• Warm engine operation.
• Above idle speed.

1. Spark Plug Cover
2. Oil Filler Cap
3. Oil Filler Cap Seal
4. Camshaft Cover
5. Camshaft Cover Nut
6. Camshaft Cover Washer
7. Camshaft Cover Gasket
8. Seal
9. Hydraulic Tappet Adjuster
10. Valve Key
11. Valve Spring Cap
12. Valve Spring
13. Valve Stem Seal
14. Camshaft Cover Stud
15. Freeze Plug
16. Exhaust Manifold
17. Nut
18. Exhaust Manifold Heat Shield
19. Oxygen Sensor
20. Bolt
21. Bolt
22. Thermostat Housing
23. Exhaust Mainfold Gasket
24. Cylinder Head
25. Camshaft Gear
26. Thermostat Adapter Seal
27. Nut
28. Washer
29. Cylinder Head Gasket
30. Exhaust Valve
31. Intake Valve
32. Camshaft Seal
33. Washer
34. Camshaft Gear Bolt
35. Camshaft
36. Plug
37. Stud
38. Engine Coolant Temperature Sensor
39. Coolant Temperature Sensor
40. Bolt
41. Front Camshaft Cap
42. Plug
43. Valve Guide
44. Intermediate Camshaft Cap
45. Washer
46. Head Bolt
47. Exhaust Gas Recirculation Pipe
48. Intake Manifold
49. VGIS Manifold Gasket
50. Throttle Body
51. Intake VGIS Manifold
52. Intake Manifold Gasket

1. Piston Ring Set
2. Piston
3. Piston Pin
4. Connecting Rod
5. Connecting Rod Bearing Set
6. Connecting Rod Bolt
7. Oil Level Gauge Stick
8. Gauge Stick Tube
9. Connecting Piece
10. Oil Filter
11. Hose Clamp
12. Engine Ventilation Hose
13. Engine Ventilation Pipe
14. Bolt
15. Oil Separator Gasket
16. Crankshaft Pulley Bolt
17. Washer
18. Crankshaft Pulley
19. Crankshaft Gear
20. Rear Timing Belt Cover
21. Bolt
22. Water Pump
23. Oil Pump
24. Seal Ring
25. Oil Pump Body Gasket
26. Engine Block
27. Pressure Relief Valve Plunger
28. Spring
29. Oil Pump Seal Ring
30. Bolt Plug
31. Crankshaft Bearing Set
32. Crankshaft
33. Shaft Seal Ring
34. Flywheel (Manual Transaxle)
35. Bolt (Manual Transaxle)
36. Bolt
37. Bracket
38. Bolt
39. Crankshaft Position Sensor
40. Flexible Plate (Automatic Transaxle)
41. Bolt (Automatic Transaxle)
42. Crankshaft Main Bearing Cap
43. Bolt
44. Oil Pan
45. Threaded Ring
46. Oil Pan Drain Plug
47. Bolt
48. Bracket
49. Oil Suction Pipe
50. Bolt
51. Bolt
52. Timing Belt
53. Cover Seal
54. Cover
55. Bolt
56. Idler Pulley
57. Rear Cover Bolt
58. Bolt
59. Auto Tensioner
60. Seal
61. Bolt
62. Seal
63. Ring Gear
64. Gear
65. Knock Sensor
66. Bolt
67. Plug
68. Oil Pressure Switch
69. Cover
70. Bolt
71. Intake Manifold-to-Engine Block Bracket
72. Exhaust Gas Recirculation Solenoid

---

1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Disconnect the breather hoses from the valve cover.
4. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.
5. Disconnect the clip at the valve cover.
6. Remove the spark plug cover bolts and cover.
Installation Notice

Tightening Torque

8 N•m (71 lb-in)




---





7. Disconnect the ignition wires at the spark plugs.
8. Remove the valve cover bolts.
Installation notice

Tightening Torque

8 N•m (71 lb-in)

9. Remove the valve cover.
10. Remove the valve cover gasket from the valve cover.
11. Installation should follow the removal procedure in the reverse order.

---

1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine after it stalls for 10 seconds to rid the fuel system of fuel pressure.



---





3. Drain the engine coolant. Refer to "Section 1D, Engine Cooling".
4. Disconnect the negative battery cable
5. Remove the air filter housing bolts and the air filter housing assembly.
6. Remove the air inlet duct bolts and air inlet duct
Installation notice

Tightening Torque

8 N•m(71 lb-in)




---





7. Disconnect the intake air temperature (IAT) sensor connector.
8. Disconnect the breather hose from the valve cover.
9. Remove the air intake tube from the throttle body.



---





10. Disconnect the camshaft position (CMP) sensor connector.
11. Disconnect the oxygen sensor connector.
12. Disconnect the engine coolant temperature (ECT) sensor connector.
13. Disconnect the coolant temperature gauge connector.
14. Disconnect the EGR valve connector.
15. Remove the electronic ignition (EI) system ignition coil. Refer to "Section 1F, Engine Controls".



---





16. Disconnect the coolant hose from the throttle body.
17. Disconnect the coolant hose from the cylinder head.



---





18. Disconnect the upper radiator hose at the thermostat housing.



---





19. Remove the air cleaner housing bolts.
20. Remove the air cleaner housing.
21. Remove the right front wheel. Refer to "Section 2E, Tires and Wheels".
22. Remove the right front wheel well splash shield.



---





23. Disconnect the upper radiator hose at the thermostat housing.
24. Remove the serpentine accessory drive belt. Refer to "Section 6B, Power Steering Pump".
25. Remove the crankshaft pulley bolt.
26. Remove the crankshaft pulley.



---





27. Remove the upper front timing belt cover bolts.
28. Remove the upper front timing belt cover.
29. Remove the lower front timing belt cover bolts.
30. Align the camshaft gear timing marks.
31. Remove the lower front timing belt cover.



---





32. Slightly loosen the water pump retaining bolts.
33. Rotate the water pump counterclockwise using the timing belt adjuster J-42492 to relieve the timing belt tension.
34. Remove the timing belt. Refer to "Timing Belt" in this section.



---





35. Disconnect the engine ventilation hose at the camshaft cover.
36. Remove the oil filler cap.
37. Remove the spark plug cover bolts.
38. Remove the spark plug cover.
39. Disconnect the ignition wires from the spark plugs.
40. Remove the camshaft cover nuts.
41. Remove the camshaft cover washers.
42. Remove the camshaft cover and the camshaft cover gasket.



---





Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.
43. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
44. Remove the intake camshaft gear.
45. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
46. Remove the exhaust camshaft gear.



---





47. Remove the timing belt automatic tensioner bolts.
48. Remove the timing belt automatic tensioner.



---





49. Remove the timing belt idler pulley bolt.
50. Remove the timing belt idler pulley.
51. Remove the right engine mount. Refer to "Engine Mount" in this section.



---





52. Remove the rear timing belt cover bolts.
53. Remove the rear timing belt cover.



---





54. Remove the exhaust flex pipe retaining nuts at the exhaust manifold studs.
55. Disconnect all of the necessary vacuum hoses and the brake booster hose at the intake manifold.



---





56. Disconnect the fuel return line at the fuel pressure regulator.
57. Disconnect the fuel feed line at the fuel rail.
58. Remove the generator upper retaining bolt.
59. Disconnect the heater inlet hose at the cylinder head.
60. Disconnect the surge tank coolant hose at the throttle body.



---





61. Remove the upper intake manifold support bracket bolts at the intake manifold.



---





62. Disconnect the throttle cable at the throttle body and the intake manifold.
63. Loosen all of the cylinder head bolts gradually and in the sequence shown.
64. Remove the cylinder head bolts.
65. Remove the cylinder head with the intake manifold and the exhaust manifold attached.
Notice : Prevent any engine oil or coolant from entering the cylinders when removing the cylinder head.
66. Remove the cylinder head gasket.
67. Installation should follow the removal procedure in the reverse order.

---

1. Clean the gasket surfaces of the cylinder head and the engine block.
2. Make sure the gasket surfaces of the cylinder head and the engine block are free of nicks and heavy scratches.
3. Clean the cylinder head bolts.
4. Inspect the cylinder head for warpage. Refer to "Cylinder Head and Valve Train Components" in this section.

---

1. Remove the timing belt. Refer to "Timing Belt" in this section.
2. Remove the valve cover. Refer to "Valve Cover" in this section.
Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.



---





3. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
Installation notice

Tightening Torque

67.5 N•m(49 lb-in)

4. Remove the intake camshaft gear.
5. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
Installation notice

Tightening Torque

67.5 N•m (49 lb-in)




---





6. Remove the exhaust camshaft gear.
7. Remove the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.
Installation notice
8. Remove the intake/exhaust camshaft caps. Maintain the correct positions for installation.
9. Remove the intake/exhaust camshaft.
10. Installation should follow the removal procedure in the reverse order.

---

Tools Required


KM-470-B Angular Torque Gauge
1. Disconnect the negative battery cable.
2. Remove the air filter housing bolts.
3. Remove the air filter housing assembly.
4. Disconnect the manifold air temperature (MAT) sensor connector.
5. Remove the air cleaner outlet hose from the throttle body.
6. Remove the breather tube from the camshaft cover.



---





7. Remove the air cleaner housing bolts.
8. Remove the air cleaner housing.
9. Remove the right front wheel. Refer to "Section 2E, Tires and Wheels".
10. Remove the right front wheel well splash shield.



---





11. Remove the serpentine accessory drive belt. Refer to "Section 6B, Power Steering Pump".
12. Remove the crankshaft pulley bolt.
13. Remove the crankshaft pulley.



---





14. Remove the upper front timing belt cover bolts.
15. Remove the upper front timing belt cover.
16. Remove the lower front timing belt cover bolts.
17. Remove the lower front timing belt cover.
18. Install the crankshaft pulley bolt.



---





19. Rotate the crankshaft at least one full turn clockwise using the crankshaft pulley bolt.
20. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.



---





21. Align the camshaft gear timing marks.



---





22. Slightly loosen the water pump retaining bolts.
23. Rotate the water pump clockwise using the timing belt adjuster J-42492.



---





24. Rotate the water pump clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch in the timing belt automatic tensioner bracket.



---





25. Tighten the water pump retaining bolts.
26. Rotate the crankshaft two full turns clockwise using the crankshaft pulley.
27. Loosen the water pump retaining bolts.



---





28. Using the timing belt adjuster J-42492, rotate the water pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the pointer on the timing belt automatic tensioner bracket.



---





29. Tighten the water pump retaining bolts.
Tighten
Tighten the water pump retaining bolts to 10 N•m (89 lb-in).


30. Remove the crankshaft pulley bolt.
31. Install the upper and lower front timing belt covers.
32. Install the upper and lower front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 10 N•m (89 lb-in).




---





33. Install the crankshaft pulley.
34. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 20 N•m (15 lb-ft).


35. Install the serpentine accessory drive belt. Refer to "Section 6B, Power Steering Pump".



---





36. Install the right front wheel well splash shield.
37. Install the right front wheel. Refer to "Section 2E, Tires and Wheels".
38. Install the air cleaner housing.
39. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 N•m (89 lb-in).

---

KM-470-B Angular Torque Gauge
1. Disconnect the negative battery cable.
2. Remove the air filter housing bolts.
3. Remove the air filter housing assembly.



---





4. Disconnect the intake air temperature (IAT) sensor connector.
5. Disconnect the breather hose from the valve cover.
6. Remove the air intake tube from the throttle body.



---





7. Remove the serpentine accessory drive belt. Refer to "Section 6B, Power Steering Pump".
8. Remove the crankshaft pulley bolt.
9. Remove the crankshaft pulley.



---





10. Remove the upper front timing belt cover bolts.
11. Remove the upper front timing belt cover.
12. Remove the lower front timing belt cover bolts.
13. Remove the lower front timing belt cover.
14. Install the crankshaft pulley bolt.



---





15. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.



---





16. Slightly loosen the water pump retaining bolts.
17. Using the timing belt adjuster J-42492, rotate the water pump counterclockwise to release the tension on the timing belt.
18. Remove the right engine mount bracket. Refer to "Engine Mount" in this section.



---





19. Remove the timing belt.
20. Installation should follow the removal procedure in the reverse order.

---

1. Remove the right front wheel well splash shield.
2. Disconnect the oil pressure switch connector.



---





3. Install the adapter KM-135 in place of the oil pressure switch.
4. Connect the pressure gauge KM-498-B to the adapter.
5. Start the engine and check the oil pressure at idle speed and engine temperature of 803C (1763F). The minimum oil pressure should be 30 kPa (4.35 psi).
6. Stop the engine and remove the pressure gauge KM-498-B and the adapter KM-135.



---





7. Install the oil pressure switch.
Tighten
Tighten the oil pressure switch to 30 N•m (22 lb-ft).


8. Connect the oil pressure switch connector.
9. Install the right front wheel well splash shield.
10. Check the oil level. Pour oil until it reaches the full mark.

---

1. Disconnect the negative battery cable.
2. Remove the power steering pump, if equipped. Refer to "Section 6A, Power Steering System".
3. Remove the timing belt. Refer to "Timing Belt" in this section.
4. Remove the rear timing belt cover. Refer to "Rear Timing Belt Cover" in this section.
5. Disconnect the oil pressure switch connector.



---





6. Remove the crankshaft position sensor bolt.
7. Remove the crankshaft position sensor.
8. Remove the oil pan. Refer to "Oil Pan" in this section.
9. Remove the oil suction pipe and support bracket bolts.
10. Remove the oil suction pipe.



---





11. Remove the oil pump retaining bolts.
12. Carefully separate the oil pump and gasket from the engine block and the oil pan.
13. Remove the oil pump.

---

1. Clean the oil pump and the engine block gasket mating surface areas.
2. Remove the safety relief valve bolt.
3. Remove the safety relief valve and the spring.
4. Remove the oil pump-to-crankshaft seal.



---





5. Remove the oil pump rear cover bolts.
6. Remove the rear cover.

---

1. Disconnect the negative battery cable.
2. Remove the right front wheel. Refer to "Section 2E, Tires and Wheels".
3. Remove the right front wheel well splash shield.
4. Drain the engine oil from the engine crankcase.
5. Remove the exhaust front pipe. Refer to "Section 1G, Engine Exhaust".



---





6. Remove the reaction lower rod. Refer to "Reaction Lower Rod" in this section.
7. Remove the oil pan-to-transaxle housing retaining bolts.
Installation notice

Tightening Torque

75 N•m(55 lb-in)

8. Remove the oil pan retaining bolts.
Installation notice

Tightening Torque

10 N•m(89 lb-in)

9. Remove the oil pan from the engine block.
10. Remove the oil pan gasket from the oil pan.
11. Installation should follow the removal procedure in the reverse order.

---

1. Clean the oil pan sealing surface.
2. Clean the engine block sealing surface.
3. Clean the oil pan retaining bolts.
4. Clean the oil pan attaching bolt holes in the engine block.

---

1. Remove the air filter housing bolts.
2. Remove the air filter housing assembly.



---





3. Support the engine assembly using the engine assembly support fixture DW110-160.



---





4. Remove the reaction upper rod and the reaction upper rod bracket bolts.
Installation notice

Tightening Torque

75 N•m(55 lb-in)

5. Remove the reaction upper rod and the reaction upper rod bracket.



---





6. Remove the engine mount bracket retaining bolt/ nuts.
Installation notice

Tightening Torque

60 N•m(44 lb-in)

7. Remove the engine mount bracket.



---





8. Remove the serpentine accessory drive belt. Refer to "Section 6B, Power Steering Pump"
9. Remove the front timing belt cover bolts and the front timing belt cover.



---





10. Align the crankshaft pulley timing mark with the pointer, and the camshaft gears with the timing marks on the rear cover, by turning the crankshaft gear bolt.
11. Loosen the timing belt automatic tensioner bolt.
12. Turn the hex-key tab to relieve belt tension.
13. Remove the timing belt.



---





14. Remove the timing belt idler pulley bolt/nut.
Installation notice

Tightening Torque

25 N•m(18 lb-in)

15. Remove the timing belt idler pulleys.



---





16. Remove the engine mount retaining bolts.
17. Remove the engine mount.
Installation notice

Tightening Torque

55 N•m(44 lb-in)

18. Installation should follow the removal procedure in the reverse order.

---

1. Raise and suitably support the vehicle.
2. Remove the front fascia splash shield and engine under cover. Refer to Section 9N, Frame and Underbody.
3. Remove the reaction lower rod bracket bolt/nut.
4. Remove the reaction lower rod bracket.
Installation notice

Tightening Torque

69 N•m(49 lb-in)




---





5. Remove the reaction lower rod mount bolt.
6. Remove the reaction lower rod mount.
Installation notice

Tightening Torque

55 N•m(41 lb-in)

7. Installation should follow the removal procedure in the reverse order.

---

1. Remove the fuel pump fuse.
2. Start the engine. Crank the engine after it stalls for 10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the negative battery cable.
4. Remove the air filter housing bolts.
5. Remove the air filter housing assembly.



---





6. Disconnect the manifold air temperature (MAT) sensor connector.
7. Disconnect the breather hose from the valve cover.
8. Remove the air intake tube from the throttle body.
9. Disconnect the idle air control (IAC) valve connector.
10. Disconnect the throttle position sensor (TPS) connector.
11. Disconnect the coolant temperature sensor (CTS) connector.
12. Disconnect the engine CTS connector.
13. Disconnect the heater inlet hose from the cylinder head.
14. Disconnect the surge tank coolant hose at the throttle body.



---





15. Disconnect the throttle cable from the throttle body and the intake manifold.
16. Disconnect the vacuum hose at the fuel pressure regulator.



---





17. Remove the fuel injector rail and fuel injectors as an assembly. Refer to Section 1F, Engine Controls.
18. Remove the intake manifold support bracket upper bolt.
Installation notice

Tightening Torque

22 N•m(16 lb-in)

19. Remove the intake manifold support bracket lower bolt.
Installation notice

Tightening Torque

40 N•m(30 lb-in)

20. Remove the evaporative (EAP) emission canister purge solenoid bracket bolt and reposition the canister purge solenoid clear of the repair area.



---





21. Remove the intake manifold retaining bolts/nuts in the sequence shown.
22. Remove the intake manifold.
Installation notice

Tightening Torque

28 N•m(18 lb-in)

23. Remove the intake manifold gasket.
24. Clean the sealing surfaces of the intake manifold and the cylinder head.
25. Installation should follow the removal procedure the reverse order.

---

1. Disconnect the negative battery cable.
2. Remove the air inlet duct bolts.
3. Remove the air inlet duct assembly.



---





4. Disconnect the oxygen sensor connector.
5. Remove the exhaust manifold heat shield bolts.
6. Remove the exhaust manifold heat shield.
Installation notice

Tightening Torque

15 N•m(11 lb-in)




---





7. Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs.
Installation notice

Tightening Torque

35 N•m(26 lb-in)

8. Remove the oxygen sensor.



---





9. Remove the exhaust manifold retaining nuts in the sequence shown.
10. Remove the exhaust manifold and exhaust manifold gasket
11. Clean the sealing surfaces of the exhaust manifold and the cylinder head.
Installation notice

Tightening Torque

25 N•m

---

1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to "Timing Belt" in this section.
3. Remove the valve cover. Refer to "Valve Cover" in this section.



---





Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.
4. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
5. Remove the intake camshaft gear.
6. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
7. Remove the exhaust camshaft gear.

---

1. Remove the timing belt and the timing belt cover. Refer to "Timing Belt" in this section.
2. Remove the camshaft gears. Refer to "Camshaft Gears" in this section.
3. Remove the crankshaft gear.
4. Remove the timing belt automatic tensioner bolts.
5. Remove the timing belt automatic tensioner.



---





6. Remove the timing belt idler pulley bolt.
Installation notice

Tightening Torque

40 N•m (30lb-in)

7. Remove the timing belt idler pulley.



---





8. Remove the rear timing belt cover bolts.
9. Remove the rear timing belt cover.
10. Installation should follow the removal procedure in the reverse order.

---

Important : On vehicles equipped with manual trans-axle, the manual transaxle must be removed before the engine is removed. Refer to "Section 5B, Manual Trans-axle".
1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine after it stalls for 10 seconds to rid the fuel system of fuel pressure.
3. Remove the air filter bolts and the air filter assembly.
4. Remove the air inlet duct bolts the air inlet duct.



---





5. Disconnect the manifold intake temperature (IAT) sensor connector.
6. Disconnect the breather hose from the valve cover.
7. Disconnect the air intake tube from the throttle body.



---





8. Drain the engine coolant. Refer to "Section 1D, Engine Cooling".
9. Discharge the air conditioning system, if equipped. Refer to "Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System".
10. Remove the battery and battery tray. Refer to "Section 1E, Battery and Battery Tray".



---





11. Remove the fuse box cover.
12. Remove the battery lead nut at the fuse box.
13. Disconnect the battery lead at the fuse box.
14. Disconnect the engine wiring harness connectors.



---





15. Remove the surge tank. Refer to "Section 1D, Engine Coolant".
16. Disconnect the backup switch connector from the transaxle case.



---





17. Disconnect the gear shift control guide with the bolt.



---





18. Disconnect the upper radiator hose at the thermostat housing.
19. Disconnect the power steering pressure hose and the power steering suction hose from the power steering pump. Refer to "Section 6A, "Power Steering System".
20. Disconnect the A/C compressor hose assembly and the connector from the compressor. Refer to "Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System".



---





21. Remove the front wheel. Refer to "Section 2E, Tires and Wheels".
22. Remove the front wheel well splash shield. Refer to "Section 9R, Body Font End".
23. Remove the front exhaust pipe. Refer to "Section 1G, Engine Exhaust".



---





24. Disconnect the heater inlet hose at the heater core.
25. Disconnect the heater outer hose at the heater core.



---





26. Disconnect the vacuum line from the charcoal canister purge solenoid.
27. Disconnect the brake vacuum hose at the intake manifold.



---





28. Disconnect the A/C compressor connector at the A/C compressor coil.
29. Disconnect the lower radiator hose at the coolant pipe.
30. Disconnect the fluid cooler inlet hose from the trans-axle.
31. Disconnect the fluid cooler outlet hose from the transaxle.



---





32. Remove the right side engine mount and forward engine mount. Refer to "Forward Engine Mount" in this section.
33. Remove the cross member. Refer to "Section 2C, Front Suspension".
34. Disconnect the drive axle assembly from the trans-axle.



---





35. Using the power pack stand DW110-010, support the engine and transaxle.
36. Remove the right side engine mount. Refer to "Right Side Engine Mount" in this section.
37. Remove the transaxle mount. Refer to "Section 5A, "Automatic Transaxle".
38. Slowly lift the vehicle.
39. Disconnect the engine assembly from the transaxle assembly. Refer to "Section 5A, "Automatic Trans-axle".
40. Installation should follow the removal procedure in the reverse order.

---

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 oil pan. Refer to "Oil Pan" in this section.
3. Remove the oil suction pipe bolts.
4. Remove the oil suction pipe.



---





5. Move the piston to the bottom of the piston stroke.
6. Mark the connecting rod cap for position.
7. Remove the connecting rod cap bolts.
8. Remove the connecting rod cap and the lower connecting rod bearing.
9. Remove the upper piston connecting rod bearing.
10. Ridge ream the cylinder wall.



---





Caution : Use care when handling the piston. Worn piston rings are sharp and may cause injury.
11. Remove the piston.
12. Use a piston ring expander tool to expand the piston rings.
13. Remove the piston rings.



---





14. Remove the piston pin from the piston and connecting rod assembly using the piston pin service set KM-427.
15. Separate the piston from the connecting rod.

---

1. Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted, replace the connecting rod.
2. Inspect the connecting rod bearings.
3. Inspect the connecting rod lower end for wear.
4. Inspect the connecting rod upper end for scoring.
5. Inspect the crankshaft rod bearing journal for wear. Refer to "Engine Specifications" in this section.
6. Inspect the piston for scoring, cracks, and wear.
7. Inspect the piston for taper using a micrometer.



---





8. Inspect the piston for fit to the connecting rod.



---





9. Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge. Refer to "Engine Specifications" in this section.
10. Inspect the bearing bore for concentricity and alignment using a bore gauge. Refer to "Engine Specifications" in this section. If the bearing bore is beyond specifications, replace the engine block.
11. Inspect the engine block cylinder bore for wear, runout, ridging and taper using a bore gauge. Refer to "Engine Specifications" in this section.
12. Inspect the engine block cylinder bore for glazing. Lightly hone the cylinder bore as necessary.

---

1. Align the notch on the piston and the connecting rod so that the proper sides will be facing the front of the engine.
2. Install the piston pin guide through the piston and the connecting rod.
3. Coat the piston pin with clean oil.
4. Install the piston pin into the opposite side of the piston.
5. Install the piston pin into the piston and connecting rod assembly using the piston pin service set KM-427.



---





6. Select a set of new piston rings.
7. Measure the piston ring gap using a feeler gauge. Refer to "Engine Specifications" in this section.
8. Increase the piston ring gap by carefully filing off excess material if the piston ring gap is below specifications.



---





9. Measure the piston ring side clearance using a feeler gauge. Refer to "Engine Specifications" in this section.
10. If the piston ring is too thick, try another piston ring
11. If no piston ring can be found that fits to specifications, the piston ring may be ground to size with emery paper placed on a sheet of glass.



---





12. Install a piston oil ring, the expander, then the second piston oil ring to the bottom ring groove of the piston.
13. Install the second compression ring to the middle ring groove of the piston.
14. Install the top compression ring to the top ring groove of the piston.



---





15. Use a piston ring expander to install the piston rings. Do not expand the piston rings beyond the expansion necessary for installation.
16. Stagger the piston oil rings, the oil ring rail gaps, the second compression ring, and the top compression ring in relation to the notch on the top of the piston.



---





17. Lubricate the cylinder wall and the piston rings with clean engine oil.
18. Install the piston using a ring compressor and a wood handle. Guide the lower connecting rod end to prevent damaging the crankshaft journal.
19. Install the connecting rod cap and bearings. Refer to "Crankshaft Bearings and Connecting Rod Bearings -Gauging Plastic"in this section.
1. Gauging Plastic" in this section.



---





20. Install the connecting rod cap bolts.
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 bolts one turn of 30 degrees plus one turn of 15 degrees.




---





21. Install the oil suction pipe.
22. Install the oil suction pipe bolts.
Tighten
Tighten the oil suction pipe bolts to 10 N•m (89 lb-in).


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

---

---

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 engine coolant temperature (ECT) sensor.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust manifold retaining nuts in the sequence shown.
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.
8. Remove the exhaust manifold studs.



---





9. Remove the thermostat housing mounting bolts.
10. Remove the thermostat housing assembly.
11. Remove the fuel rail assembly. Refer to "Section 1F, Engine Controls".
12. Remove the coolant bypass housing mounting bolts and the housing.



---





13. Remove the intake manifold retaining nuts and retaining bolt in the sequence shown.
14. Remove the intake manifold.
15. Remove the intake manifold gasket.



---





16. Remove the direct ignition system (DIS) coil and the exhaust gas recirculation (EGR) mounting bracket bolts.
17. Remove the DIS ignition coil and the EGR mounting bracket and ignition wires.
18. Remove the intake manifold studs.
19. Remove the spark plugs.



---





20. Remove the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.



---





21. Remove the intake camshaft caps. Maintain the correct positions for installation.
22. Remove the intake camshaft.
23. Remove the intake valve tappet adjusters.
24. Remove the exhaust camshaft caps. Maintain the correct positions for installation.
25. Remove the exhaust camshaft.
26. Remove the exhaust valve tappet adjusters.



---





27. Compress the valve springs with the valve spring compressor KM-348 and the adapter KM-653.
28. Remove the valve retainers.
29. Remove the valve spring compressor KM-348 and the adapter KM-653.
30. Remove the valve spring caps.
31. Remove the valve springs. Maintain the original position of the valve springs for installation.



---





32. Remove the valves. Maintain the original position of the valves for installation.
33. Remove the valve stem seals.

---

1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion, and blow-by.
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 0.025mm (0.00linch) maximum.



---





6. Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder head height should be 133.975 to 134.025 mm (5.274 to 5.276 inches). If the cylinder head height is less than 133.9 mm (5.271 inches), replace the cylinder head.
7. Inspect all threaded holes for damage.
8. Inspect valve seats for excessive wear and burned spots.

---

1. Inspect the valve stem tip for wear.
2. Inspect the valve key grooves and the 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 that refacing the valve would result in a sharp edge, replace the valve.
7. Inspect the valve spring. If the valve spring ends are not parallel, replace the valve spring.
8. Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as required.

---

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.

---

1. Lubricate the valve seat 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. Check the contact pattern on the valve head and in the cylinder head.
4. Clean the valves, the valve guides, and the cylinder head.

---

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. Ensure that the angle at the valve face is 45 degrees.
4. Inspect the assembly height of the intake valves and the exhaust valves.

---

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



---





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

Size	Reamer	Production Code	Service Code
Normal	-	-	K
0.075	KM-805	1	K1
0.150	-	2	K2




---





3. Ream the valve guide from the upper side of the cylinder head to the next oversize.
4. After reaming, cross out the code and emboss the valve guide with the new code.

---

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:
• Valve seat - A 45-degree surface using the cutter KM-340-13.
• Upper correction angle - A 30-degree surface using the cutter KM-340-13.
• Lower correction angle - A 60-degree surface using the cutter KM-340-26.
3. Clean the chipping from the cylinder head.
4. Inspect the dimension for the valve seat width.
• Intake: 1.2 to 1.4 mm (0.047 to 0.055 inch).
• Exhaust: 1.4 to 1.8 mm (0.055 to 0.070 inch).
5. Inspect the assembly height of the intake valves and the exhaust valves. If the dimension is exceeded, install new valves. Inspect the assembly height of the intake valves and the exhaust valves again. If the valve assembly height is still too large despite replacing the valves, replace the cylinder head.

---

1. Coat the valve stems with engine oil.
2. Insert the valves in the cylinder head in their original positions.
3. Insert the valve spring seats.
4. Push the accompanying assembly sleeve onto the valve stem.
5. Insert the new valve stem seat.
6. Carefully drive the valve stem seal onto the stop with light taps.
7. Install the valve springs in their original positions.
8. Install the valve spring caps.



---





9. Compress the valve springs with the valve spring compressor KM-348 and adapter KM-653.
10. Install the valve keys.
11. Remove the valve spring compressor KM-348 and adapter KM-653.



---





12. Lubricate the valve tappet adjusters with engine oil.
13. Install the valve lash adjusters.



---





14. Install the intake camshaft.
15. Install the intake camshaft bearing caps in their original positions.
16. Install the exhaust camshaft.
17. Install the exhaust camshaft bearing caps in their original positions.
18. Install the camshaft bearing cap bolts.
19. Tighten the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.
Installation notice

Tightening Torque

8 N•m (71lb-in)




---





20. Install the spark plugs.
Installation notice

Tightening Torque

20 N•m (15lb-in)

21. Install the EI system ignition coil and EGR mounting bracket and bolts.
Installation notice

Tightening Torque

Left Lower Side: 20 N•m (15lb-ft) Others: 30 N•m (22lb-ft)

22. Install the EI system ignition coil and EGR.
Installation notice

Tightening Torque

8 N•m (71lb-ft)




---





23. Install the intake manifold studs.
24. Install the intake manifold gasket.
25. Install the intake manifold.
26. Install the intake manifold retaining nuts and retaining bolt in the sequence shown.
Installation notice

Tightening Torque

22 N•m (16lb-ft)




---





27. Install the fuel rail assembly. Refer to "Section 1F, Engine Controls".
28. Install the thermostat housing assembly.
29. Install the thermostat housing mounting bolts.
Installation notice

Tightening Torque

15 N•m (11lb-ft)

30. Install the coolant bypass housing and mounting bolts.
Installation notice

Tightening Torque

15 N•m (11lb-ft)




---





31. Install the exhaust manifold studs.
32. Install the exhaust manifold gasket.
33. Install the exhaust manifold.
34. Install the exhaust manifold retaining nuts in the se- quence shown.
Installation notice

Tightening Torque

1st stage: 2nd stage: 3rd stage: 4th stage:

13 N•m (10lb-ft): 9,10,6,5,8,7,2,1,3,4 13 N•m (10lb-ft) 9,10,6,5,8,7,2,1,3,4 15 N•m (11lb-ft) 9,10,6,5,8,7,2,1,3,4 15 N•m (11lb-ft) 9,10,6,5,8,7,2,1,3,4,9,10,6

35. Install the exhaust manifold heat shield.
36. Install the exhaust manifold heat shield bolts.
Installation notice

Tightening Torque

15 N•m (11lb-ft)

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

---

1. Remove the engine. Refer to "Engine" in this section.
2. Remove the flywheel or flexible plate bolts.
3. Remove the flywheel or the flexible plate.



---





4. Remove the crankshaft rear oil seal.
5. Mounts the engine assembly on the engine stands KM-412.



---





6. Remove the front timing belt cover bolts.
7. Remove the front timing belt cover.
8. Remove the crankshaft pulley bolts.
9. Remove the crankshaft pulley.



---





10. Loosen the timing belt automatic tensioner bolt.
11. Rotate the timing belt automatic tensioner hex-clockwise to release the tension.
12. Remove the timing belt idler pulley bolt and nut.
13. Remove the timing belt idler pulleys.



---





14. Remove the timing belt.
15. Remove the engine mount retaining bolts.
16. Remove the engine mount.



---





17. Disconnect the breather tubes from the valve cover.
18. Remove the spark plug cover bolts.
19. Remove the spark plug cover.
20. Disconnect the ignition wires from the spark plugs.
21. Remove the valve cover bolts.
22. Remove the valve cover washers.
23. Remove the valve cover and the valve cover gasket.



---





Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.
24. While holding the intake camshaft firmly in place, remove the intake camshaft bolt.
25. Remove the intake camshaft gear.
26. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft bolt.
27. Remove the exhaust camshaft gear.



---





28. Remove the crankshaft timing belt gear bolt.
29. Remove the crankshaft timing belt gear.



---





30. Remove the rear timing belt cover screws/bolt.
31. Remove the rear timing belt cover.



---





32. Rotate the engine on the engine overhaul stand KM-412.



---





33. Remove the oil pan retaining bolts.
34. Remove the oil pan.
35. Remove the oil suction pipe and support bracket bolts.
36. Remove the oil suction pipe.
37. Remove the crankshaft bearing bridge and oil pan scraper bolts.
38. Remove the oil pan scraper.
39. Remove the crankshaft bearing bridge bolts.
40. Remove the crankshaft bearing bridge.



---





41. Remove the oil pump retaining bolts.
42. Remove the oil pump.



---





43. Mark the order of the connecting rod bearing caps.
44. Remove the connecting rod bearing cap bolts for all of the pistons.
45. Remove the connecting rod bearing caps and the lower connecting rod bearings.



---





46. Mark the order of the crankshaft bearing caps.
47. Remove the crankshaft bearing cap bolts.
48. Remove the crankshaft bearing caps and the lower crankshaft bearings.
49. Remove the crankshaft.
50. Clean the parts, as needed.

---

1. Coat the crankshaft bearings with engine oil.
2. If replacing the crankshaft, transfer the pulse pickup sensor disc to the new crankshaft.



---





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



---





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. Install the crankshaft bearing caps and the bolts.
Installation notice

Tightening Torque

50 N•m (37lb-ft)+ 45° + 15°




---





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



---





14. Apply a bead of adhesive sealing compound to the grooves of the crankshaft bearing caps.
15. Install the crankshaft bearing caps to the engine block.
16. Tighten the crankshaft bearing caps using new bolts.
Installation notice

Tightening Torque

50 N•m (37lb-ft)+ 45° + 15°




---





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.
17. Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).
18. Cut the plastic gauging threads to the length of the connecting rod bearing width. Lay them axially between the connecting rod journals and the connecting rod bearings.
19. Install the connecting rod bearing caps.
Installation notice

Tightening Torque

35 N•m (26lb-ft)+ 45° + 15°




---





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



---





23. Install the connecting rod bearing caps to the connecting rods.
24. Tighten the connecting rod bearing caps using new bolts.
Installation notice

Tightening Torque

35 N•m (26lb-ft)+ 45° + 15°




---





25. Install the oil pump.
26. Install the oil pump retaining bolts.
Installation notice

Tightening Torque

10 N•m (89lb-in)




---





27. Install the lower block support bracket and bolts.
Installation notice

Tightening Torque

20 N•m (15lb-ft) +45°

28. Install the lower block support bracket splash shield and bolts.
Installation notice

Tightening Torque

20 N•m (15lb-ft) +45°

29. Install the oil suction pipe.
30. Install the oil suction pipe on the oil pump bolts.
Installation notice

Tightening Torque

8 N•m (71lb-in)

31. Install the oil suction pipe support bracket bolts.
Installation notice

Tightening Torque

20 N•m (15lb-ft) +45°




---





32. Coat the new oil pan gasket with sealant.
33. Install the oil pan gasket to the oil pan.
34. Install the oil pan.
35. Install the oil pan retaining bolts.
Installation notice

Tightening Torque

20 N•m (15lb-ft)




---





36. Rotate the engine on the engine overhaul stand KM-412.



---





37. Install the rear timing belt cover.
38. Install the rear timing belt cover bolts.
Installation notice

Tightening Torque

10 N•m (89lb-in)

39. Install the crankshaft gear and bolt.
Installation notice

Tightening Torque

130 N•m (96lb-ft) + 40° ± 5°

40. Install the engine mount and retaining bolts.
Installation notice

Tightening Torque

60 N•m (44lb-ft)




---





41. Install the timing belt automatic tensioner.
42. Install the timing belt automatic tensioner bolts.
Installation notice

Tightening Torque

25 N•m (18lb-ft)

43. Install the timing belt idler pulleys.
44. Install the timing belt idler pulley bolt and nut.
Installation notice

Tightening Torque

25 N•m (18lb-ft)

Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.



---





45. Install the intake camshaft gear.
46. Install the intake camshaft gear bolt while holding the intake camshaft firmly in place.
Installation notice

Tightening Torque

50 N•m (37lb-ft) + 60° +15°

47. Install the exhaust camshaft gear.
48. Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place.
Installation notice

Tightening Torque

50 N•m (37lb-ft) + 60° +15°




---





49. Install the timing belt. Refer to "Timing Belt" in this section.
50. Adjust the timing belt tension. Refer to "Timing Belt Check and Adjust" in this section.
51. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear camshaft cover to cylinder head seal.
52. Install the valve cover and the valve cover gasket
53. Install the valve cover bolts.
54. Connect the ignition wires to the spark plugs.
55. Install the spark plug cover and bolts.
56. Connect the breather tube to the camshaft cover.



---





57. Install the front timing belt cover.
58. Install the front timing belt cover bolts.
59. Install the engine lifting device.
60. Remove the engine from the engine overhaul stand KM-412.



---





61. Install a new crankshaft rear oil seal using installer J-36792 or KM-635.



---





62. Install the flywheel or flexible plate.
63. Install the flywheel or the flexible plate bolts.
Installation notice

Tightening Torque (Flywheel Bolts)	60 N•m (48lb-ft) + 30° +15°
Tightening Torque (Flexible Plate Bolts)	65 N•m (48lb-ft)

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

---

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



---





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. Install the crankshaft bearing caps.
11. Install the crankshaft bearing cap bolts.
Installation notice

Tightening Torque

50 N•m (37lb-ft) +45° +15°




---





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.

---

1. Coat the connecting rod bearings with engine oil.
2. Install the upper connecting rod bearings into the connecting rod journals.
3. Install the upper connecting rod bearings into the connecting rod journals.
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.
4. Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).
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.
Installation notice

Tightening Torque

35 N•m (26lb-ft) +45° +15°




---





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.

Application	Description (Manual and Automatic)
	1.6L DOHC
. General Data:
Engine Type	A15DMS
Displacement	1598 cm³ (91.4 in³)
Bore Stroke	79.0 X 81.5mm (3.11in. X 3.21in.)
Compressed Ratio	9.5 ± 0.2:1
Firing Order	1-3-4-2
. Cylinder Bore:
Diameter	79.0 mm(3.4 in.)
Out of Round (Maximum)	0.0065 mm(0.00025 in.)
Taper	0.0065 mm(0.00025 in.)
. Piston:
Diameter	78.970 mm(3.109 in.)
Clearance to Bore	0.030 ± 0.010 mm(0.0012 ± 0.0004 in.)
. Piston Rings:
Ring, End Gap: Top Compression	0.2-0.3 mm(0.0079-0.118 in.)
: 2nd Compression	0.5-0.6 mm(0.02-0.024 in.)
Groove Clearance: Top Compression	0.030-0.065 mm(0.0012-0.0026 in.)
: 2nd Compression	0.050-0.082 mm(0.003-0.0032 in.)
. Piston Pin:
Diameter	17.990-17.995 mm(0.708-0.787 in.)
Pin Off-Set	0.8 ± 0.1 mm (0.0315 ± 0.004 in.)
. Camshaft:
Lift Intake	8.5 mm(0.335 in.)
Lift Exhaust	8.5 mm(0.335 in.)
End Play	0.10-0.25 mm(0.004-0.0089 in.)
Journal OD: No.1	29.935-26.95 mm (1.178-1.179 in.)
No.2	29.935-26.95 mm(1.060-1.061 in.)
No.3	29.935-26.95 mm(1.060-1.061 in.)
No.4	29.935-26.95 mm(1.060-1.061 in.)
No.5	29.935-26.95 mm(1.060-1.061 in.)
Camshaft Cap To Camshaft Journal Clearance (All)	0.05-0.089 mm(0.002-0.0034 in.)
. Crankshaft:
Main Journal:Diameter (All)	54.982-54.994 mm(2.164-2.165 in.)
Taper (Maximum)	0.005 mm(0.0001 in.)
Out of Round (Maximum)	0.004 mm(0.0001 in.)
Main Bearing Clearance(All)	0.010-0.026 mm(0.0004-0.001 in.)
Crankshaft End Play	0.05-0.28 mm(0.002-0.011 in.)
Connecting Rod Journal: Diameter (All)	42.971-42.987 mm(1.691-1.692 in.)
Taper (Maximum)	0.005 mm(0.0001 in.)
Out of Round (Maximum)	0.004 mm(0.0001 in.)
Rod Bearing Clearance(All)	0.019-0.071 mm(0.0007-0.0028 in.)
Rod Side Clearance	0.070-0.242 mm(0.0027-0.009 in.)
. Valve System:
Valve Lash Compensators	Hydraulic
Face Angle (All)	45~45.25°
Seat Angle (All)	90°
Seat Runout (Maximum, All)	0.05 mm(0.002 in.)
Face Runout (Maximum, All)	0.03 mm(0.0012 in.)
Seat Width: Intake	1.17-1.57 mm(0.046-0.062 in.)
Exhaust	1.07-1.47 mm(0.042-0.058 in.)
Valve Guide inside Diameter (All)	6.00-6.02 mm(0.236-0.237 in.)
Valve Stem Diameter (All):Intake	5.955-5.970 mm(0.567-0.235 in.)
Exhaust	5.935-0.5980 mm(0.233-0.235 in.)
Valve Diameter (All): Intake	30.3± 0.12 mm(1.19± 0.0047 in.)
Exhaust	26.0± 0.14 mm(1.02± 0.0055 in.)
Valve Spring Loads: Valve Open	580-26N(428-19lbs)@23.0 mm(0.90 in.)
Valve Closed	260"13N(192"9lbs)@32.0 mm(1.25 in.)
Valve Spring Free Lenght	41.20 mm(1.622 in.)
. Oil Pump:
Gap BEtween Oil Pump Body and Out Rotor	0.400-0.484 mm(0.0157~0.019 in.)
Out Rotor Side Clearance	0.45~0.100 mm(0.02~0.004 in.)
Inner Rotor Side Clearance	0.035~0.085 mm(0.001~0.003 in.)
Relief Valve Spring Free Lenght	81 mm(3.2 in.)
. Sealants and Adhesives:
Rear Main Bearing Cap	GE p/n RTV 159
Oil Pan Bolts	HN 1256 (Loctite @ 242)
Oil Pump Bolts	HN 1256 (Loctite @ 242)
Oil Pan Pickup Tube Bolts	HN 1256 (Loctite @ 242)
Oil Gallery Plug	HN 1256 (Loctite @ 242)
Coolant Jacket Caps and Plugs (Freeze Plugs)	HN 1756 (Loctite @ 962)
Exhaust Manifold Studs/Nuts	Anti-seize Compound (HMC Spec HN1325)

Application	N•m	Lb-Ft	Lb-in
Air Cleaner Housing Bolts	10	-	89
Camshaft Cap Bolts	16	12	-
Camshaft Cover Nuts	10	-	89
Connecting Rod Bearing Cap Bolts	25 +30° +15°	18 +30° +15°	-
Coolant Temperature Sensor	20	15	-
Crankshaft Bearing Cap Bolts	50 +45° +15°	37 +45° +15°	-
Crankshaft Cover Nuts	10	-	89
Crankshaft Position Sensor Retaining Bolt	10	-	89
Crankshaft Pulley Bolts	20	15	-
Cylinder Head Bolts (Cylinder Head Mounting Bolts)	25 +70° +70° +50°	18 +70 ° +70° +50 °	-
Direct Ignition System Coil Mounting Bolts	10	-	89
Direct Ignition System Coil Mounting Bracket Bolts	10	-	89
Engine Mount Attaching Bolts	30	22	-
Engine Mount Bracket Attaching Bolts/Nuts	55	41	-
Exhaust Camshaft Gear Bolts	67.5	49	-
Exhaust Flex Pipe-to-Catalytic Converter or Connecting Pipe Retaining Nuts	35	26	-
Exhaust Flex Pipe-to-Exhaust Manifold Retaining Nuts	35	26	-
Exhaust Gas Recirculation Valve Adapter Bolts	25	18	-
Exhaust Manifold Heat Shield Bolts	13	10	-
Exhaust Manifold Retaining Nuts	25	18	-
Flexible Plate Bolts	45	33	-
Flexible Plate Inspection Cover Bolts	10	-	89
Flywheel Bolts	35 +30° +15°	25 +30° +15°	-
Flywheel Inspectin Cover Bolts	12	-	106
front Timing Belt Cover Bolts (Upper and Lower)	10	-	89
Fuel Rail Assembly Bolts	25	18	-
Fuel Rail Retaining Bolts	25	18	-
Generator Upper Retaining Bolt	20	15	-
Intake Camshaft Gear Bolt	67.5	49	-
Intake Manifold Retaining Bolts/Nuts	25	18	-
Intake Manifold Support Bracket Lower Bolt	40	30	-
Intake Manifold Support Bracket Upper Bolts	25	18	-
Lower Front Timing belt Cover Bolts	10	-	89
Oil Pan Flange Bolts	75	55	-
Oil Pan Retaining Bolts	10	-	89
Oil Pan Drain Plug	55	40	-
Oil Pressure Switch	30	22	-
Oil Pump Bolts	10	-	89
Oil Pump Rear Cover Bolts	6	-	53
Oil Pump Retaining Bolts	10	-	89
Oil Suction Pipe or Support Bracket Bolts	10	-	89
Rear Timing Belt Cover Bolts	10	-	89
Safety Relief Valve Bolts	30	22	-
Spark Plug Cover Bolts	3	-	27
Spark Plugs	25	18	-
Thermostat Housing Mounting Bolts	20	15	-
Throttle Cable Bracket Bolts	8	-	71
Timing Belt Automatic Tensioner Bolts	25	18	-
Timing Belt Idler Pulley Bolts	40	30	-
Transaxle Bell Housing Bolts	45	33	-
Transzxle Torque Converter Bolts	45	33	-
Upper Front Timing Belt Cover Bolts	10	-	89
Water Pump Retaining Bolts	10	-	89

	J-42492 Timing Belt Adjuster
	KM-470-B Angular Torque Gauge
	J-28467-B Engine Assembly Support Fixture
	KM-427 Piston Pin Service Set
	MKM-571-B Gauge
	KM-340-O Cutter Set Includes: KM-340-7 Guide Drift KM-340-13 Cutters KM-340-26 Cutters
	KM-348 Valve Spring Compressor
	KM-653 Adapter
	KM-805 Valve Guide Reamer
	KM-412 Engine Overhaul Stand
	KM-498-B Pressure Gauge
	X-28467-560 Engine Assembly Support Channel
	KM-635 Crankshaft Rear Oil Seal Installer
	J-36792 Crankshaft Rear Oil Seal Installer
	KM-135 Adapter