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UNIT REPAIR


T3B11B94
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Cylinder Head and Valve Train Components

Tools Required

MKM-571-B Gauge
KM-253 Valve Guide Reamer
KM-254 Valve Guide Reamer
KM-255 Valve Guide Reamer
KM-340-0 Cutter Set
KM-340-7 Guide Drift
KM-340-13 Cutters
KM-340-26 Cutters
KM-348 Valve Spring Compressor
KM-419 Distance Gauge

Disassembly Procedure

  1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.
  2. Remove the coolant temperature sensor.

    3. T3B11B95
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  3. Remove the exhaust manifold heat shield bolts.
  4. Remove the exhaust manifold heat shield.
  5. Remove the exhaust manifold nuts.
  6. Remove the exhaust manifold.
  7. Remove the exhaust manifold gasket.
  8. Remove the exhaust manifold studs.
  9. Remove the spark plugs.

    10. T3B11B96
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  10. Remove the intake manifold retaining nuts.
  11. Remove the intake manifold.
  12. Remove the intake manifold gasket.
  13. Remove the intake manifold studs.

    14. T3B11B97
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  14. Remove the thermostat housing mounting bolts.
  15. Remove the thermostat housing.
  16. Remove the thermostat and thermostat gasket.

    17. T3B11B98
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  17. Using the valve spring compressor KM-348, compress the valve springs.
  18. Remove the valve keys.
  19. Remove the valve spring plates.
  20. Remove the valve springs.
  21. Remove the valves.
  22. Remove the valve stem oil seals.
  23. Remove camshaft carrier alignment pins.

T3B11B99
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Cylinder Head Inspection

  1. Clean the sealing surfaces.
  2. Inspect the cylinder head gasket and the mating surfaces for leaks, corrosion, and blowby.
  3. Inspect the cylinder head for cracks.
  4. Inspect the length and the width of the cylinder head using a feeler gauge and a straight edge.
  5. Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be flat within 0.15 mm (0.0059 inch) maximum.

    6. T3B11B1A
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  6. Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder head height should be 95.90 to 96.10 mm (3.775 to 3.783 inches). If the cylinder head height is less than 95.9 mm (3.775 inches), replace the cylinder head.
  7. Inspect all threaded holes for damage.
  8. Inspect the valve seats for excessive wear and burned spots.

T3B11B1B
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Valve Inspection

  1. Inspect valve stem tip wear.
  2. Inspect the valve keeper grooves and oil seal grooves for chips and wear.
  3. Inspect the valves for burns or cracks.
  4. Inspect the valve stem for burrs and scratches.
  5. Inspect the valve stem. The valve stem must be straight.
  6. Inspect the valve face for grooving. If the groove is so deep the refacing would result in a sharp edge, replace the valve.

    7. T3B11B1C
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  7. Inspect the valve spring. If the valve spring ends are not parallel, replace the valve spring.
  8. Measure the valve spring height. Refer to "Engine Specifications" in this section. If the valve spring height does not match the specifications, replace the valve spring.

T3B11B1D
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Cleaning Procedure

  1. Clean the cylinder head.
  2. Clean the valve guides.
  3. Clean all of the threaded holes.
  4. Clean the valves of carbon, oil and varnish.

T3B11B1E
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Cylinder Head Overhaul

Valve Grind-in

  1. Lubricate the valve stem using a fine-grained paste.
  2. Lift the valve rhythmically from the seat with a commercially available valve grinding tool in order to distribute the paste.

    3. T3B11B1F
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  3. Check the contact pattern on the valve head and in the cylinder head.
  4. Clean the valves, the valve guides, and the cylinder head.

T3B11B1G
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Valve Grind

  1. Ensure that there are no crater line burns on the valve cone.
  2. The valve may be reground only two times. Do not grind the valve stem end.
  3. The angle at the valve face angle is 46 degrees.

    4. T3B11B1H
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  4. Check the valve stem projection using the distance gauge KM-419.

T3B11B1I
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Valve Guide Ream

  1. Measure the diameter of the valve guide using the gauge MKM-571-B and a commercially available inside micrometer.

    2. Important : Valve oversizes may already have been fitted in production.

  2. An oversize code is on the valve guide and the valve stem end. The following table gives the correct size, reamer, and production code for each service code.

    3. Size
    Reamer
    Production Code
    Service Code
    Normal
    -
    -
    K
    0.075
    KM-253
    1
    K1
    0.150
    KM-254
    2
    K2
    0.250
    KM-255
    -
    A
  3. Ream the valve guide from the upper side of the cylinder head to the next oversize. After reaming, cross out the code and emboss the valve guide with the new code.

T3B11B1J
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Valve Seat -- Cut

  1. Place the cylinder head on wooden blocks.
  2. Cut the intake and the exhaust valve seats using the guide drift KM-340-7 as follows:

    3. T3B11B1H
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  3. Clean the chippings from the cylinder head.
  4. Inspect the dimension for the proper valve seat width.
  5. Inspect the valve stem projection using the distance gauge KM-419.

    6. T3B11B1K
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  6. If the dimension is exceeded, install new valves and then check the valve stem projection again. Refer to "Valve Grind" and "Valve Grind-In" in this section.
  7. If the valve stem projection is still too large despite replacing the valves, replace the cylinder head.

T3B11B98
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Assembly Procedure

  1. Install the camshaft carrier alignment pins.
  2. Install the valve stem oil seals.
  3. Coat the valves with engine oil.
  4. Install the valves.
  5. Install the valve springs.
  6. Using the valve spring compressor KM-348, compress the valve springs.
  7. Install the valve keys.
  8. Install the valve spring plate.

    9. T3B11B97
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  9. Install the thermostat and the gasket.
  10. Install the thermostat housing.
  11. Install the thermostat housing mounting bolts.

    12. Tighten
    Tighten the thermostat housing mounting bolts to 20 N•m (15 lb-ft).


    T3B11B96
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  12. Install the intake manifold studs.
  13. Install the intake manifold gasket.
  14. Install the intake manifold.
  15. Install the intake manifold retaining nuts.

    16. Tighten
    Tighten the intake manifold retaining nuts to 25 N•m (18 lb-ft).


    T3B11B95
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  16. Install the spark plugs.

    17. Tighten
    Tighten the spark plugs to 25 N•m (18 lb-ft).

  17. Install the exhaust manifold studs.
  18. Install the exhaust manifold gasket.
  19. Install the exhaust manifold.
  20. Install the exhaust manifold nuts.

    21. Tighten
    Tighten the exhaust manifold nuts to 25 N•m (18 lb-ft).


    T3B11B94
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  21. Install the exhaust manifold heat shield.
  22. Install the exhaust manifold heat shield bolts.

    23. Tighten
    Tighten the exhaust manifold heat shield bolts to 15 N•m (11 lb-ft).

  23. Install the coolant temperature sensor.

    24. Tighten
    Tighten the coolant temperature sensor to 20 N•m 15 lb-ft).

  24. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.

T3B11B1L
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Crankshaft

Tools Required

MKM-412 Engine Overhaul Stand
J-42492 Timing Belt Adjuster
KM-470-B Angular Torque Gauge
J-36792 or KM-635 Crankshaft Rear Oil Seal Installer

Notice : Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation.

Disassembly Procedure

  1. Remove the engine. Refer to "Engine"in this section.
  2. Remove the flywheel bolts.
  3. Remove the flywheel.
  4. Remove the crankshaft rear oil seal.
  5. Mount the engine assembly on the engine overhaul stand MKM-412.

    6. T3B11B1M
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  6. Remove the upper timing belt cover bolts.
  7. Remove the upper timing belt cover.
  8. Remove the lower timing belt cover bolts.
  9. Remove the lower timing belt cover.

    10. T3B11B56
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  10. Slightly loosen the three coolant pump retaining bolts.
  11. Rotate the coolant pump using timing belt adjuster
  12. J-42492 to remove the tension from the timing belt. Remove the timing belt.

    13. T3B11B35
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  13. Remove the valve cover bolts.
  14. Remove the valve cover and the valve cover gasket.

    15. Notice : Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation.

  15. While holding the camshaft firmly in place, remove the camshaft gear bolt.
  16. Remove the camshaft gear.

    17. T3B11B1N
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  17. Remove the timing belt automatic tensioner bolt.
  18. Remove the timing belt automatic tensioner.
  19. Remove the rear timing belt cover bolts.
  20. Remove the rear timing belt cover.
  21. Remove the crankshaft timing belt gear.

    22. T3B11B62
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  22. Rotate the engine on the engine overhaul stand MKM-412.
  23. Remove the oil pan retaining bolts.
  24. Remove the oil pan.
  25. Remove the oil pickup tube bolts.
  26. Remove the oil pump pickup tube.

    27. T3B11B63
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  27. Remove the oil pump retaining bolts.
  28. Remove the oil pump.

    29. T3B11B1O
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  29. Mark the order of the rod bearing caps.
  30. Remove the connecting rod cap bolts for all of the pistons.
  31. Remove the connecting rod bearing caps and the lower connecting rod bearings.
  32. Remove the upper connecting rod bearings.

    33. T3B11B1P
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  33. Mark the order of the crankshaft bearing caps.
  34. Remove the crankshaft bearing cap bolts.
  35. Remove the crankshaft bearing caps.
  36. Remove the crankshaft bearings from the crankshaft bearing caps.
  37. Remove the crankshaft.
  38. Remove the crankshaft bearings from the engine block.
  39. Clean the parts, as necessary.

T3B11B1Q
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Assembly Procedure

  1. With crankshaft and bearings in place, plastic gauge all bearing clearances. Refer to "Crankshaft Bearings and Connecting Rod Bearings -- Gauging Plastic" in this section.
  2. Inspect the crankshaft end play with the crankshaft bearings installed.
  3. Check for permissible crankshaft end play. Refer to "Engine Specifications"in this section.

    4. T3B11B1R
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  4. With the crankshaft mounted on the front and the rear crankshaft bearings, check the middle crankshaft journal for permissible out-of-round (runout). Refer to "Engine Specifications" in this section.

    5. T3B11B1S
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  5. Coat the crankshaft bearings with engine oil.
  6. Apply a bead of adhesive sealing compound to the grooves of the rear crankshaft bearing cap.
  7. Install the crankshaft bearings in the engine block.
  8. Install the crankshaft.

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  9. Install the crankshaft bearings to the crankshaft bearing caps.
  10. Install the crankshaft bearing caps.

    11. Notice : Do not reuse the old crankshaft bearing cap bolts. Damage to the engine could result.

  11. Install new crankshaft bearing cap bolts.

    12. Tighten
    Tighten the crankshaft bearing cap bolts to 50 N•m (37 lb-ft). Using the angular torque gauge KM-470-B, tighten the crankshaft bearing cap bolts another 45 degrees plus 15 degrees.

  12. Install the upper connecting rod bearings to the connecting rods.
  13. Install the lower connecting rod bearings to the connecting rod bearing caps

    14. T3B11B1U
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  14. Install the connecting rod bearing caps to the connecting rods.

    15. Notice : Do not reuse the old connecting rod bearing cap bolts. Damage to the engine could result.

  15. Install new connecting rod bearing cap bolts.

    16. Tighten
    Tighten the connecting rod bearing cap bolts to 25 N•m (18 lb-ft). Using the angular torque gauge KM-470-B, tighten the connecting rod bearing cap bolts another 30 degrees plus 15 degrees.


    T3B11B63
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  16. Install the oil pump.
  17. Install the oil pump retaining bolts.

    18. Tighten
    Tighten the oil pump retaining bolts to 10 N•m (89 lbin).


    T3B11B62
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  18. Install the oil pump/pickup tube.
  19. Install the oil pump/pickup tube bolts.

    20. Tighten
    Tighten the oil pump/pickup tube and support bracket bolts to 10 N•m (89 lb-in).


    T3B11B66
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  20. Install the oil pan gasket to the oil pan.
  21. Install the oil pan.

    22. Important : Install the oil pan within 5 minutes after applying the liquid gasket to the oil pan.

  22. Install the oil pan retaining bolts.

    23. Tighten
    Tighten the oil pan retaining bolts to 10 N•m (89 lb-in).


    T3B11B1N
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  23. Install the crankshaft timing belt gear.
  24. Install the rear timing belt cover.
  25. Install the rear timing belt cover bolts.

    26. Tighten
    Tighten the rear timing belt cover bolts to 10 N•m (89 lb-in).

  26. Install the timing belt automatic tensioner.
  27. Install the timing belt automatic tensioner bolt.

    28. Tighten
    Tighten the timing belt automatic tensioner bolt to 20 N•m (15 lb-ft).


    T3B11B35
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    Notice : Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation.

  28. Install the camshaft gear.
  29. Install the camshaft gear bolt while holding the camshaft firmly in place.

    30. Tighten
    Tighten the camshaft gear bolt to 45 N•m (33 lb-ft).


    T3B11B54
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  30. Install the timing belt.
  31. Adjust the timing belt tension. Refer to "Timing Belt Check and Adjust" in this section.
  32. Install the valve cover gasket and the valve cover.
  33. Install the valve cover bolts.

    34. Tighten
    Tighten the valve cover bolts to 10 N•m (89 lb-in).

  34. Install the lower timing belt cover.
  35. Install the lower timing belt cover bolts.

    36. Tighten
    Tighten the lower timing belt cover bolts to 10 N•m (89 lb-in).


    T3B11B1U
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  36. Install the power steering pump.
  37. Install the power steering pump mounting bolts.

    38. Tighten
    Tighten the power steering pump mounting bolts to 25 N•m (18 lb-ft).

  38. Install the upper timing belt cover.
  39. Install the upper timing belt cover bolts.

    40. Tighten
    Tighten the upper timing belt cover bolts to 10 N•m (89 lb-in).

  40. Install the engine lifting device.
  41. Dismount the engine from the engine overhaul stand MKM-412.
  42. Install the crankshaft rear oil seal using installer J-36972 or KM-635.

    43. T3B11B1L
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  43. Install the flywheel.
  44. Install the flywheel bolts.

    45. Tighten
    Tighten the flywheel bolts to 35 N•m (26 lb-ft) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the flywheel bolts another 30 degrees plus 15 degrees.

  45. Install the engine. Refer to "Engine" in this section.

T3B11B1Q
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Crankshaft Bearings and Connecting Rod Bearings - Gauging Plastic

Tools Required

KM-470-B Angular Torque Gauge

Inspection Procedure - Crankshaft

  1. Coat the crankshaft bearings with engine oil.
  2. Install the upper crankshaft bearings into the engine block crankshaft journals.
  3. Install the lower crankshaft bearings into the crankshaft bearing caps.
  4. Install the crankshaft.
  5. Inspect the crankshaft end play with the crankshaft bearings installed.
  6. Check for permissible crankshaft end play. Refer to "Engine Specifications"in this section.

    7. T3B11B1R
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  7. With the crankshaft mounted on the front and the rear crankshaft bearings, check the middle crankshaft journal for permissible out-of-round (runout). Refer to "Engine Specifications" in this section.

    8. T3B11B1V
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    Important : Grease the crankshaft journals and lubricate the crankshaft bearings slightly so that the plastic gauging thread does not tear when the crankshaft bearing caps are removed.

  8. Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging (ductile plastic threads).
  9. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the crankshaft journals and the crankshaft bearings.

    10. T3B11B1T
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  10. Install the crankshaft bearing caps.
  11. Install the crankshaft bearing cap bolts.

    12. Tighten
    Tighten the crankshaft bearing cap bolts to 50 N•m (37 lb-ft). Using the angular torque gauge KM-470-B, tighten the crankshaft bearing cap bolts another 45 degrees plus 15 degrees.


    T3B11B1W
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  12. Remove the crankshaft bearing caps.
  13. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
  14. Inspect the bearing clearances for permissible tolerance ranges. Refer to "Engine Specifications"in this section.

T3B11B1V
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Inspection Procedure - Connecting Rods

  1. Coat the connecting rod bearings with engine oil.

    2. Important : Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the plastic gauging thread does not tear when the connecting rod bearing caps are removed.

  2. Install the upper connecting rod bearings into the connecting rod journals.
  3. Install the lower connecting rod bearings into the connecting rod bearing caps.
  4. Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).

    5. T3B11B93
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  5. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the connecting rod journals and the connecting rod bearings.
  6. Install the connecting rod bearing caps.
  7. Install the connecting rod bearing cap bolts.

    8. Tighten
    Tighten the connecting rod bearing cap bolts to 25 N•m (18 lb-ft). Using the angular torque gauge KM-470-B, tighten the crankshaft cap bolts another 30 degrees plus 15 degrees.


    T3B11B1W
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  8. Remove the connecting rod bearing caps.
  9. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
  10. Inspect the bearing clearance for permissible tolerance ranges. Refer to "Engine Specifications" in this section.


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