Engine Mechanical: 1D-16

Check to ensure that all removed parts are back in

3 place.
Reinstall any necessary parts which have not been
reinstalled.
Adjust accelerator cable play, referring to Accelerator
4 2
1
Cable Adjustment (For A/T and M/T Models): .
Refill cooling system referring to Cooling System
Flush and Refill: in Section 1F.
Upon completion of installation, turn ignition switch
ON but engine OFF and check for fuel leaks.
I4RS0A140004-01 Finally, start engine and check for engine coolant
5) Remove intake manifold (1) and EGR pipe (2) from leaks.
cylinder head, and then remove its gasket and O-
ring.

2
I3RM0A140018-01

Installation
Reverse removal procedure for installation noting the
followings.
Use new intake manifold O-ring.
Use new EGR pipe gasket and O-ring.
Tighten EVAP canister purge valve bracket bolt to
specified torque.
Tightening torque
EVAP canister purge valve bracket bolt: 5 Nm (
0.5 kgf-m, 4.0 lb-ft)
Install intake manifold bolt (2) and nut (1) as shown in
figure.

2
I4RS0A140005-01
1D-17 Engine Mechanical:

Engine Mountings Components

S4RS0B1406011

I4RS0B140008-02

[A]: For M15 engine with A/T 9. Engine right mounting nut 21. Engine rear mounting body bracket bolt
 Engine Mechanical: 1D-18

[B]: For M15 engine with M/T 10. Engine right mounting bolt 22. Engine rear mounting No.3 bracket bolt
[C]: For M13 engine with M/T 11. Engine left mounting bush bolt 23. Yellow mark
[D]: For M13 engine with Automated Manual 12. Engine left mounting No.1 bracket bolt 24. Vehicle forward
Transaxle
1. Engine right mounting bracket 13. Engine left mounting No.2 bracket bolt (short) 25. Engine rear mounting stiffener
2. Engine right mounting 14. Engine left mounting No.2 bracket bolt (long) 26. Engine rear mounting stiffener bolt
3. Engine left mounting No.1 bracket 15. Engine left mounting bracket nut 27. Engine rear mounting No.4 bracket bolt
4. Engine left mounting 16. Engine left mounting nut : 65 Nm (6.5 kgf-m, 47.0 lb-ft)
5. Engine left mounting No.2 bracket 17. Engine rear mounting bolt : 55 Nm (5.5 kgf-m, 40.0 lb-ft)
6. Engine rear mounting 18. Engine rear mounting No.1 bracket bolt : 85 Nm (8.5 kgf-m, 61.5 lb-ft)
7. Engine rear mounting No.1 bracket 19. Engine rear mounting bush bolt : 25 Nm (2.5 kgf-m, 18.0 lb-ft)
8. Engine rear mounting No.2 bracket 20. Engine rear mounting No.2 bracket bolt

Engine Assembly Removal and Installation

S4RS0B1406012 4
Removal 1
1) Initialize TCM (Automated Manual Transaxle)
referring to TCM (Automated Manual Transaxle)
Initialization: in Section 5D.
2) Set clutch to specific position before removing
automated manual transaxle assembly referring to
Clutch Position Control: in Section 5D.
3) Relieve fuel pressure according to Fuel Pressure 3
Relief Procedure: in Section 1G. 2

I3RM0A140022-01
4) Disconnect negative and positive cable at battery.
16) With hose connected, detach A/C compressor from
5) Remove battery and tray.
its bracket (if equipped) referring to Compressor
6) Remove engine hood after disconnecting windshield Assembly Removal and Installation: in Section 7B.
washer hose.
7) Remove right and left side engine under covers. ! CAUTION
8) Remove A/C compressor belt by referring to Suspend removed A/C compressor at a place
Compressor Drive Belt Removal and Installation: in where no damage will be caused during
Section 7B. removal and installation of engine assembly.
9) Drain engine oil referring to Engine Oil and Filter
Change: in Section 0B. 17) Disconnect the following electric wires:
10) Drain transaxle oil referring to Automated Manual TP sensor (1) (for A/T and M/T models)
Transaxle Oil Change: in Section 5D, Manual MAP sensor (2)
Transaxle Oil Change: For M13 Engine Model in ECT sensor (3)
Section 5B, Manual Transaxle Oil Change: For
EGR valve (4)
M15 Engine Model in Section 5B or A/T Fluid
Change: in Section 5A. CMP sensor (5)
11) Drain coolant referring to Cooling System Draining: IAC valve (6) (for A/T and M/T models)
in Section 1F. Ignition coil assembly (7)
12) Remove cowl top plate referring to Cowl Top Injectors (8)
Components: in Section 9K. Heated oxygen sensor (9)
13) Disconnect MAF sensor coupler (1). Oil control valve (10) (for engine with VVT system)
14) Remove air cleaner case (2) and resonator (3). Engine oil pressure switch (11)
15) Remove canister purge hose (4) from EVAP canister CKP sensor (12)
purge valve.
Knock sensor (13)
VSS (14)
Back up light switch (15) (for M/T and Automated
Manual Transaxle models)
Generator (16)
Starting motor (17)
Ground terminal (18) from cylinder block
Battery ground cable (19) from transaxle
1D-19 Engine Mechanical:

Output shaft speed sensor (VSS) (28) (for A/T

model)
Solenoid valve (29) (for A/T model)
Transmission range sensor (30) (for A/T model)
Input shaft speed sensor (31) (for A/T and
Automated Manual Transaxle models)
Magnet clutch switch of A/C compressor (if
equipped)
Electric throttle body assembly connector (for
Automated Manual Transaxle model)
Clutch actuator motor (34) (for Automated Manual
Transaxle model)
Clutch stroke sensor (35) (for Automated Manual
Transaxle model)
Shift actuator motor (36) (for Automated Manual
Transaxle model)
Shift stroke sensor (37) (for Automated Manual
Transaxle model)
Select actuator motor (38) (for Automated Manual
Transaxle model)
Select stroke sensor (39) (for Automated Manual
Transaxle model)
Neutral start switch (33) (for Automated Manual
Transaxle model)
Each wire harness clamps
18) Remove fuse box from its bracket.
19) Disconnect the following cables:
Accelerator cable (20) (for A/T and M/T models)
Gear select control cable (21) (for M/T model)
Gear shift control cable (22) (for M/T model)
A/T select cable (32) (for A/T model)
20) Disconnect the following hoses:
A/T fluid cooler hoses
Brake booster hose (24) from intake manifold
Radiator inlet and outlet hoses (25) from each
pipe
Heater inlet and outlet hoses (26) from each pipe
Fuel feed hoses (27) from fuel feed pipe
21) With hose connected, detach clutch operating
cylinder (23). (for M/T model)

! CAUTION
Suspend removed clutch operating cylinder
at a place where no damage will be caused
during removal and installation of engine
assembly.
 Engine Mechanical: 1D-20

[A]: For M/T model

[D] 9 [E] 5 [B]: For A/T model
[C]: For Automated Manual Transaxle model
[D]: For M15 engine
[E]: For M13 engine

10 11 9
22) Disconnect right and left drive shaft joints from
differential gear referring to Front Drive Shaft
7
Assembly Removal and Installation: in Section 3A.
5 8
NOTE
4
2
For engine and transaxle removal, it is not
3
24 necessary to remove drive shafts from
27
20 steering knuckle.
1
23) Remove exhaust No.1, No.2 and center pipes
25 referring to Exhaust Manifold Removal and
26
Installation: in Section 1K.
6
24) Support engine assemble by using supporting
17 13 16
device referring to Engine Supporting Points: in
Section 0A.
25) Remove suspension frame referring to Front
Suspension Frame, Stabilizer Bar and/or Bushings
14 18 12 Removal and Installation: in Section 2B.
26) Remove engine rear mounting from engine rear
[A]
mounting No.1 bracket.
21
22 27) Support engine and transaxle with jack, and then
15
19
remove supporting device.
28) Remove engine left mounting bracket nuts (1) and
engine right mounting nuts (2).
23
[B] 28

29

30

31
32 1

[C]

33
15

31

34 38
I4RS0A140008-01
37 36 29) Before removing engine with transaxle from engine
35 compartment, recheck to make sure all hoses,
39
electric wires and cables are disconnected from
engine and transaxle.
I4RS0B140009-01
30) Lower engine with transaxle from engine
compartment.
1D-21 Engine Mechanical:

! CAUTION Tightening torque

Engine left mounting bracket nut (a): 55 Nm (
Before lowering engine, to avoid damage to 5.5 kgf-m, 40.0 lb-ft)
A/C compressor and clutch operating Engine right mounting nut (b): 65 Nm (6.5 kgf-
cylinder, make clearance by rising them. Be m, 47.0 lb-ft)
sure not to damage suspended A/C
compressor and clutch operating cylinder.

1, (a)

2, (b)

I4RS0A140009-01

31) Disconnect transaxle from engine, referring to

Manual Transaxle Unit Dismounting and
Remounting: For M13 Engine Model in Section 5B,
Manual Transaxle Unit Dismounting and
Remounting: For M15 Engine Model in Section 5B,
Automatic Transaxle Unit Dismounting and I4RS0A140010-01

Remounting: in Section 5A or Automated Manual 5) Support engine assemble by using supporting

Transaxle Unit Dismounting and Remounting: in device referring to Engine Supporting Points: in
Section 5D. Section 0A.
32) Remove clutch cover and clutch disk referring to 6) Install engine rear mounting to engine rear mounting
Clutch Cover, Clutch Disc and Flywheel Removal No.1 bracket.
and Installation: in Section 5C.
Tightening torque
Engine rear mounting bush bolt: 55 Nm (5.5
Installation
kgf-m, 40.0 lb-ft)
1) Install clutch cover and clutch disk referring to
Clutch Cover, Clutch Disc and Flywheel Removal 7) Install suspension frame referring to Front
and Installation: in Section 5C (for M/T model) or Suspension Frame, Stabilizer Bar and/or Bushings
Clutch Cover and Clutch Disc Removal and Removal and Installation: in Section 2B.
Installation: in Section 5D (for Automated Manual 8) Remove supporting device.
Transaxle model). 9) Install exhaust No.1, No.2 and center pipes referring
2) Connect transaxle to engine referring to Manual to Exhaust Pipe and Muffler Removal and
Transaxle Unit Dismounting and Remounting: For Installation: in Section 1K.
M13 Engine Model in Section 5B, Manual 10) Connect drive shaft joints referring to Front Drive
Transaxle Unit Dismounting and Remounting: For Shaft Assembly Removal and Installation: in Section
M15 Engine Model in Section 5B, Automatic 3A.
Transaxle Unit Dismounting and Remounting: in
11) Reverse disconnected hoses, cables and electric
Section 5A or Automated Manual Transaxle Unit
wires for connection noting the followings.
Dismounting and Remounting: in Section 5D.
Tighten nuts to specified torque.
3) Lift engine and transaxle into engine compartment
with jack. Tightening torque
4) Install engine left mounting bracket nuts (1) and Starting motor terminal nut: 11 Nm (1.1 kgf-m,
engine right mounting nuts (2). 8.0 lb-ft)
Tighten these nuts to specified torque. Generator terminal nut: 6 Nm (0.6 kgf-m, 4.5 lb-
ft)
12) Install air cleaner case and resonator.
13) Install cowl top referring to Cowl Top Components:
in Section 9K.
 Engine Mechanical: 1D-22

14) Install A/C compressor to its bracket (if equipped) 19) Refill engine with engine oil referring to Engine Oil
referring to Compressor Assembly Removal and and Filter Change: in Section 0B.
Installation: in Section 7B. 20) Refill transaxle with transaxle oil referring to
15) Adjust A/C compressor belt tension (if equipped) Automated Manual Transaxle Unit Dismounting and
referring to Compressor Drive Belt Inspection and Remounting: in Section 5D, Manual Transaxle Oil
Adjustment: in Section 7B. Change: For M13 Engine Model in Section 5B,
16) Adjust accelerator cable play referring to Manual Transaxle Oil Change: For M15 Engine
Accelerator Cable Adjustment (For A/T and M/T Model in Section 5B or A/T Fluid Change: in
Models): in this section. Section 5A.
17) Check to ensure that all removed parts are back in 21) Install battery and tray.
place. 22) Connect positive and negative cable at battery.
Reinstall any necessary parts which have not been 23) Verify that there is no fuel leakage, coolant leakage,
reinstalled. oil leakage and exhaust gas leakage at each
18) Refill cooling system with coolant referring to connection.
Cooling System Flush and Refill: in Section 1F.

Timing Chain Cover Components

S4RS0B1406013

I4RS0B140010-02

[A]: For engine with VVT 8. Timing chain cover mounting 17. Oil control valve
nut
[B]: For engine without VVT 9. Oil gallery pipe No.1 18. Oil control valve mounting nut
1. Crankshaft pulley bolt 10. Copper washer 19. Cap
2. Crankshaft pulley 11. Oil gallery pipe No.1 bolt : 11 Nm (1.1 kgf-m, 8.0 lb-ft)
3. Oil seal 12. Oil gallery pipe No.2 : 25 Nm (2.5 kgf-m, 18.0 lb-ft)
: Apply engine oil to oil seal lip.
1D-23 Engine Mechanical:

4. Timing chain cover 13. Oil gallery pipe No.2 bolt : 30 Nm (3.0 kgf-m, 22.0 lb-ft)
: Apply sealant 99000-31140 to the mating
surface of cylinder and cylinder head.
: Apply sealant 99000-31260 to the mating
surface of timing chain cover referring to the
figure of Step 4) of Installation under Timing
Chain Cover Removal and Installation: .
5. Pin 14. Oil gallery pipe No.3 : 150 Nm (15.0 kgf-m, 108.5 lb-ft)
6. Cap bolt 15. Oil gallery pipe No.3 bolt : Do not reuse.
7. Timing chain cover mounting bolts 16. O-ring
: Apply engine oil.

Timing Chain Cover Removal and Installation

S4RS0B1406014

! CAUTION

Keep working table, tools and hands clean

while overhauling.
Use special care to handle aluminum parts
so as not to damage them.
Do not expose removed parts to dust.
Keep them always clean.

Removal I2RH0B140052-01

1) Remove engine assembly from vehicle referring to 5) Remove cylinder head cover referring to Cylinder
Engine Assembly Removal and Installation: . Head Cover Removal and Installation: .
2) Remove water pump / generator drive belt referring 6) Remove oil pan referring to Oil Pan and Oil Pump
to Water Pump / Generator Drive Belt Removal and Strainer Removal and Installation: in Section 1E.
Installation: in Section 1F. 7) Remove water pump pulley.
3) Remove crankshaft pulley bolt. 8) Remove A/C bracket from cylinder block.
To lock crankshaft pulley (1), use special tool with it 9) For engine with VVT, remove oil gallery pipes No.2
as shown in the figure. (1) and No.3 (2).
Special tool
(A): 0991768221
1

I3RH0B140021-01

10) Remove cap (1) from timing chain cover (2).

11) Remove timing chain cover (2).
I2RH0B140051-01

4) Remove crankshaft pulley (1).

If it is hard to remove, use special tools as shown in
the figure.
Special tool 1
(A): 0994436011
(B): 0992658010

2
I3RH0B140022-01

12) Remove oil control valve from timing chain cover

referring to Oil Control Valve Removal and
Installation (For Engine with VVT): .
 Engine Mechanical: 1D-24

Installation
1) Clean sealing surface on timing chain cover, cylinder
block and cylinder head.
Remove oil, old sealant and dust from sealing
surface.
2) Install oil seal (1) to timing chain cover, if removed.

NOTE
When installing new oil seal, press fit to
timing chain cover (2) by using special tool
(bearing installer) as shown in the figure.

Drive in dimension
a: 1.5 mm (0.06 in.)
Special tool
(A): 0991375810

I3RH0B140025-01

5) Apply engine oil to oil seal lip, then install timing

chain cover (1). Tighten bolts and nut to specified
torque.

NOTE
I2RH0B140058-01
Before installing timing chain cover, check
3) Install oil control valve to timing chain cover referring that pin is securely fitted.
to Oil Control Valve Removal and Installation (For
Engine with VVT): . Tightening torque
4) Apply sealant A to mating surface of cylinder and Timing chain cover bolt (a): 25 Nm (2.5 kgf-m,
cylinder head and B to mating surface of timing 18.0 lb-ft)
chain cover as shown in the figure. Timing chain cover nut (b): 25 Nm (2.5 kgf-m,
18.0 lb-ft)
A: Sealant 9900031140
B: Sealant 9900031260 6) Apply engine oil to new O-rings (2) and install them
to cap (3).
Sealant amount for timing chain cover
7) Install cap (3) to timing chain cover (1).
Width a: 3 mm (0.12 in.)
Tighten bolts to specified torque.
Height b: 2 mm (0.08 in.)
Tightening torque
Cap bolt (c): 25 Nm (2.5 kgf-m, 18.0 lb-ft)

3
2

(c)

(b)

1
(a)

I4RS0B140011-02

8) For engine with VVT, install new O-ring (1) to oil

gallery pipes No.2 (2) and No.3 (3).
1D-25 Engine Mechanical:

9) For engine with VVT, install oil gallery pipes No.2 Timing Chain Cover
and No.3 to cylinder head (4) and timing chain cover Inspect strainer (1) of oil passage for driving intake cam
(5). timing sprocket assembly (VVT actuator).
Tighten bolts to specified torque. If clog or foreign matter exists, clean strainer.
Tightening torque
Oil gallery pipe No.2 and No.3 bolt (a): 11 Nm (
1.1 kgf-m, 8.0 lb-ft)

(a)
1
2 1
3
(a)

4
I3RH0B140028-01
5

Oil Control Valve Removal and Installation (For

Engine with VVT)
S4RS0B1406016
I3RH0B140027-01

10) Install water pump pulley. Removal

Remove oil gallery pipe No.1 (1) and oil control valve (2)
11) Install cylinder head cover referring to Cylinder
from timing chain cover (3).
Head Cover Removal and Installation: .
12) Install oil pan referring to Oil Pan and Oil Pump Installation
Strainer Removal and Installation: in Section 1E.
1) Install new O-ring (4) to oil control valve.
13) Install crankshaft pulley (1). Tighten bolt (2) to
2) Install oil control valve to timing chain cover.
specified torque. To lock crankshaft pulley, use
Tighten nuts to specification.
special tool with it as shown in the figure.
Tightening torque
Special tool
Oil control valve mounting nut (a): 11 Nm (1.1
(A): 0991768221
kgf-m, 8.0 lb-ft)
Tightening torque
3) Install oil gallery pipe No.1 with new copper washers
Crankshaft pulley bolt (a): 150 Nm (15.0 kgf-m,
(5) to timing chain cover.
108.5 lb-ft)
Tighten bolts to specification.
Tightening torque
Oil gallery pipe No.1 bolt (b): 30 Nm (3.0 kgf-m,
21.5 lb-ft)

(a)
I2RH0B140056-01 5
14) Install engine assembly to vehicle referring to
Engine Assembly Removal and Installation: .
3
Timing Chain Cover Inspection 1
S4RS0B1406015

Oil Seal
Check oil seal lip for fault or other damage. Replace as (b)
5
necessary. I3RM0A140027-01
 Engine Mechanical: 1D-26

Oil Control Valve Inspection (For Engine with

VVT) 1
S4RS0B1406017
2

Oil Control Valve

1) Inspect strainer (1) and mating surface (2) of oil
control valve for clog or damage. Clean oil control
valve if clog or foreign matter is present on strainer
or mating surface of oil control valve. I3RM0A140028-01

Replace oil control valve if its mating surface is

damaged. Oil Gallery Pipe
Inspect oil gallery pipes No.1, No.2 (2) and No.3 (3).
2) Check resistance between terminals of oil control
Replace if crack, deformation or clog exists.
valve.
Oil control valve resistance
6.7 7.7 (at 20 C (68 F))
3

I3RH0B140030-01

Timing Chain and Chain Tensioner Components

S4RS0B1406018

I4RS0A140012-01

1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly : 25 Nm (2.5 kgf-m, 18.0 lb-ft)
2. Timing chain 6. Chain tensioner adjuster mounting bolt : 11 Nm (1.1 kgf-m, 8.0 lb-ft)
: Apply engine oil.
3. Timing chain No.1 guide 7. Timing chain tensioner bolt
: Apply engine oil to sliding surface.
4. Timing chain tensioner 8. Timing chain No.1 guide bolt
: Apply engine oil to sliding surface.
1D-27 Engine Mechanical:

Timing Chain and Chain Tensioner Removal Installation

and Installation
S4RS0B1406019 ! CAUTION
After timing chain is removed, never turn
Removal
crankshaft and camshafts independently
! CAUTION more than such an extent (a, b) as shown
in the figure.
After timing chain is removed, never turn If turned, interference may occur between
crankshaft and camshafts independently piston and valves and valves themselves,
more than its allowable turning range and parts related to piston and valves may be
described in Installation. damaged.
If turned, interference may occur between
piston and valves and valves themselves, 1) Check that match marks (1) on intake and exhaust
and parts related to piston and valves may be camshaft timing sprockets are in match with notches
damaged. (2) on cylinder head as shown in the figure.
2) Set key (3) and turn crankshaft to position key on
1) Remove timing chain cover referring to Timing
upside of crankshaft.
Chain Cover Removal and Installation: .
2) By turning crankshaft, align camshafts and
crankshaft at specific position as follows. 1

a) Align both intake and exhaust camshaft timing

sprocket marks (1) with notches (2) of cylinder
head respectively. 1
2
b) For engine with VVT, align crankshaft sprocket
key (3) with notch of cylinder block (4). b b b b
For engine without VVT, position crankshaft 4
sprocket key (3) at upside of crankshaft as
shown in figure.
3) Remove timing chain tensioner adjuster assembly
(5).
4) Remove timing chain tensioner (6).
a a
5) Remove timing chain No.1 guide (7). 5

6) Remove timing chain (8) with crankshaft timing

sprocket (9).

8 3
I4RS0A140021-01
1
a: 90 4. Camshaft (IN and EX) allowable turning range.
By marks on camshaft timing sprocket within 15 from notches
1 on cylinder head on both right and left.
b: 15 5. Crankshaft allowable turning range.
By key on crankshaft, within 90 from top on both right and left.
2
6
7 3) Install timing chain by aligning dark blue plate (1) of
timing chain and triangle mark (2) on camshaft
timing sprocket as shown in the figure.
4) Fit crankshaft timing sprocket to timing chain by
aligning gold plate (3) of timing chain and circle mark
(4) on crankshaft timing sprocket. Then install
crankshaft timing sprocket fitted with chain to
5
crankshaft.
3
4

I3RH0B140032-01
 Engine Mechanical: 1D-28

6) Apply engine oil to sliding surface of chain tensioner

[A] (1) and install chain tensioner and spacer.
Tighten tensioner bolt to specified torque.
[C]
Tightening torque
Timing chain tensioner bolt (a): 25 Nm (2.5 kgf-
2 m, 18.0 lb-ft)
C
1 2
1
Approx.
Approx.
60
30

[B]
1 2
1
Approx.
Approx.
60 I2RH0B140063-01
30
7) Check that match marks (1) on intake and exhaust
camshaft timing sprockets are in match with dark
blue plates (2) of timing chain and match mark (3) on
crankshaft timing sprocket is in match with gold plate
(4) of timing chain.

4
3
I4RS0B140012-02

[A]: For engine with VVT

[B]: For engine without VVT
[C]: View C

5) Apply engine oil to sliding surface of timing chain

No.1 guide (1) and install it as shown in the figure.
Tighten guide bolts to specified torque.
Tightening torque
Timing chain No.1 guide bolt (a): 11 Nm (1.1
kgf-m, 8.0 lb-ft)

I2RH0B140062-01
1D-29 Engine Mechanical:

Tightening torque
[A] Timing chain tensioner adjuster bolt (a): 11 Nm
(1.1 kgf-m, 8.0 lb-ft)
[C]

C
1 2
1
Approx.
Approx.
60
30

I2RH0B140066-01
[B]
1 2
10) Apply engine oil to timing chain, and then turn
1 crankshaft clockwise by 2 revolutions and check that
Approx.
60
Approx. match marks (1) are at the following specific
30
positions.
Intake and exhaust camshaft timing sprockets are
in match with notches (2) on cylinder head and
key (3).
For engine with VVT, crankshaft sprocket key (3)
is in match with notch of cylinder block (4).
For engine without VVT, crankshaft sprocket key
(3) is on upside of crankshaft as shown in figure.

4
3
I4RS0B140012-02

[A]: For engine with VVT

[B]: For engine without VVT
[C]: View C

8) Screw in plunger (1) by turning body (2) in arrow

direction and install a retainer (3) (wire) to hold
plunger in place.

I2RH0B140065-01

9) Install timing chain tensioner adjuster assembly (1)

with a retainer (2).
Tighten adjuster bolts to specified torque and then
remove a retainer from chain tensioner adjuster
assembly.
 Engine Mechanical: 1D-30

Timing Chain and Chain Tensioner Inspection

[A] S4RS0B1406020

1 Timing Chain No.1 Guide

Check shoe (1) for wear or damage.
1

3
4
I2RH0B140068-01

Timing Chain Tensioner

Check shoe (1) for wear or damage.
[B]

1
1
2

I2RH0B140069-01
3

Crankshaft Timing Sprocket

Check teeth of sprocket for wear or damage.

I4RS0B140013-01

[A]: For engine with VVT

[B]: For engine without VVT

11) Install timing chain cover referring to Timing Chain

Cover Removal and Installation: .
12) Perform Steps 9) to 14) of Installation of Timing
Chain Cover Removal and Installation: .

I2RH0B140070-01

Timing Chain
Check timing chain for wear or damage.

I2RH01140077-01
1D-31 Engine Mechanical:

Timing Chain Tensioner Adjuster

Check that tooth surface (1) are free from damage.

I2RH0B140071-01
 Engine Mechanical: 1D-32

Camshaft, Tappet and Shim Components

S4RS0B1406021

I4RS0B140014-01

[A]: For engine with VVT 4. Exhaust camshaft 9. Camshaft bearing

: Install a bearing half with some holes to upper side of intake
camshaft No.1 bearing.
[B]: For engine without VVT 5. Shim : 60 Nm (6.0 kgf-m, 43.5 lb-ft)
: Shim No. on it faces tappet side.
1. Intake camshaft 6. Tappet : 11 Nm (1.1 kgf-m, 8.0 lb-ft)
2. Intake camshaft sprocket assembly 7. Camshaft housing : Apply engine oil to sliding surface of each part.

3. Intake camshaft sprocket bolt 8. Camshaft housing bolt

1D-33 Engine Mechanical:

Camshaft, Tappet and Shim Removal and

Installation
S4RS0B1406022 1

! CAUTION

Keep working table, tools and hands clean

while overhauling.
Use special care to handle aluminum parts
so as not to damage them.
Do not expose removed parts to dust.
I3RH0B140039-01
Keep them always clean.
8) Remove tappets (2) with shims (1).
Removal
1) Remove timing chain cover referring to Timing
Chain Cover Removal and Installation: .
2) Remove timing chain referring to Timing Chain and
Chain Tensioner Removal and Installation: .
3) For engine with VVT, with hexagonal section (1) of
intake camshaft (2) held stationary with spanner or
the like, loosen mounting bolt of intake cam timing
sprocket assembly (3) and remove it.

! CAUTION I2RH0B140074-01

Never attempt to loosen mounting bolt with

Installation
intake cam timing sprocket assembly held
stationary. Failure to follow this could result 1) Install tappets and shims to cylinder head.
in damage to lock pin. Apply engine oil around tappet and then install it to
Do not loosen bolt a because intake cam cylinder head.
timing sprocket assembly is not serviceable.
NOTE
When installing shim, make sure to direct
shim No. side toward tappet.
1
2
a
3

I3RM0A140030-01

4) Loosen camshaft housing bolts in such order as

indicated in the figure and remove them.
I2RH0B140075-01

12 13 20 21 16 17 8 9 2) For engine with VVT, install camshaft bearing (1) to

2 cylinder head.

5 ! CAUTION
3
Do not apply engine oil to camshaft bearing
4
back.
1 Only a upper half bearing of intake camshaft
10 11 18 19 14 15 6 7
bearing No.1 has some holes. Other
I3RM0A140031-01 bearings.
5) Remove camshaft housings.
6) Remove intake and exhaust camshafts.
7) For engine with VVT, remove camshaft bearing (1).
 Engine Mechanical: 1D-34

I3RH0B140039-01
I3RM0A140033-01
3) Install intake camshaft (1) and exhaust camshaft (2). 6) Check position of camshaft housings.
Align knock pin (3) and match mark (4) with notches Embossed marks are provided on each camshaft
(5) as shown in the figure. housing, indicating position and direction for
NOTE installation. Install housings as indicated by these
marks.
Before installing camshafts, turn crankshaft
until key position faces upward.
Refer to Timing Chain and Chain Tensioner
Removal and Installation: .

[A] 2
1

I2RH0B140078-01

A: I: Intake side or E: Exhaust side

B: Position from timing chain side
C: Pointing to timing chain side
3
4
7) After applying engine oil to housing bolts, tighten
5
them temporarily first. Then tighten them by the
[B] numerical order in the figure. Tighten a little at a time
1 2
and evenly among bolts and repeat tightening
b sequence two or three times before they are
a
tightened to specified torque.
Tightening torque
Camshaft housing bolt (a): 11 Nm (1.1 kgf-m,
8.0 lb-ft)

4 4 10 9 2 1,(a) 6 5 14 13
20
5
I4RS0B140015-01 17

[A]: For engine with VVT 19

[B]: For engine without VVT 18
a: Approx. 30 21
b: Approx. 60
12 11 4 3 8 7 16 15
I3RH0B140041-01
4) Apply engine oil to sliding surface of each camshaft
and camshaft journal then install them as shown in 8) For engine with VVT, with hexagonal section (1) of
the figure. intake camshaft (2) held stationary with spanner or
the like, tighten bolt of intake cam timing sprocket
5) Install camshaft housing pins (1) as shown in the
assembly (3) to specification.
figure.
Tightening torque
Intake cam timing sprocket bolt (a): 60 Nm (6.0
kgf-m, 43.5 lb-ft)
1D-35 Engine Mechanical:

Cam height Standard Limit

44.399 44.559 mm 44.28 mm
Exhaust cam
1 (1.748 1.754 in.) (1.743 in.)
3
2
(a)

I3RH0B140042-01

9) Install timing chain with crankshaft sprocket referring

to Timing Chain and Chain Tensioner Removal and
Installation: .
10) Install timing chain cover referring to Timing Chain
Cover Removal and Installation: . I2RH0B140080-01

11) Check valve lashes referring to Valve Lash

(Clearance) Inspection: . Camshaft Runout
12) Perform Steps 9) to 14) of Installation of Timing Set camshaft between two V blocks, and measure its
Chain Cover Removal and Installation: . runout by using a dial gauge.
If measured runout exceeds limit, replace camshaft.
Camshaft, Tappet and Shim Inspection Camshaft runout limit
S4RS0B1406023 0.10 mm (0.0039 in.)
Intake Cam Timing Sprocket Assembly
Fit intake cam timing sprocket assembly to camshaft (2)
and hold hexagonal section of camshaft by using
spanner or the like.
Check if sprocket (1) is not turned by hand.
If moved, replace intake cam timing sprocket assembly.

I2RH0B140081-01

1 2 Camshaft Journal Wear

Check camshaft journals and camshaft housings for
pitting, scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder
head with housing. Never replace cylinder head without
replacing housings.

I3RH0B140043-01

Cam Wear
Using a micrometer, measure cam height a. If
measured height underruns its limit, replace camshaft.
Cam height a
[For engine with VVT]
I2RH0B140082-01
Cam height Standard Limit
44.929 45.089 mm 44.80 mm Check clearance by using gauging plastic. Checking
Intake cam procedure is as follows.
(1.769 1.775 in.) (1.764 in.)
44.399 44.559 mm 44.28 mm 1) Clean housings and camshaft journals.
Exhaust cam
(1.748 1.754 in.) (1.743 in.) 2) Remove all tappets with shims.
3) Install camshafts to cylinder head.
[For engine without VVT]
Cam height Standard Limit 4) Place a piece of gauging plastic to full width of
44.919 45.079 mm 44.80 mm journal of camshaft (parallel to camshaft).
Intake cam 5) Install camshaft housing.
(1.768 1.775 in.) (1.764 in.)
 Engine Mechanical: 1D-36

6) Tighten camshaft housing bolts in such order as Item Standard

indicated in the figure a little at a time till they are Intake side No.1 26.940 26.955 mm
tightened to specified torque. housing (1.0606 1.0612 in.)
Exhaust side No.1 26.934 26.955 mm
NOTE
housing (1.0604 1.0612 in.)
Do not rotate camshaft while gauging plastic 22.934 22.955 mm
is installed. Others
(0.9029 0.9037 in.)

Tightening torque [For engine without VVT system]

Camshaft housing bolt (a): 11 Nm (1.1 kgf-m, Item Standard
8.0 lb-ft) Intake and Exhaust 26.934 26.955 mm
side No.1 housing (1.0604 1.0612 in.)
10 9 2 1,(a) 6 5 14 13
22.934 22.955 mm
Others
20 (0.9029 0.9037 in.)
17
Camshaft journal bearing bore [B]
19
[For engine with VVT system]
18
21
Item Standard
Intake side No.1

12 11 4 3 8 7 16 15 housing
I3RH0B140041-01 Exhaust side No.1 27.000 27.021 mm
7) Remove housing, and using scale (2) on gauging housing (1.0630 1.0638 in.)
plastic envelop, measure gauging plastic (1) width at 23.000 23.021 mm
its widest point. Others
(0.9055 0.9063 in.)
Camshaft journal clearance
[For engine without VVT system]
[For engine with VVT system]
Item Standard
Standard Limit
Intake and Exhaust 27.000 27.021 mm
Intake side 0.020 0.072 mm 0.10 mm
side No.1 housing (1.0630 1.0638 in.)
No.1 housing (0.0008 0.0028 in.) (0.0039 in.)
23.000 23.021 mm
0.045 0.087 mm 0.12 mm Others
Others (0.9055 0.9063 in.)
(0.0018 0.0034 in.) (0.0047 in.)

[For engine without VVT system]

Standard Limit
0.045 0.087 mm 0.12 mm
(0.0018 0.0034 in.) (0.0047 in.)

I2RH0B140083-01

If measured camshaft journal clearance exceeds

limit, measure journal (housing) bore and outside
diameter of camshaft journal. Replace camshaft or
cylinder head assembly whichever the difference
from specification is greater.
I2RH0B140084-01
Camshaft journal diameter [A]
[For engine with VVT system]
1D-37 Engine Mechanical:

Wear of Tappet and Shim

Check tappet and shim for pitting, scratches, or damage.
If any malcondition is found, replace.

I2RH0B140085-01

Measure cylinder head bore and tappet outside diameter

to determine cylinder head-to-tappet clearance. If
clearance exceeds limit, replace tappet or cylinder head.
Cylinder head to tappet clearance
Standard: 0.025 0.066 mm (0.0010 0.026 in.)
Limit: 0.15 mm (0.0059 in.)
Tappet outside diameter [A]
Standard: 30.959 30.975 mm (1.2189 1.2195 in.)
Cylinder head tappet bore [B]
Standard: 31.000 31.025 mm (1.2205 1.2215 in.)

I2RH0B140086-01
 Engine Mechanical: 1D-38

Valves and Cylinder Head Components

S4RS0B1406024

I4RS0A140015-01

1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8)

: Be sure to tighten cylinder head bolt (M8) after
securing the other cylinder head bolt (M10).
2. Valve spring retainer 8. Valve guide : Tighten 20 Nm (2.0 kgf-m, 14.5 lb-ft), 40 Nm (4.0 kgf-
m, 29.0 lb-ft), 60 and 60 by the specified procedure.
3. Valve spring 9. Cylinder head bolt (M10) : 25 Nm (2.5 kgf-m, 18.0 lb-ft)
: Never reuse cylinder head bolts once disassembled it
due to plastic deformation tightening. Be sure to use new
cylinder head bolts when installing.
4. Valve stem seal 10. Cylinder head : Do not reuse.
5. Valve spring seat 11. Cylinder head gasket : Apply engine oil to sliding surface of each part.
: TOP mark provided on gasket comes to crankshaft
pulley side, facing up.
6. Intake valve 12. Knock pin

Valves and Cylinder Head Removal and 3) Remove cylinder head cover referring to Cylinder
Installation Head Cover Removal and Installation: .
S4RS0B1406025
4) Remove timing chain cover referring to Steps 2) to
11) of Removal in Timing Chain Cover Removal
Removal
and Installation: .
1) Remove engine assembly from vehicle referring to
5) Remove timing chain referring to Steps 2) to 6) of
Engine Assembly Removal and Installation: .
Removal in Timing Chain and Chain Tensioner
2) Remove oil pan referring to Oil Pan and Oil Pump Removal and Installation: .
Strainer Removal and Installation: in Section 1E.
1D-39 Engine Mechanical:

6) Remove intake and exhaust camshafts referring to 4) Make sure that oil jet (venturi plug) (1) is not
Steps 3) to 8) of Removal in Camshaft, Tappet and clogged. If it is not installed, install it as specified
Shim Removal and Installation: . torque.
7) Loosen cylinder head bolts in such order as Tightening torque
indicated in the figure by using a 12 corner socket Venturi plug (a): 5 Nm (0.5 kgf-m, 3.5 lb-ft)
wrenches and remove them.

NOTE
Dont forget to remove bolt (M8) (1) as
shown in the figure.
Never reuse cylinder head bolts once
disassembled it due to plastic deformation
tightening. Be sure to use new cylinder
head bolts when installing.

I2RH0B140089-01

5) Install cylinder head to cylinder block.

Apply engine oil to new cylinder head bolts and
tighten them gradually as follows.
a) Tighten cylinder head bolts (1 10) to 20 Nm
(2.0 kgf-m, 14.5 lb-ft) according to numerical
order as shown by using a 12 corner socket
wrenches.
b) In the same manner as in Step a), tighten them
to 40 Nm (4.0 kgf-m, 29.0 lb-ft).
I2RH0B140088-01

8) Check all around cylinder head for any other parts c) Turn all bolts 60 according to numerical order in
required to be removed or disconnected and remove the figure.
or disconnect whatever necessary. d) Repeat Step c).
9) Remove exhaust manifold, if necessary referring to e) Tighten bolt A to specified torque.
Exhaust Manifold Removal and Installation: in
NOTE
Section 1K.
10) Remove cylinder head with intake manifold and Be sure to tighten M8 bolt A after securing
exhaust manifold. Use lifting device, if necessary. the other bolts.

Tightening torque
Installation
Cylinder head bolt for M8 (a): 25 Nm (2.5
1) Clean mating surface of cylinder head and cylinder kgf-m, 18.0 lb-ft)
block. Remove oil, old gasket and dust from mating Cylinder head bolt for M10 (b): 20 Nm (2.0
surface. kgf-m, 14.5 lb-ft), 40 Nm (4.0 kgf-m, 29.0 lb-ft)
2) Install knock pins (1) to cylinder block. and then retighten by turning through to 60
3) Install new cylinder head gasket (2) to cylinder block. twice
Top or Triangle/circle mark provided on gasket
comes to crankshaft pulley side, facing up (toward
cylinder head side).

I2RH0B140091-01

I4RS0B140018-01
 Engine Mechanical: 1D-40

NOTE Valves and Cylinder Head Disassembly and

If they are reused, check thread diameters
Assembly
S4RS0B1406026
of cylinder head bolt (1) for deformation
according to the follows and replace them Disassembly
with new ones if thread diameter difference 1) For ease in servicing cylinder head, remove intake
exceeds limit. manifold, injectors, exhaust manifold from cylinder
Measure each thread diameter of cylinder head.
head bolt (1) at A on 83.5 mm (2.81 in.) 2) Using special tools (Valve lifter), compress valve
from seat side of flange bolt and B on spring and then remove valve cotters (1) also by
115 mm (4.53 in.) from seat side of flange using special tool (Forceps).
bolt by using a micrometer (2).
Then calculate difference in diameters (A Special tool
B). If it exceeds limit, replace with new (A): 0991614510
one. (B): 0991614521
(C): 0991684511
Cylinder head bolt diameter measurement
points
a: 83.5 mm (2.81 in.)
b: 115 mm (4.53 in.)
Cylinder head bolt diameter difference
(deformation)
Limit (A B): 0.1 mm (0.004 in.)

1
A B

1 2

I2RH0B140092-01 I2RH0B140093-01

6) Install camshafts, tappet and shim referring to 3) Release special tools (Valve lifter), and remove
Camshaft, Tappet and Shim Removal and spring retainer and valve spring.
Installation: . 4) Remove valve from combustion chamber side.
7) Install timing chain referring to Timing Chain and 5) Remove valve stem seal (1) from valve guide and
Chain Tensioner Removal and Installation: . valve spring seat (2).
8) Install timing chain cover referring to Timing Chain
Cover Removal and Installation: .
9) Install cylinder head cover referring to Cylinder
Head Cover Removal and Installation: .
10) Install oil pan referring to Oil Pan and Oil Pump
Strainer Removal and Installation: in Section 1E.
1D-41 Engine Mechanical:

NOTE
Do not reuse valve stem seal once
disassembled. Be sure to use new seal when
assembling.

I2RH0B140096-01

2) Install valve guide to cylinder head.

Heat cylinder head uniformly at a temperature of 80
to 100 C (176 to 212 F) so that head will not be
distorted, and drive new valve guide into hole with
I2RH0B140094-01
special tools.
6) Using special tool (Valve guide remover), drive valve Drive in new valve guide until special tool (Valve
guide out from combustion chamber side to valve guide installer) contacts cylinder head.
spring side. After installing, make sure that valve guide protrudes
Special tool by specified dimension a from cylinder head.
(A): 0991644910 Special tool
(A): 0991658210
NOTE
(B): 0991656011
Do not reuse valve guide once disassembled.
Be sure to use new valve guide (oversize) NOTE
when assembling.
Never reuse valve guide once
disassembled. Make sure to install new
valve guide (Oversize).
Intake and exhaust valve guides are
identical.

Valve guide protrusion (In and Ex)

a: 11.3 mm (0.44 in.)

I2RH0B140095-01

7) Place disassembled parts except valve stem seal

and valve guide in order so that they can be installed
in their original position.

Assembly
1) Before installing valve guide into cylinder head, ream
guide hole with special tool (10.5 mm reamer) so as
to remove burrs and make it truly round.
Special tool
I2RH0B140097-01
(A): 0991634542
3) Ream valve guide bore with special tool (5.5 mm
(B): 0991637320
reamer). After reaming, clean bore.
Special tool
(A): 0991634542
(B): 0991634550
 Engine Mechanical: 1D-42

I2RH0B140096-01 I2RH0B140099-01

4) Install valve spring seat to cylinder head. 7) Install valve spring and spring retainer.
5) Install new valve stem seal (1) to valve guide. Each valve spring has top end (large-pitch end (1))
After applying engine oil to seal and spindle of and bottom end (small-pitch end (2)). Be sure to
special tool (Valve guide installer handle), fit oil seal position spring in place with its bottom end (small-
to spindle, and then install seal to valve guide by pitch end) facing the bottom (valve spring seat side).
pushing special tool by hand.
After installing, check to be sure that seal is properly
fixed to valve guide.
Special tool
(A): 0991798221
(B): 0991658210

NOTE
Do not reuse seal once disassembled. Be
sure to install new seal.
When installing, never tap or hit special
I2RH0B140100-01
tool with a hammer or else. Install seal to
guide only by pushing special tool by A: Valve spring retainer side

hand. Tapping or hitting special tool may B: Valve spring seat side

cause damage to seal.

8) Using special tools (Valve lifter), compress valve
spring and fit two valve cotters (1) into groove in
valve stem.

NOTE
When compressing the valve spring, be
carefully to free from damage in inside face
of tappet installing hole.

Special tool
(A): 0991614510
(B): 0991614521
(C): 0991684511

I2RH0B140098-01

6) Install valve to valve guide.

Before installing valve to valve guide, apply engine
oil to stem seal, valve guide bore and valve stem.

I2RH0B140101-01
1D-43 Engine Mechanical:

9) Install intake manifold referring to Intake Manifold 11) Install exhaust manifold referring to Exhaust
Removal and Installation: . Manifold Removal and Installation: in Section 1K.
10) Install fuel injectors referring to Fuel Injector
Removal and Installation: in Section 1G.

Valves and Valve Guides Inspection

S4RS0B1406027

Valve Guide

Valve stem-to-guide clearance

Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide
clearance.
Be sure to take reading at more than one place along the length of each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
Valve stem and valve guide specification
[For M15 engine]
Item Standard Limit
In 5.465 5.480 mm (0.2150 0.2157 in.)
Valve stem diameter [A]
Ex 5.440 5.455 mm (0.2142 0.2148 in.)
Valve guide bore [B] In & Ex 5.500 5.512 mm (0.2165 0.2170 in.)
In 0.020 0.047 mm (0.0008 0.0018 in.) 0.070 mm (0.0028 in.)
Stem-to-guide clearance
Ex 0.045 0.072 mm (0.0017 0.0028 in.) 0.090 mm (0.0035 in.)

[For M13 engine]

Item Standard Limit
In 5.465 5.480 mm (0.2150 0.2157 in.)
Valve stem diameter [A]
Ex 5.440 5.455 mm (0.2142 0.2148 in.)
Valve guide bore [B] In & Ex 5.485 5.510 mm (0.2160 0.2170 in.)
In 0.005 0.045 mm (0.0002 0.0017 in.) 0.070 mm (0.0028 in.)
Stem-to-guide clearance
Ex 0.030 0.070 mm (0.0012 0.0027 in.) 0.090 mm (0.0035 in.)

I4RS0B140016-01

Valve stem end deflection

If bore gauge is not available, check end deflection of
valve stem with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end
deflection.
If deflection exceeds its limit, replace valve stem and
valve guide.
Valve stem end deflection limit
In: 0.14 mm (0.005 in.)
Ex: 0.18 mm (0.007 in.)

IYSQ01141096-01
 Engine Mechanical: 1D-44

Valve

Visual inspection
Remove all carbon from valves.
Inspect each valve for wear, burn or distortion at its
face and stem end, as necessary, replace it.
Inspect valve stem end face for pitting and wear. If
pitting or wear is found there, valve stem end may be
resurfaced, but not too much to grind off its chamber.
When it is worn out too much that its chamber is gone,
I2RH01140136-01
replace valve.
Seating contact width
Create contact pattern on each valve in the usual
manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotatingly tapping seat
with valve head. Valve lapper (tool used in valve lapping)
must be used.
Pattern produced on seating face of valve must be a
continuous ring without any break, and the width of
pattern must be within specified range.
Standard seating width a revealed by contact
pattern on valve face
I2RH01140135-01
[For M15 engine]
Intake and Exhaust: 1.0 1.4 mm (0.0389 0.0551
Valve head thickness
in.)
Measure thickness a of valve head. If measured
[For M13 engine]
thickness exceeds limit, replace valve.
Intake and Exhaust: 1.1 1.3 mm (0.0433 0.0512
Valve head thickness a (In and Ex) in.)
Standard: 1.25 1.55 mm (0.049 0.061 in.)
Limit: 0.9 mm (0.035 in.)

I2RH0B140103-01

I2RH0B140102-01
Valve seat repair
A valve seat not producing a uniform contact with its
Valve head radial runout valve or showing width of seating contact that is out of
Check each valve for radial runout with a dial gauge and specified range must be repaired by regrinding or by
V block. To check runout, rotate valve slowly. If runout cutting and regrinding and finished by lapping.
exceeds its limit, replace valve. 1) Exhaust valve seat:
Valve head radial runout Use valve seat cutters (1) to make two cuts as
Limit: 0.08 mm (0.003 in.) illustrated in the figure. Two cutters must be used:
the first for making 22 angle (for M15 engine) or 15
angle (for M13 engine), and the second for making
45 angle. The second cut must be made to produce
desired seat width.
Seat width for exhaust valve seat
[For M15 engine]
a: 1.0 1.4 mm (0.0389 0.0551 in.)
1D-45 Engine Mechanical:

[For M13 engine] Cylinder Head Inspection

a: 1.1 1.3 mm (0.0433 0.0512 in.) S4RS0B1406028
Remove all carbon deposits from combustion
2) Intake valve seat: chambers.
Use valve seat cutters (1) to make three cuts as
illustrated in the figure. Three cutters must be used: NOTE
the 1st for making 22 angle, the 2nd for making 60 Do not use any sharp-edged tool to scrape
angle, and 3rd for making 45 angle. The 3rd cut off carbon deposits. Be careful not to scuff or
(45) must be made to produce desired seat width. nick metal surfaces when decarbonizing. The
Seat width for intake valve seat same applies to valves and valve seats, too.
[For M15 engine]
b: 1.0 1.4 mm (0.0389 0.0551 in.)
[For M13 engine]
b: 1.1 1.3 mm (0.0433 0.0512 in.)
3) Valve lapping:
Lap valve on seat in two steps, first with coarse size
lapping compound applied to face and the second
with fine-size compound, each time using valve
lapper according to usual lapping method.

I2RH0B140105-01

Check cylinder head for cracks on intake and exhaust

ports, combustion chambers, and head surface. Using
a straightedge and thickness gauge, check flatness of
gasketed surface at a total of 6 locations. If distortion
limit is exceeded, correct gasketed surface with a
surface plate and abrasive paper of about #400
(Waterproof silicon carbide abrasive paper): place
abrasive paper on and over surface plate, and rub
gasketed surface against paper to grind off high spots.
Should this fail to reduce thickness gauge readings to
within limit, replace cylinder head.
Leakage of combustion gases from this gasketed joint
is often due to warped gasketed surface: such
leakage results in reduced power output.
Distortion for cylinder head surface on piston side
Limit: 0.03 mm (0.001 in.)

I4RS0B140017-01

[A]: For M15 engine

[B]: For M13 engine
 Engine Mechanical: 1D-46

Valve Spring Inspection

S4RS0B1406029

Valve Spring Free Length and Preload

Referring to data, check to be sure that each spring is in
sound condition, free of any evidence of breakage or
weakening. Remember, weakened valve springs can
cause chatter, not to mention possibility of reducing
power output due to gas leakage caused by decreased
seating pressure.
Valve spring free length
Standard: 36.83 mm (1.450 in.)
Limit: 35.83 mm (1.411 in.)
Valve spring preload
Standard: 107 125 N (10.7 12.5 kg) for 31.50 mm
(23.6 27.6 lb/1.240 in.)
Limit: 102 N (10.2 kg) for 31.50 mm (22.5 lb/1.240 in.)

I2RH0B140106-01

Distortion of manifold seating faces:

Check seating faces of cylinder head for manifolds,
using a straightedge and thickness gauge, in order to
determine whether these faces should be corrected or
cylinder head replaced.
Distortion for cylinder head surface on intake and
exhaust manifold
Limit: 0.05 mm (0.002 in.)
I2RH01140143-01

Spring Squareness
Use a square and surface plate to check each spring for
squareness in terms of clearance between end of valve
spring and square. Valve springs found to exhibit a
larger clearance than limit must be replaced.
Valve spring squareness
Limit: 1.6 mm (0.063 in.)

I2RH0B140107-01

I2RH01140144-01
1D-47 Engine Mechanical:

Pistons, Piston Rings, Connecting Rods and Cylinders Components

S4RS0B1406030

I2RH0B140108-01

[A]: 1) Tighten all nuts to 15 Nm (1.5 kgf-m). 7. Connecting rod bearing

2) Then retighten all nuts by turning through 45.
3) Repeat Step 2) again.
1. Top ring 8. Piston pin
2. 2nd ring 9. Piston pin circlip
3. Oil ring 10. Bearing cap nut
4. Piston : Tightening torque
5. Connecting rod : Apply engine oil to sliding surface of each part.
: See A
6. Connecting rod bearing cap : Do not reuse.
: See B
A: Apply engine oil to sliding surface except inner surface of big end, and rod bolts. Make sure rod bolt diameter when reuse it due to plastic deformation
tightening. Refer to Piston Pins and Connecting Rods Inspection: .
B: Point arrow mark on cap to crankshaft pulley side.

Pistons, Piston Rings, Connecting Rods and

Cylinders Removal and Installation
S4RS0B1406031

Removal
1) Remove engine assembly from vehicle referring to
Engine Assembly Removal and Installation: .
2) Remove cylinder head referring to Valves and
Cylinder Head Removal and Installation: .
3) Mark cylinder number on all pistons, connecting rods
and connecting rod caps using silver pencil or quick
drying paint.
I2RH0B140109-01
4) Remove rod bearing caps. 6) Decarbonize top of cylinder bore before removing
5) Install guide hose (1) over threads of rod bolts. piston from cylinder.
This prevents damage to bearing journal and rod bolt 7) Push piston and connecting rod assembly out
threads when removing connecting rod. through the top of cylinder bore.
 Engine Mechanical: 1D-48

Installation
1) Apply engine oil to pistons, rings, cylinder walls,
connecting rod bearings and crank pins.

NOTE
Do not apply oil between connecting rod and
bearing or between bearing cap and bearing.

2) Install guide hoses (1) over connecting rod bolts.

These guide hoses protect crank pin and threads of
rod bolt from damage during installation of
connecting rod and piston assembly. I2RH0B140111-01

5) Install bearing cap (1):

Point arrow mark (2) on cap to crankshaft pulley
side.
After applying engine oil to rod bolts and tighten cap
nuts (3) gradually as follows.
a) Tighten all cap nuts to 15 Nm (1.5 kgf-m, 11.0 lb-
ft).
b) Retighten them to 45.
c) Repeat Step b) once again.

NOTE
I2RH01140147-01 Before installing bearing cap, make sure that
3) When installing piston and connecting rod assembly checking for connecting rod bolt
into cylinder bore, point front mark (1) on piston head deformation. Refer to Piston Pins and
to crankshaft pulley side. Connecting Rods Inspection: .

Tightening torque
Connecting rod bearing cap nut (a): 15 Nm
(1.5 kgf-m, 11.0 lb-ft) and then retighten by
turning through 45 twice

I2RH0B140110-01

A: Crankshaft pulley side

B: Flywheel side

4) Install piston and connecting rod assembly into

cylinder bore. Use special tool (Piston ring
compressor) to compress rings. Guide connecting I2RH0B140112-01
rod into place on crankshaft.
6) Install cylinder head referring to Valves and Cylinder
Using a hammer handle, tap piston head to install
Head Removal and Installation: .
piston into bore. Hold ring compressor firmly against
cylinder block until all piston rings have entered
cylinder bore. Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly
Special tool S4RS0B1406032
(A): 0991677310
Disassembly
1) Using piston ring expander, remove two
compression rings (Top and 2nd) and oil ring from
piston.
2) Remove piston pin from connecting rod as follows.
a) Ease out piston pin circlips (1), as shown.
1D-49 Engine Mechanical:

As indicated in the figure, 1st and 2nd rings have

T mark respectively. When installing these piston
rings to piston, direct marked side of each ring
toward top of piston.
1st ring (1) differs from 2nd ring (2) in thickness,
shape and color of surface contacting cylinder
wall.
Distinguish 1st ring from 2nd ring by referring to
the figure.
When installing oil ring (3), install spacer first and
then two rails.
I2RH0B140113-01

b) Force piston pin out.

I2RH0B140116-01

4) After installing three rings (1st, 2nd and oil rings),

distribute their end gaps as shown in the figure.

I2RH0B140114-01

Assembly
1) Decarbonize piston head and ring grooves using a
suitable tool.
2) Install piston pin to piston (1) and connecting rod (2):
a) After applying engine oil to piston pin and piston IYSQ01142102-01
pin holes in piston and connecting rod. 1. Arrow mark 4. Oil ring upper rail gap
b) Fit connecting rod as shown in the figure. 2. 1st ring end gap 5. Oil ring lower rail gap
3. 2nd ring end gap and oil ring spacer gap
c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).
Cylinders, Pistons and Piston Rings Inspection
S4RS0B1406033
NOTE
Circlip should be installed with its cut part Cylinder
facing as shown in the figure. Install so that
circlip end gap comes within such range as Visual inspection
indicated by arrow. Inspect cylinder walls for scratches, roughness or ridges
which indicate excessive wear. If cylinder bore is very
rough or deeply scratched, or ridged, rebore cylinder and
use over size piston.

Cylinder bore diameter, taper and out-of-round

Using a cylinder gauge (1), measure cylinder bore in
thrust and axial directions at two positions (a and b)
as shown in the figure.
If any of the following conditions is noted, rebore
cylinder.
1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions
I2RH0B140115-01 exceeds taper limit.
3) Install piston rings to piston: 3) Difference between thrust and axial measurements
exceeds out-of-round limit.
 Engine Mechanical: 1D-50

Cylinder bore diameter Standard size (new piston with coating): 77.969
[For M15 engine] 77.984 mm (3.0697 3.0702 in.)
Standard: 78.000 78.014 mm (3.0709 3.0714 Oversize (0.50 mm (0.0196 in.)): 78.453 78.468 mm
in.) (3.0887 3.0893 in.)
Limit: 78.050 mm (3.073 in.)
[For M13 engine]
Standard: 78.000 78.014 mm (3.0709 3.0714
in.)
Limit: 78.114 mm (3.075 in.)
Cylinder taper and out-of-round
Limit: 0.10 mm (0.004 in.)
I2RH01140157-01

NOTE
Piston clearance
If any one of four cylinders has to be rebored,
Measure cylinder bore diameter and piston diameter to
rebore all four to the same next oversize.
find their difference which is piston clearance. Piston
This is necessary for the sake of uniformity
clearance should be within specification as follows. If it is
and balance.
out of specification, rebore cylinder and use oversize
piston.

NOTE
Cylinder bore diameters used here are
measured in thrust direction at two positions.

Piston clearance
Standard (used piston): 0.032 0.061 mm (0.0013
0.0024 in.)
Standard (new piston with coating): 0.016 0.045
mm (0.0006 0.0018 in.)
Limit: 0.161 mm (0.0065 in.)

I2RH0B140117-01

a: 50 mm (1.96 in.)
b: 100 mm (3.94 in.) (For M15 engine)
b: 95 mm (3.74 in.) (For M13 engine)

Piston

Visual inspection I4RS0A140022-01

Inspect piston for faults, cracks or other damages. a: 19.5 mm (0.77 in.)
Damaged or faulty piston should be replaced.
Ring groove clearance
Piston diameter Before checking, piston grooves must be clean, dry and
As indicated in the figure, piston diameter should be free of carbon deposits.
measured at a position 19.5 mm (0.77 in.) (a) from Fit new piston ring (1) into piston groove, and measure
piston skirt end in the direction perpendicular to piston clearance between ring and ring land by using thickness
pin. gauge (2). If clearance is out of specification, replace
piston.
Piston diameter specification
Standard size (used piston): 77.953 77.968 mm
(3.0690 3.0696 in.)
1D-51 Engine Mechanical:

Ring groove clearance

Standard Limit
0.03 0.07 mm
Top ring 0.12 mm (0.0047 in.)
(0.0012 0.0028 in.)
0.02 0.06 mm
2nd ring 0.10 mm (0.0039 in.)
(0.0008 0.0024 in.)
0.03 0.17 mm
Oil ring
(0.0012 0.0067 in.)

I2RH01140161-01

a: 120 mm (4.72 in.)

Piston Pins and Connecting Rods Inspection

S4RS0B1406034
I2RH01140159-01

Piston Pin
Piston Ring
Visual inspection
Piston ring end gap Check piston pin, connecting rod small end bore and
To measure end gap, insert piston ring (2) into cylinder piston bore for wear or damage, paying particular
bore and then measure the gap by using thickness attention to condition of small end bore bush. If pin,
gauge (1). connecting rod small end bore or piston bore is badly
If measured gap exceeds limit, replace ring. worn or damaged, replace pin, connecting rod and/or
NOTE piston.

Decarbonize and clean top of cylinder bore Piston pin clearance

before inserting piston ring. Check piston pin clearance in small end and piston.
Replace connecting rod and/or piston if its small end is
Piston ring end gap
badly worn or damaged or if measured clearance
Item Standard Limit exceeds limit.
0.20 0.35 mm
Top ring 0.7 mm (0.0276 in.) Piston pin clearance in connecting rod small end
(0.0079 0.0138 in.)
0.35 0.50 mm Standard: 0.003 0.014 mm (0.0001 0.0006 in.)
2nd ring 1.0 mm (0.0394 in.) Limit: 0.05 mm (0.00020 in.)
(0.0138 0.0197 in.)
0.20 0.70 mm Piston pin clearance in piston
Oil ring 1.2 mm (0.0472 in.)
(0.0079 0.0276 in.) Standard: 0.006 0.017 mm (0.00024 0.00067 in.)
Limit: 0.05 mm (0.0020 in.)
Small-end bore
20.003 20.011 mm (0.7875 0.7878 in.)
Piston pin dia.
19.997 20.000 mm (0.7873 0.7874 in.)
Piston bore
20.006 20.014 mm (0.7876 0.7880 in.)
 Engine Mechanical: 1D-52

I4RH01140053-01

Connecting rod bolt deformation (Plastic

deformation tightening bolt)
Measure each thread diameter of connecting rod bolt (2)
at A on 32 mm (1.25 in.) from bolt mounting surface
and B on 40 mm (1.57 in.) from bolt mounting surface
by using a micrometer (3).
Calculate difference in diameters (A B). If it is
exceeds limit, replace connected rod (1).
Connecting rod bolt measurement points
a: 32 mm (1.25 in.)
I4RS0A140023-01 b: 40 mm (1.57 in.)
Connecting rod bolt diameter difference
Connecting Rod
Limit (A B): 0.1 mm (0.004 in.)
Big-end side clearance
Check big-end of connecting rod for side clearance, with
rod fitted and connected to its crank pin in the normal
manner. If measured clearance is found to exceed its
limit, replace connecting rod.
Big-end side clearance
Standard: 0.25 0.40 mm (0.0098 0.0157 in.)
Limit: 0.55 mm (0.0217 in.)

I2RH0B140148-01
I2RH0B140119-01
Connecting rod alignment
Mount connecting rod on aligner to check it for bow and Crank Pin and Connecting Rod Bearings
twist. If measured value exceeds the limit, replace it. Inspection
S4RS0B1406035
Connecting rod alignment
Limit on bow: 0.05 mm (0.0020 in.) Crank Pin Diameter
Limit on twist: 0.10 mm (0.0039 in.) Inspect crank pin for uneven wear or damage. Measure
crank pin for out-of-round or taper with a micrometer. If
crank pin is damaged or out-of round or taper is out of
limit, replace crankshaft or regrind crank pin to undersize
and use undersize bearing.
1D-53 Engine Mechanical:

Crank pin diameter Connecting Rod Bearing Visual Inspection

Connecting rod Inspect bearing shells for signs of fusion, pitting, burn or
Crank pin diameter flaking and observe contact pattern. Bearing shells
bearing size
41.982 42.000 mm found in defective condition must be replaced.
Standard
(1.6528 1.6535 in.)
0.25 mm (0.0098 in.) 41.732 41.750 mm Connecting Rod Bearing Clearance
undersize (1.6430 1.6437 in.) 1) Before checking bearing clearance, clean bearing
and crank pin.
Out-of-round 2) Install bearing in connecting rod and bearing cap.
AB
3) Place a piece of gauging plastic (1) to full width of
Taper crank pin as contacted by bearing (parallel to
ab crankshaft), avoiding oil hole.
Crank pin taper and out-of-round
Limit: 0.01 mm (0.0004 in.)

I2RH0B140121-01

4) Install rod bearing cap (1) to connecting rod.

When installing cap, be sure to point arrow mark (2)
on cap to crankshaft pulley side, as shown in the
figure. After applying engine oil to rod bolts, tighten
cap nuts (3) gradually as follows.
a) Tighten all cap nuts to 15 Nm (1.5 kgf-m, 11.0 lb-
ft)
b) Retighten them to 45
c) Repeat Step b) once again.
I2RH0B140120-01
Tightening torque
Connecting Rod Bearing General Information Connecting rod bearing cap nut (a): 15 Nm
Service connecting rod bearings are available in (1.5 kgf-m, 11.0 lb-ft) and then retighten by
standard size and 0.25 mm (0.0098 in.) undersize turning through 45 twice
bearing, and standard size bearing has 5 kinds of
bearings differing in tolerance.
For identification of undersize bearing, it is painted red at
the position as indicated in the figure, undersize bearing
thickness is 1.605 1.615 mm (0.0632 0.0635 in.) at
the center of it.

I2RH0B140122-01

5) Remove cap and using a scale (1) on gauging

plastic envelope (2), measure gauging plastic (2)
width at the widest point (clearance).
I2RH01140164-01
If clearance exceed its limit, use a new standard size
1. Red paint bearing referring to Selection of Connecting Rod
Bearings: .
After selecting new bearing, recheck clearance.
 Engine Mechanical: 1D-54

Connecting rod bearing clearance

Standard: 0.029 0.047 mm (0.0011 0.0018 in.)
Limit: 0.065 mm (0.0026 in.)

I2RH0B140123-01

6) If clearance can not be brought to its limit even by

using a new standard size bearing, use next thicker
bearing and recheck clearance or regrind crank pin
to undersize and use 0.25 mm undersize bearing. I3RH0A140017-01

[A]: Connecting rod big end inside diameter number

Selection of Connecting Rod Bearings [B]: Weight indication mark

NOTE 2) Next, check crankshaft pin diameter. On crank web

If bearing is in malcondition, or bearing No.3, four alphabets are stamped as shown in the
clearance is out of specification, select a figure.
new standard bearing according to the Three kinds of alphabet (A, B and C) represent
following procedure and install it. the following crankshaft pin diameter respectively.
For example, stamped A indicates that
When replacing crankshaft or connecting
corresponding crankshaft pin diameter is 41.994
rod and its bearing due to any reason,
42.000 mm (1.6533 1.6534 in.).
select new standard bearings to be
installed by referring to numbers stamped Crankshaft pin outer diameter
on connecting rod and its cap and/or Stamped
alphabets stamped on crank web of No.3 Crankshaft pin diameter
alphabet
cylinder. A 41.9940 42.0000 mm (1.6533 1.6534 in.)
B 41.9880 41.9939 mm (1.6531 1.6532 in.)
1) Check stamped numbers on connecting rod and its C 41.9820 41.9879 mm (1.6529 1.6530 in.)
cap as shown.
Three kinds of numbers (1, 2 and 3) represent
the following connecting rod big end inside
diameters.
For example, stamped number 1 indicates that
corresponding connecting rod big end inside
diameter is 45.000 45.006 mm (1.7717 1.7718
in.).
Connecting rod big end inside diameter
Stamped
Connecting rod big end inside diameter
numbers
1 45.0000 45.0060 mm (1.7717 1.7718 in.)
2 45.0061 45.0120 mm (1.7719 1.7721 in.)
3 45.0121 45.0180 mm (1.7722 1.7723 in.)

I3RH0A140018-01

[A]: Crankshaft pin diameter for No.1 cylinder

[B]: Crankshaft pin diameter for No.2 cylinder
[C]: Crankshaft pin diameter for No.3 cylinder
[D]: Crankshaft pin diameter for No.4 cylinder
1D-55 Engine Mechanical:

3) There are five kinds of standard bearings differing in

thickness. To distinguish them, they are painted in
the following colors at the position as indicated in the
figure.
Each color indicated the following thickness at the
center of bearing.
Standard size of connecting rod bearing
thickness
Color
Bearing thickness
painted
Blue 1.4991 1.5020 mm (0.05902 0.05913 in.)
Yellow 1.4961 1.4990 mm (0.05890 0.05901 in.)
Nothing 1.4931 1.4960 mm (0.05878 0.05889 in.)
Black 1.4901 1.4930 mm (0.05867 0.05877 in.)
Green 1.4870 1.4900 mm (0.05855 0.05866 in.)

I3RH0A140019-01

1. Paint

4) From number stamped on connecting rod and its cap

and alphabets stamped on crank web No.3,
determine new standard bearing to be installed to
connecting rod big end inside, by referring to the
table.
For example, if number stamped on connecting rod
and its cap is 1 and alphabet stamped on crank
web No.3 is B, install a new standard bearing
painted in Black to its connecting rod big end
inside.
Specification of new standard connecting rod
bearing size
Number stamped on
connecting rod and its cap
(connecting rod big end
inside diameter)
1 2 3
Alphabet stamped A Green Black Nothing
on crank web No.3 B Black Nothing Yellow
(Crankshaft pin
C Nothing Yellow Blue
diameter)
New standard bearing to be
installed.
 Engine Mechanical: 1D-56

Main Bearings, Crankshaft and Cylinder Block Components

S4RS0B1406036

I4RS0A140016-01

1. CKP sensor (if equipped) 11. Rear oil seal 21. Oil filter adapter bolt
: See A
2. Knock sensor 12. Input shaft bearing (For A/T and M/T 22. Spring pin
models)
1D-57 Engine Mechanical:

3. Cylinder block 13. Flywheel or drive plate 23. Sensor plate bolt
4. Venturi plug 14. Main bearing cap 24. Oil pressure switch
5. Main bearing 15. Flywheel or drive plate bolt : 22 Nm (2.2 kgf-m, 16.0 lb-ft)
: See B
6. Sensor plate 16. Rear oil seal housing mounting bolt : 5 Nm (0.5 kgf-m, 4.0 lb-ft)
7. Crankshaft timing sprocket key 17. Main bearing cap No.2 bolt : 70 Nm (7.0 kgf-m, 51.0 lb-ft)
8. Crankshaft 18. Main bearing cap No.1 bolt : Tighten 25 Nm (2.5 kgf-m, 18.0 lb-ft) by the specified
: See D procedure.
9. Thrust bearing 19. O-ring : Tighten 30 Nm (3.0 kgf-m, 22.0 lb-ft), 50 Nm (5.0 kgf-
m, 36.5 lb-ft) and 60 by the specified procedure.
10. Rear oil seal housing 20. Oil filter adapter case : 11 Nm (1.1 kgf-m, 8.0 lb-ft)
: See C
A: When installing CKP sensor, use new sensor mounting bolt. : 13 Nm (1.3 kgf-m, 9.5 lb-ft)
B: Upper half of bearing has an oil groove. : 10 Nm (1.0 kgf-m, 7.5 lb-ft)
C: Apply sealant 99000-31250 to mating surface. : Do not reuse.
D: Make sure main bearing cap No.1 bolt deformation when reuse it due to plastic : Apply engine oil to inside / sliding surface.
deformation tightening referring to Main Bearings Inspection: .

Main Bearings, Crankshaft and Cylinder Block

Removal and Installation
S4RS0B1406037

Removal
1) Remove engine assembly from vehicle referring to
Engine Assembly Removal and Installation: .
2) Remove clutch cover, clutch disc and flywheel (drive
plate for A/T) by using special tool.
Special tool
(A): 0992417810
I2RH0B140127-01

6) Remove crankshaft from cylinder block.

Installation

NOTE
Use new bearing cap No.1 bolts. They are
deformed once they are used because they
are plastic deformation tightening bolts.
All parts to be installed must be perfectly
clean.
I2RH0B140125-01 Be sure to oil crankshaft journals, journal
3) Remove piston and connecting rod referring to bearings, thrust bearings, crankpins,
Pistons, Piston Rings, Connecting Rods and connecting rod bearings, pistons, piston
Cylinders Removal and Installation: . rings and cylinder bores.
4) Remove rear oil seal housing (1). Journal bearings, bearing caps,
connecting rods, rod bearings, rod bearing
caps, pistons and piston rings are in
combination sets. Do not disturb such
combination and make sure that each part
goes back to where it came from, when
installing.

1) Install sensor plate (1) to crankshaft (2) and tighten

bolts to specified torque.

NOTE
I2RH0B140126-01 When installing sensor plate, align spring pin
5) Loosen main bearing cap No.1 and No.2 bolts in (3) on crankshaft and hole of sensor plate.
such order as indicated in the figure and remove
Tightening torque
them.
Sensor plate bolt (a): 11 Nm (1.1 kgf-m, 8.0 lb-ft)
 Engine Mechanical: 1D-58

a) Tighten bolts ((1) (10)) to 30 Nm (3.0 kgf-m,

22.0 lb-ft) according to numerical order as shown
by using a 12 corner socket wrenches.
b) In the same manner as in Step a), tighten them
to 50 Nm (5.0 kgf-m, 36.5 lb-ft).
c) In the same manner as in Step a), retighten them
to 60.
d) Tighten bolts ((11) (20)) to 25 Nm (2.5 kgf-m,
18.0 lb-ft) according to numerical order as
shown.

I2RH0B140128-01 Tightening torque

2) Install main bearings to cylinder block. Main bearing cap No.1 bolt ((1) (10)): 30
Upper half of bearing (1), has an oil groove (2). Nm (3.0 kgf-m, 22.0 lb-ft), 50 Nm (5.0 kgf-m,
Install it to cylinder block (3), and the other half 36.5 lb-ft) and then retighten by turning
without oil groove to bearing cap. through 60
Make sure that two halves are painted in the same Main bearing cap No.2 bolt ((11) (20)): 25
color. Nm (2.5 kgf-m, 18.0 lb-ft)

! CAUTION
After tightening cap bolts, check to be sure
that crankshaft rotates smoothly when
turning it by 12 Nm (1.2 kgf-m, 9.0 lb-ft)
torque or below.

I2RH0B140129-01

3) Install thrust bearings (1) to cylinder block between

No.2 and No.3 cylinders. Face oil groove (2) sides to
crank webs.
4) Confirm that dowel pins (3) are installed to intake
side of each journal.
I2RH0B140131-01

7) If necessary, press-fit rear oil seal (1) to oil seal

housing (2) by using special tool as shown in the
figure.
Special tool
(A): 0991197820
Crank rear oil seal installing position
(dimension)
a: 2 mm (0.08 in.)

I2RH0B140130-01

5) Install crankshaft to cylinder block.

6) Install bearing cap to cylinder block, making sure to
point arrow mark (on each cap) to crankshaft pulley
side. Fit them sequentially in ascending order, 1, 2,
3, 4 and 5, starting from pulley side.
After applying engine oil to main bearing cap No.1
bolts ((1) (10)) and main bearing cap No.2 bolts
((11) (20)), tighten them gradually as follows.
I4RS0A140017-01
1D-59 Engine Mechanical:

8) Apply sealant to mating surface of rear oil seal

housing (1).
A: Water tight sealant 9900031250
Sealant amount for rear oil seal housing
Width: a: 3 mm (0.12 in.)
Height b: 2 mm (0.08 in.)

I2RH0B140134-01

11) Install piston and connecting rod referring to

Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation: .
12) Install cylinder head referring to Valves and Cylinder
Head Removal and Installation: .
I4RS0A140018-01 13) Install camshafts, tappet and shim referring to
9) Install rear oil seal housing (1) and tighten bolts to Camshaft, Tappet and Shim Removal and
specified torque by using special tool. Installation: .
Special tool 14) Install timing chain referring to Timing Chain and
(A): 0991197720 Chain Tensioner Removal and Installation: .
15) Install timing chain cover referring to Timing Chain
Tightening torque
Cover Removal and Installation: .
Rear oil seal housing bolt: 11 Nm (1.1 kgf-m, 8.0
lb-ft) 16) Install cylinder head cover referring to Cylinder
Head Cover Removal and Installation: .
17) Install oil pan referring to Oil Pan and Oil Pump
Strainer Removal and Installation: in Section 1E
18) Install engine assembly to vehicle referring to
Engine Assembly Removal and Installation: .

Crankshaft Inspection
S4RS0B1406038

Crankshaft Runout
Using a dial gauge, measure runout at center journal.
Rotate crankshaft slowly. If runout exceeds its limit,
I4RS0A140019-01
replace crankshaft.
A: Crankshaft side
Crankshaft runout
10) Install flywheel (drive plate for A/T). Limit: 0.02 mm (0.0008 in.)
Using special tool, lock flywheel or drive plate, and
tighten flywheel or drive plate bolts to specified
torque.

NOTE
Use new flywheel or drive plate bolts.

Special tool
(A): 0992417810
Tightening torque I2RH0B140135-01
Flywheel or drive plate bolt (a): 70 Nm (7.0 kgf-
m, 51.0 lb-ft) Crankshaft Thrust Play
1) Measure this play with crankshaft set in cylinder
block in the normal manner, that is with thrust
bearing (1) and journal bearing caps installed.
 Engine Mechanical: 1D-60

Thickness of crankshaft thrust bearing NOTE

Standard: 2.500 mm (0.0984 in.) After checking the thrust play, make sure that
Oversize (0.125 mm (0.0049 in.)): 2.563 mm thread deformation of each bearing cap No.1
(0.1009 in.) bolt referring to Main Bearing Cap No.1
Bolt in Main Bearings Inspection: .

I2RH0B140136-01

2) Tighten main bearing cap No.1 bolts (1) (10) and

main bearing cap No.2 bolts (11) (20) gradually as I2RH01140183-01

follows.
a) Tighten bolts (1) (10) to 30 Nm (3.0 kgf-m, Out-of-Round and Taper (Uneven Wear) of Journals
22.0 lb-ft) according to numerical order in the An unevenly worn crankshaft journal shows up as a
figure. difference in diameter at a cross section or along its
length (or both). This difference, if any, is determined by
b) In the same manner as in Step a), tighten them taking micrometer readings. If any one of journals is
to 50 Nm (5.0 kgf-m, 36.5 lb-ft). badly damaged or if amount of uneven wear in the sense
c) In the same manner as in Step a), retighten them exceeds its limit, regrind or replace crankshaft.
to 60.
Crankshaft out-of-round and taper
d) Tighten bolts (11) (20) to 25 Nm (2.5 kgf-m, Limit: 0.01 mm (0.0004 in.)
18.0 lb-ft) according to numerical order in the
figure. Out-of-round
AB
Tightening torque
Main bearing cap No.1 bolt ((1) (10)): 30 Taper
Nm (3.0 kgf-m, 22.0 lb-ft), 50 Nm (5.0 kgf-m, ab
36.5 lb-ft) and then retighten by turning
through 60
Main bearing cap No.2 bolt ((11) (20)): 25
Nm (2.5 kgf-m, 18.0 lb-ft)

I2RH0B140138-01

Main Bearings Inspection

S4RS0B1406039

I2RH0B140137-01
General Information
3) Use a dial gauge to read displacement in axial
(thrust) direction of crankshaft. Service main bearings are available in standard size
If its limit is exceeded, replace thrust bearing with and 0.25 mm (0.0098 in.) undersize, and each of them
new standard one or oversize one to obtain standard has 5 kinds of bearings differing in tolerance.
thrust play. Upper half of bearing (1) has oil groove (2) as shown
in the figure.
Crankshaft thrust play Install this half with oil groove to cylinder block.
Standard: 0.11 0.31 mm (0.0043 0.0122 in.)
Limit: 0.35 mm (0.0138 in.) Lower half of bearing does not have an oil groove.
1D-61 Engine Mechanical:

Tightening torque
Main bearing cap No.1 bolt ((1) (10)): 30
Nm (3.0 kgf-m, 22.0 lb-ft), 50 Nm (5.0 kgf-m,
36.5 lb-ft) and then retighten by turning
through 60
Main bearing cap No.2 bolt ((11) (20)): 25
Nm (2.5 kgf-m, 18.0 lb-ft)

I2RH0B140139-01

Visual Inspection
Check bearings for pitting, scratches, wear or damage.
If any malcondition is found, replace both upper and
lower halves. Never replace either half without replacing
the other half.
I2RH0B140137-01
Main Bearing Clearance 5) Remove bearing caps and using scale (1) on
NOTE gauging plastic envelop (2), measure gauging plastic
width at its widest point. If clearance exceeds its
Do not rotate crankshaft while gauging limit, replace bearing. Always replace both upper
plastic is installed. and lower inserts as a unit.
A new standard bearing may produce proper
Check clearance by using gauging plastic according to clearance. If not, it will be necessary to regrind
the following procedure. crankshaft journal for use of 0.25 mm undersize
1) Remove bearing caps. bearing.
2) Clean bearings and main journals. After selecting new bearing, recheck clearance.
3) Place a piece of gauging plastic (1) the full width of Main bearing clearance
bearing (parallel to crankshaft) on journal, avoiding [For M15 engine]
oil hole. Standard: 0.021 0.041 mm (0.0008 0.0016 in.)
Limit: 0.054 mm (0.0021 in.)
[For M13 engine]
Standard: 0.025 0.045 mm (0.0010 0.0018 in.)
Limit: 0.065 mm (0.0026 in.)

I2RH0B140140-01

4) Tighten main bearing cap No.1 bolts (1) (10) and

main bearing cap No.2 bolts (11) (20) gradually as
follows.
a) Tighten bolts (1) (10) to 30 Nm (3.0 kgf-m, I2RH0B140141-01

22.0 lb-ft) according to numerical order in the

figure. Selection of Main Bearings
b) In the same manner as in Step a), tighten them
Standard bearing
to 50 Nm (5.0 kgf-m, 36.5 lb-ft).
If bearing is in malcondition, or bearing clearance is out
c) In the same manner as in Step a), retighten them of specification, select a new standard bearing according
to 60. to the following procedure and install it.
d) Tighten bolts (11) (20) to 25 Nm (2.5 kgf-m, 1) First check journal diameter. As shown in the figure,
18.0 lb-ft) according to numerical order in the crank web No.2 has stamped numbers.
figure.
 Engine Mechanical: 1D-62

Three kinds of numbers (1, 2 and 3) represent For example of M15 engine, stamped A or 1
the following journal diameters. indicates that corresponding bearing cap bore
Stamped numbers on crank web No.2 represent diameter is 56.0000 56.0060 mm (2.2048 2.2049
journal diameters marked with an arrow in the figure in.).
respectively. For example of M15 engine, stamped
Crankshaft bearing cap bore
number 1 indicates that corresponding journal
[For M15 engine]
diameter is 51.9940 52.0000 mm (2.0471 2.0472
in.). Stamped
Bearing cap bore diameter (without
alphabet
Crankshaft journal diameter bearing)
(number)
[For M15 engine] 56.0000 56.0060 mm
A or 1
Stamped (2.2048 2.2049 in.)
Journal diameter
numbers 56.0061 56.0120 mm
B or 2
51.9940 52.0000 mm (2.2050 2.2051 in.)
1
(2.0471 2.0472 in.) 56.0121 56.0180 mm
C or 3
51.9880 51.9939 mm (2.2052 2.2054 in.)
2
(2.0468 2.0470 in.)
51.9820 51.9879 mm [For M13 engine]
3
(2.0465 2.0467 in.) Stamped
Bearing cap bore diameter (without
alphabet
[For M13 engine] bearing)
(number)
Stamped 49.0000 49.0060 mm
Journal diameter A or 1
numbers (1.9292 1.9293 in.)
44.9940 45.0000 mm 49.0061 49.0120 mm
1 B or 2
(1.7715 1.7716 in.) (1.9294 1.9296 in.)
44.9880 44.9939 mm 49.0121 49.0180 mm
2 C or 3
(1.7712 1.7714 in.) (1.9297 1.9298 in.)
44.9820 44.9879 mm
3
(1.7710 1.7711 in.)

I2RH0B140143-01

I2RH0B140142-01

2) Next, check bearing cap bore diameter without

bearing. On mating surface of cylinder block, five
alphabets are stamped as shown in the figure.
Three kinds of alphabets (A, B and C) or
numbers (1, 2 and 3) represent the following
cap bore diameters.
Stamped alphabets or numbers on cylinder block
represent bearing cap bore diameter marked with an
arrow in the figure respectively.
1D-63 Engine Mechanical:

3) There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following
colors at the position as indicated in the figure.
Each color indicated the following thickness at the center of bearing.
Standard size of crankshaft main bearing thickness
[For M15 engine]
Color
Bearing thickness
painted
Purple 1.992 1.996 mm (0.07843 0.07858 in.)
Brown 1.995 1.999 mm (0.07855 0.07870 in.)
Green 1.998 2.002 mm (0.07867 0.07882 in.)
Black 2.001 2.005 mm (0.07878 0.07893 in.)
Colorless
2.004 2.008 mm (0.07890 0.07906 in.)
(no paint)

[For M13 engine]

Color
Bearing thickness
painted
Pink 1.990 1.994 mm (0.0783 0.0785 in.)
Purple 1.993 1.997 mm (0.0785 0.0786 in.)
Brown 1.996 2.000 mm (0.0786 0.0787 in.)
Green 1.999 2.003 mm (0.0787 0.0789 in.)
Black 2.002 2.006 mm (0.0788 0.0790 in.)

I2RH01140191-01

1. Paint

4) From number stamped on crank web No.2 and alphabets stamped on cylinder block, determine new standard
bearing to be installed to journal, by referring to the table shown.
For example of M15 engine, if number stamped on crank web No.2 is 1 and alphabet stamped on cylinder block
is B, install a new standard bearing painted in Brown to its journal.
New standard size crankshaft main bearing specification
[For M15 engine]
Number stamped on crank web No.2 (Journal diameter)
1 2 3
A or 1 Purple Brown Green
Alphabet stamped on cylinder
B or 2 Brown Green Black
block (Cap bore dia.)
C or 3 Green Black Colorless
New standard bearing to be installed

[For M13 engine]

Number stamped on crank web No.2 (Journal diameter)
1 2 3
A or 1 Pink Purple Brown
Alphabet stamped on cylinder
B or 2 Purple Brown Green
block (Cap bore dia.)
C or 3 Brown Green Black
New standard bearing to be installed

5) Using scale (1) on gauging plastic (2), check bearing clearance with newly selected standard bearing.
If clearance still exceeds its limit, use next thicker bearing and recheck clearance.
 Engine Mechanical: 1D-64

I2RH0B140141-01

6) When replacing crankshaft or cylinder block due to any reason, select new standard bearings to be installed by
referring to number stamped on new crankshaft or alphabets stamped on new cylinder block.

Undersize bearing (0.25 mm (0.0098 in.))

0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness.
To distinguish them, each bearing is painted in the following colors at such position as indicated in the figure.
Each color represents the following thickness at the center of bearing.
Undersize of crankshaft main bearing thickness
[For M15 engine]
Color painted Bearing thickness
Red and Purple 2.117 2.121 mm (0.08335 0.08350 in.)
Red and Brown 2.120 2.124 mm (0.08347 0.08362 in.)
Red and Green 2.123 2.127 mm (0.08359 0.08374 in.)
Red and Black 2.126 2.130 mm (0.08371 0.08385 in.)
Red only 2.129 2.133 mm (0.08382 0.08397 in.)

[For M13 engine]

Color painted Bearing thickness
Red and Pink 2.115 2.119 mm (0.0833 0.0834 in.)
Red and Purple 2.118 2.122 mm (0.0834 0.0835 in.)
Red and Brown 2.121 2.125 mm (0.0835 0.0837 in.)
Red and Green 2.124 2.128 mm (0.0836 0.0838 in.)
Red and Black 2.127 2.131 mm (0.0837 0.0839 in.)

I2RH01140192-01

1. Paint

If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows.
a. Regrind journal to the following finished diameter.
Finished journal diameter
[For M15 engine]
51.7320 51.7500 mm (2.0367 2.0374 in.)
[For M13 engine]
44.7320 44.7500 mm (1.7611 1.7618 in.)
1D-65 Engine Mechanical:

b. Using micrometer, measure regrind journal diameter.

Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
c. Using journal diameter measured above and alphabets stamped on cylinder block, select an undersize bearing
by referring to the following table.
Check bearing clearance with newly selected undersize bearing.

I2RH0B140144-01

New undersize crankshaft main bearing specification

[For M15 engine]
Measured journal diameter
51.7320 51.7379 mm 51.7380 51.7439 mm 51.7440 51.7500 mm
(2.0367 2.0369 in.) (2.0370 2.0371 in.) (2.0372 2.0373 in.)
A (1) Red and Green Red and Brown Red and Purple
Alphabets stamped
B (2) Red and Black Red and Green Red and Brown
on cylinder block
C (3) Red only Red and Black Red and Green
Undersize bearing to be installed

[For M13 engine]

Measured journal diameter
44.7320 44.7379 mm 44.7380 44.7439 mm 44.7440 44.7500 mm
(1.7611 1.7613 in.) (1.7614 1.7615 in.) (1.7616 1.7618 in.)
A (1) Red and Brown Red and Purple Red and Pink
Alphabets stamped
B (2) Red and Green Red and Brown Red and Purple
on cylinder block
C (3) Red and Black Red and Green Red and Brown
Undersize bearing to be installed

Main Bearing Cap No.1 Bolt

Measure each thread diameter main bearing cap No.1 1
bolts (1) at A on 60 mm (2.36 in.) from seat side of A B

flange bolt and B on 90 mm (3.54 in.) from seat side of

flange bolt by using a micrometer (2).
Calculate difference in diameters (A B).
a
If it exceeds limit, replace with new one.
b
Main bearing cap No.1 bolt diameter measurement
1
points 2

a: 60 mm (2.36 in.)
b: 90 mm (3.54 in.)
Main bearing cap No.1 bolt diameter difference
Limit (A B): 0.2 mm (0.008 in.)

I2RH0B140145-01