CFE Turbo - Engine PDF

WORKSHOP MANUAL
ENGINE OVERHAUL
S4P
Model YR 2011
English Edition RDCE-110S4P020-04
Destination: ALL
November 2011 Printed in Malaysia
Copyright ©
Perusahaan Otomobil
Nasional Sdn. Bhd.
(Company No.: 100995-U)
Printed in Malaysia 30 November 2011 Eng
WORKSHOP MANUAL -
Group Index /I
00 GENERAL ................................................................................... 00/1 - 00/14

11A ENGINE <S4P-CFE> ............................................................... 11A/1 - 11A/130
All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

- WORKSHOP MANUAL
/ II Group Index
NOTE

GENERAL 00
Content /1
00 GENERAL
OUTLINE OF CHANGES ............................................................... 00/2
DESCRIPTION ......................................................................... 00/2
TABLE OF CHANGE ITEMS & REFERENCE MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
OUTLINE OF CHANGE ITEMS ..................................................... 00/5
AIR BAG SYSTEM INFORMATION .................................................. 00/6

WARNING ............................................................................ 00/6
HOW TO USE THIS MANUAL ....................................................... 00/7

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS .... 00/7
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
DEFINITION OF TERMS ............................................................ 00/7
STANDARD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
REFERENCE VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
INDICATION OF TIGHTENING TORQUE ......................................... 00/7
EXPLANATION OF MANUAL CONTENTS ........................................ 00/8
ENGINE MODEL AND SERIAL NUMBER LOCATION ............................. 00/11
TIGHTENING TORQUE ................................................................ 00/11

STANDARD PARTS TIGHTENING TORQUE ...................................... 00/11
TIGHTENING TORQUE OF FLANGE BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/11
TIGHTENING TORQUE OF BOLT (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/11
TIGHTENING TORQUE OF FLANGE NUT (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/12
TIGHTENING TORQUE SCREW (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/12
TIGHTENING TORQUE STUD (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/12
PRECAUTION BEFORE SERVICE ..................................................... 00/12

00 GENERAL
/2 OUTLINE OF CHANGES
OUTLINE OF CHANGES WEO000OLINE11001
DESCRIPTION
This bulletin updates information on CamPro engine and is additional supplement to WORKSHOP
MANUAL ENGINE OVERHAUL Pub. No: RDCE-08OS4P020–00 (CamPro Basic) and RDCE-08OS4P020–04
(CamPro-CFE) which contains changes/modifications/updates/additional information due to the intro-
duction of Charged Fuel Efficient (CFE) fitted on CamPro engine.
TABLE OF CHANGE ITEMS & REFERENCE MANUALS
This table indicates those changes and/or addition, etc. have been made; the change items are listed
in the sequence in which they are presented in this bulletin. Please use this table for reference when
performing repair or overhaul procedures which related to CamPro-CFE engine.
LEGEND :
: The symbol indicates a system which is no changes has been made and the information is
not in this supplement manual. The respective item/system should be referred to the pre-
vious supplement or/and basic manual.
: The symbol indicates a system which a changes and/or addition has been made and the
information is presented in this supplement manual.
: The symbol indicates a system is not equipped in the vehicle of the respective manual
(Basic or Supplement).
PUB. NO: RDCE-080S4P020 –
CHANGE CLASSIFICATION BASIC BULLETIN
00 01 02 03 04 (NEW)
GRP 00 – GENERAL
CamPro
CamPro-CPS
Engine & Transmis-
CamPro - IAFM
sion Model
CamPro-IAFM+
CamPro-CFE
Engine Model &
Serial Number Loc- –
ation
GRP 11A- ENGINE <S4P>
CamPro
CamPro-CPS
Specifications CamPro-IAFM
CamPro-IAFM+
CamPro-CFE

GENERAL 00
OUTLINE OF CHANGES /3

00 01 02 03 04 (NEW)
CamPro
CamPro-CPS
Special tools CamPro-IAFM
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Alternator and igni-
CamPro-IAFM
tion system
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Timing belt CamPro-IAFM
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Fuel and emission
CamPro-IAFM
control system
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Water pump and
CamPro-IAFM
water hose
CamPro-IAFM+
CamPro-CFE

00 GENERAL
/4 OUTLINE OF CHANGES

00 01 02 03 04 (NEW)
CamPro
CamPro-CPS
Intake and exhaust
CamPro-IAFM
manifold
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Camshaft and tap-
CamPro-IAFM
pet
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Cylinder head and
CamPro-IAFM
valve
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Oil pump and oil
CamPro-IAFM
pan
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Piston and connect-
CamPro-IAFM
ing rods
CamPro-IAFM+
CamPro-CFE

GENERAL 00
OUTLINE OF CHANGES /5

00 01 02 03 04 (NEW)
CamPro
CamPro-CPS
Crankshaft and cyl-
CamPro-IAFM
inder block
CamPro-IAFM+
CamPro-CFE
OUTLINE OF CHANGE ITEMS

GRP 11A–ENGINE <S4P-CFE>
Change Items Reference Page Description of Changes
Special Tools • New special tools for CamPro-
11A/10
CFE engine overhaul
Alternator and Ignition System • New design, procedure spark
• Installation service points plug for CamPro-CFE engine.
– Spark plug • New design, procedure cam
– Cam shaft sensor position sensor for CamPro-CFE
– Oil control valve 11A/14 engine.
• Additional part is included to
correspond with the CamPro-CFE
engine – Oil control valve.
Fuel and Emission Control System

• New design fuel rail assy for
• Removal service points 11A/25
CamPro-CFE engine.
– Fuel rail assy
Intake Manifold
• New design intake manifold for
• Removal and installation service points 11A/28
CamPro-CFE engine.
– Intake manifold
Exhaust Manifold • New design, procedure and
graphic for CamPro-CFE engine
• Removal and installation service points
is included.
– Turbocharger heatshield bracket
• Additional part is included to
– Exhaust manifold heatshield
– Exhaust manifold 11A/31 engine – Turbocharger assy, tur-
– Brace support bracket
bocharger heatshield bracket,
– Turbocharger assy
brace support bracket, recircula-
– Recirculation pump
tion pump, oil drain pipe and oil
– Oil drain pipe
feed pipe.
– Oil feed pipe
Timing Belt • New design, procedure and
• Removal and Installation service points graphic for CamPro-CFE engine
11A/41
is included – VVT sprocket and
mechanical tappet.

00 GENERAL
/6 AIR BAG SYSTEM INFORMATION
Change Items Reference Page Description of Changes

Water Pump and Water Hose • Additional part is included to
• Removal and installation service points 11A/54 correspond with the CamPro-CFE
– Oil cooler engine – Oil cooler.
Cylinder Head and Valves • Additional special tool is in-
cluded to correspond with the
• Removal and Installation
CamPro-CFE engine – Cylinder
– Tappet
head valve jig.
11A/85
• New procedure for removal and
installation CamPro-CFE engine
is included – Mechanical tappet
and cylinder head
Oil Pump and Oil Pan • Additional part is included to
• Removal and Installation 11A/96 correspond with the CamPro-CFE
– Windage tray engine – Windage tray.
Piston and Connecting Rods
• Installation & removal service points • New design, procedure and
– Piston 11A/104
graphic for CamPro-CFE engine.
– Connecting rod
– Piston pin and piston pin circlip
Crankshaft and Cylinder Block • New design, procedure and
graphic for CamPro-CFE engine.
• Removal and Installation service points
11A/117 • Additional part is included to
– Direct damper flywheel <CVT3>
– Crankshaft assy
engine – Oil jet.
– Oil jet
AIR BAG SYSTEM INFORMATION WEO000BSERV11001
This vehicle has an air bag system which will supplement the seat belt in certain frontal collisions. The
air bag is not a substitute for the seat belt in any type of collision. The drivers and all other occupants
should wear seat belts at all times. Warning if the “SRS” warning light does not illuminate for several
seconds when the ignition key is turned to “ON” or the engine is started or if the warning light stays
on while driving, take the vehicle to your nearest authorized dealer immediately. Also if the vehicle's
front end is damaged or if the airbag has deployed, take the vehicle for service immediately. The air
bag system must be inspected by an authorized dealer ten years after the date of vehicle registration.
Read the “SRS” section of your owner's manual before driving for important information about op-
eration and service of the air bag system. When you are going to discard your gas generator or vehicle,
please see your dealer.
WARNING
(1) Improper service or maintenance of any component of the SRS or any SRS —related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative.)
(2) SRS components should not be subjected to heat over 85 °C (185 °F) , so remove the SRS-ECU, air
bag module and clock spring before drying or baking the vehicle after painting.
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized dealer.
(4) Dealer personnel must thoroughly review Chassis Manual, and especially its GROUP 52B - Supple-
mental Restraint System (SRS), before beginning any service or maintenance of any component
of the SRS or any SRS-related component.

GENERAL 00
HOW TO USE THIS MANUAL /7
NOTE :
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring
warnings.
HOW TO USE THIS MANUAL WEO000READS11001
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however, that for engine and transmission-related component
parts, this manual covers only on-vehicle inspections, adjustments and the removal and installation
procedures for major components. For detailed information concerning the inspection, checking, ad-
justment, disassembly and reassembly of the engine, transmission and major components after they
have been removed from the vehicle, please refer to separate manuals covering the engine and the
transmission.
ON-VEHICLE SERVICE
“On-Vehicle Service” is a procedure for performing inspections and adjustments of particularly import-
ant locations with regard to the construction and for maintenance and servicing, but other inspections
(for looseness, play, cracking, damage and etc.) must also be performed.
INSPECTION
Under this title are presented inspection and checking procedures to be performed by using special
tools and measuring instruments and by feeling but for actual maintenance and servicing procedures,
visual inspections should always be performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value as the standard for judging the quality of a part of assembly on inspection or the
value to which the part or assembly is corrected and adjusted. It is given by tolerance.
LIMIT
Shown the standard for judging the quality of a part or assembly on inspection and means the max-
imum or minimum value within which the part or assembly must be kept functionally or in strength.
It is a value established outside the range of standard value.
REFERENCE VALUE
Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly
and adjustment procedures, and so they can be completed in a shorter time).
CAUTION :
Indicates the presentation of information particularly vital to the worker during the performance of
maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or
damage to component parts, or a reduction of component or vehicle function or performance, etc.
INDICATION OF TIGHTENING TORQUE
The tightening torque shown in this manual is a basic value with a tolerance of ±10% except the fol-
lowing cases when the upper and lower limits of tightening torques are given.
1. The tolerance of the basic value is within ±10%
2. Special bolts or nuts are in use.
3. Special tightening methods are used.

00 GENERAL
/8 HOW TO USE THIS MANUAL
EXPLANATION OF MANUAL CONTENTS WEO000READS11002
DOIIC000R9001

GENERAL 00
HOW TO USE THIS MANUAL /9
SYMBOL DESCRIPTION
A Indicates the group title
B Indicates the section title
C Indicates the group number
D Indicates the page number
E Component Diagram
A diagram of the component parts is provided near the front of each section in order
to give a reader a better understanding of the installed condition of the component
parts.
F Denotes non reusable part
G Denotes tightening torque.
For bolts and nuts which do not have a tightening torque listed, refer to the “Tighten-
ing torque”
H Symbol for lubrication sealants and adhesives.
Information concerning the locations for lubrication and for application of sealants
and adhesives is provided, by using symbols, in the diagrams of component parts or
on the page following the component parts page, and explained.
Grease (multipurpose grease unless there is a brand

or type specified)
DOIIC000R9058
Sealant or adhesive
DOIIC000R9059
Brake fluid or automatic transmission fluid

DOIIC000R9060
Engine oil, gear oil or air condition compressor oil

DOIIC000R9061
Adhesive tape or butyl rubber tape.

DOIIC000R9062
Indicates procedures to be performed before the work in that section is started, and
J
procedures to be performed after the work in that section is finished.
Maintenance and servicing Procedures
The number provided within the diagram individual the sequence for maintenance
and servicing procedures.
1. A diagram of the components part is provided near the front of each section in
K order to give the reader a better understanding of the installed condition of
component parts.
2. The number provided within the diagram indicate the sequence for maintenance
and servicing procedures; the symbol N indicates a non reusable part; the tightening
torque is provided where applicable.
Removal steps:
The part designation number correspond to the number in the illustration to indicate
removal steps.

00 GENERAL
/ 10 HOW TO USE THIS MANUAL
SYMBOL DESCRIPTION
Disassembly steps:
The part designation number correspond to the number in the illustration to indicate
disassembly steps.
Installation steps:
Specified in case installation is impossible in reverse order of removal steps
Reassembly steps:
Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted
if reassembly is possible in reverse order of disassembly steps.
Classifications of major maintenance/service points
When there are major points relative to maintenance and serving procedures (such as
L essential maintenance and service points, maintenance and service standard values,
information regarding the use of special tools, etc.) these are arranges together as
major maintenance and service points and explained in detail.
Indicates that there are essentials point for removal

or disassembly.
DOIIC000R9052
Indicates that there are essential point for installation

or reassembly
DOIIC000R9051
Indicates that there are essential points for both

DOIIC000R9053
M Operating procedures, caution etc. on removal, installation disassembly and reassembly

and reassembly are described.
N Table for graphic explaination

GENERAL 00
ENGINE MODEL AND SERIAL NUMBER LOCATION / 11
ENGINE MODEL AND SERIAL

NUMBER LOCATION WEO000GINFO11001
1. The engine model number is stamped at the

cylinder block as shown in the following.
Engine Model Engine Displacement

S4PH-CFE 1561 cm³ (95.25 cu.in)
2. The engine serial number is stamped near
the engine model number.
Engine serial number [Example]

DOINE11AR11151 AA0201 to YY9999
TIGHTENING TORQUE WEO000TTORQ11001
General tightening torque is as shown in the following table.

The specified part tightening torque is shown at the beginning of each group.
STANDARD PARTS TIGHTENING TORQUE
TIGHTENING TORQUE OF FLANGE BOLT
Classification
Flange bolt (Dia.) Thread size (Pitch x length) Specified torque
M5 0.6 mm (0.024 in) ± 0.1 kgm (1 Nm, 0.72
0.8 x 30 mm (0.031 x 1.18 in)
ft.lbs)
1.0 x 10 mm (0.039 x 0.39 in)
1.0 x 12 mm (0.039 x 0.47 in)
1.0 x 18 mm (0.039 x 0.71 in)
M6 1.0 x 20 mm (0.039 x 0.79 in) 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
1.0 x 25 mm (0.039 x 0.98 in)
1.0 x 35 mm (0.039 x 1.38 in)
1.0 x 50 mm (0.039 x 1.97 in)
1.25 x 16 mm (0.049 x 0.63 in)
1.25 x 25 mm (0.049 x 0.98 in)
2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
1.25 x 30 mm (0.049 x 1.18 in)
M8
1.25 x 40 mm (0.049 x 1.57 in)
1.25 x 70 mm (0.049 x 2.76 in) 1.2 kgm (12 Nm, 8.68 ft.lbs) ± 0.1 kgm (1
1.25 x 100 mm (0.049 x 3.94 in) Nm, 0.72 ft.lbs)
1.25 x 18 mm (0.049 x 0.71 in) SP 4.5-5.2 kgm (45-52 Nm, 32.55-37.61 ft.lbs)
1.25 x 25 mm (0.049 x 0.98 in) 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
M10 1.25 x 35 mm (0.049 x 1.38 in) 3.3-3.7 mm (0.13-0.15 in)
TIGHTENING TORQUE OF BOLT (SPECIAL)
Classification
Bolt (Dia.) Thread size (Pitch x length) Specified torque
M8 43 mm (1.69 in) 2.0 kgm (20 Nm, 14.47 ft.lbs) + 60°

00 GENERAL
/ 12 PRECAUTION BEFORE SERVICE
Classification
Bolt (Dia.) Thread size (Pitch x length) Specified torque
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs) + 4.0 kgm (40 Nm, 28.93
ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 5.0
M9 160 mm (6.3 in) ± 0.35 mm (0.014 in)
kgm (50 Nm, 36.16 ft.lbs) ± 0.2 kgm (2 Nm,
1.45 ft.lbs) + 60°(min), 64° (max) and
60°(min), 64° (max).
1.25 x 105 mm (0.049 x 4.13 in) 3.3-3.7 mm (0.13-0.15 in)
M10
4.91 kgm (49.1 Nm, 35.51 ft.lbs) ± 5.39 kgm
69 mm (2.72 in)
(53.9 Nm, 38.99 ft.lbs)
17.5 mm (0.69 in) 5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.2 kgm (2
26 mm (1.02 in) Nm, 1.45 ft.lbs) + 60°± 2°
M12
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 mm
30 mm (1.18 in)
(0.008 in) + 40 ± 2°
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2
M14 70 mm (2.76 in)
Nm, 1.45 ft.lbs) +120° ± 4°
TIGHTENING TORQUE OF FLANGE NUT (SPECIAL)
Classification
Flange nut (Dia.) Thread size (Pitch) Specified torque
M6 1.0 mm (0.039 in) 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
TIGHTENING TORQUE SCREW (SPECIAL)
Classification
Screw (Dia.) Thread size (Pitch) Specified torque
M6
TIGHTENING TORQUE STUD (SPECIAL)
Classification
Stud (Dia.) Thread size (Pitch x length) Specified torque
M6 1.0 x 50 mm (0.039 x 1.97 in) 0.5 kgm (5 Nm, 3.62 ft.lbs)
1.25 x 40 mm (0.049 x 1.57 in)
1.25 x 65 mm (0.049 x 2.56 in)
PRECAUTION BEFORE SERVICE WEO000BSERV11002
When the engine or transmission is disassembled and reassembled, pay attention to the following.

GENERAL 00
PRECAUTION BEFORE SERVICE / 13
Removal and Disassembly For prevention of wrong installation or reas-

sembly and for ease of operation, put mating
mark (A) to the parts where no function is ad-
versely affected.
DOIIE00AR9001
Tightening Torque Tighten the part properly to specified torque.
DOIIE00AR9002
Replacement Part When oil seal, O-ring, packing and gasket have
been removed, be sure to replace them with
new parts.
However, rocker cover gasket may be reused if
it is not damaged.
DOIIE00AR9003
Oil and Grease Before reassembly, apply specified oil to the

rotating and sliding parts.
DOIIE00AR9004

00 GENERAL
/ 14 PRECAUTION BEFORE SERVICE
Special Tool Be sure to use Special Tools when their use is

specified for the operation. Use of substitute
tools will resulting malfunction of the part or
damage it.
DOIIE00AR9005
Sealant Use specified brand of sealant.

Use of sealant other than specified sealant may
cause water or oil leaks.
DOIIE00AR9006
Rubber Part Do not stain timing belt and V-belt with oil or
water.
Therefore, do not cleaned the pulley and
sprocket with detergent.
DOIIE00AR9007
Genuine Part When the part is replace, be sure to use Proton

genuine part.
For selection of appropriate part, refer to the
Parts Catalog.
DOIIE00AR9008

ENGINE <S4P-CFE> 11A
Content /1
11A ENGINE <S4P-CFE>

SPECIFICATIONS ....................................................................... 11A/4
SERVICE SPECIFICATIONS .......................................................... 11A/4
TORQUE SPECIFICATIONS ......................................................... 11A/5
NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING 11A/9
BOLTS ..................................................................................
SEALANTS ............................................................................ 11A/9
FORM-IN-PLACE GASKET(FIPG) ................................................... 11A/9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/10
Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/10
From-in-Place Gasket Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/10
SPECIAL TOOLS ........................................................................ 11A/10
ALTERNATOR AND IGNITION SYSTEM ............................................ 11A/14

REMOVAL AND INSTALLATION ................................................... 11A/14
REMOVAL SERVICE POINTS ....................................................... 11A/16
INSTALLATION SERVICE POINTS .................................................. 11A/17
FEAD BELT ROUTE .................................................................. 11A/22
FUEL AND EMISSION CONTROL SYSTEM ........................................ 11A/25

INTAKE MANIFOLD ................................................................... 11A/28

EXHAUST MANIFOLD ................................................................ 11A/31

TIMING BELT ........................................................................... 11A/41

REMOVAL AND INSTALLATION .................................................. 11A/41
WATER PUMP AND WATER HOSE ................................................. 11A/54

CAMSHAFT AND TAPPET ........................................................... 11A/63

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/65
INSPECTION .......................................................................... 11A/84
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/84

/2 Content
CYLINDER HEAD AND VALVES ..................................................... 11A/85

INSPECTION .......................................................................... 11A/92
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/92
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/93
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/93
OIL PUMP AND OIL PAN ............................................................. 11A/96

REMOVAL SERVICE POINT ......................................................... 11A/98
INSPECTION .......................................................................... 11A/102
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/102
PISTON AND CONNECTING RODS ................................................. 11A/104

INSPECTION .......................................................................... 11A/108
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/108
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) . . . . . . . . . . . . . . . . . . . . . . 11A/108
CRANKSHAFT AND CYLINDER BLOCK ............................................ 11A/117

INSPECTION .......................................................................... 11A/120
CRANKSHAFT OIL CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/120
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/120
BORING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/121
REMOVAL AND INSTALLATION SERVICE POINTS ............................. 11A/128

Content /3
NOTE

/4 SPECIFICATIONS
SPECIFICATIONS WEO11ASPECS11008
SERVICE SPECIFICATIONS
Items Standard Limit
Camshaft
Intake 27.05 mm (1.06 in) 26.55 mm (1.05 in)
Camshaft cam height
Exhaust 26.70 mm (1.05 in) 26.20 mm (1.03 in)
Camshaft journal diameter 27.94-27.96 mm (1.1-1.1 in) —
Cylinder head and valves
Flatness of cylinder head gasket surface 0.1 mm (0.004 in) or less —
Cylinder head gasket surface grinding limit (includ- 0.2 mm (0.008 in)
—
ing grinding of cylinder block gasket surface) (E)
Cylinder head overall height 134.7 mm (5.3 in)±0.25 mm
—
(0.01 in)
Cylinder head bolt nominal length 160 mm (6.3 in) 0.35 mm (0.014 in)
Intake 1.0 mm (0.039 in) 0.5 mm (0.02 in)
Valve margin
Intake 5.0 mm (0.2 in) —
Valve stem diameter
Exhaust 5.0 mm (0.2 in) —
Intake 0.02-0.047 mm (0.001-0.002 0.10 mm (0.004 in)
in)
Valve stem-to-guide clearance
Exhaust 0.03-0.057 mm (0.001-0.002 0.15 mm (0.006 in)
in)
Valve face angle 45°± 0.25° —
Intake 44.6 mm (1.76 in) —
Valve stem projection
Intake 101.50 mm (4 in) 101.00 mm (3.98 in)
(E)
Overall valve length
(E)
Intake 38.17 mm (1.5 in) 37.17 mm (1.46 in)
(E)
Valve spring free height
(E)
Valve spring load / installed height Intake 22.5 kg (225 N, 49.61
—
lbs)/30.27 mm (1.19 in)
Exhaust 22.5 kg (225 N, 49.61
—
lbs)/30.27 mm (1.19 in)
Valve spring squareness 1.59° 3° (E)
Valve seat contact width 0.9-1.3 mm (0.035-0.051 in) —
Valve guide internal diameter 5.0 mm (0.2 in) —
Valve guide projection Intake 12.0 mm (0.47 in) —
Oil pump and oil pan
Oil pump tip clearance 0.06-0.18 mm (0.002-0.007
—
in)

SPECIFICATIONS /5
Items Standard Limit

Oil pump side clearance 0.03-0.10 mm (0.001-0.004
—
in)
Oil pump body clearance 0.04-0.10 mm (0.002-0.004 0.35 mm (0.014 in)
in)
Pistons and connecting rods
Piston outside diameter 75.975 mm (2.99 in) —
No. 1 ring 0.03-0.05 mm (0.001-0.002
—
in)
Piston ring side clearance
No. 2 ring 0.02-0.04 mm (0.001-0.002
—
in)
No. 1 ring 0.2-0.35 mm (0.008-0.014 in) 0.5 mm (0.02 in)
No. 2 ring 0.37-0.57 mm (0.015-0.022 0.5 mm (0.02 in)
Piston ring and gap clearance
in)
Oil ring 0.2-0.5 mm (0.008-0.02 in) 1.0 mm (0.039 in)
Piston pin O.D. 18.0 mm (0.71 in) —
Crankshaft pin oil clearance 0.02-0.044 mm (0.001-0.002 0.1 mm (0.004 in)
in)
Connecting rod big end side clearance 0.1-0.25 mm (0.004-0.01 in) 0.4 mm (0.016 in)
Crankshaft and cylinder block
Crankshaft end play 0.05-0.18 mm (0.002-0.007 0.25 mm (0.01 in)
in)
Crankshaft journal diameter 48.0 mm (1.89 in) —
Crankshaft pin diameter 46.0 mm (1.81 in) —
Crankshaft journal oil clearance 0.02-0.044 mm (0.001-0.002 0.1 mm (0.004 in)
in)
Cylinder block gasket surface flatness 0.03 mm (0.001 in) —
Cylinder block gasket surface grinding limit (includ- 0.2 mm (0.008 in)
—
ing grinding of cylinder head gasket surface)
Cylinder block overall height 255.85-256.15 mm (10.07-
—
10.08 in)
Cylinder block cylindricity 0.025 mm (0.001 in) —
Cylinder block I.D. (Bore) 76.0 mm (2.99 in) —
Piston to cylinder clearance 0.01-0.03 mm (0-0.001 in) —
TORQUE SPECIFICATIONS WEO11ASPECS11010
Items Value
Alternator, power steering pump, air-cond compressor and ignition system
Water pump pulley bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Alternator bolt (alternator side) 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Alternator pivot nut 3.3-3.7 kgm (33-37 Nm, 23.87-26.76 ft.lbs)
M8 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Fead belt tensioner bolt
M10 4.8-5.2 kgm (48-52 Nm, 34.72-37.61 ft.lbs)
Oil level gauge guide bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)

/6 SPECIFICATIONS
Items Value
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45
TV damper bolt
ft.lbs) + 120°± 4°
1.75 kgm (17.5 Nm, 12.66 ft.lbs) ± 0.25 kgm (2.5
Spark plug
Nm, 1.81 ft.lbs)
Plug top coil bolt
ft.lbs)
Cam shaft sensor bolt
ft.lbs)
Oil control valve bolt 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Power steering pump bolt 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Air-cond compressor bolt 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Timing belt
Upper 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Timing belt cover bolt
Lower 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2 Nm,
Timing belt tensioner bolt
1.45 ft.lbs)
Bolt M8 2.4 - 2.6 kgm (24 - 26 Nm, 17.36 - 18.81 ft.lbs)
Engine mounting bracket
Bolt M10 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)
(left)
Nut 3.3-3.7 kgm (33-37 Nm, 23.87-26.76 ft.lbs)
Back plate bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Intake 5.5-6.5 kgm (55-65 Nm, 39.78-47.01 ft.lbs)
Camshaft sprocket bolt 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45
Exhaust
ft.lbs) + 40±2°
VVT bolt cap 3.0- 3.4 kgm (30- 34 Nm, 21.7- 24.59 ft.lbs)
Fuel system and emission system
Bracket harness fuel rail 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Throttle body bolt and bracket 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Fuel rail bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Water pump
Thermostat pipe assembly bolt 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Coolant temperature sensor 2.5-2.9 kgm (25-29 Nm, 18.08-20.98 ft.lbs)
Water pump bolt
ft.lbs)
M6 0.9- 1.1 kgm (9- 11 Nm, 6.51- 7.96 ft.lbs)
Bracket oil cooler
M10 3.3- 3.5 kgm (33- 35 Nm, 23.87- 25.32 ft.lbs)
Exhaust manifold and intake manifold
MAP sensor bolt
ft.lbs)
Intake manifold bolt and nut
0.72 ft.lbs)
Exhaust manifold heatshield bolt
1.45 ft.lbs)

SPECIFICATIONS /7
Items Value
Step Remark Value
(Nut no.1 to
no. 8 in as- 2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2 Nm,
1
cending or- 1.45 ft.lbs)
Exhaust manifold nut der)
(Nut no.1 to
no. 8 in as- 2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2 Nm,
2
cending or- 1.45 ft.lbs)
der)
Turbocharger heatshield bracket 0.9- 1.1 kgm (9- 11 Nm, 6.51- 7.96 ft.lbs)
Bolt
3.62 ft.lbs)
Brace support bracket
Nut
1.45 ft.lbs)
Turbocharger assy
3.62 ft.lbs)
Bracket bolt 0.6- 0.8 kgm (6- 8 Nm, 4.34- 5.79 ft.lbs)
Oil feed pipe
Banjo bolt 1.45- 1.75 kgm (14.5- 17.5 Nm, 10.49- 12.66 ft.lbs)
Bolt allen 0.9- 1.1 kgm (9- 11 Nm, 6.51- 7.96 ft.lbs)
Oil drain pipe
Banjo bolt 1.45- 1.75 kgm (14.5- 17.5 Nm, 10.49- 12.66 ft.lbs)
Pulse width modulation (PWM)
ft.lbs)
Electronic compressor relief valve (ECRV)
1.45 ft.lbs)
Lifting eye bolt 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Camshaft and Tappet lash adjuster
Cam cover bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Bearing cap bolt 0.9- 1.1 kgm (9- 11 Nm, 6.51- 7.96 ft.lbs)
Cylinder head and valves

/8 SPECIFICATIONS
Items Value
Step Remark Value
One bolt at
a time. Fol-
A low se-
1.45 ft.lbs)
quence no. 1
to no. 10
One bolt at
a time. Fol-
B low se-
ft.lbs)
quence no. 1
Cylinder head bolt to no. 10
One bolt at
a time. Fol-
C low se- 90°(min)
quence no. 1
to no. 10
One bolt at
a time. Fol-
D low se- 90°(min)
quence no. 1
to no. 10
Oil pump and oil pan
Oil pan bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Drain plug
3.62 ft.lbs)
Oil pan windage tray
ft.lbs)
Oil pan baffle bolt
ft.lbs)
Oil pick up pipe bolt
ft.lbs)
Front case bolt
ft.lbs)
Oil filter 1.2-1.6 kgm (12-16 Nm, 8.68-11.57 ft.lbs)
Relief valve
3.62 ft.lbs)
Oil pump backplate screw
1.45 ft.lbs)
Crank sensor 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Stud (Special) 0.8 - 1.2 kgm (8 - 12 Nm, 5.79 - 8.68 ft.lbs)
Pistons and connecting rods
2.2 kgm (22 Nm, 15.91 ft.lbs) ±0.2 kgm (2 Nm, 1.45
Connecting rod bolt
ft.lbs) + 90° ± 5°
Crankshaft and cylinder block
Direct damper flywheel bolt (DDF) 8.0- 9.0 kgm (80- 90 Nm, 57.86- 65.1 ft.lbs)
Rear plate bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Rear oil seal case bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)

SPECIFICATIONS /9
Items Value
Bearing cap bolt 4.91-5.39 kgm (49.1-53.9 Nm, 35.51-38.99 ft.lbs)
Oil pressure switch
ft.lbs)
Oil jet bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.2 kgm (2 Nm, 1.45
ft.lbs)
Knock sensor 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Target wheel (Patch lock screw) 0.9- 1.1 kgm (9- 11 Nm, 6.51- 7.96 ft.lbs)
NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTS WEO11ASPECS11011
Part of the engine use plastic region tightening bolts. The tightening procedure for these is different
from that of conventional bolts and is described in relevant parts of this manual. Note that plastic
region tightening bolts have fixed service limits. These are indicated in relevant parts of this manual
and must be strictly observed.
• Plastic region tightening bolts are used for the following applications:
1. Cylinder head bolts
• The tightening procedure is basically as follows:
After tightening a bolt to the specified torque, tighten the bolt with 2 times additional torque
angle.
The fist torque angle must within 60° (min) and 64° (max). It will be followed by second torque
angle with also within 60° (min) and 64° (max).
The exact tightening procedure differs depending on the bolt and is described in relevant parts
of this manual.
SEALANTS
Items Specified sealant Quantity
Oil pan
Threebond 1207F
Oil seal rear
Bushing knock
Threebond
Pin dowel
Plug tapper
TB 2403
Backplate cover bolt
Cylinder head (Cam bearing cap) TB 1110B
As required
Intake manifold bracket bolt TB 2440B
TB 1130
Oil pressure switch
3M ATD Part No.8660 or equivalent
Direct damper flywheel bolt
3M Nut Locking Part No.4171 or equivalent
Engine coolant temperature sensor
Piston – Connecting rod Yugen Kugyo Standards DS-711 or equival-
ent
FORM-IN-PLACE GASKET(FIPG) WEO11ASPECS11012
The engine has several areas where the form-in place gasket (FIPG) is in use. To ensure that the gasket
fully servesits purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too
thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing
of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore , it is absolutely ne-
cessary to apply the gasket evenly without a break, while observing the correct bead size.

/ 10 SPECIAL TOOLS
The FIPG used in the engine is a room temperature vulcanization (RTV) type and is supplied in a
100–gram tube (Part No. MD970389, MD997110 or PC111001). Since the RTV hardens as it reacts with
the moisture in the atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No.
MD970389, can be used for sealing both engine oil and coolant, while Part No. MD970389, MD997110
or PC111001 can only be used for engine oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly
striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in
between the joined surfaces. In this case, however, care must be taken to prevent damage to the
joined surfaces. For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available.
Be sure to use the special tool to remove the oil pan. <Except aluminium die-cast oil pans>
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
From-in-Place Gasket Application
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. also be sure to encircle the bolt
hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition,
do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of
time (about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
SPECIAL TOOLS WEO11ASTOOL11004
Tool Number Name Use

EZT 0011 Crankshaft rear oil Installation of crankshaft
seal installer rear oil seal
DOIHC11AR04045
MD998054 Oil pressure switch Removal and installation of

wrench oil pressure switch
DOIIE11AR9004

SPECIAL TOOLS / 11

MD998304 Crankshaft front oil Installation of crankshaft
seal installer front oil seal
DOIIE11AR9005
MD998305 Crankshaft front oil Guide for installation of

seal guide crankshaft front oil seal
DOIIE11AR9006
MB991653 Cylinder head bolt Removal and installation of

wrench (10) cylinder head bolt
DOIIE11AR9016
MB991396 Oil filter wrench Removal and installation of

engine oil filter (When using
the oil filter of MD135737)
DOIIC012R9001
MD998770 Oxygen (Lambda) Removal and installation of

sensor wrench Oxygen (Lambda) sensor and
coolant temperature sensor
DOIIC015R9001
Mot. 59104 Angle gauge To get accurate angle during

00 00 059 104 installing cylinder head bolt
and TV damper bolt
DOIGE11AR03136
EZT 0001 Valve collet installer To insert valve collet into

valve groove accurately
DOIGE11AR03132

/ 12 SPECIAL TOOLS

EZT 0002 Valve collet remover To remove valve collet
DOIGE11AR03162
EZT 0003 TV damper stopper To lock TV damper from

turning
DOIGE11AR03105
EZT 0005 Valve stem seal plier To install and remove valve
stem seal and spring seat
from valve
DOIGE11AR03104
EZT 0006 Camshaft oil seal in- Installation of camshaft oil

staller seal
DOIGE11AR03155
EZT 0007 TV damper bolt To turn crankshaft sprocket

dummy during aligning timing belt
DOIGE11AR03146
EZT 0008 Con rod jig To guide connecting rod and

connecting rod bearing dur-
ing installation
DOIGE11AR03160
To prevent camshaft sprock-

Camshaft Sprocket
EZT 0004 et from turning during in-
Stopper
stalling timing belt
DOIGE11AR03134

SPECIAL TOOLS / 13
EZT 0044 Flywheel Stopper To lock flywheel
DOIME11AR11051
To support valve during re-

Cylinder Head Valve
EZT 0046 moving and installing valve
Jig
collet
DOIME11AR11053
Holding camshaft sprocket

MB990767 End Yoke holder when loosening or tighten-
ing bolt (used MD998715)
DOIIE11AR9002
Holding camshaft sprocket

MD998715 Pin (2–off) when loosening or tighten-
ing bolt (used MD990767)
DOIIE11AR9008
To lock VVT camshaft before

EZT 0043 VVT Camshaft Stopper loosening or tightening VVT
camshaft sprocket.
DOINE11AR12013

/ 14 ALTERNATOR AND IGNITION SYSTEM
ALTERNATOR AND IGNITION SYSTEM WEO11ASASSY10002
REMOVAL AND INSTALLATION
DOINE11AR10001

ALTERNATOR AND IGNITION SYSTEM / 15
Pre-removal and post-installation operation.

● Cam shaft sensor (Refer Workshop Manual Chassis GROUP 13A, Fuel- On Vehicle Service- Cam shaft
sensor)
● Alternator (Refer Workshop Manual Chassis GROUP 016- Alternator Disassembly And Reassembly
Service Point)
● Spark plug (Refer Workshop Manual Chassis GROUP 016, Ignition System- Inspection)
● Plug top coil (Refer Workshop Manual Chassis GROUP 016, Ignition System- Inspection)
● Oil control valve (Refer Workshop Manual Chassis GROUP 13A, Fuel- On Vehicle Service- Oil Control
Valve Installation Service Point)
: Non-reusable parts
Removal steps :
1. Plug top coil
2. Spark plug
3. Cam shaft sensor
4. Oil control valve
5. Fead belt
6. Fead belt tensioner
7. Alternator
8. Water pump pulley
9. Power steering pump
10. Air-cond compressor
11. TV damper pulley
12. Oil level gauge
13. Oil level gauge guide
T1 : 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T2 : 1.75 kgm (17.5 Nm, 12.66 ft.lbs) ± 0.25 kgm (2.5 Nm, 1.81 ft.lbs)
T4 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T5 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T6 : 3.3 - 3.7 kgm (33 - 37 Nm, 23.87 - 26.76 ft.lbs)
T7 : 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 120° ± 4°
T8 : 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)

REMOVAL SERVICE POINTS WEO11ASPROC10001
WATER PUMP PULLEY REMOVAL

1. Before removing fead belt, loosen 3 pieces
water pump pulley bolts.
Symbol Description
A Ratchet
B Water pump pulley bolts
DOINE11AR11041
TV DAMPER BOLT AND TV DAMPER

REMOVAL
1. Use the special tool (EZT 0003) to hold the
TV damper in order to loose TV damper bolt.
Symbol Description
A TV damper bolt
B TV damper pulley
C Dowel
D Crankshaft
E Sprocket crankshaft
DOIGE11AR03156

INSTALLATION SERVICE POINTS

TV DAMPER BOLT AND TV DAMPER
INSTALLATION
1. Hold TV damper by using special tool (EZT
0003).
Symbol Description
A TV damper bolt
B TV damper pulley
C Dowel
D Crankshaft
E Sprocket crankshaft
2. Tighten TV damper bolt to the specified
torque.
Specified torque (T7):
Steps Specified torque

3.0 kgm (30 Nm, 21.7 ft.lbs) ±
1
0.2 kgm (2 Nm, 1.45 ft.lbs)
DOINE11AR11085
3. By using the special tool (MOT 591-04),

tighten the TV damper bolt by turning at
120° ± 4°.
DOINE11AR11156

WATER PUMP PULLEY INSTALLATION

1. Locate water pump pulley on the front case.
The “FRONT” marking on the water pump
pulley is facing towards the mechanic.
NOTE :
Make sure the ‘FRONT’ making must be the
same direction with water pump ‘DOT’ mark.
2. Install and tighten the bolts to the specified
torque.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Symbol Description
A Water pump pulley
B Water pump
C Bolt
D “FRONT” marking
DOIGE11AR03003
CAM POSITION SENSOR INSTALLATION

1. Tighten the cam position sensor bolt to the
specified torque.
Specified torque :
0.72 ft.lbs)
Symbol Description
A Cam position sensor
B Bolt
DOINE11AR11042

ALTERNATOR INSTALLATION
1. Install alternator lower bolt and nut to the
front cover assy. Pre-tighten 2 to 3 times the
alternator lower nut and lift up the alternat-
or to the correct position.
Symbol Description
A Alternator lower bolt
B Alternator lower nut
DOINE11AR11043
2. Tighten the alternator upper bolt to the

specified torque.
Specified torque :
2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Symbol Description
C Alternator upper bolt
DOINE11AR11157
3. Tighten alternator lower nut to the specified

torque.
Specified torque :
3.3 - 3.7 kgm (33 - 37 Nm, 23.87 - 26.76 ft.lbs)
Symbol Description
B Alternator lower nut
DOINE11AR11044

SPARK PLUG INSTALLATION

1. Install spark plug to cylinder head assy to the
specified torque.
Specified torque :
1.75 kgm (17.5 Nm, 12.66 ft.lbs) ± 0.25 kgm
(2.5 Nm, 1.81 ft.lbs)
Spark plug gap :

0.6 - 0.7 mm (0.024 - 0.028 in)
Symbol Description
A Spark plug
DOINE11AR11046
PLUG TOP COIL INSTALLATION

1. Ensure the plug top coil rubber shoulder
should seat properly on cam cover lip.
2. Tighten plug top coil to the specified torque.
Specified torque :
0.72 ft.lbs)
Symbol Description
A Section view
B Plug top coil rubber shoulder
DOINE11AR11045

OIL CONTROL VALVE INSTALLATION

1. Before installing the oil control valve to the
cylinder head, make sure the filter element
and o-ring are fixed properly in the oil con-
trol valve.
Insert the oil control valve into the cylinder
head and tighten the bolt to the specified
torque.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
CAUTION :
Ensure the filter element installed correctly
in order to prevent wrong installation and
cause engine operation failure.
Symbol Description
A Oil control valve
B O-ring
C Filter element
DOINE11AR11047

FEAD BELT ROUTE WEO11ASASSY10005
DOINE11AR11048
Symbol Description
1 Fead belt tensioner
2 TV damper
3 Air-cond compressor pulley
4 Power steering pulley
5 Water pump upper pulley
6 Alternator pulley
7 Water pump lower pulley
T5 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T8 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)

REMOVAL SERVICE POINTS

FEAD BELT REMOVAL
1. Insert ratchet into square hole on tensioner
arm.
2. Push the ratchet towards engine intake side
and pull out the fead belt from the alternat-
or.
3. Loosen the fead belt tensioner half way.
4. Remove the fead belt between the slot of
the loosed tensioner.
DOINE11AR11049

FEAD BELT INSTALLATION
1. Locate fead belt on top of power steering
pulley and tv damper.
DOIGE11AR03009
2. Install fead belt tensioner assy to the front

case as shown in the illustration. Tighten
fead belt tensioner bolt to the specified
torque.
Standard value torque :
2.2-2.6 kgm (22-26 Nm, 15.91-

T5
18.81 ft.lbs)
4.8-5.2 kgm (48-52 Nm, 34.72-
T8
37.61 ft.lbs)
DOINE11AR11072
3. Wrap the fead belt around the tensioner

roller nicely.
NOTE :
Make sure the word “MITSUBOSHI” on the
fead belt is facing outward.
Symbol Description
A Fead belt
DOINE11AR11158

4. Insert ratchet into square hole on tensioner

arm.
Symbol Description
A Ratchet
DOIGC11AR03029
5. Wrap the fead belt around the pulleys anti-

clockwise in the sequence of 1 → 2 → 3 → 4
Symbol Description
A Ratchet
1 TV damper
2 Air-cond compressor pulley
3 Power steering pulley
4 Water pump pulley
DOIGC11AR03030
6. While ensuring no slack, push the ratchet

(A) toward engine to replace the fead belt
and then complete the belt installation
around alternator pulley and water pump
pulley.
Symbol Description
A Ratchet
5 Alternator pulley
6 Water pump pulley
Release the tensioner in position. Check and
DOINE11AR11050
adjust to ensure fead belt in correct and
good position.

FUEL AND EMISSION CONTROL SYSTEM / 25
FUEL AND EMISSION CONTROL SYSTEM WEO11ASASSY10009
DOINE11AR11125

• Injector (Refer Workshop Manual Chassis GROUP 13A- Injector)
— Lubricate all o-rings injector with engine oil during reassembly

: Non–reusable parts
Removal steps :
1. Bracket harness fuel rail 8. Throttle body seal
2. Fuel rail assy
3. Injector clip
4. O-ring
5. Injector
6. Bracket harness throttle body
7. Throttle body
T1 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)

/ 26 FUEL AND EMISSION CONTROL SYSTEM
INJECTORS REMOVAL
1. Remove the injector clip using screw driver.
2. Pull out the injector from fuel rail. Take care
not to drop the injectors.
Symbol Description
A Injector clip
B Fuel rail
C Injector
DOINE11AR11037 D Screw driver

INJECTORS INSTALLATION
1. Fit a new o-ring, on the injector.
Symbol Description
A O-ring
2. Coat the o-ring with oil.
CAUTION :
(1) Be sure not to let oil get into the fuel
rail.
DOIME13BR07004 (2) Beware not to insert injector slantingly.
3. Insert the injector top end onto the fuel rail

while turning the injector in both directions.
Make sure the injector turns smoothly. If the
injector does not turn smoothly, probable
cause is the O-ring which can bind in the fuel
rail.
Symbol Description
B Injector
C Fuel rail
DOINE11AR11039

FUEL AND EMISSION CONTROL SYSTEM / 27
4. Install a new injector clip by sliding the open

end onto the fuel rail and the injector slot.
Confirm that the injector clip is in close con-
tact with the fuel rail and the injector slot.
Symbol Description
D Injector clip
E Injector slot
DOIME13BR07006
THROTTLE BODY INSTALLATION

1. Install the throttle body gasket into the in-
take manifold groove.
2. Fix the throttle body to the intake manifold.
3. Tighten the 4 pcs throttle body bolt to the
specified torque.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Symbol Description
A Throttle body gasket
DOINE11AR11040
B Intake manifold groove
C Throttle body
D Throttle body bolts

/ 28 INTAKE MANIFOLD
INTAKE MANIFOLD WEO11ASASSY11019
DOINE11AR11128

• Intake manifold (Refer Workshop Manual Chassis GROUP 015- Disassembly And Reassembly Service
Point)
Removal steps :
1. Map sensor 6. Fuel vapor hose 2
2. Hose clamp 7. Breather hose 1 (Part load)
3. Purge solenoid valve 8. High tension clamp
4. Fuel vapor hose 1 9. Breather hose 2
5. No-return valve 10. Intake manifold

INTAKE MANIFOLD / 29

WEO11ASPROC11029
MAP SENSOR INSTALLATION

Install MAP sensor to intake manifold and tight-
en to the specified torque.
Specified torque (T1) :
0.72 ft.lbs)
Symbol Description
DOINE11AR11119
A MAP sensor
B Intake manifold
NO-RETURN VALVE INSTALLATION

Before installing the no-return valve, ensure the
arrow direction is facing to the electronic throttle
body.
Symbol Description
A No-return valve
B Arrow
DOIME11AR07014
INTAKE MANIFOLD INSTALLATION

1. Install intake manifold gasket into the intake
manifold groove as shown in the illustration.
Symbol Description
A Intake manifold gasket
B Intake manifold
C Intake manifold groove
DOINE11AR11121

/ 30 INTAKE MANIFOLD
2. Install intake manifold to the cylinder head

and then tighten bolt flange and nut to the
specified torque.
Tighten the bolt flange according to the se-
quence numbers as shown in the illustration.
Specified torque (C and E) :
2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.1 kgm (1
Nm, 0.72 ft.lbs)
Symbol Description
C Bolts
DOINE11AR11120
D Intake manifold
E Nuts
3. Install oil cooler bracket to the intake mani-
fold and then tighten the bracket bolt to the
following specified torque.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Symbol Description
A Bracket bolts
B Intake manifold
DOINE11AR11122

EXHAUST MANIFOLD / 31
EXHAUST MANIFOLD WEO11ASASSY11021
DOINE11AR11172
Pre-removal and post-installation.

• Turbocharger assy (Refer Workshop Manual Chassis GROUP 015 - Turbocharger Assy Disassembly
And Reassembly Service Point)
• Recirculation pump (Refer Workshop Manual Chassis GROUP 014 - Recirculation Pump Removal
And Installation)
Removal steps :
1. Oil feed pipe 10. Exhaust manifold gasket
2. Recirculation pump 11. Exhaust manifold
3. Oil drain pipe

4. Oil drain pipe gasket
5. Turbocharger assy
6. Turbocharger gasket
7. Turbocharger heatshield
bracket
8. Exhaust manifold heat-
shield
9. Brace support bracket

/ 32 EXHAUST MANIFOLD
T1 :0.6 - 0.8 kgm (6 - 8 Nm, 4.34 - 5.79 ft.lbs)

T2 :0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T3 :1.45 - 1.75 kgm (14.5 - 17.5 Nm, 10.49 - 12.66 ft.lbs)
T4 :2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T5 :2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.5 kgm (5 Nm, 3.62 ft.lbs)
T6 :2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs)
T7 : Tightening torque procedures for exhaust manifold
Steps Torque Bolt numbers
2.8 kgm (28 Nm, 20.25 ft.lbs) ±
A
0.2 kgm (2 Nm, 1.45 ft.lbs) Bolt no. 1 to no.8
2.8 kgm (28 Nm, 20.25 ft.lbs) ± In ascending order
B
0.2 kgm (2 Nm, 1.45 ft.lbs)

RECIRCULATION PUMP REMOVAL

1. Remove recirculation pump hose upper
clamp from turbocharger coolant feed pipe.
2. Then, remove recirculation pump hose lower
clamp from cylinder block.
Symbol Description
A Recirculation pump
Recirculation pump hose upper
B
DOINE11AR11079
clamp
C Coolant feed pipe
D Turbocharger assy
Recirculation pump hose lower
E
clamp
F Cylinder block
OIL FEED PIPE REMOVAL

1. Remove oil feed pipe banjo upper bolt.
Symbol Description
A Banjo upper bolt
DOINE11AR11078
2. Remove oil feed pipe banjo side bolt and oil

feed pipe bracket bolt.
Symbol Description
B Oil feed pipe banjo side bolt
C Oil feed pipe bracket bolt
DOINE11AR11123

OIL DRAIN PIPE REMOVAL

1. Remove oil drain pipe screw and gasket
lower side as shown in the illustration.
Symbol Description
A Oil drain pipe screw
B Gasket lower side
C Allen key
DOINE11AR10004
TURBOCHARGER ASSY REMOVAL

1. Remove 3 pcs nut turbocharger assy as shown
in the illustration.
Symbol Description
A Turbocharger assy
B Exhaust manifold
C Cylinder block
D Turbocharger assy nut
DOINE11AR11081

EXHAUST MANIFOLD HEATSHIELD

REMOVAL
1. Remove 4 pcs bolt exhaust manifold heat-
shield.
Symbol Description
A Exhaust manifold
B Exhaust manifold heatshield
C Bolt
DOINE11AR11138
BRACE SUPPORT BRACKET REMOVAL

1. Remove bolt and nut brace support bracket
as shown in illustration.
Symbol Description
A Exhaust manifold
B Brace support bracket
C Bolt
D Nut
DOINE11AR11139
EXHAUST MANIFOLD REMOVAL

1. Remove 8 pcs nut exhaust manifold.
Symbol Description
A Exhaust manifold
DOINE11AR11140


TURBOCHARGER ASSY INSTALLATION
1. Install turbocharger gasket as shown in the
illustration.
Symbol Description
A Turbocharger gasket
Turbocharger gasket part
B
number
C Turbocharger assy
D Exhaust manifold
DOINE11AR11137
2. Install turbocharger assy to exhaust manifold

and tighten the nut to the specified torque.
Specified torque (A) :
2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
Symbol Description
A Exhaust manifold nut
B Exhaust manifold
C Turbocharger assy
DOINE11AR10007

OIL DRAIN PIPE INSTALLATION

1. Insert gasket slot into pipe oil drain as shown
2. Install oil drain pipe allen bolt to cylinder
block and tighten to the specified torque.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Symbol Description
A Oil drain pipe allen bolt
B Oil drain pipe gasket
C Oil drain pipe
DOINE11AR10004
OIL FEED PIPE INSTALLATION

1. Pre-tighten banjo bolt with cooper washer
to the turbocharger as shown in the view C
and view D.
2. Then, tighten bolt banjo with cooper washer
to the specified torque.
1.45 - 1.75 kgm (14.5 - 17.5 Nm, 10.49 - 12.66
ft.lbs)
3. Tighten the oil feed pipe bracket to the spe-

cified torque.
0.6 - 0.8 kgm (6 - 8 Nm, 4.34 - 5.79 ft.lbs)
Symbol Description
A Cooper washer
B Banjo bolt
E Oil feed pipe bracket
DOINE11AR10010

RECIRCULATION PUMP INSTALLATION

1. Sub-assy recirculation pump is installed onto
the assy-engine before assy-transmission in-
stalled.
2. Install recirculation pump hose to turbo into
coolant feed pipe on turbocharger and se-
cure with clip A.
3. Install recirculation pump hose into connect-
or on cylinder block and secure with clip B.
4. Install sub-assy recirculation pump onto the
assy-transmission as show and secure with
bolt to specified torque.
Specified torque :
2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Symbol Description
A Clip A
B Clip B
C Recirculation pump
D Coolant feed pipe
NOTE :
1) Ensure the recirculation pump hose to turbo,
recirculation pump hose to block are free from
DOINE11AR11124 damage, foreign particles and oil.
2) Ensure install with fixing holes and white mark
is towards specified direction.
3) Use the specified clips.
EXHAUST MANIFOLD INSTALLATION

1. Install exhaust manifold gasket to cylinder
head studs as shown in the illustration.
NOTE :
Ensure the ‘UP’ marking at exhaust manifold
is facing to the exhaust manifold side.
Symbol Description
A Exhaust manifold gasket
B Exhaust manifold
DOINE11AR11141 C ‘UP’ marking

2. Install exhaust manifold (B) to cylinder head

studs.
According to the tightening sequence as
shown in the illustration, tighten the nuts to
the specified torque.
Step Torque Sequence proced-
ure
2.8 kgm (28
Nm, 20.25
1 ft.lbs) ± 0.2
kgm (2 Nm, Bolt no. 1 to no.
1.45 ft.lbs) 8
2.8 kgm (28 (In ascending or-
Nm, 20.25 der)
2 ft.lbs) ± 0.2
kgm (2 Nm,
1.45 ft.lbs)
DOINE11AR11142
EXHAUST MANIFOLD HEATSHIELD

INSTALLATION
1. Install exhaust manifold heatshield onto cyl-
inder head and then tighten to the specified
torque.
2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Symbol Description
A Exhaust manifold heatshield
DOINE11AR11143

BRACE SUPPORT BRACKET INSTALLATION

1. Install brace support bracket at cylinder block
and exhaust manifold sides.
2. Secure support brace by finger, tightening
bolt and nut .
3. Tighten the bolt and nut to the specified
tightening torque.
Symbol Description
A Bolt
B Nut
C Brace support bracket
Specified torque nut ( T1 ) :
2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
Specified torque bolt ( T2 ) :

2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.5 kgm (5
Nm, 3.62 ft.lbs)
DOINE11AR11083

TIMING BELT / 41
TIMING BELT WEO11ASASSY10006
DOINE11AR11114
Removal steps :
1. Timing belt upper cover 6. Crankshaft sprocket
2. Timing belt lower cover 7. VVT bolt cap
3. Engine mounting bracket 8. Camshaft exhaust sprocket
4. Timing belt tensioner 9. Camshaft VVT sprocket
5. Timing belt 10. Backplate cover
T1 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T3 : 3.3 - 3.7 kgm (33 - 37 Nm, 23.87 - 26.76 ft.lbs)
T4 : 2.4 - 2.6 kgm (24 - 26 Nm, 17.36 - 18.81 ft.lbs)
T5 : 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)
T6 : 3.0 - 3.4 kgm (30 - 34 Nm, 21.7 - 24.59 ft.lbs)

/ 42 TIMING BELT
TIMING BELT AND TIMING BELT TENSIONER

REMOVAL
1. Remove the timing belt upper cover stud bolt
from cylinder head by using standard tool.
Symbol Description
Timing belt upper cover stud
A
bolt
DOINE11AR11159
2. Align camshaft sprocket timing marks “A”

with cam cover marks “B”.
NOTE :
Ensure that crankshaft is safe position (90°
ATDC) for cylinder no. 1
Symbol Description
A Camshaft sprocket timing marks
B Cam cover marks
DOINE11AR11020
3. By using the special tool (EZT 0007), align the

crankshaft sprocket dowel pin to the front
case marking at one o’clock position.
Symbol Description
C Crankshaft sprocket dowel pin
D Front case marking
E TV damper bolt
DOIGE11AR03141
4. Insert the special tool in between two cam-

shaft sprockets in order to ensure the cam-
shaft sprockets “STOP” from turning.
Symbol Description
A Special tool (EZT 0004)
DOINE11AR11155

TIMING BELT / 43
5. If the timing belt is to be reuse, draw an ar-

row on the belt to indicate the rotation dir-
ection before removing the belt. This will
ensure the timing belt is fitted correctly
when it is reused.
DOINE11AR11023
6. Loosen the timing belt tensioner bolt by us-

ing ratchet. Then, remove the timing belt
tensioner and timing belt together.
CAUTION :
To remove the tensioner bolt, make sure to
use the correct socket in order to prevent
tensioner head bolt from damage and wear.
Symbol Description
A Single type socket box
B Ratchet
DOINE11AR11021 C Timing belt tensioner
CAMSHAFT VVT SPROCKET BOLT REMOVAL

1. Turn camshaft intake (VVT) and camshaft
exhaust until both sprockets marks located
at 5 o’clock position.
NOTE :
The position of the camshaft VVT locator
suppose to be at the top of the camshaft and
the exhaust locator suppose to be at the
bottom of the camshaft. At this position,
both camshafts are at the rest condition
without any pressure from the valves.
DOINE11AR12001

/ 44 TIMING BELT
2. Prepare a piece of clean cloth with an approx-

imate dimension as shown. Place the clean
cloth on the cylinder head at the area for the
special tool placement. Then, position the
special tool (EZT 0043) on top of the clean
cloth. The camshaft VVT locator position now
suppose to be align with the special tool
grooves. The special tool will lock the cam-
shaft VVT locator from turning during
loosening the sprocket bolt.
NOTE :
The purpose of using the clean cloth is to
DOINE11AR12002
avoid scratches on the cylinder head surface.
3. By using 2 pieces of cam cover bolts, fix the
special tool (EZT 0043) to the cylinder head
by pre-tightening the 2 pieces of bolts.
CAUTION :
Do not apply any torque on the 2 pieces cam
cover bolts. It might damage the camshafts.
DOINE11AR12003
4. Loosen the camshaft VVT sprocket bolt.
DOINE11AR12004
5. Remove the camshaft VVT sprocket from

engine.
DOINE11AR12005

TIMING BELT / 45
CAMSHAFT EXHAUST SPROCKET BOLT

REMOVAL
1. By using special tool as shown in the illustra-
tion, lock the camshaft exhaust sprocket.
2. Loosen the camshaft exhaust bolt.
Symbol Description
A Ring spanner
B Special tool (MB990767)
C Special tool (MD998715)
DOINE11AR11184

WEO11ASPROC10005
CAMSHAFT INLET (VVT) SPROCKET BOLT

INSTALLATION
1. Install the camshaft VVT sprocket into the
engine and pre-tighten the camshaft VVT
sprocket bolt accordingly.
NOTE :
The position of the camshaft VVT locator
suppose to be at the top of the camshaft and
DOINE11AR12006
the exhaust locator suppose to be at the
bottom of the camshaft. At this position,
both camshafts are at the rest condition
without any pressure from the valves.
2. Prepare a piece of cloth with an approximate
dimension as shown. Place the clean cloth
on the cylinder head at the area for the spe-
cial tool placement. Then, position the special
tool (EZT 0043) on top of the clean cloth. The
camshaft VVT locator position now suppose
to be align with the special tool grooves. The
special tool will lock the camshaft VVT locat-
or from turning during loosening the
sprocket bolt.
NOTE :
DOINE11AR12002
avoid scratches on the cylinder head surface.

/ 46 TIMING BELT

by pre-tightening the 2 pieces of bolts.
CAUTION :
4. Tighten the camshaft VVT sprocket to the
specified tightening torque.
Specified torque :
1.45 ft.lbs)
DOINE11AR12003
VVT BOLT CAP INSTALLATION

1. By using special tool (EZT 0043), lock the
camshaft VVT sprocket as shown in the illus-
tration.
2. Tighten the VVT bolt cap to the specified
torque.
Specified torque :
3.0 - 3.4 kgm (30 - 34 Nm, 21.7 - 24.59 ft.lbs)
Symbol Description
A Ratchet
DOINE11AR12008
B Socket
C Camshaft inlet (VVT) sprocket
D Special tool (EZT 0043)

TIMING BELT / 47

INSTALLATION
1. Place the camshaft exhaust sprocket on the
camshaft exhaust dowel pin as shown in the
illustration.
Symbol Description
A Camshaft exhaust dowel pin
DOINE11AR11104
2. By using special tool (MD998715), lock the

camshaft exhaust sprocket and tighten the
camshaft exhaust sprocket bolt to the spe-
cified torque as shown in the illustration.
Specified torque :
1.45 ft.lbs)
Symbol Description
A Special tool (MB990767)
B Special tool (MD998715)
DOINE11AR11185 C Torque wrench
TIMING BELT AND TIMING BELT TENSIONER

INSTALLATION
1. Align camshaft sprocket timing marks “B”
with cam cover marks “ A” and lock the
sprocket by using special tool as shown in il-
lustration.
NOTE :
Ensure that crankshaft is in a safe position
(90° ATDC) for cylinder no.1.
Symbol Description
DOINE11AR11027
A Cam cover marks

/ 48 TIMING BELT
Symbol Description
B Camshaft sprocket timing
marks
C Special tool (EZT 0004)
2. By using the special tool (EZT 0007) align the
crankshaft sprocket dowel pin to the front
case marking at one o’clock position.
Symbol Description
D Front case marking
E TV damper bolt
DOIGE11AR03024
3. Fit timing belt tensioner bearing by putting

the timing belt tensioner foot into the core
plug and ensure the allen key hole is posi-
tioned opposite to the foot as shown in illus-
tration.
Symbol Description
A Timing belt tensioner
B Timing belt tensioner foot
C Core plug
D Allen key hole
DOINE11AR11058 E Timing belt tensioner bolt
4. Pre-tighten the timing belt tensioner bolt by
hand.
5. Before installing the reused timing belt,
make sure the arrow mark on top of the
timing belt is facing to the right direction.
DOIGE11AR03177

TIMING BELT / 49
6. Firstly, fit timing belt halfway on to crank-

shaft sprocket and camshaft sprockets. Then,
fit timing belt around timing belt tensioner
pulley and push fully the timing belt onto all
sprockets and pulley as shown in the illustra-
tion.
Caution:
Ensure no slack along span 1 [S1] and span
2 [S2] area.
DOINE11AR11051
7. Turn the timing belt tensioner clockwise until

timing belt tensioner pointer indicator is ex-
actly over the right hand side edge of indic-
ator notch (refer view A). Then, tighten the
tensioner bolt whilst holding the Allen key
in place.
Specified torque :
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
Symbol Description
A Timing belt tensioner
Timing belt tensioner
B
pointer indicator
C Indicator notch
D Allen key
E Ratchet
DOINE11AR11053

/ 50 TIMING BELT
8. By using the special tool (EZT 0007) with TV

damper bolt, rotate the engine twice (720º
crankshaft rotation). Ensure the crankshaft
dowel pin marking is align back to the front
case.
CAUTION :
Remove special tool (EZT 0004) from it posi-
tion before rotating the crankshaft sprocket.
Symbol Description
E TV damper bolt
DOINE11AR11161
9. When the indicator stops within the nominal

position at the centre of the indicator notch,
the timing belt is in the required timing belt
tension specification as shown in the illustra-
tion.
DOINE11AR11052

TIMING BELT / 51
10. If the indicator does not stops within the

nominal position, insert the Allen key and
retain the installation shaft’s position while
loosening the tensioner bolt with torque
wrench. Then using the Allen key, slowly ro-
tate the installation shaft anti-clockwise until
the indicator moves to the free arm position
as shown. (View D)
Symbol Description
A Allen key
B Torque wrench
DOINE11AR11055
11. Rotate tensioner bearing clockwise until the

pointer is positioned in the centre of the
notch scale as shown. (View C)
12. Retighten tensioner bolt whilst holding the
Allen key in place.
Specified torque :
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
Symbol Description
A Allen key
B Torque wrench
DOINE11AR11056

/ 52 TIMING BELT
13. By using the special tool (EZT 0007) with TV

damper bolt, rotate the engine twice (720º
crankshaft rotation). Ensure the crankshaft
dowel pin marking is align back to the front
case.
CAUTION :
Remove special tool (EZT 0004) from it posi-
tion before rotating the crankshaft sprocket.
Symbol Description
A Camshaft sprocket timing marks
B Cam cover marks
D Front case marks
DOINE11AR11057
14. If the indicator stops within the nominal po-

sition at the centre of the indicator notch,
the timing belt is in the required timing belt
tension specification. If the indicator still
does not stops in the middle of the indicator
notch, repeat procedures no.1 until no.14.
DOINE11AR11052

TIMING BELT / 53
16. After checking the timing belt tension, insert

again the special tool in between the two
camshaft sprockets in order to make sure the
camshaft sprockets “STOP” from turning.
Symbol Description
DOINE11AR11155
17. Then, turn TV damper bolt anti-clockwise to

loosen TV damper bolt and special tool.
Remove TV damper bolt and special tool be-
fore installing timing belt cover.
Symbol Description
A TV damper bolt
B Special tool (EZT 0007)
DOINE11AR11162
TIMING BELT LOWER COVER AND UPPER

COVER INSTALLATION
1. Install timing belt lower cover (B) assy to en-
gine front cover lower side and tighten the
bolt flange.
0.9 -1.1 kgm (9 -11 Nm, 6.51 -7.96 ft.lbs)
2. Install timing belt upper cover (A) assy to

cylinder head front side and tighten the bolt
flange.
DOINE11AR11032 Specified torque (T1) :
0.9 -1.1 kgm (9 -11 Nm, 6.51 -7.96 ft.lbs)

/ 54 WATER PUMP AND WATER HOSE
WATER PUMP AND WATER HOSE WEO11ASASSY10010
DOINE11AR11094

• Oil cooler (Refer Workshop Manual Chassis GROUP 014- Oil Cooler Disassembly And Reassembly
Service Point)
— Sealant
Removal steps :
1. Retainer clip 9. Water pump seal
2. Washer 10. Water pump
11. Oil cooler
3. Thermostat
4. Thermostat seal
5. Thermostat pipe assy
6. Return hose
7. Seal
8. Coolant temperature sensor

WATER PUMP AND WATER HOSE / 55
T1 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)

T3 : 2.5 - 2.9 kgm (25 - 29 Nm, 18.08 - 20.98 ft.lbs)
T4 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T5 : 3.3 - 3.5 kgm (33 - 35 Nm, 23.87 - 25.32 ft.lbs)
T6 : 0.35 - 0.40 kgm (3.5 - 4 Nm, 2.53 - 2.89 ft.lbs)

ENGINE COOLANT TEMPERATURE SENSOR

REMOVAL
Use special tool to remove the engine coolant
temperature sensor.
DOIGE11AR03123
THERMOSTAT REMOVAL
1. Use circlip plier to remove retainer clip.
2. Then,use a screw driver to pry out the wash-
er.
3. The thermostat can be removed by using
plier.
Symbol Description
A Circlip plier
B Retainer clip
C Thermostat pipe
DOINE11AR11009
D Washer
E Thermostat

OIL COOLER REMOVAL

1. Remove oil cooler bracket bolts (E).
2. Release all oil cooler hose clamps as shown
Symbol Description
A Oil feed hose
B Oil return hose
C Feed coolant hose
D Return coolant hose
E Oil cooler bracket bolt
F Oil cooler
DOINE11AR11012
THERMOSTAT PIPE ASSY REMOVAL

1. Release coolant return hose clamp from cyl-
inder head.
2. Remove bolts bracket thermostat pipe.
Symbol Description
Bolt thermostat pipe at cylinder
A
block
Coolant return hose from cylinder
B
block
DOINE11AR11013

WEO11ASPROC10024
THERMOSTAT INSTALLATION
1. Fit the thermostat seal to the thermostat se-
curely.
2. Fit the thermostat into thermostat pipe assy
as shown in illustration.
NOTE :
Ensure the bleed hole is at the top position
.25 ° ± 5 °.
DOINE11AR11014

Symbol Description
A Thermostat pipe assy
B Thermostat seal
C Thermostat
D Washer
E Retainer clip
3. Fit securely the washer and insert retainer
clip using circlip plier into thermostat pipe
assy securely.
NOTE :
(1) Make sure the retainer clip holes is in
lower position.
(2) Ensure the thermostat washer and retain-
er clip are properly inserted in the groove
(F).
DOINE11AR11015

THERMOSTAT PIPE ASSY INSTALLATION

1. Apply a small amount of soap water to the
thermostat seal at the thermostat pipe as-
sembly. Press the water pump case assembly
while twist it left and right . Careful to not
damage the thermostat seal.
2. If the seal does not turn smoothly, the seal
is probably being clamped. Disconnect the
thermostat pipe assembly and check the seal
for any damage. Then, re-insert the new
thermostat pipe assembly seal and repeat
procedure no.1.
3. Tighten the thermostat pipe bolt to the spe-
cified torque.
Specified torque :
2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Symbol Description
A Thermostat seal
B Thermostat pipe
C Return hose
D Thermostat pipe assy bolt
E Front case
DOINE11AR11016
OIL COOLER INSTALLATION

NOTE :
Use soap water for easy assembly of oil cooler
hoses.
1. Install the oil return hose to the cylinder
block. Fix the hose clamp according to the
hose clamp marking as shown in the illustra-
tion.
2. Install the oil feed hose to the front case. Fix
the hose clamp according to the hose clamp
marking as shown in the illustration.
DOINE11AR11069
CAUTION :
(Procedure no.2 and no.3)
The hose clamp shall be securely positioned
after the bulge area.
Symbol Description
A Oil return hose
B Oil feed hose
C ‘Norma’ hose clamp
D Oil cooler
E Cylinder block
F Front case

3. Install the coolant feed hose to the front

case.
CAUTION :
Fix the hose clamp according to the hose
clamp marking as shown in the illustration.
Symbol Description
A Coolant feed hose
B Hose clamp
C Oil cooler
D Hose clamp marking
DOINE11AR11070
4. Install the coolant return hose to the thermo-

stat pipe.
CAUTION :
Fix the hose clamp according to the hose
clamp marking as shown in the illustration.
Symbol Description
A Coolant return hose
B Hose clamp
C Oil cooler
D Thermostat pipe
E Hose clamp marking
DOINE11AR11071

5. Push clamp (F) on hose A and B over the

bulge and tighten as shown in the illustra-
tion.
NOTE :
Ensure that the half circle lies on the swaged
section of the stub pipe.
Symbol Description
A Oil return hose
B Oil feed hose
C “Norma” clamp
D Oil cooler
E Hose clamp marking
DOINE11AR11090
6. Pre-tighten all 4 pcs oil cooler bracket bolts

as shown in the illustration.
DOINE11AR11091
7. Tighten all 4 pcs oil cooler bracket bolts to

NOTE :
Ensure there is no gap between bracket ,oil
cooler and inlet manifold
Specified torque (for bolt A) :
3.3 - 3.5 kgm (33 - 35 Nm, 23.87 - 25.32 ft.lbs)
Specified torque (for bolt B) :

0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
DOINE11AR11092

Symbol Description
Oil cooler lower bracket
A
bolt
Oil cooler upper bracket
B
bolt
C Oil cooler bracket
ENGINE COOLANT TEMPERATURE SENSOR

INSTALLATION
1. If reused the engine coolant temperature
sensor, apply the specified sealant to the
thread.
Specified sealant :
3M Nut Locking Part No. 4171 or equivalent.
DOIGE11AR03039
2. Use special tool (MD998770) to tighten the

engine coolant temperature sensor to the
specified torque.
Specified torque :
2.5 - 2.9 kgm (25 - 29 Nm, 18.08 - 20.98 ft.lbs)
DOIGE11AR03123

CAMSHAFT AND TAPPET / 63
CAMSHAFT AND TAPPET WEO11ASASSY10013
DOINE11AR11093

/ 64 CAMSHAFT AND TAPPET
— Sealant
— Lubricate all internal parts with engine oil during reassembly
Removal steps :
1. Breather hose (Full load)
2. Breather hose (Part load)
3. Oil filler cap
4. Cam cover
5. Cam cover seal
6. Camshaft oil seal
7. Front camshaft cap
8. VVT camshaft
9. Exhaust camshaft
10. Tappet
T1 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)

INSPECTION
TAPPET SELECTION PROCEDURE
CAUTION :
(1) The tappet clearance measurements should only be done after a minimum 2 hours of soaking.
(2) Ensure that cam sprocket timing marks in line with cam cover timing marks (crank is 90° ATDC).
(3) Cylinder head must be clamped with cylinder block to get achieve precise tappet clearance
measurement.
(4) Rotate cam sprocket clockwise direction as below sequence and measure the clearance using
thickness gauge.
Side Cam rotation Cam lobe number measurement

0° 1&2
90° 5&6
Inlet
180° 7&8
270° 3&4
0° 5&6
90° 7&8
Exhaust
180° 3&4
270° 1&2
(5) Measure clearances X and Y (16 places) using a thickness gauge.
X = 0.2 ± 0.05
X = 0.3 ± 0.05
(6) If incorrect, select new tappets for correct clearance by using formula below.
Intake grade = Z + ( X – 0.2 )
Intake grade = Z + ( Y – 0.3 )
Symbol Description
X Tappet clearance for intake
Y Tappet clearance for exhaust
Z Tappet grade dimension
(7) Remove camshafts and known tappets, lubricate selected grade of tappets with oil and locate
in cylinder head assy.
(8) Install camshafts and caps without using sealant on front caps.
(9) Verify clearance X and Y (16 places) using a thickness gauge.
(10) Apply sealant as shown and install front caps.
(11) The sequence to secure camshaft front cap and camshaft intermediate cap as below :
Sequence 1st 2nd 3rd 4th 5th

Cam cap inlet I3 I4 I2 I5 I1
Cam cap exhaust E3 E4 E2 E5 E1

DOINE11AR11116
Symbol Description
A Intake camshaft
B Exhaust camshaft
C Tappets
D Cylinder head assy

DOINE11AR10012
1. STEP 1
1.1 Align markings (A) at VVT sprocket and exhaust camshaft sprocket to the cam cover top
marking 0°( 12 o’clock ) as shown in the illustration.
Symbol Description
A Camshaft sprockets marking
I Intake side
E Exhaust side
1.2 Measure tappet clearance using thickness gauge (View B) between tappet top surface and
camshaft lobe :
Camshaft lobe number for tappet clearance

Camshaft sprocket angle
Intake side Exhaust side
0°
No.1 and No.2 No.5 and No.6
(12 o’clock)

DOINE11AR11163
2. STEP 2
2.1 Set markings (A) of VVT sprocket and exhaust camshaft sprocket at 90°( 3 o’clock ) as shown
Symbol Description
I Intake side
E Exhaust side
camshaft lobe as below :

90°
(3 o’clock)

DOINE11AR11004
3. STEP 3
Symbol Description
I Intake side
E Exhaust side

180°
(6 o’clock)

DOINE11AR11005
4. STEP 4
Symbol Description
I Intake side
E Exhaust side

270°
(9 o’clock)
5. Note all 16 pieces tappet clearance as shown in table below.
Tappet No. Tappet clearance measurement, X (intake)

1 X1
2 X2
3 X3
4 X4

Tappet No. Tappet clearance measurement, X (intake)

5 X5
6 X6
7 X7
8 X8
Tappet No. Tappet clearance measurement, Y (exhaust)
1 Y1
2 Y2
3 Y3
4 Y4
5 Y5
6 Y6
7 Y7
8 Y8
CAMSHAFT BEARING CAP REMOVAL

1. Loosen all bearing caps bolts based on the
loosening sequence as shown in the illustra-
tion.
Symbol Description
I Intake side
E Exhaust side
DOINE11AR11064
TAPPET REMOVAL
1. Remove tappets using magnet tool (A).
CAUTION :
Do not mix the original tappet position.
DOIGE11AR03052

2. Refer tappet grade at all tappets as shown

in the illustration (inside the tappet).
3. Note all tappets grade in table below.
DOINE11AR11063
Tappet No. Tappet grade dimension Z (intake)

1 Z1
2 Z2
3 Z3
4 Z4
5 Z5
6 Z6
7 Z7
8 Z8
Tappet No. Tappet grade dimension Z (exhaust)
1 Z1
2 Z2
3 Z3
4 Z4
5 Z5
6 Z6
7 Z7
8 Z8

CAMSHAFT VVT SPROCKET BOLT REMOVAL

1. Turn camshaft VVT sprocket and camshaft
exhaust sprocket until both sprocket’s marks
are positioned at 5 o’clock.
NOTE :
Ensure the position of camshaft VVT locator
is at the top of VVT camshaft, while the ex-
haust camshaft locator is at the bottom of
exhaust camshaft. At this position, both
camshafts are at the rest condition without
any pressure from the valves.
Symbol Description
A Camshaft VVT sprocket
B Camshaft exhaust sprocket
C Marking at 5 o’clock position
DOINE11AR12001

imate dimension as shown in the illustration.
DOINE11AR12002
3. Place the clean cloth on the cylinder head as

shown in the illustration.
NOTE :
avoid scratches on the cylinder head surface
during positioning special tool (EZT 0043).
DOINE11AR12009

4. Before fixing the special tool (EZT 0043) on

the cylinder head, ensure the special tool
groove (VVT side) is align with the camshaft
VVT locator (underneath cloth).
Symbol Description
B Special tool groove (VVT side)
C Clean cloth
DOINE11AR12010

by pre-tightening the bolts. The special tool
will lock the camshaft VVT locator from
turning during loosening the sprocket bolt.
CAUTION :
DOINE11AR12003
6. Loosen the camshaft VVT sprocket bolt as

DOINE11AR12004
7. Remove the camshaft VVT sprocket from

engine as shown in the illustration.
DOINE11AR12005


REMOVAL
1. By using special tool as shown in the illustra-
tion, lock the camshaft exhaust sprocket.
2. Loosen the camshaft exhaust bolt.
Symbol Description
A Ring spanner
B Special tool (MB990767)
C Special tool (MD998715)
DOINE11AR11184

TAPPET INSTALLATION
1. Refer table below for tappet clearance spe-
cification.
DOIGE11AR03122
Type Tappet clearance specification

Intake X = 0.2 mm ± 0.05 mm
Exhaust Y = 0.3 mm ± 0.05 mm
Tappet clearance measurement Clearance specification Description
X1 0.23 mm Reuse old tappet
X1 < 0.17 mm Replace with new tappet
X1 > 0.23 mm Replace with new tappet
2. Refer formula below for intake and exhaust
tappet grade identification.
Intake Grade :
Z + ( X – 0.2 mm )
Exhaust Grade :
Z + ( Y – 0.3 mm )
Symbol Description ( in mm)

Z Tappet grade dimension
FOR EXAMPLE, THE CALCULATION BELOW
SHOWS THE INTAKE TAPPET GRADE SELECTION.
Z + (X – 0.2mm) : 3.000 + (0.3 – 0.2)
: 3.000 + (0.1)

: 3.100 mm
Due to 3.100 mm is very close to 3.105 mm, select
tappet grade 08
Mechanical tappet grade Dimension (A)

01 3.000
02 3.015
03 3.030
04 3.045
05 3.060
06 3.075
07 3.090
08 3.105
09 3.120
10 3.135
11 3.150
12 3.165
13 3.180
14 3.195
15 3.210
16 3.225
17 3.240
18 3.255
19 3.270
20 3.285
21 3.300
22 3.315
23 3.330
24 3.345
25 3.360
26 3.375
27 3.390
28 3.405
29 3.420
30 3.435
31 3.450
32 3.465
33 3.480
34 3.495
35 3.510
36 3.525
37 3.540
38 3.555
39 3.570

Mechanical tappet grade Dimension (A)

40 3.585
41 3.600
42 3.615
43 3.630
44 3.645
45 3.660
46 3.675
47 3.690
3. Apply minimum sufficient amount of engine
oil on the tappet and insert all tappets inside
cylinder head assy.
DOINE11AR11066
CAMSHAFT INSTALLATION
1. Apply engine oil to the camshafts.
2. Install the camshafts on the cylinder head.
Be careful not to confuse the VVT camshaft
with the exhaust camshaft.
Symbol Description
A VVT camshaft
Half moon shape at end portion
B
of VVT camshaft.
DOINE11AR11067
CAMSHAFT BEARING CAP INSTALLATION

1. Surface should be clean, dry and free from
grease and debris.
2. Apply sealant on front camshaft bearing cap
Specified sealant :
TB1110B 2 mm (0.079 in) bead size.
Symbol Description
A Front camshaft bearing cap
DOINE11AR11062

3. Before installing the other bearing caps, ar-

range the bearing caps by referring the
stamped identification marking on each the
bearing caps.
Identifica-
tion mark- Description
ing
A I (Intake side), E (exhaust side)
B Bearing caps number
C Arrow facing to timing belt
side
DOIGE11AR03056
4. Tighten bearing caps bolt using the following

tightening sequence order.
Sequence 1st 2nd 3rd 4th 5th

VVT cam-
I3 I4 I2 I5 I1
shaft cap
Exhaust
camshaft E3 E4 E2 E5 E1
cap
Steps Operation
Tighten camshaft caps in se-
quence using minimum force
S1
leaving an even gap between
cam caps and cylinder head.
Tighten camshaft cap evenly in
S2
sequence until the gap is closed
Tighten camshaft cap in se-
quence order to the specified
S3 torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 -
7.96 ft.lbs)
Symbol Description
A Front camshaft bearing cap
DOINE11AR11060
B Leave even gap
C Bearing cap intermediate
I Intake side
E Exhaust side
NOTE :
Do not splash engine oil on the VVT camshaft
and exhaust camshaft cap cylinder head area.

5. Verify again all 16 pieces tappets clearance

using thickness gauge.
Symbol Description
A Thickness gauge
B Camshaft lobe
6. If the tappets clearance is not within tappet
clearance specification , remove again all
camshaft bearing caps and select the correct
new tappet.
DOINE11AR10013
VVT CAMSHAFT OIL SEAL INSTALLATION

oil to oil seal housing and oil seal lip.
2. Install special tool (inner) at the VVT cam-
shaft as shown in the illustration.
Symbol Description
A Special tool EZT 0006 (inner)
B VVT camshaft
C Oil seal housing
DOINE11AR11176
3. Securely insert new oil seal through the spe-

cial tool (inner).
Symbol Description
A Oil seal
B Special tool EZT 0006 (inner)
DOINE11AR11177
4. Slowly and carefully knock the oil seal by

using special tool (outer).
5. Then, remove the special tool (inner) and
continue knocking the oil seal until it prop-
erly fitted at oil seal housing by using the
special tool (outer).
Symbol Description
A Oil seal
B Special tool EZT 0006 (outer)
C Mallet
DOINE11AR11178

EXHAUST CAMSHAFT OIL SEAL

INSTALLATION
oil to oil seal housing and oil seal lip.
2. Insert oil seal into the special tool (inner) and
then by using another part of the special tool
(outer), knock in the oil seal carefully using
mallet as shown in the illustration.
Symbol Description
A Oil seal housing
B Special tool EZT 0006 (inner)
C Special tool EZT 0006 (outer)
D Mallet
E Oil seal
CAUTION :
Do not damage the oil seal during installa-
tion.
DOINE11AR11179
CAMSHAFT VVT SPROCKET BOLT

INSTALLATION
NOTE :
Ensure the position of camshaft VVT locator is
at the top of VVT camshaft, while the exhaust
camshaft locator is at the bottom of exhaust
camshaft. At this position, both camshafts are at
the rest condition without any pressure from the
valves.
DOINE11AR12011
1. Install the camshaft VVT sprocket into the

engine and pre-tighten the camshaft VVT
sprocket bolt accordingly.
Symbol Description
A Camshaft VVT sprocket
DOINE11AR12006


imate dimension as shown in the illustration.
DOINE11AR12002
3. Place the clean cloth on the cylinder head as

NOTE :
avoid scratches on the cylinder head surface
during positioning special tool (EZT 0043).
DOINE11AR12009
4. Before fixing the special tool (EZT 0043) on

the cylinder head, ensure the special tool
groove (VVT side) is align with the camshaft
VVT locator (underneath cloth).
Symbol Description
B Special tool groove (VVT side)
C Clean cloth
DOINE11AR12010

by pre-tightening the bolts. The special tool
will lock the camshaft VVT locator from
turning during loosening the sprocket bolt.
CAUTION :
DOINE11AR12003

6. Tighten the camshaft VVT sprocket to the

specified tightening torque.
Specified torque :
1.45 ft.lbs)
DOINE11AR12012
VVT CAP BOLT INSTALLATION

1. By using special tool (EZT 0043), lock the
camshaft VVT sprocket as shown in the illus-
tration and then tighten the VVT cap bolt to
Specified torque :
3.0 - 3.4 kgm (30 - 34 Nm, 21.7 - 24.59 ft.lbs)
Symbol Description
A Torque wrench
DOINE11AR12008
B Socket
C Camshaft VVT sprocket
D Special tool (EZT 0043)


INSTALLATION
1. Place the camshaft exhaust sprocket on the
camshaft exhaust dowel pin as shown in the
illustration.
Symbol Description
A Camshaft exhaust dowel pin
DOINE11AR11104
2. By using special tool (MD998715), lock the

camshaft exhaust sprocket and tighten the
camshaft exhaust sprocket bolt to the spe-
cified torque as shown in the illustration.
Specified torque :
1.45 ft.lbs)
Symbol Description
A Special tool (MB990767)
B Special tool (MD998715)
DOINE11AR11185 C Torque wrench
OIL FILLER CAP INSTALLATION

Clean oil cap and cam cover sealing face from oil
trace/debris using soft cloth during oil change
or oil top-up.
DOINE11AR11065

INSPECTION
CAMSHAFT
Measure the cam heights and replace the cam-
shaft if any height exceeds the specified limit.
Identification
Standard value
mark
Intake 45.05 mm (1.77 in)
Exhaust 44.70 mm (1.76 in)
Limit Value
Intake 44.55 mm (1.75 in)
Exhaust 44.20 mm (1.74 in)
Symbol Description
A Cam lobes heights measurement
B Micro meter
C Cam position lobes measurement
D Camshaft
DOIGE11AR06170

CYLINDER HEAD AND VALVES / 85
CYLINDER HEAD AND VALVES WEO11ASASSY10014
DOIGE11AR03059

/ 86 CYLINDER HEAD AND VALVES
— Lubricate all internal parts with engine oil during reassembly

Removal steps :
1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
4. Intake valve collet
5. Intake valve spring retainer
6. Intake valve spring
7. Intake valve
8. Exhaust valve collet
9. Exhaust valve spring retainer
10. Exhaust valve spring
11. Exhaust valve
12. Intake valve stem seal and spring seat
13. Exhaust valve stem seal and spring seat
14. Intake valve guide
15. Exhaust valve guide
16. Intake valve seat
17. Exhaust valve seat
18. Cylinder head
Steps Value Remarks
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2 kgm (2 • One bolt at a time
A
Nm, 1.45 ft.lbs) • Follow sequence No.1 to 10
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 for step A, B and C.
B • Repeat each step until all
Nm, 1.45 ft.lbs)
bolts achieve specification.
C 90° (Min)
D 90° (Min)

CYLINDER HEAD BOLT REMOVAL

1. Use special tool to loose the bolts in se-
quence order and then use hand to untight-
en completely the bolts as shown in the illus-
tration.
2. After loosening all bolts engine, remove the
cylinder head assy from engine.
CAUTION :
The plug guides cannot be replaced or change,
be careful not to damage or deform the plug
guides when removing the cylinder head bolts.
Symbol Description
TBS Timing belt side
DOIGE11AR03143
VALVE COLLET REMOVAL

1. Locate cylinder head assy on top of the spe-
cial tool as shown in the illustration.
Symbol Description
A Cylinder head assy
DOIME11AR11024
2. Before using special tool, ensure the special

tool stopper is located at the shown location.
Symbol Description
B Special tool (EZT 0002) stopper
DOINE11AR11164

3. Knock the valve spring retainer with mallet

in order to remove valve collet.
Symbol Description
A Cylinder head assy
DOIME11AR11025
4. Remove valve collet from special tool at the

shown location.
Symbol Description
A Valve collet
B EZT 0002
DOIME11AR11026
VALVE STEM SEAL AND SPRING SEAT

REMOVAL
1. Use special tool to remove valve steam seal
and spring seat.
Symbol Description
DOINE11AR11165


VALVE STEM SEAL AND SPRING SEAT
INSTALLATION
1. Use special tool to install the valve stem seal
and spring seat into the intake and exhaust
valve guide.
Symbol Description
A Valve stem seal and spring
seat
B Valve guide
CAUTION :
Do not reuse the removed valve stem seals.
DOINE11AR11166
INTAKE VALVE AND EXHAUST VALVE

INSTALLATION
1. Apply engine oil to the intake valve and ex-
haust valve.
2. Install the intake valve and exhaust valve to
the cylinder head side.
Symbol Description
C Intake or exhaust valve
DOIGE11AR03125

VALVE SPRING INSTALLATION

1. Install intake valve and exhaust valve into
cylinder head, then locate on the special tool
Symbol Description
Intake valve and exhaust
B
valve
C Cylinder head
DOINE11AR11167
2. Locate valve spring on intake valve or ex-

haust valve.
3. Align and locate valve spring retainer over
intake valve or exhaust valve.
Symbol Description
D Valve spring
E Valve spring retainer
DOIGE11AR03126
VALVE COLLET INSTALLATION

1. Insert the valve collet to the special tool as
Symbol Description
1 Bigger semi circumference
2 Smaller semi circumference
CAUTION:
Make sure the smaller semi circumference
facing outward when inserting the collet
DOIGE11AR03063
into the special tool.

2. Be careful to press down the special tool (EZT

0001) until ‘click’ sound is heard.
Remove special tool and check the valve col-
lets position. Make sure the valve collets are
fix securely into it's position.
Symbol Description
F Valve collets
DOIME11AR11030
3. Put out the special tool (EZT 0046), then

knock the valve use roll bar to make sure
valve collets is properly fixed in it’s position.
DOIME11AR11031
CYLINDER HEAD BOLT INSTALLATION

1. When installing the cylinder head bolts,
check that the shank length (A) of each bolt
meets the limit. If the limit is exceeded, re-
place the bolt.
Specification :
160 mm (6.3 in) ± 0.35 mm (0.014 in)
2. Install the washers as illustrated.

3. Apply engine oil to the bolt threads and
washers.
DOIGE11AR03065

4. According to the tightening sequence as

shown in the illustration, tighten the bolts
Symbol Description
TBS Timing belt side
DOIGE11AR03066
TIGHTENING PROCEDURES (SERVICE) :

Steps Value Remarks
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2 kgm
A • One bolt at time.
(2 Nm, 1.45 ft.lbs)
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm • Follow sequence No. 1 to 10 for steps
B A, B, & C.
(2 Nm, 1.45 ft.lbs)
• Repeat each step until all bolts achieve
C 90° (Min) specification.
D 90° (Min)
5. By using special tool (Mot.591.04), tighten
all bolts to the specified torque.
Symbol Description
A Special tool (Mot.591.04)
DOINE11AR11168
INSPECTION
CYLINDER HEAD
1. Check the cylinder head gasket surface for
flatness by using a straightedge and thickness
gauge.
Standard value :
0.1 mm (0.004 in)
2. If the service limit is exceeded, correct to

meet the specification.
Grinding limit :
DOIIE11AR9066 * 0.2 mm (0.008 in)
*Includes / combined with cylinder block

grinding

Cylinder head height (Specification when

new) :
134.7 mm (5.3 in) ± 0.1 mm (0.004 in)
VALVE
1. Check the valve face for correct contact. If
incorrect, reface using a valve refacer. Valve
should make a uniform contact with the seat
at the centre of valve face.
2. If the margin (B) is smaller than the service
limit, replace the valve.
Standard value :
Intake : 1.5 mm (0.059 in) ± 0.15 mm (0.006
in)
Exhaust : 1.95 mm (0.077 in) ± 0.15 mm
(0.006 in)
DOIIE11AR9067
3. Measure the valve total length. If the meas-

urement is less than the specified valve, re-
place the valve.
Items Standard
103.53 mm (4.08 in) ± 0.20 mm
Intake
(0.008 in)
102.28 mm (4.03 in) ± 0.20 mm
Exhaust
(0.008 in)
VALVE SPRING
1. Measure the valve spring free height. If the
height is less than the limit value, replace the
valve spring.
Standard value :
38.17 mm (1.5 in)
Limit :
37.17 mm (1.46 in)
Symbol Description
DOIGE11AR06173 A Valve spring
B Vernier caliper

2. Place the spring on a flat surface next to a

steel square. Rotate the spring while check-
ing for a gap between the side of the spring
and the steel square.
3. Measure the squareness of the valve spring
and if the limit is exceeding the limit value,
replace the valve spring.
Standard value :
1 mm or less
Limit :
2 mm
DOIGE11AR06172
Symbol Description
C Squareness
D Valve spring
E Steel square

NOTE

/ 96 OIL PUMP AND OIL PAN
OIL PUMP AND OIL PAN WEO11ASASSY10015
DOINE11AR11095

OIL PUMP AND OIL PAN / 97
— Sealant
— Apply engine oil to all moving parts before installation
Removal steps :
1. Oil filter 14. Front oil seal
2. Oil drain plug 15. Front case
3. Gasket 16. Front case seal
4. Crank angle sensor 17. Oil pump backplate
5. Oil pan 18. Oil pump inner rotor
6. 19. Oil pump outer rotor
Windage tray
7. 20. Stud (Special)
Baffle
8. Oil pick up pipe
9. Oil seal
10. Relief valve plug
11. Relief valve seal
12. Relief valve spring
13. Relief valve piston
T1 : 0.8 - 1.2 kgm (8 - 12 Nm, 5.79 - 8.68 ft.lbs)
T4 : 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
T8 : 1.2-1.6 kgm (12-16 Nm, 8.68-11.57 ft.lbs)

REMOVAL SERVICE POINT WEO11ASPROC10013
OIL PAN REMOVAL

1. Remove 19 pieces oil pan bolts.
DOIME11AR11034
2. Remove the hidden oil pan bolt at the

transmission side (A).
Symbol Description
A Two bolts hidden at the loc-
ations shown.
B Oil pan
DOIME11AR11033
3. Pry out the oil pan by using the flat screw

driver as shown in illustration.
CAUTION :
Slowly perform to avoid deformation of the
oil pan flange.
DOIME11AR11035


FRONT CASE INSTALLATION
1. Clean the surfaces on the cylinder block and
front case surfaces.
2. Locate front case seal in front case groove.
Symbol Description
A Front case seal
3. Align the oil pump rotor back plate to the
crankshaft.
DOINE11AR11130 4. Align dowel holes to the dowels at cylinder
block.
5. Fix the front case to cylinder block properly.
FRONT OIL SEAL INSTALLATION

1. Place the special tool on the crankshaft's
front end and apply engine oil to its outer
circumference.
DOIGE11AR03099
2. Apply engine oil to the oil seal lip, then push

the oil seal along the guide by hand until it
touches the front case. Tap the oil seal into
place by using the special tool.
DOIGE11AR03100

OIL PICKUP PIPE INSTALLATION

1. Slowly insert the oil pick up pipe oil seal to
the oil pan hole. Carefully do not damage
the oil seal during installation. After installa-
tion, check condition the pipe fitting.
2. If the oil seal does not turn smoothly, the oil
seal is probably being clamped. Remove the
oil seal and check for any damage. If the oil
seal is damage, install a new oil seal by re-
peating step no.1.
3. Tighten the oil pick up pipe bolts to the
DOIGE11AR03112 specified torque.
1.45 ft.lbs)
4. Tighten the baffle bolts in the sequence or-

der to the specified torque.
0.72 ft.lbs)
Symbol Description
A Baffle
DOINE11AR11088
5. Tighten the windage tray bolts in the se-

quence order to the specified torque.
Specified torque :
0.72 ft.lbs)
Symbol Description
A Windage tray
DOINE11AR11089

OIL PAN INSTALLATION

1. Clean the mating surfaces of the cylinder
block and oil pan from sealant. Wipe off the
pre-lubrication oil using isoprophyl alcohol.
2. Apply a 3 mm (0.12 in) ± 1 mm (0.039 in)
bead of form-in-place gasket to the outer
circumference of the oil pan flange.
Symbol Description
A Bolt hole
Specified sealant :
DOIGE11AR03070 Part No. MD970389 (Sealant – Threebond
TB1207F).
3. Tighten the bolts in the sequence order

0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
DOINE11AR11087
OIL FILTER INSTALLATION

1. Clean the oil filter mounting surface on the
front case.
2. Apply a small amount of engine oil to the o-
ring at the new oil filter.
Symbol Description
A Oil filter o-ring
DOIGE11AR03111

3. Attach oil filter to housing thread and rotate

until oil filter seal is seated against seal face.
4. Use the special tool (MB991396) to tighten
the oil filter to the specified torque.
Specified torque (T8) : 1.2 - 1.6 kgm (12 - 16
Nm, 8.68 - 11.57 ft.lbs)
DOIGE11AR03071
CRANK ANGLE SENSOR INSTALLATION

1. Apply soap water to crank angle sensor and
tighten the crank sensor screw by using torx
0.72 ft.lbs)
Symbol Description
A Crank angle sensor
DOIGE11AR03072
B Target wheel
C Screw special
INSPECTION
OIL PUMP
1. Fit the oil pump rotors into the front case.
2. Check the tip clearance using a thickness
gauge.
Standard value :
0.06 - 0.18 mm (0.002 - 0.007 in)
Symbol Description
A Oil pump rotors
DOINE11AR11169
B Front case
C Thickness gauge

3. Check the side clearance using a straight

edge and thickness gauge.
Standard value :
0.03 - 0.10 mm (0.001 - 0.004 in)
Symbol Description
A Oil pump rotors
B Straight edge
C Thickness gauge
DOINE11AR11170
4. Check the body clearance using a thickness

gauge.
Standard value :
0.04 - 0.10 mm (0.002 - 0.004 in)
Limit :
0.35 mm (0.014 in)
Symbol Description
A Oil pump rotors
B Front case
DOINE11AR11171 C Thickness gauge

/ 104 PISTON AND CONNECTING RODS
PISTON AND CONNECTING RODS WEO11ASASSY10017
DOINE11AR11152

PISTON AND CONNECTING RODS / 105
— Apply engine oil to all moving parts before installation

Removal steps :
1. Connecting rod bolt
2. Connecting rod cap
3. Connecting rod bearing
4. Piston and connecting rod assembly
5. Connecting rod bearing
6. Piston ring No.1
7. Piston ring No.2
8. Oil ring
9. Piston pin circlip
10. Piston pin
11. Piston
12. Connecting rod

CONNECTING ROD CAP REMOVAL

1. Indicate a marking at the side of the connect-
ing rod big end as shown in the illustration.
CAUTION :
To facilitate reassembly, please do not punch
the connecting rod.
DOIME11AR11056
2. Remove the connecting rod caps bolts and

then remove the connecting rod cap.
Symbol Description
A Crankshaft
B Connecting rod cap
DOIME11AR11057
CONNECTING ROD, PISTON PIN AND PISTON

REMOVAL
1. Insert special tool into the connecting rod
and then remove the connecting rod prop-
erly from cylinder block.
CAUTION :
Do not scratch the crankshaft surface.
Symbol Description
A EZT 0008
DOIME11AR11058
2. NOTE :
1) Due to piston pin circlip position is differ-
ent for ‘FRONT’ and ‘REAR’ side, only remove
the ‘FRONT’ side piston pin circlip as shown
2) If reused the piston and piston pin, the
piston pin circlip at ‘REAR’ side must be re-
moved . In order to remove the circlip, care-
fully push the circlip open end to 12 o’clock
or 6 o’clock before removing the circlip using
small screw driver.
DOINE11AR11180

Symbol Description
A Piston pin circlip
B Piston ‘FRONT’ side mark
By using small screw driver, carefully pry-out
the piston pin circlip from connecting rod
pin oil groove as shown in the illustration.
CAUTION :
Do not scratch the piston circlip housing
surface.
Symbol Description
A Connecting rod
B Piston pin circlip
C Small screw driver
DOINE11AR11173 D Pin oil groove
3. Pull out piston pin from piston and connect-
ing rod.
Symbol Description
A Piston pin
B Piston
C Connecting rod
DOINE11AR11102
4. If the part is in good condition, keep the

piston, piston pin, and connecting rod togeth-
er. Do not mix-up pistons, piston pins, and
connecting rods from different cylinders.
DOINE11AR11100

INSPECTION WEO11ASPROC10017
PISTON RINGS
1. Check the piston ring side clearance. If the
clearance exceeds the specified limit, replace
the ring or piston, or booth.
Standard value :
No. 1 ring : 0.03-0.05 mm (0.001-0.002 in)
No. 2 ring : 0.02-0.04 mm (0.001-0.002 in)
DOIIE11AR9087
2. Insert the piston ring into the cylinder bore

and push it down with a piston (A). Ensure
that the piston's crown is in contact with the
ring such that the ring is at 90° to the cylin-
der wall. Then, measure the end gap (C) with
a thickness gauge. If the gap is too large,
replace the piston ring (B).
Standard values :
No. 1 ring : 0.20-0.35 mm (0.008-0.014 in)
No. 2 ring : 0.37-0.57 mm (0.015-0.022 in)
Oil ring : 0.2-0.5 mm (0.008-0.02 in)
DOIGE11AR03076 Limits :
No. 1 ring : 0.5 mm (0.02 in)
No. 2 ring : 0.75 mm (0.03 in)
Oil ring : 1.0 mm (0.039 in)
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC

GAUGE METHOD)
1. Wipe all oil off the crankshaft pin and con-
necting rod bearing.
2. On the pin, place a plastic gauge that is cut
to the same length as the bearing's width.
The plastic gauge must be centered on the
pin in parallel with the pin's axis.
3. Gently place the connecting rod cap in posi-
tion and tighten the bolts to the specified
torque.
4. Remove the bolts and gently remove the
DOIIE11AR9089
connecting rod cap.
5. Measure the compressed part of the plastic
gauge at its widest point using the scale
printed on the plastic gauge bag.
Standard value :
0.02-0.044 mm (0.001-0.002 in)
Limit :
0.1 mm (0.004 in)


WEO11ASPROC10018
PISTON / PISTON PIN AND CONNECTING

ROD INSTALLATION
1. Refer cylinder bore identification marks at
cylinder block top surface as shown in the il-
lustration.
2. Select correct piston size according to the
cylinder bore identification mark. The piston
size outer diameter identification mark is
painted on top of piston surface. Ensure that
marks are same as cylinder bore identifica-
tion mark.
For example,
Cylinder
bore identi-
A B A A
fication
mark
Piston size
outer dia-
meter identi- A B A A
fication
mark
DOINE11AR11111
3. CAUTION :
By using air gun, clean piston, piston pin and
piston pin circlip groove in order to remove
all dust and chips.
Before installing the piston to the connecting
rod, ensure the ‘DOT’ marking at piston and
connecting rod are facing in same direction
Symbol Description
A ‘ DOT’ marking
B Piston
DOINE11AR11105
C Connecting rod
4. Prior to the installation of piston pin, apply
a sufficient amount of lubrication to the
outer surface pin and small end bore of the
connecting rod.
Lubrication type : Engine oil or non-water
soluble press oil (Yugen Kugyo Standards
DS-711 or equivalent)
DOINE11AR11106

5. Press the piston pin through the connecting

rod small end bore until it is stopped by
circlip located at the other side of piston
bore.
DOINE11AR11107
6. Insert piston pin circlip into piston pin groove

by positioning the open end circlip at 12
o’clock direction as shown in the illustration.
NOTE :
If install new piston pin circlip at ‘REAR’ side
piston, ensure the piston pin circlip is in-
stalled at 12 o’clock position as shown in the
illustration.
Symbol Description
A Piston pin circlip
DOINE11AR11181
B Piston ‘FRONT’ mark
CAUTION :
(1) The circlip can only be reused until 3
times removal only.
(2) Do not use the piston and connecting
rod assy if additional load is required to
insert pin into the piston.
(3) When installing the piston pin, be sure
to keep the piston pin square with the
small end bore of the connecting rod.
(4) When reinstalling the piston pin, make
sure that the clearance fit is within the
specification as shown in the table be-
low.
Connect-
Piston Pin ing rod Clearance
Lenght of
outside small end (calcu-
Pin
diameter inside dia- lated)
meter
Ø19 ( 0, - 19.012 ± 0.007 – 54 ( 0, -
0.005 ) 0.005 0.022 0.3 )

7. Carefully, press-in the piston pin circlip by

hand and then push-in the circlip by using
small screw driver.
Symbol Description
A Connecting rod
B Piston pin circlip
C Small screw driver
D Pin oil groove
CAUTION :
Use cloth to cover the circlip during installa-
DOINE11AR11182 tion in order to avoid the circlip missing.
OIL CONTROL RING INSTALLATION

1. Fit the oil control ring spacer into the piston
ring groove. Then, fit the upper and lower
side rails.
Symbol Description
A Upper and lower side rails
B Oil control ring spacer
1 Groove ring compression top
2 Groove ring compression
second
NOTE :
(1) Apply minimum engine oil at the groove.
(2) The spacer and side rails are reversible.
Spacer and side rail sizes are color-coded as
follows :
Part Colour
Gap clearance
name mark
0.2 kgm (2 Nm, 1.45
Side rails None ft.lbs) ± 0.005 kgm (0.05
Nm, 0.036 ft.lbs)
0.02 - 0.05 kgm (0.2 - 0.5
Spacer White
Nm, 0.14 - 0.36 ft.lbs)
DOINE11AR11112
2. To install a side rail, fit one end of the rail

(C) into the groove then press the rest of the
rail into position by hand as shown in the il-
lustration.
CAUTION :
Do not fit side rails using a piston ring ex-
pander as they may break.
3. After installing 3 pieces of oil ring, check the
upper and lower side rails condition and en-
sure it can be turned smoothly.
DOIIE11AR9094

COMPRESSION TOP RING (1R) /

COMPRESSION SECOND RING (2R) INSTALLATION
1. Using a ring expander, fit the piston ring No.
2 and ring No. 1 with their identification
marks facing upward (on the piston crown
side).
Symbol Description
A Ring expander
DOIIE11AR9095
2. Refer table below for identification paint

marks on piston rings.
Symbol Part name Color paint

Compression
A Yellow
top ring
Compression
B Blue
second ring
DOINE11AR11110
3. Refer table below for identification stamping

marks on piston rings.
I.D mark Part name Gap clearance

Compres-
0.2 - 0.35 mm
1R sion top
(0.008 - 0.014 in)
ring
Compres-
0.37 - 0.57 mm
2R sion second
(0.015 - 0.022 in)
ring
DOINE11AR11113
PISTON AND CONNECTING ROD ASSEMBLY

INSTALLATION
1. Remove connecting rod cap.
2. Select and install the proper connecting rod
bearing.
3. Set special tool for the piston insertion on
reamer bolt of the connecting rod.
Symbol Description
4. Apply engine oil to the piston rings, oil ring,
DOIGE11AR03161 connecting rod bearing, and cylinder bore.

CAUTION :
Ensure the cylinder bore is flawless. Else,
rebore it to the following specifications.
5. Align the gaps of the piston rings and oil ring
(side rails and spacer) as shown in the illustra-
tion.
Symbol Description
A Side rail (ring - oil - control)
B Ring - compression - top
C Ring - compression - second and
spacer (ring - oil - control)
D Piston pin
DOIIE11AR9097
6. Ensure all arrow marking on top of the pis-

tons are facing to timing belt side as shown
Symbol Description
Arrow marking facing timing
A
belt side
DOINE11AR11174

7. Compress the piston rings tightly with a

suitable ring compression tool, then press
the piston and connecting rod assembly fully
into the cylinder bore. Do not strike the pis-
ton hard since the piston rings may break
and the crank pin may be nicked.
NOTE :
(1) Ensure that the identification marks on
the piston crown coincide with those on
the cylinder block top surface.
(2) Ensure the ‘←’ mark is facing to timing
belt side.
DOIIE11AR9098
(3) Ensure to make the notch by the locking
around the bearing on the same time
8. Remove the special tool ( EZT0008 ) from
connecting rod.
9. Install and pre-tighten bolt connecting rod
by hand. Then, tighten to the specified
torque.
Specified torque :
2.2 kgm (22 Nm, 15.91 ft.lbs) + 90°
CONNECTING ROD BEARING INSTALLATION

1. Select bearings according to the crankshaft
and connecting rod identification marks or
color codes.
Symbol Description
P Pin number for con rod bearing
IM Con rod bearing identification
mark position
A Con rod bearing
DOINE11AR11117

BEARING SELECTION TABLE

CRANKSHAFT & CON ROD COMBINATION
Crankshaft identific- Con rod / bore identifica- Bearing selected Oil clearance (mm)
ation mark tion mark
A 1 0.020 – 0.036
1 B 1 0.024 – 0.044
C 2 0.024 – 0.040
A 1 0.024 – 0.044
2 B 2 0.020 – 0.044
C 3 0.020 – 0.040
A 2 0.024 – 0.040
3 B 3 0.020 – 0.040
C 3 0.028 – 0.044
2. The connecting rod identification mark is
stamped at big end bore portion as shown
Symbol Description
A Big end bore identification mark
DOIME11AR11040
3. The connecting rod bearing identification

mark is painted on the bearing top surface
Symbol Description
A Identification mark
4. The example to select the correct connecting
rod bearing is shown in table below.
Crankshaft identific-
ation mark (pin no.1 2 1 1 2
until pin no.4)
DOINE11AR11175 Connecting rod
identification mark A C B B
(example)
Select correct con-
necting rod bearing 1 2 1 2
number

CONNECTING ROD CAP INSTALLATION

1. Aligning the marks made during disassembly,
fit the bearing cap onto the connecting rod.
If the connecting rod is new and has no index
mark, ensure that the front marks on the
connecting rod and connecting rod cap are
on the same side.
Symbol Description
A Front marks
DOIME11AR11041
2. Check that the connecting rod big end side

clearance confirms with specifications.
Standard value :
0.10 - 0.25 mm (0.004 - 0.01 in)
Limit:
0.4 mm (0.016 in)
DOIGE11AR03085
CONNECTING ROD BOLT INSTALLATION

CAUTION :
To fit the connecting rod bolts with the cylinder
head in place, the spark plugs must be removed
beforehand.
1. Pre-tighten all the connecting rod cap bolts.
2. Tighten the bolts to the specified torque.
Specified torque :
2.2 kgm (22 Nm, 15.91 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
DOIGE11AR03086
3. Then, using the special tool ( Mot.59104 ),
tighten the connecting rod bolts according
to the specified torque angle.
Torque angle :
90° ± 5°

CRANKSHAFT AND CYLINDER BLOCK / 117
CRANKSHAFT AND CYLINDER BLOCK WEO11ASASSY10018
DOINE11AR11131

/ 118 CRANKSHAFT AND CYLINDER BLOCK
— Sealant
— Patch Lock Screw (TB1300)
— Apply engine oil to all moving parts before installation.
Removal steps :
1. Direct damper flywheel (DDF) bolt 9. Crankshaft assy
2. Direct damper flywheel (DDF) 10. Crankshaft bearing (lower)
3. Rear plate 11. Bearing cap
4. Rear oil seal 12. Bearing cap bolts
13. Cylinder block
5. Rear oil seal case
14. Knock sensor
6. Crankshaft bushing
15. Oil pressure switch
7. Target wheel 16. Oil jet
8. Crankshaft bearing (upper)
T2 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T3 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T4 : 8.0 - 9.0 kgm (80 - 90 Nm, 57.86 - 65.1 ft.lbs)
T5 : 4.91 - 5.39 kgm (49.1 - 53.9 Nm, 35.51 - 38.99 ft.lbs)

OIL PRESSURE SWITCH REMOVAL

1. Disconnect the oil pressure switch terminals.
2. By using the special tool (MD998054), remove
the oil pressure switch (A).
CAUTION :
Take care not to damage the oil pressure
switch when removing it.
DOINE11AR11153
DIRECT DAMPER FLYWHEEL (DDF)

REMOVAL
1. Lock the Direct Damper Flywheel (A) by using
special tool (B).
2. Then, loosen the 5 pieces bolts (C) as shown
Symbol Description
Direct Damper Flywheel
A
(DDF)
DOINE11AR11132
C Direct Damper Flywheel bolts

INSPECTION WEO11ASPROC10021
CRANKSHAFT OIL CLEARANCE

The crankshaft oil clearance can be measured
easily using a plastic gauge (A).
To check the crankshaft oil clearance with a
plastic gauge, carry out the following procedure:
1. Wipe all oil off the crankshaft journal and
the bearing's inside surface.
2. Install the crankshaft.
3. Cut the plastic gauge such that its length
DOIIE11AR9105 matches the width of the bearing, then place
it on the journal along the journal's axis.
4. Gently fit the crankshaft bearing cap and
tighten the bolt to the specified torque.
5. Remove the bolts and gently remove the
crankshaft bearing cap.
6. Using the scale printed on the plastic gauge
bag, measure the plastic gauge's crushed
section at its widest point.
Standard value :
0.018 - 0.036 mm (0.001 - 0.001 in)
Limit :
0.1 mm (0.004 in)
DOIIE11AR9106
NOTE :
The crankshaft pins and journals are fillet-rolled
(B) and must not be machined to undersize di-
mensions.
DOIIE11AR9107
CYLINDER BLOCK
1. Visually check for cracks, rust, and corrosion,
and inspect the cylinder block using a flaw
detecting agent. Rectify defects where pos-
sible or replace the cylinder block.
2. Ensure that the top surface is free of gasket
chips and other foreign material. Check the
cylinder block's top surface for distortion
using a straight edge and thickness gauge.
Standard value :
0.03 mm (0.001 in)
DOIIE11AR9108

Limit :
0.1 mm (0.004 in)
3. Check the cylinder walls for cracks and

seizure marks. If defects are evident, bore all
the cylinders to oversize or replace the cylin-
der block.
4. Using a cylinder gauge, measure each cylin-
der's bore and cylindricity. If any cylinder is
severely worn, bore all the cylinders to over-
size and replace the piston and piston rings
accordingly. Take measurements at the
points shown.
Standard value :
Cylinder bore : 76.0 mm (2.99 in)
Cylinder stroke : 86.0 mm (3.39 in)
Cylindricity : 0.025 mm (0.001 in) or less
DOIIE11AR06001
BORING CYLINDER
1. Oversize pistons to be used should be determ-
ined on the basis of the cylinder with the
largest bore.
2. Oversize pistons are available with the fol-
lowing oversize dimensions: 0.25 mm (0.01
in), and 0.50 mm (0.02 in), 0.75 mm (0.03 in)
and 1.00 mm (0.039 in). Measure the diamet-
er of the piston to be used. Boring must be
carried out such that the piston-to-cylinder
clearance complies with the standard value.
The piston 's diameter should be measured
DOIGE11AR03088
at the points shown.
3. Calculate the boring finish dimension based
on the piston diameter dimension.
• [Boring finish dimension] = [piston O.D. (A)]
+ [piston-to-cylinder clearance (0.01 - 0.03
mm (0 - 0.001 in))] – [honing margin (0.02
mm)]
4. Bore each cylinder to the calculate boring
finish dimension.
CAUTION :
To prevent distortion caused by heat in-
creases during boring, bore the cylinders in
the following order : No.2, No. 4, No. 1, No.
3.
5. Hone the cylinders to the final finish dimen-
sion (piston O.D. (A) + piston-to-cylinder
clearance).
6. Check the clearance between the pistons and
cylinders.

Standard value :
0.01 - 0.03 mm (0 - 0.001 in)

WEO11ASPROC10022
OIL PRESSURE SWITCH INSTALLATION

1. Apply the specified sealant to the thread of
oil pressure switch.
Specified sealant :
TB 1130
2. Use the special tool (MD998054) to tighten

the oil pressure switch to the specified
torque.
Specified torque :
1.45 ft.lbs)
3. Install the oil pressure switch terminal.

CAUTION :
• Apply sealant such that none is squeezed out
past end of the thread.
• Do not over-tighten the oil pressure switch.
DOIGE11AR03119
KNOCK SENSOR INSTALLATION

1. Install the knock sensor to cylinder block and
tighten the bolt flange
Specified torque :
2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Symbol Description
A Knock sensor
NOTE :
The knock sensor terminal shall facing out-
DOIGE11AR03089 ward 90°.

PISTON COOLING JET INSTALLATION

1. Apply engine oil to the bolt thread and pis-
ton cooling jet.
2. Install piston cooling jet into cylinder block
assy.
3. Tighten the bolt to the specified torque.
Specified torque :
0.8 - 1.2 kgm (8 - 12 Nm, 5.79 - 8.68 ft.lbs)
DOINE11AR11068
CRANKSHAFT JOURNAL BEARING

INSTALLATION
1. Select bearings according to the crankshaft
identification marks. If they are not identifi-
able, measure the crankshaft journals and
choose bearings to match the measurements.
Example : Shaft 1 + Bore 2 = Bearing 3.
Symbol Description
JR Journal
IM Identification mark positions
A Main bearing identification
mark position
B Con rod bearing identifica-
tion mark position
DOINE11AR11018

CRANKSHAFT JOURNAL CYLINDER BLOCK BEARING SELECTED
Crankshaft Bearing iden- OIL CLEAR-
Outer diamet- Bore identi- Inner diamet- Bearing thick- ANCE (mm)
identifica- tification
er (mm) fication mark er (mm) ness (mm)
tion mark mark
0 52.000- 1 1.988-1.991 0.018 – 0.036
52.006
1 52.006- 2 1.991-1.994 0.018 – 0.036
1 47.994-48.000
52.012
2 52.012- 3 1.994-1.997 0.018 – 0.036
52.018


CRANKSHAFT JOURNAL CYLINDER BLOCK BEARING SELECTED
Crankshaft Bearing iden- OIL CLEAR-
Outer diamet- Bore identi- Inner diamet- Bearing thick- ANCE (mm)
identifica- tification
er (mm) fication mark er (mm) ness (mm)
tion mark mark
0 52.000- 2 1.991-1.994 0.018 – 0.036
52.006
1 52.006- 3 1.994-1.997 0.018 – 0.036
2 47.988-47.994
52.012
2 52.012- 4 1.997-2.000 0.018 – 0.036
52.018
0 52.000- 3 1.994-1.997 0.018 – 0.036
52.006
1 52.006- 4 1.997-2.000 0.018 – 0.036
3 47.982-47.988
52.012
2 52.012- 5 2.000-2.003 0.018 – 0.036
52.018
2. Identification marks showing the cylinder
block bearing bore diameter are stamped in
the position shown. Bearings must be selec-
ted and installed in accordance with these
identification marks.
Symbol Description
A First reading start from right
side to left side
B Timing belt side
C Cylinder block top surface
DOINE11AR11019
3. In order to select correct crankshaft main
bearing , refer the main bearing identifica-
tion mark at crankshaft and cylinder block.
For example,
At crankshaft
(journal no.1
2 3 3 2 2
until journal
no.5)
At cylinder
block (right side 1 2 0 2 2
to left side)
Select main
bearing identific- 3 5 3 4 4
ation number

4. The main bearing identification number is

painted on the main bearing outer surface
Symbol Description
B Painted identification mark
DOIGE11AR03083
5. Except for the center bearing, all the upper

bearings are grooved. The center bearings
are grooveless and have flanges. The center
bearings are the same at the top and bottom.
Symbol Description
E Grooveless (No groove)
F Gooved
Lower bearing (No. 1, 2, 3, 4
G
and 5)
Upper bearing (No. 1, 2, 4 and
H
DOINE11AR11183
5)
I Center upper bearing (No. 3)
6. The lower bearing are all grooveless.
BEARING CAP INSTALLATION

1. On the bottom surface of each bearing cap
is the cap's number and an arrow . Starting
at the timing belt side, fit the bearing caps
in numerical order. Ensure that the arrows
point towards the timing belt side.
2. Apply engine oil to the threaded portion and
bearing surface.
DOIGE11AR03093

3. Tighten the bearing cap bolts according to

tightening order as illustration.
Specified torque :
4.91 - 5.39 kgm (49.1 - 53.9 Nm, 35.51 - 38.99
ft.lbs)
DOIGE11AR03094
4. After fitting the bearing caps, measure the

end play at the crankshaft. If the measure-
ment exceeds the specified limit, replace the
crankshaft bearings.
Standard value :
0.07 - 0.195 mm (0.003 - 0.008 in)
Limit :
0.25 mm (0.01 in)
DOIGE11AR03116

REAR OIL SEAL INSTALLATION

1. Apply a small mount of engine oil to the en-
tire circumference of the oil seal lip.
2. Tap in the oil seal with the mallet as show in
the illustration.
Symbol Description
B Rear oil seal
C Crankshaft rear oil seal housing
D Mallet
DOIHC11AR04048
REAR OIL SEAL CASE INSTALLATION

1. Apply liquid gasket to the rear oil seal case
at the illustrated position (if it has no pre-
formed gasket attached)
Specified sealant :
Part No. MD970389 or equivalent (RTV seal-
ant, TREEBOND TB1207F).
CAUTION :
Squeeze the liquid gasket uniformly so that
there is no break in the gasket nor is there
DOIGE11AR03097 too much gasket.
2. Apply a suitable amount of engine oil to the
entire periphery of the oil seal lip and install
the oil seal on the cylinder block.

DIRECT DAMPER FLYWHEEL (DDF)

INSTALLATION
1. Clean off sealant, oil and deposits from the
threaded portion, tightening bolts and from
the threaded holes on the crankshaft.
2. Apply engine oil to the bolt flange and to
the threaded holes on the crankshaft.
3. Apply sealant to the threaded portion of the
bolt ( if the bolt is reused ).
Specified sealant :
3M Nut Locking Part No. 4171 or equivalent
DOINE11AR11134
4. Install direct dual flywheel to the crankshaft
rear end as illustration and fit the bolt.
Symbol Description
A Cylinder block
B Direct damper flywheel (DDF)
C Direct damper flywheel bolt
1. Using the flywheel stopper to secure direct
damper flywheel and then tighten the direct
damper flywheel bolts to the specified
torque.
Service tightening torque :
8.0 - 9.0 kgm (80 - 90 Nm, 57.86 - 65.1 ft.lbs)
Symbol Description
A Direct damper flywheel (DDF)
C Direct damper flywheel bolt
DOINE11AR11132 2. Lock the Direct Damper Flywheel (A) by using
special tool (B).
3. Then, loosen the 5 pieces bolts (C) as shown
REMOVAL AND INSTALLATION SERVICE

POINTS WEO11ASPROC10023
TARGET WHEEL REMOVAL

1. Insert an equivalent size of rubber pad into
the vice to avoid the crankshaft journal from
scratch as shown in the illustration.
Symbol Description
A Vice
B Rubber pad
DOIGE11AR09002

2. During fixing the crankshaft at vice, make

sure the rubber pad is firmly hold at the
crankshaft.
Symbol Description
A Vice
B Rubber pad
C Target wheel
D Crankshaft
DOIGE11AR09003
3. Clean the target wheel surface and patch

lock screw properly.
Steps Description
Spray an anti-rust to remove
A
any rust or dirt on the surface.
Use compress air to blow and
B
clean the surface.
Wipe with cloth to ensure the
C patch lock allen key head is
free from any rust or dirt.
DOIGE11AR09010
4. Use a ratchet together with an allen key to

remove 3 pieces of patch lock screws from
the target wheel.
CAUTION :
• It is highly recomended to use socket type
allen key to prevent any damage on the
patch lock allen key head.
• Ensure patch lock allen key head is clean
before removal.
Symbol Description
C Target wheel
DOIGE11AR09007

Symbol Description
D Crankshaft
E Socket with allen key
F Patch lock screw
G Ratchet
TARGET WHEEL INSTALLATION

Install new patch lock screw into target wheel
with the specified torque as shown in the illustra-
tion.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Symbol Description
C Target wheel
D Crankshaft
DOIGE11AR09007 E Socket with allen key
F Patch lock screw
G Ratchet

S4P Model YR 2011 English Edition RDCE-110S4P020-04 November 2011 Printed in Malaysia

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What is the manual about?

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What are some of the main sections covered in the manual?

WORKSHOP MANUAL

00 GENERAL ................................................................................... 00/1 - 00/14

Printed in Malaysia 30 November 2011 Eng

Printed in Malaysia 30 November 2011 Eng

AIR BAG SYSTEM INFORMATION .................................................. 00/6

HOW TO USE THIS MANUAL ....................................................... 00/7

ENGINE MODEL AND SERIAL NUMBER LOCATION ............................. 00/11

TIGHTENING TORQUE ................................................................ 00/11

PRECAUTION BEFORE SERVICE ..................................................... 00/12

Printed in Malaysia 30 November 2011 Eng

OUTLINE OF CHANGES WEO000OLINE11001

Printed in Malaysia 30 November 2011 Eng

PUB. NO: RDCE-080S4P020 –

Special tools CamPro-IAFM

Timing belt CamPro-IAFM

Printed in Malaysia 30 November 2011 Eng

PUB. NO: RDCE-080S4P020 –

Printed in Malaysia 30 November 2011 Eng

PUB. NO: RDCE-080S4P020 –

OUTLINE OF CHANGE ITEMS

Fuel and Emission Control System

Printed in Malaysia 30 November 2011 Eng

Change Items Reference Page Description of Changes

AIR BAG SYSTEM INFORMATION WEO000BSERV11001

Printed in Malaysia 30 November 2011 Eng

HOW TO USE THIS MANUAL WEO000READS11001

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

Printed in Malaysia 30 November 2011 Eng

EXPLANATION OF MANUAL CONTENTS WEO000READS11002

Printed in Malaysia 30 November 2011 Eng

Grease (multipurpose grease unless there is a brand

Brake fluid or automatic transmission fluid

Engine oil, gear oil or air condition compressor oil

Adhesive tape or butyl rubber tape.

Printed in Malaysia 30 November 2011 Eng

Indicates that there are essentials point for removal

Indicates that there are essential point for installation

Indicates that there are essential points for both

M Operating procedures, caution etc. on removal, installation disassembly and reassembly

Printed in Malaysia 30 November 2011 Eng

ENGINE MODEL AND SERIAL

1. The engine model number is stamped at the

Engine Model Engine Displacement

Engine serial number [Example]

TIGHTENING TORQUE WEO000TTORQ11001

General tightening torque is as shown in the following table.

Printed in Malaysia 30 November 2011 Eng

PRECAUTION BEFORE SERVICE WEO000BSERV11002

Printed in Malaysia 30 November 2011 Eng

Removal and Disassembly For prevention of wrong installation or reas-

Tightening Torque Tighten the part properly to specified torque.

Oil and Grease Before reassembly, apply specified oil to the

Printed in Malaysia 30 November 2011 Eng

Special Tool Be sure to use Special Tools when their use is

Sealant Use specified brand of sealant.