align the crankshaft sprocket keys with illustrated
• Slowly insert the exhaust camshaft sprocket into positions.
the normal position of the exhaust camshaft
assembly with its knock pin hole facing straight Link plate (orange)
Timing mark
upward.
2. Install the exhaust camshaft sprocket.
3. Make sure that the exhaust camshaft sprocket is
securely inserted into the bottom and that the
exhaust camshaft sprocket does not rotate with
the hexagonal portion of the camshaft secured
with a wrench.
AK502910 AE

3. Align the link plate (orange) with the timing mark

of the exhaust camshaft sprocket and loop the
timing chain.

Timing mark Link plate (blue)

AK502738

4. Hold the hexagonal portion of the camshaft with a

wrench and tighten the camshaft sprocket bolt to
the specified torque of 59 ± 5 N⋅m.
AK502757AK
>>C<< TIMING CHAIN INSTALLATION
4. Align the link plate (blue) with the timing mark of
Timing mark the inlet V.V.T. sprocket to loop the timing chain.
Rotate the inlet V.V.T. sprocket by one or two
teeth to align with the timing mark.

Link plate
(blue)
Timing mark AK502735AE

5. Align the timing mark of the crankshaft sprocket

with the link plate (blue) to loop the timing chain.
Because the timing chain slacks, hold it to prevent
Crankshaft key
the timing mark from coming off the link plate.

AK502924 AC
 ENGINE OVERHAUL 11B-29
TIMING CHAIN

Timing mark Timing mark

INSPECTION
M1113026701216
link plate (orange) link plate (blue)
INLET V.V.T. SPROCKET
CAUTION
Never overhaul the V.V.T. sprocket.
Retard
port Tape
Advance
port
Exhaust Inlet V.V.T.
camshaft sprocket
sprocket timing mark
timing mark

Advance Retard Make a hole

port port
AK800281AC

1. Seal with a tape all the inlet camshaft ports for the
advanced angle and the retarded angle.
Crankshaft 2. Make a hole on the port for the advanced angle.
Timing mark
sprocket link plate (blue)
timing mark
AK901201AD

6. Make sure that the timing mark of each sprocket

is aligned with the link plate of the timing chain at
all of three locations.
7. Install the timing chain guide and tensioner lever. The hexagonal
part

>>D<< TIMING CHAIN TENSIONER

INSTALLATION AK800282AC

CAUTION
Fix the camshaft on a vise not to damage it.
Wire 3. Fixing the hexagonal area of the inlet camshaft on
a vise, install the inlet V.V.T. sprocket.

Ratchet release hole x Stopper pin

A

Plunger fixed hole

AK502854 AE

1. Install the timing chain tensioner on the cylinder

block and tighten it to the specified torque of 10 ±
2 N⋅m. x
x-x
Housing
2. Remove the hard wire (piano wire or the like) of AK800283 AC

φ1.5 or hexagonal bar wrench (1.5 mm) from the CAUTION

timing chain tensioner. This enables the plunger When applying air pressure, keep in mind that oil
of the timing chain tensioner to push the tensioner could splash.
lever to keep the timing chain tight.
4. By applying air pressure slowly to the holed port
for the advanced angle, remove the stopper pin.
11B-30 ENGINE OVERHAUL
TIMING CHAIN

5. Turn the inlet V.V.T. sprocket housing in the right

and left directions. Check it smoothly moves in the
range of A (approximately
12.5°<4B11>,approximately 20°<4B12>)
NOTE: The stopper pin is locked in the most
retarded angle position.
6. .After the check, remove the inlet V.V.T. sprocket
from the inlet camshaft
7. Completely remove the tape sealing the inlet
AK502758
camshaft ports for the advanced angle and for the
retarded angle. 3. Use a thickness gauge to measure clearance
between the camshaft and valve tappet.
VALVE CLEARANCE ADJUSTMENT
Standard value (cold engine)
Measure valve clearance in the following procedure. Inlet side: 0.20 ± 0.03 mm
Check and adjust the valve clearance with the timing Exhaust side: 0.30 ± 0.03 mm
chain installed.
4. If measured values are out of the standard value,
CAUTION record measured values.
Always rotate the crankshaft clockwise.
Timing mark Timing mark

AK502545 AF
AK901129AC

1. Rotate the crankshaft clockwise to align the timing 5. Rotate the crankshaft by one turn clockwise to set
mark of the inlet V.V.T. sprocket and the exhaust the No. 4 piston at top dead centre on the
camshaft sprocket with the top surface of the compression stroke.
cylinder head as illustrated. (Set the No. 1 piston NOTE: The timing mark of the exhaust camshaft
at top dead centre on the compression stroke.) sprocket must be at the illustrated position.

Exhaust valve side Exhaust valve side

No.1 No.3 No.2 No.4
7

5
1
3
7

5
1
3

9
9

1 1
1 1

6
4
2

8
6
4
8

6
2
4
8

6
2
4

1 2
1 2

1 0
1 0

5
1
3

5
1

No.1 No.2 No.3 No.4

Inlet valve side AK502387AM Inlet valve side AK502388AJ

2. Valve clearance can be measured at the 6. Valve clearance can be measured at the
illustrated location in this condition. illustrated location in this condition.
7. If measured values are out of the standard value,
record measured values.
8. If the measured value is out of the standard value,
replace the valve tappet.
 ENGINE OVERHAUL 11B-31
TIMING CHAIN

NOTE: There are 47 kinds of valve tappets at 9. Select a valve tappet in the following procedure.
intervals of 0.015 mm in the range between 3.000 (1) Measure thickness of a removed valve tappet.
and 3.690 mm. (2) Calculate thickness of a valve tappet so that
Wall
valve clearance meets the standard value.
thickness A: Thickness of valve tappet to be selected
B: Thickness of removed valve tappet
C: Measured valve clearance
Formula
Inlet side: A = B + (C − 0.20 mm)
Exhaust side: A = B + (C − 0.30 mm)
Refer to "Removal and installation of camshaft" for
removal, installation and inspection procedure of
AK304938 AB
valve tappets.
11B-32 ENGINE OVERHAUL
CAMSHAFT

CAMSHAFT
REMOVAL AND INSTALLATION
M1113026900950

5
17 ± 3 N·m 6 5
30 ± 2 N·m 12 ± 1 N·m
5
6
4
5
3 4 9

7 8

Apply engine oil to

all moving parts 11
before installation.

10

2
1

10 ± 2 N·m

AKB00211 AB

Removal steps Removal steps (Continued)

>>C<< 1. Oil feeder control valve (OCV) inlet >>B<< 7. Bearing
>>C<< 2. O-ring >>B<< 8. Inlet camshaft
<<A>> >>B<< 3. Front camshaft bearing cap >>B<< 9. Exhaust camshaft
<<A>> >>B<< 4. Oil feeding camshaft bearing cap 10. Bearing
<<A>> >>B<< 5. Camshaft bearing cap <<B>> >>A<< 11. Valve tappet
<<A>> >>B<< 6. Thrust camshaft bearing cap
 ENGINE OVERHAUL 11B-33
CAMSHAFT

REMOVAL SERVICE POINTS >>B<< CAMSHAFT / BEARING / THRUST

<<A>> FRONT CAMSHAFT BEARING CAMSHAFT BEARING CAP / CAMSHAFT
CAP / OIL FEEDING CAMSHAFT BEAR- BEARING CAP / OIL FEEDING
ING CAP / CAMSHAFT BEARING CAP / CAMSHAFT BEARING CAP / FRONT
THRUST CAMSHAFT BEARING CAP CAMSHAFT BEARING CAP
REMOVAL INSTALLATION

2
6 10 12 8
4 5 9 11 7
Identification
3 mark
5 9 11 7
1 12 8
6 10
AK502389AC AK502969AC

CAUTION 1. When replacing a camshaft bearing, select a

Loosing the installation bolts for the camshaft bearing with the size corresponding to the
bearing cap at the same time causes the valve identification mark in the table below.
spring force, which makes the installation bolts Front camshaft bearing cap Camshaft bearing
jump out, resulting in the damaged threads. identification
Identificati Inner diameter
Always loose them in several stages. mark
on mark mm
First remove a mounting bolt of the front camshaft
bearing cap and then a mounting bolt of each cam- 1 40.000 − 40.008 1
shaft bearing cap in the order shown in the illustra- 2 40.008 − 40.016 2
tion.
3 40.016 − 40.024 3
2. Install camshaft bearings on the cylinder head.
<<B>> VALVE TAPPET REMOVAL
Pick out valve tappets with fingers and store Notch
removed valve tappets with tags describing the
installed position attached for reassembly.

INSTALLATION SERVICE POINTS

>>A<< VALVE TAPPET INSTALLATION
Install valve tappets at the same position based on
tags describing the installed position for reassembly. Identification mark
Oil hole AK702204AC

3. The identification mark of the camshaft bearing is

painted at the illustrated position.
11B-34 ENGINE OVERHAUL
CAMSHAFT

Timing chain side

Dowel pin
(1) (2)

4 1

3 3

2 4

1 2
AK502390 AC AK503814AC

4. Set the dowel pins of the camshaft at the 7. Tighten each front camshaft bearing cap
illustrated positions. mounting bolt to the temporarily torque of 17 ± 3
N⋅m in the order of number shown (1).
8. Tighten each front camshaft bearing cap
mounting bolt to the specified torque of 30 ± 2
N⋅m in the order of number shown (2).
Identification mark
E 2

Cap No.
>>C<< O-RING / OIL FEEDER CONTROL
VALVE INSTALLATION
CAUTION
• The O-ring must not be reused.
• Wind non-adhesive tape (seal tape, etc.)
7 3 1 5
around the notch of the oil passage of the oil
feeder control valve before installing the
8 4 2 6 O-ring to prevent damage. Damage to the
O-ring causes oil leakage.

8 4 2 6

7 3 1 5 Tape

AK503813 AC

5. Install them upon checking the identification mark

so as not to misidentify cap No. and to confuse
the inlet side with the exhaust side.
AK303651AE
Identification mark
I: Inlet side 1. Apply a small amount of engine oil to the O-ring of
E: Exhaust side the oil feeder control valve.
6. Tighten each camshaft bearing cap mounting bolt 2. Install the oil feeder control valve on the cylinder
to the specified torque of 12 ± 1 N⋅m in the order head.
of number shown in the figure in two or three 3. Tighten the oil feeder control valve to the specified
steps. torque of 10 ± 2 N⋅m.
 ENGINE OVERHAUL 11B-35
CAMSHAFT

INSPECTION
M1113027000961

CAMSHAFT Plastigage

AK503391AC

6. Measure the Plastigage whose width is most

compressed using the scale printed on the
AK503020AC
Plastigage bag. When the measured value
Measure camshaft height (camshaft major axis). If deviates from the standard one, replace the
the height exceeds the limit, replace the camshaft. bearing.
Standard value: Standard value: 0 − 0.032 mm
Inlet: 43.25 mm
Exhaust: 45.00 mm CAUTION
When the bearing is used again, be careful not to
Limit: reverse the cylinder head side and the camshaft
Inlet: 42.75 mm side at the installation.
Exhaust: 44.50 mm
VALVE TAPPET
CAMSHAFT BEARING (METAL) OIL
CLEARANCE (PLASTIGAGE METHOD) Under view
Thickness stamp
1. Thoroughly wipe oil on the outside diameter of the
camshaft and the inside diameter of the bearing. 3.
0 0 0

2. Install the bearing to the camshaft.

Plastigage

AK703500AE

1. Check the Thickness stamp.

Wall
thickness
AK503390 AC

3. Put straightly the Plastigage having the length of

the bearing width on the journal axis, centring the
axis.
4. Carefully install the bearing cap. Tighten the bolt
as instructed in >>B<< Bolt Installation Point.
AK304938 AB
5. Remove the bolt and the bearing cap carefully.
2. If the measured value in the table value is not in
agreement with the value in the table to the
Thickness stamp, replace the valve tappet.
There are 47 kinds of valve tappets at intervals of
0.015 mm in the range between 3.000 and 3.690
mm.
11B-36 ENGINE OVERHAUL
CAMSHAFT

Thickness Thickness Thickness Thickness Thickness Thickness

stamp stamp stamp
3.000 3.000 mm 3.240 3.240 mm 3.480 3.480 mm
3.015 3.015 mm 3.255 3.255 mm 3.495 3.495 mm
3.030 3.030 mm 3.270 3.270 mm 3.510 3.510 mm
3.045 3.045 mm 3.285 3.285 mm 3.525 3.525 mm
3.060 3.060 mm 3.300 3.300 mm 3.540 3.540 mm
3.075 3.075 mm 3.315 3.315 mm 3.555 3.555 mm
3.090 3.090 mm 3.330 3.330 mm 3.570 3.570 mm
3.105 3.105 mm 3.345 3.345 mm 3.585 3.585 mm
3.120 3.120 mm 3.360 3.360 mm 3.600 3.600 mm
3.135 3.135 mm 3.375 3.375 mm 3.615 3.615 mm
3.150 3.150 mm 3.390 3.390 mm 3.630 3.630 mm
3.165 3.165 mm 3.405 3.405 mm 3.645 3.645 mm
3.180 3.180 mm 3.420 3.420 mm 3.660 3.660 mm
3.195 3.195 mm 3.435 3.435 mm 3.675 3.675 mm
3.210 3.210 mm 3.450 3.450 mm 3.690 3.690 mm
3.225 3.225 mm 3.465 3.465 mm
 ENGINE OVERHAUL 11B-37
CYLINDER HEAD AND VALVES

CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION
M1113006903463

35 ± 2 N·m +90˚ +90˚ 35 ± 2 N·m +90˚ +90˚

3
1
2 4

8 7

15 9
11 12
17
13 16

18
21

19
20
10
14

5
Apply engine oil to
all moving parts
before installation.
6

AK703803AD

Removal steps Removal steps (Continued)

>>D<< 1. Cylinder head bolt <<A>> >>B<< 11. Retainer lock
>>D<< 2. Cylinder head bolt washer 12. Valve spring retainer
>>D<< 3. Cylinder head bolt & washer 13. Valve spring
assembly 14. Exhaust valve
>>C<< 4. Cylinder head assembly <<B>> >>A<< 15. Valve stem seal
>>C<< 5. Cylinder head gasket <<B>> >>A<< 16. Valve stem seal
6. Oil feeder control valve (OCV) filter 17. Inlet valve guide
<<A>> >>B<< 7. Retainer lock 18. Exhaust valve guide
8. Valve spring retainer 19. Inlet valve seat
9. Valve spring 20. Exhaust valve seat
10. Inlet valve 21. Cylinder head
11B-38 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS

<<A>> RETAINER LOCK REMOVAL >>A<< VALVE STEM SEAL INSTALLA-
TION
MB992089 CAUTION
• The valve stem seal must not be reused.
• Do not damage the tappet wall during assem-
bly.
• Be sure to use a special tool to install the
valve stem seal. Poor installation causes oil
MD998735 loss via valve guides.
• If oil is not applied, the valve stem seal may
AK502741AC
rise to the surface after it is press fitted.
CAUTION
Be careful not to allow retainer holder C to inter-
fere with the wall of the tappet hole and to dam-
age it.
Use a special tool to compress the valve spring and
to remove the retainer lock.
• Valve spring compressor (MD998735)
• Retainer holder C (MB992089)
NOTE: Store removed parts such as valves and
springs with tags describing cylinder No. and AK503378AD
installed position attached for reassembly.
1. Apply a thin coat of engine oil to a new valve stem
<<B>> VALVE STEM SEAL REMOVAL seal.

MB992085

MD998737

AK502742AC
Valve stem seal AK502782AC

Use special tool Valve stem seal pliers (MB992085) 2. Use special tool Valve stem seal installer
to firmly pinch the base (larger external shape) of the (MD998737) to press fit the valve stem seal into
stem seal and twist it right and left for pulling out. the valve guide with the valve stem used as a
guide.
 ENGINE OVERHAUL 11B-39
CYLINDER HEAD AND VALVES

>>B<< RETAINER LOCK INSTALLATION

MB992089

MD998735

AK502741AC
Ø2 to Ø3 mm
Use a special tool to compress the valve spring and
to install the retainer lock.
• Valve spring compressor (MD998735)
• Retainer holder C (MB992089)

>>C<< CYLINDER HEAD GASKET /

CYLINDER HEAD ASSEMBLY
INSTALLATION Timing chain side

Degrease

AK602942AC

3. As shown in the illustration, apply a 2.5 ± 0.5 mm

of sealant to the top face of cylinder block.
Specified sealant:
Bottom face of cylinder head
ThreeBond 1217G or equivalent
4. Install the cylinder head gasket.
Degrease
NOTE: Check that the centre of the liquid gasket
is located toward the cylinder gasket in the posi-
tion specified in the illustration.
5. As shown in the illustration, apply a 2.5 ± 0.5 mm
of sealant to the top face of cylinder head gasket.
Specified sealant:
ThreeBond 1217G or equivalent
Top face of cylinder block
6. Install the cylinder head assembly.
AK602902AC

1. Completely remove the liquid gasket on the upper >>D<< CYLINDER HEAD BOLT
plane of the cylinder block and the lower plane of INSTALLATION
the cylinder head. 1. Install new cylinder head bolts and washers in the
CAUTION following procedure.
Sufficiently check that there is no residual oil on NOTE: Cylinder head bolts and washers must not
the place where degreasing is performed. If fin- be reused.
gerprints are left, do not touch it with bare hands 2. Apply an appropriate amount of engine oil to top
after the degreasing, since the oils from your fin- and bottom surfaces of washers and threaded
gers will harm the seal ability. portion of bolts.
2. Degrease the place specified in the illustration. 3. Install cylinder head bolts to the cylinder head.
11B-40 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

NOTE: Bolts and washers are different parts for 2. Completely remove oil, scale, sealant, carbon,
bolts on the timing chain side. etc. After cleaning oil passages, blow air to make
sure that they are not clogged.
Timing chain side

8 6 1 3 9

10 4 2 5 7

AK502392 AC
AK502740
4. Tighten cylinder head bolts in several steps to the
specified torque of 35 ± 2 N⋅m according to the CAUTION
assembly order. The grinding limit shall be within 0.2 mm in com-
bination with the cylinder block to be assembled.
Paint mark
3. For the flatness on the cylinder head bottom,
Paint mark
measure distortion using a straight edge and free
90˚ 90˚ gauge. If the distortion exceeds the limit, grind
and repair it.
Distortion on bottom
Standard value: Within 0.05 mm
Limit: 0.2 mm
Paint mark Paint mark
Grinding limit: 0.2 mm
Cylinder head height: 128.5 mm
AK502523AC

5. Put a paint mark on all of cylinder head bolt heads VALVE

and cylinder head.
CAUTION
• When the tightening angle is smaller than the
specified tightening angle, the appropriate
tightening capacity cannot be secured. The bottom of valve
• When the tightening angle is larger than the seat contact facet
specified tightening angle, remove the bolt to
start from the beginning again according to Margin
the procedure.
6. Tighten the cylinder head 90° according to the AK305408AB
tightening order.
1. Repair the valve seat if contact with the valve seat
Tighten it further 90° and make sure that the paint is poor, uneven or broken.
mark on the cylinder head bolt is in a straight line
with that on the cylinder head. 2. Measure the margin.
If the limit is exceeded, replace the valve.
INSPECTION Standard value:
M1113007003106
Inlet 1.022 mm
CYLINDER HEAD Exhaust 1.094 mm
1. Check the cylinder head for water leakage, gas
leakage, damage or cracks before cleaning. Limit:
Inlet 0.522 mm
Exhaust 0.594 mm
 ENGINE OVERHAUL 11B-41
CYLINDER HEAD AND VALVES

VALVE GUIDE

Valve
Length guide

AK305409AB Stem diameter

Guide inside diameter AK300168 AE
3. Measure overall length of the valve.
Measure clearance between the valve guide and
If the limit is exceeded, replace the valve. valve stem. If the clearance exceeds the limit,
Standard value: replace the valve guide or valve, or both.
Inlet 113.18 mm Standard value:
Exhaust 105.89 mm Inlet 0.020 − 0.047 mm
Limit: Exhaust 0.030 − 0.057 mm
Inlet 112.68 mm Limit:
Exhaust 105.39 mm Inlet 0.10 mm
Exhaust 0.15 mm
VALVE SPRING
VALVE SEAT
Squareness

Contact width Valve seat

Free height

AK305410AB

AK601281AC
1. Measure free height of the spring.
If the limit is exceeded, replace the spring. Assemble the valve, then measure the contact width.
If the measurement exceeds the specified limit,
Standard value: 49.4 mm
replace the valve seat.
Limit: 48.4 mm
Standard value
2. Measure squareness of the spring. Inlet: 1.16 − 1.46 mm
If the inclination exceeds the limit, replace the Exhaust: 1.35 − 1.65 mm
spring.
CAUTION
Standard value: 2° or less If the variation in the width exceeds 0.2 mm even
Limit: 4° if the contact width is within the standard value,
replace or correct the valve sheet.

REPAIR PROCEDURE OF VALVE SEAT

1. Check clearance between valve guide and valve
and replace the valve guide if necessary before
repairing the valve seat.
11B-42 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

Inlet valve seat bore diameter:

1.16 – 1.46 mm 0.3 O.S.: 36.22 − 36.24 mm
1.35 – 1.65 mm Exhaust valve seat bore diameter:
30˚ 0.3 O.S.: 30.22 − 30.24 mm
30˚
3. Press fit the valve seat, taking care not to score
45˚ 45˚ the cylinder head bore at room temperature.
4. Ream the valve seat.
60˚ Refer to "Repair procedure of valve seat."
AK503333AC
REPLACEMENT PROCEDURE OF VALVE
2. Repair the valve seat so that seat width and seat GUIDE
angle are to the specified shape.
1. Pull out the valve guide with a press toward the
3. Lap valve and valve seat with lapping compound cylinder block side.
after repairing valve seat.
2. Ream the valve guide hole of the cylinder head to
REPLACEMENT PROCEDURE OF VALVE match it with the diameter of the oversize valve
guide to be press fitted.
SEAT
CAUTION
Do not use a valve guide with the same size as
0.5 – 1 mm that of the pulled out valve guide because it can-
not be press fitted.
Valve guide bore diameter
0.25 O.S.: 11.23 − 11.25 mm
Cut

0.5 – 1 mm

AK300719AB

1. Scrape the valve seat to be replaced from inside

to make its wall thickness thin before pulling out.
14.6 – 15.2 mm

AK603511AC

3. Press fit the valve guide to the illustrated

Valve seat
height dimension.
Standard value: 14.6 − 15.2 mm
NOTE: Press fit the valve guide from the cylinder
Oversize hole diameter
head top surface.
AK300720AB
4. After pressing fit the valve guide, insert a new
2. Repair the valve seat hole of the cylinder head to valve to check for sliding.
match it with the diameter of the oversize valve
seat to be press fitted.
 ENGINE OVERHAUL 11B-43
OIL PUMP CHAIN <4B11>

OIL PUMP CHAIN <4B11>

REMOVAL AND INSTALLATION
M1113033700572

3 2

40 N·m
130 N·m

10

11
5

10 ± 2 N·m 24 ± 2 N·m
10 ± 2 N·m

9
Apply engine oil to
all moving parts
before installation.
23 ± 2 N·m
8 26 ± 2 N·m

AKB00721AB

Removal steps Removal steps (Continued)

<<A>> >>E<< 1. Drive plate bolt >>C<< 7. Oil pump chain
2. Adapter plate <<B>> >>C<< 8. Oil pump sprocket
3. Drive plate 9. Oil pump case
>>D<< 4. Rear oil seal >>B<< 10. Crankshaft sprocket
5. Oil pump chain guide <<C>> >>A<< 11. Ladder frame
6. Oil pump tensioner lever
11B-44 ENGINE OVERHAUL
OIL PUMP CHAIN <4B11>

REMOVAL SERVICE POINTS 1. Pry the illustrated position with a screwdriver or

<<A>> DRIVE PLATE BOLT REMOVAL tap the boss with a hammer.

MB991883

AK502756
AK502869 AC

2. If the ladder frame does not come off, insert a

1. Use special tool Flywheel stopper (MB991883) to
flatblade screwdriver into the gap between the
secure the drive plate.
ladder frame and bearing cap as shown in the
2. Remove the drive plate bolt. illustration and lightly pry it to remove the ladder
frame.
<<B>> OIL PUMP SPROCKET REMOVAL
INSTALLATION SERVICE POINTS
MB991346
Oil pump sprocket
>>A<< LADDER FRAME INSTALLATION
CAUTION
Be sure to remove liquid gasket that has entered
mounting holes.
1. Completely remove liquid gasket adhering to the
cylinder block and ladder frame.
CAUTION
AK703732 AD Sufficiently check that there is no residual oil on
Fix the oil pump sprocket with a special tools Top the place where degreasing is performed. If fin-
cover wrench (MB991346), loosen a centre bolt, and gerprints are left, do not touch it with bare hands
remove the oil pump sprocket. after the degreasing, since the oils from your fin-
gers will harm the seal ability.
<<C>> LADDER FRAME REMOVAL 2. Degrease the surface where the liquid gasket is
applied and the contact surface between the
Boss
cylinder block and ladder frame.

AK502755AC
 ENGINE OVERHAUL 11B-45
OIL PUMP CHAIN <4B11>

>>B<< CRANKSHAFT SPROCKET

1 mm 8.5 mm
INSTALLATION
: Wipe clean with a rag.
: Wipe clean with a rag and degrease.

Crankshaft
3 mm

Engine
front

Crankshaft sprocket AK603521AE

1. Wipe off the dirt on the crankshaft sprocket and

1.75 mm the crankshaft using a rag, and then remove the
grease from the portion shown in the illustration.
NOTE: Remove grease to prevent a drop in the
coefficient of friction of the pressing portion
8.5 mm caused by adhesion of oil.
3 mm
2. Set the No. 1 piston at top dead centre on the
AK502868AC
compression stroke.
3. Squeeze liquid gasket of φ2.5 ± 0.5 mm in 3. Install the crankshaft sprocket to the crankshaft.
thickness and apply it to the illustrated position of
the ladder frame. >>C<< OIL PUMP SPROCKET / OIL PUMP
Specified sealant: CHAIN INSTALLATION
ThreeBond 1217G or equivalent
1. Set the No. 1 piston at top dead centre on the
compression stroke.
6 8 11
MB991346
1 4 Oil pump sprocket

2 3
9 10 5 7 12
AKB00722AC

4. Tighten the ladder frame to the specified torque of AK703732 AD

24 ± 2 N⋅m in the order shown in the illustration.

2. Using the special tool Top cover wrench
(MB991346), install the oil pump sprocket to the
oil pump case.
3. Install the oil pump chain to the crankshaft
sprocket.
4. Install the oil pump chain to the oil pump sprocket.
11B-46 ENGINE OVERHAUL
OIL PUMP CHAIN <4B11>

>>D<< REAR OIL SEAL INSTALLATION 2. Use special tool Flywheel stopper (MB991883) to
secure the drive plate.
CAUTION
Do not apply oil to the circumference of the oil
seal and oil seal pressing hole on the cylinder
block side to prevent teeth from pulling out.

MD998718

AK600847AB

3. Apply engine oil to thread of crankshaft and bolt

seat area of drive plate.
AK502871AC
4. Apply the sealant to the thread of drive plate bolt.
After applying a small amount of engine oil to the oil Specified sealant:
seal lip, use special tool Rear oil seal installer ThreeBond 1324 or equivalent
(MD998718) to press fit the oil seal.
4 7
>>E<< DRIVE PLATE BOLT
INSTALLATION 1 2
1. Clean off sealant and oil of thread of crankshaft
and drive plate bolts.
6 5

MB991883 3 AK603576 AC

5. Tighten drive plate bolt to temporary torque of 40

N⋅m in the order shown to illustration.
6. Tighten drive plate bolt to specified torque of 130
N⋅m in the order shown in the illustration.
AK502869 AC
 ENGINE OVERHAUL 11B-47
BALANCER CHAIN <4B12>

BALANCER CHAIN <4B12>

REMOVAL AND INSTALLATION
M1113032200358

3 2

40 N·m
130 N·m

10

11
10 ± 2 N·m
10 ± 2 N·m

7
6
10 ± 2 N·m
24 ± 2 N·m

5
8

Apply engine oil to

20 N·m 44 N·m 0 N·m 20 N·m +135˚ all moving parts
before installation.

AK603009 AI

Removal steps Removal steps (Continued)

<<A>> >>E<< 1. Drive plate bolt 7. Balancer shaft chain guide
2. Adapter plate <<B>> >>B<< 8. Balancer shaft module
3. Drive plate <<B>> >>B<< 9. Balancer chain
>>D<< 4. Rear oil seal <<B>> >>B<< 10.Crankshaft sprocket
<<B>> >>C<< 5. Balancer shaft chain tensioner <<C>> >>A<< 11. Ladder frame
6. Balancer shaft tensioner lever
11B-48 ENGINE OVERHAUL
BALANCER CHAIN <4B12>

REMOVAL SERVICE POINTS

<<A>> DRIVE PLATE BOLT REMOVAL

MB991883

AK502754

CAUTION
AK502869 AC The balancer shaft module must not be disas-
sembled because of assembly warranty.
1. Use special tool Flywheel stopper (MB991883) to
secure the drive plate. 3. Remove the crankshaft sprocket, balancer chain
and balancer shaft module as a unit.
2. Remove the drive plate bolts.

<<B>> BALANCER SHAFT CHAIN <<C>> LADDER FRAME REMOVAL

TENSIONER / CRANKSHAFT SPROCKET Boss
/ BALANCER CHAIN / BALANCER SHAFT
MODULE REMOVAL
CAUTION
Reliably secure the plunger of the chain ten-
sioner with hard wire to prevent it from jumping
out of the main body.

AK502755AC

1. Pry the illustrated position with a screwdriver or

tap the boss with a hammer.

AK502940

1. Push in the balancer shaft tensioner lever by hand

and push in the plunger of the chain tensioner
until it contacts the bottom. Then, insert hard wire
(piano wire, etc.) of φ1.5 or hexagonal bar wrench AK502756

(1.5 mm) into the plunger fixing hole to secure.

2. If the ladder frame does not come off, insert a
2. Remove the balancer shaft chain tensioner. flatblade screwdriver into the gap between the
ladder frame and bearing cap as shown in the
illustration and lightly pry it to remove the ladder
frame.
 ENGINE OVERHAUL 11B-49
BALANCER CHAIN <4B12>

INSTALLATION SERVICE POINTS

>>A<< LADDER FRAME INSTALLATION 4 6 9
CAUTION 1
Be sure to remove liquid gasket that has entered
mounting holes.
1. Completely remove liquid gasket adhering to the
2
cylinder block and ladder frame.
CAUTION 8 7 3 5 10
Sufficiently check that there is no residual oil on AKB00722AB

the place where degreasing is performed. If fin-

4. Tighten the ladder frame to the specified torque of
gerprints are left, do not touch it with bare hands
24 ± 2 N⋅m in the order shown in the illustration.
after the degreasing, since the oils from your fin-
gers will harm the seal ability.
>>B<< CRANKSHAFT SPROCKET /
2. Degrease the surface where the liquid gasket is
applied and the contact surface between the BALANCER CHAIN / BALANCER SHAFT
cylinder block and ladder frame. MODULE INSTALLATION
When the new balancer shaft module is installed,
supply oil to the oil pump and the balancer shaft
1 mm 8.5 mm bearing in the balancer shaft module using the fol-
lowing procedures.

3 mm

Balancer shaft sprocket

AK503559AC

1.75 mm a. Clean the inside of the removed oil pan. Put the
balancer shaft module carefully into the oil pan so
that the oil inlet can be upward.
b. Pour the engine oil so that the two-third of the
8.5 mm balancer module can be immersed.
3 mm
c. Also, pour approximate 50 cc of engine oil from
AK502868AC
the oil inlet.
3. Squeeze liquid gasket of φ2.5 ± 0.5 mm in d. By giving four clockwise rotations or more to the
thickness and apply it to the illustrated position of balancer shaft sprocket, the oil is supplied to the
the ladder frame. oil pump and the balancer shaft bearing.
Specified sealant: : Wipe clean with a rag.
ThreeBond 1217G or equivalent : Wipe clean with a rag and degrease.

Crankshaft

Engine
front

Crankshaft sprocket AK603521AE

11B-50 ENGINE OVERHAUL
BALANCER CHAIN <4B12>

1. Wipe the dirt on the crankshaft sprocket and the 6. While slanting the balancer shaft module, align
crankshaft using a rag, and then remove the the link plate (blue) of another balancer chain with
grease from the portion shown in the illustration. the timing mark of the crankshaft sprocket to loop.
NOTE: Remove grease to prevent a drop in the Gradually push in the crankshaft sprocket and fit it
coefficient of friction of the pressing portion into the key groove of the crankshaft. Then, install
caused by adhesion of oil. the balancer shaft module on the ladder frame.
NOTE: Make sure that the balancer shaft module
Balancer chain
link plate is completely intimate contact with the ladder
(orange) frame.
NOTE: Make sure that the key groove of the
crankshaft is aligned with the contact surface of
Timing mark the cylinder block and ladder frame as shown in
the illustration.

AK502753AC
Balancer shaft
module bolt
2. Align the timing mark of the balancer shaft module
sprocket with that of the balancer shaft module.
3. Insert a hexagonal bar wrench (3 mm) as
illustrated to prevent the balancer shaft module
sprocket from moving.
4. Loop the balancer chain, aligning its link plate
AK503386AC
(orange) with the timing mark.
5. Install the crankshaft sprocket on the crankshaft. 7. Apply an appropriate and minimum amount of
NOTE: Do not push in the crankshaft sprocket to engine oil to the screw thread of the balancer
the normal position. Push it in only up to the tip of shaft module bolt.
the crankshaft.

3 2

1
4
AK502804 AC

AK502754
8. Tighten bolts to the specified torque of 20 N⋅m
according to the assembly order in the illustration,
Crankshaft retighten them to 44 N⋅m, and then completely
sprocket loosen them.
timing mark Key groove

MB991614

AK503334AC

135˚

AK503158AC
 ENGINE OVERHAUL 11B-51
BALANCER CHAIN <4B12>

9. After tightening them to the specified torque of 20 CAUTION

N⋅m again, use special tool Angle gauge Install the chain tensioner precisely in place after
(MB991614) to tighten them up to 135°. installing the tensioner lever and chain guide to
10.Pull out the hexagonal bar wrench from the prevent the plunger of the chain tensioner from
balancer module sprocket. jumping out.
2. Remove the hard wire (piano wire, etc.) of φ1.5 or
Timing mark
link plate (orange) hexagonal bar wrench (1.5 mm) from the
tensioner. This enables the plunger of the chain
tensioner to push the balancer shaft tensioner
lever to keep the balancer shaft chain tight.
Crank shaft
sprocket >>D<< REAR OIL SEAL INSTALLATION
timing mark
CAUTION
Do not apply oil to the circumference of the oil
seal and oil seal pressing hole on the cylinder
block side to prevent teeth from pulling out.
Key groove

MD998718

Balancer shaft
sprocket
Timing mark timing mark
link plate (blue)
AK502923 AD
AK502871AC
11.Make sure that the respective timing mark is
aligned with each other as illustrated. After applying a small amount of engine oil to the oil
seal lip, use special tool Rear oil seal installer
12.Install the balancer chain tensioner lever and (MD998718) to press fit the oil seal.
balancer chain guide.
>>E<< DRIVE PLATE BOLT
>>C<< BALANCER SHAFT CHAIN
INSTALLATION
TENSIONER INSTALLATION
1. Clean off sealant and oil of thread of crankshaft
and drive plate bolts.

MB991883

AK502940

1. Attach the chain tensioner to the ladder frame. AK503335 AC

2. Use special tool Flywheel stopper (MB991883) to

secure the drive plate.
11B-52 ENGINE OVERHAUL
BALANCER CHAIN <4B12>

4 7

1 2

6 5

AK600847AB
3 AK603576 AC

3. Apply engine oil to thread of crankshaft and bolt 5. Tighten drive plate bolts to temporary torque of 40
seat area of drive plate. N⋅m in the order shown to illustration.
4. Apply the sealant to the thread of drive plate bolts. 6. Tighten drive plate bolts to specified torque of 130
Specified sealant: N⋅m in the order shown in the illustration.
ThreeBond 1324 or equivalent
 ENGINE OVERHAUL 11B-53
PISTON AND CONNECTING ROD

PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION
M1113008403903

6 7

5
10

11
9

Apply engine oil to 3

all moving parts
before installation. 2
5.0 N·m 20 N·m +90˚
1
AK603501AC

Removal sequence REMOVAL SERVICE POINTS

>>G<< 1. Connecting rod cap bolt
<<A>> CONNECTING ROD REMOVAL
<<A>> >>F<< 2. Connecting rod cap
>>E<< 3. Connecting rod bearing
>>E<< 4. Connecting rod bearing
>>D<< 5. Piston connecting rod assembly
>>C<< 6. Piston ring No. 1
>>C<< 7. Piston ring No. 2 Cylinder No.
>>B<< 8. Oil ring
<<B>> >>A<< 9. Piston pin
10. Piston 2
11. Connecting rod

AK502531AD
11B-54 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

Enter cylinder No. for reassembly on the side of the 1. Insert the push rod into the piston pin from the
connecting rod big end. front mark side of the piston top surface, and
attach special tool Guide D (MB991659).
<<B>> PISTON PIN REMOVAL 2. Set the piston and connecting rod assembly on
the base so that the front mark of the piston faces
Guide A: 17.9 mm upward.
Push rod Guide B 3. Use a press to push the push rod and pull out the
piston pin.
NOTE: After pulling out the piston pin, organize
pistons, piston pins and connecting rods by cylin-
Guide A: 18.9 mm
der No.
Guide C
INSTALLATION SERVICE POINTS
>>A<< PISTON PIN INSTALLATION
Guide A: 20.9 mm
Guide D
Base (MB991659) No.1

No.2

Guide A: 21.9 mm No.3

No.4

AK305415AB
J 1

J 2

J 3

J 4

J 5

Special tool Piston pin setting tool (MD998780) con-

sists of parts shown in the illustration. Use also spe-
cial tool Guide D (MB991659) to remove the piston
pin.

Front mark

A
20

AK503237AC
Push rod
1. When replacing a piston, check the cylinder bore
Piston pin size mark stamped on the illustrated position of
the cylinder block and select a corresponding
Front mark
piston from the table below.
Cylinder bore size Piston size mark
Guide D mark
A A
Base
B B or None
C C

AK603502 AC
 ENGINE OVERHAUL 11B-55
PISTON AND CONNECTING ROD

>>B<< OIL RING INSTALLATION

Piston mark size

20
A
Upper Lower
side side
rail rail
closed closed
gap gap

AK603503 AC
Spacer closed gap AK103812 AC
NOTE: The piston size mark is indicated on the
piston top face. 1. Assemble the spacer of the oil ring into the piston
2. Insert the push rod into the piston pin and attach ring groove. Then, assemble the upper side rail,
guide A. and after this assemble the lower side rail.
3. Align the front mark of the piston with that of the NOTE: Install the side rail and end gap of the
connecting rod to assemble. spacer so that they are at the position as shown in
4. Apply engine oil to the circumference of the piston the illustration.
pin.
5. Insert the guide A side of the piston pin
assembled in section 1 into the pin hole from the
front mark side of the piston.

AK304891
Guide B Guide A
CAUTION
The side rail may be broken if its end gap is wid-
ened by a ring expander as in other piston rings.
AK502517AC 2. When assembling the side rail, push it by fingers,
after fitting one end of the side rail into the piston
6. Screw guide B into guide A and open clearance
groove, for easy assembly.
between guide A and guide B by 3 mm (make the
base in line with flushed surface) to assemble. 3. After assembling the oil ring into the piston, make
sure that the side rail turns smoothly to either
7. Set the piston on special tool piston setting base
direction.
so that its front mark faces upward.
8. Use a press to press fit the piston pin. If the press
fit load is below the standard value, replace the
>>C<< PISTON RING NO. 2 / PISTON
piston pin (piston assembly) or connecting rod, or RING NO. 1 INSTALLATION
both.
Standard value: 7,500 − 17,500 N

Piston ring
expander

AK304892AB
11B-56 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

Use a piston ring expander to assemble piston rings CAUTION

with their identification marks facing upward. Piston Driving it in hard causes breakage of piston rings
rings can be assembled by hand without using the and damage to the crank pin.
piston ring expander.
4. Firmly tighten the piston ring with a ring band and
Identification mark insert the piston and connecting rod assembly.

>>E<< CONNECTING ROD BEARING

No.1 INSTALLATION
Pin identification mark position
No.2

AK502529 AF

Identification mark:
No. 1 ring: T1 or 1T
No. 2 ring: T2 or 2T

>>D<< PISTON CONNECTING ROD

ASSEMBLY INSTALLATION
1. Apply a sufficient amount of engine oil to the No.1
circumference of the piston, piston rings and oil
ring. No.2

Side rail No. 1 No.3

No.4

Piston pin AK502527AC

1. When replacing a connecting rod bearing, select

the bearing corresponding to the crankshaft pin
No. 2 Side rail outside diameter according to the crankshaft pin
AK202730 AC identification in the table below.
2. Arrange end gap positions of piston rings and oil Crankshaft pin Connecting rod
ring (side rail and spacer) as shown in the bearing
illustration. Identification Journal Identification
3. Insert the piston and connecting rod assembly mark diameter mm mark
from the top surface of the cylinder block with the 1 47.966 − 47.972 1
front mark of the piston top face facing toward the
2 47.960 − 47.966 2
timing belt side.
3 47.954 − 47.960 3
2. An identification mark of a crankshaft is stamped
at the illustrated position by No.

AK502730
 ENGINE OVERHAUL 11B-57
PISTON AND CONNECTING ROD

Identification
number

AK305607AF AK502752

3. A connecting rod bearing has an identification 2. Make sure that clearance of the thrust of the
mark at the illustrated position. connecting rod big end is appropriate.
Standard value: 0.10 − 0.25 mm
>>F<< CONNECTING ROD CAP Limit: 0.4 mm
INSTALLATION
NOTE: The connecting rod resulting from the break- >>G<< CONNECTING ROD CAP BOLT
ing process has the high insertion force. The new INSTALLATION
connecting rod assembly may possibly be difficult to 1. Check in the following procedure before reusing
remove the connecting rod. the connecting rod bolt.
If difficult to remove it, alternately strike the two bolt
heads with a plastic hammer while the connecting
rod bolt is slightly loosened, or strike the centre of the 20.5 mm
cap shaft’s inside diameter slightly and outward. X
If the outside of the cap is directly struck, the lateral
force is added to the broken-out section. Thus, pay B A
attention to the broken-out section that might be diffi-
cult to be separated or might fall. 35 mm
Clean the broken-out section before the installation
to the engine, using compression air.
AK604589AE

(1) Measure the outside diameter "A."

(2) Measure the smallest outside diameter "B"
Cylinder No.
within the range "X" shown in the illustration.
(3) If the difference of outside diameter of thread
exceeds the limit, replace the connecting rod
Notch 2 bolt.
Limit: 0.1 mm
Front mark
2. Apply engine oil to the threaded portion and seat
AK503157AD
surface of the bolt before installing it.
1. Assemble the bearing cap on the connecting rod 3. After installing each bolt and tightening it by
by aligning it with the mark put during removal. If a fingers, tighten bolts alternately to properly
new connecting rod without a mating mark is assemble the cap.
used, assemble so that the detent notch of the 4. Tighten the bolt in several steps until the torque
bearing is on the same side as illustrated. reaches 5.0 N⋅m.
5. Tighten the bolt in several steps until the torque
reaches 20 N⋅m.
11B-58 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

Press down ring

with piston
90˚
Front mark

Paint mark Paint mark

Piston ring
End gap
AK502749AC AK503370AG

6. Put a paint mark on the bolt head as illustrated. 2. Put piston rings into the cylinder bore, press them
7. Put a paint mark on the connecting rod at 90° against the piston top face, and push them in.
position in the tightening direction of the bolt with After achieving squareness, measure the end gap
reference to the paint mark position of the bolt. with a thickness gauge. If the end gap is
CAUTION excessive, replace piston rings.
• When the tightening angle is smaller than the Standard value:
specified tightening angle, the appropriate No. 1 ring: 0.15 − 0.28 mm <4B11>
tightening capacity cannot be secured. No. 1 ring: 0.15 − 0.25 mm <4B12>
• When the tightening angle is larger than the No. 2 ring: 0.30 − 0.45 mm <4B11>
specified tightening angle, remove the bolt to No. 2 ring: 0.25 − 0.40 mm <4B12>
start from the beginning again according to Oil ring: 0.10 − 0.35 mm
the procedure. Limit:
8. Tighten the bolt 90°, and make sure that the paint No. 1 ring: 0.8 mm
mark of the connecting rod is aligned with that of No. 2 ring: 0.8 mm
the bolt. Oil ring: 1.0 mm

INSPECTION CRANKSHAFT PIN OIL CLEARANCE

M1113008502703

PISTON RINGS (PLASTIGAGE METHOD)

1. Wipe oil off the crankshaft pin and connecting rod
bearing.
2. Place a Plastigage in length equal to the bearing
width on the pin shaft straight in alignment with
the shaft centre.

AK502751

1. Check clearance between piston rings and ring Plastigage

grooves. If the limit is exceeded, replace piston
rings or piston, or both.
Standard value:
No. 1 ring: 0.03 − 0.07 mm AK503373AC

No. 2 ring: 0.03 − 0.07 mm 3. Carefully install the connecting rod cap and
Limit: 0.1 mm tighten bolts to the specified torque of 5.0 N⋅m →
20 N⋅m → +90°.
4. Remove bolts and gently remove the connecting
rod cap.
 ENGINE OVERHAUL 11B-59
CRANKSHAFT AND CYLINDER BLOCK

5. Measure the crushed Plastigage width (area most

widely crushed) using a scale printed on the
Plastigage bag.
Standard value: 0.018 − 0.045 mm
Limit: 0.1 mm

Plastigage

AK503374AC

CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSTALLATION
M1113008704286

6 5

11 ± 1 N·m

4 3

Apply engine oil to 26.5 ± 2.0 N·m +45˚

all moving parts
before installation.
1

AK604556AC
11B-60 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

Removal steps 2. Install the thrust bearing so that the grooved side
>>E<< 1. Crankshaft bearing cap bolt is on the crankshaft weight side.
>>E<< 2. Crankshaft bearing cap
>>D<< 3. Crankshaft bearing lower
<<A>>
>>C<< CRANKSHAFT BEARING UPPER
4. Crankshaft
>>C<< 5. Crankshaft bearing upper INSTALLATION
>>B<< 6. Thrust bearing
>>A<< 7. Crankshaft sensing ring
8. Cylinder block No.1

REMOVAL SERVICE POINT No.2

<<A>> CRANKSHAFT REMOVAL No.3

When temporarily placing the crankshaft with the No.4
crankshaft sensing ring attached, temporarily place it
on a V-block to prevent teeth of the sensing ring from No.5
deforming.
NOTE: If a tooth bends, be sure to replace the crank-
J 1

J 2

J 3

J 4

J 5

shaft sensing ring with a new one.

INSTALLATION SERVICE POINTS

>>A<< CRANKSHAFT SENSING RING
INSTALLATION
Crankshaft sensing ring
1

AK502530 AC

1. When replacing the crankshaft bearing upper,

3 select a bearing with the size corresponding to the
2 cylinder block journal diameter in the table below.

AKB00121AC
Groove
Tighten crankshaft sensing ring bolts to the torque of
11 ± 1 N⋅m in the tightening order shown in the illus-
tration.
Identification
>>B<< THRUST BEARING INSTALLATION mark
1. Install the thrust bearing on the No. 3 bearing on
the cylinder block side. Application of engine oil AK502396 AF
makes the installation easy.
2. The crankshaft bearing upper has an identification
mark at the illustrated position.
Cylinder block Crankshaft
bearing
Identification Journal Identification
mark diameter mm mark
Groove 1 56.000 − 56.006 1
2 56.006 − 56.012 2
AK502394 AD 3 56.012 − 56.018 3
3. Install the selected crankshaft bearing upper.
 ENGINE OVERHAUL 11B-61
CRANKSHAFT AND CYLINDER BLOCK

3. Install the selected crankshaft bearing lower.

>>D<< CRANKSHAFT BEARING LOWER
INSTALLATION >>E<< CRANKSHAFT BEARING CAP /
CRANKSHAFT BEARING CAP BOLT
Journal identification mark position
INSTALLATION

10 6 2 3 7

9 5 1 4 8
No.1
No.2

No.3 AK502395 AC

1. Install the crankshaft bearing cap with reference

No.4 to the identification mark as illustrated.

No.5

AK502528AC

1. When replacing the crankshaft bearing lower, Shank length

select a bearing with the size corresponding to the
crankshaft journal diameter in the table below.
AK402401AC

2. Make sure that the shank length of the bolt is at or

below the limit before installing the crankshaft
bearing cap bolt. If the length exceeds the limit,
replace the bolt with a new one.
Identification Limit: 75.5 − 76.5 mm
mark
3. Apply engine oil to the threaded portion and seat
surface of the bolt.
AK502418AF 4. Tighten crankshaft bearing cap bolts to the torque
of 26.5 ± 2.0 N⋅m according to the tightening
2. The crankshaft bearing lower has an identification order.
mark at the illustrated position.
Crankshaft Crankshaft MB991614
bearing
Identification Journal Identification 45˚
mark diameter mm mark
0 51.985 − 51.988 0
1 51.982 − 51.985 1
2 51.979 − 51.982 2
3 51.976 − 51.979 3 AK502750AC

4 51.973 − 51.976 4
11B-62 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

CAUTION 4. Carefully install the bearing cap and tighten the

• When the tightening angle is smaller than the bolt according to the main point of installation
specified tightening angle, the appropriate >>B<<.
tightening capacity cannot be secured. 5. Remove the bolt, and then carefully remove the
• When the tightening angle is larger than the crankshaft bearing cap.
specified tightening angle, remove the bolt to
start from the beginning again according to
the procedure.
5. Use special tool Angle gauge (MB991614) to
tighten bolts 45° according to the tightening order.

AK502748

6. Measure the crushed Plastigage width (area most

widely crushed) using a scale printed on the
Plastigage bag.
Standard value: 0.012 − 0.030 mm
AK503375 Limit: 0.1 mm
6. Check axial play of the crankshaft after installing
the crankshaft bearing cap. If the axial play CYLINDER BLOCK
exceeds the limit, replace the thrust bearing. 1. Visually check the cylinder block for scratch, rust
Standard value: 0.05 − 0.25 mm and corrosion. Use a flaw detecting agent to
Limit: 0.4 mm check for cracks. If it is found faulty, repair or
replace it.
INSPECTION
M1113008802823

CRANKSHAFT OIL CLEARANCE

(PLASTIGAGE METHOD)
Oil clearance can be easily measured by using a
"Plastigage."
When using a "Plastigage," perform measurement in
the following procedure.
1. Fully wipe oil off the outside diameter of the
crankshaft and inside diameter of the bearing. AK502746
2. Assemble the crankshaft.
2. Measure distortion on the top surface of the
cylinder block using a straight edge and thickness
gauge.
If distortion exceeds the limit, grind and repair it.
A gasket or the like must not be adhered to the
top surface of the cylinder block during
measurement.
Distortion on bottom
Standard value: Within 0.05 mm
AK502747 Limit: 0.2 mm
3. Place a Plastigage in length equal to the bearing Grinding limit: 0.2 mm
width on the journal shaft straight in alignment 3. Check the cylinder wall for scratch or seizure. If
with the shaft centre. there is any defect, replace the cylinder block.
 ENGINE OVERHAUL 11B-63
CRANKSHAFT AND CYLINDER BLOCK

Measuring points are as shown in the illustration.

Standard value
Cylinder bore: 86 mm <4B11>
Cylinder bore: 88 mm <4B12>
Cylindricity: 0.15 mm
12 mm

AK503371AC

4. Measure the bore and cylindricity of the cylinder

using a cylinder gauge.
If the cylinder is excessively worn, repair the
cylinder and replace the piston and piston rings.