Engine Disassembling and Assembling

Engine, disassembling and assembling

CAUTION!

- If large amounts of metal shavings or small metal particles are found in the engine oil, caused by wear of crankshaft and connecting rod bearings, thoroughly clean the oil passages to remove contaminants and help prevent later damage.
- The oil cooler cannot be sufficiently cleaned, and must be replaced.






Part I: Timing Components





1 Tensioner
2 Bolt
- Tighten to: 25 Nm (18ft lb)
- For mounting bracket -11-; 35 Nm (26 ft lb)
3 Tensioning lever
4 Dust sleeve
5 Bolt
- Tighten to: 10 Nm (7ft lb)
6 Drive belt guard, lower
7 Drive belt guard, upper
8 Nut
- Tighten to: 45 Nm (33 ft lb)
9 Tensioner pulley
10 Drive belt
- Before removing mark running direction
- Check for wear
- Do not kink
11 Mounting bracket
12 Drive belt guard
13 Drive belt guard, rear
14 Drive belt sprocket, intermediate shaft
15 Bolt
- Tighten to: 80 Nm (59ft lb)
- To loosen and tighten use holding fixture 3036
16 Drive belt sprocket, crankshaft
17 Bolt
- Tighten to: 90 Nm (66ft lb) plus 1/4- turn (9O °)
- Always replace
- To loosen and tighten use special tool 3099
- Lubricate threads and shoulder
- Turning 1/4- turn (90 °) further can be done in stages
18 Pulley, coolant pump
- For ribbed belt
19 Ribbed belt
- Before removing, mark running direction
20 Vibration damper, crankshaft
- Also serves as pulley for ribbed belt
- Assembly only possible in one position (holes are offset)
21 V-belt
22 Pulley, coolant pump
- For V-belt
23 Pulley, crankshaft
- For V-belt


Part II: Cylinder Head

Cylinder Head, Servicing:

1 Pressure Regulating Valve For Crankcase Breather
2 Grommet
3 Upper Intake Manifold Bolt
- Tighten to: 20 Nm (15 ft. lbs.).
4 Upper Intake Manifold
5 Upper Intake Manifold Gasket
- Al;ways replace.
6 Cap
- Replace if gasket is damaged.
7 Cylinder Head (Valve) Cover Nut
- Tighten to: 10 Nm (7 ft. lbs.).
8 Cylinder Head (Valve) Cover
9 Reinforcement Strip
10 Oil Deflector
11 Cylinder Head Bolt
- Loosen and tighten as outlined in procedure below.
- Always replace.
12 Cylinder Head (Valve) Cover Gasket
- Always replace.
13 Cylinder Head
- When replacing head, replace engine coolant.
- Refer to Testing and Inspection.
14 Cylinder Head Gasket
- Always replace.
- When replacing gasket, replace engine coolant.
15 Camshaft Sprocket
- Note position when installing drive belt, refer to Timing Components.
16 Hook Eye
17 Rear Toothed Timing Belt Guard
18 Toothed Timing Belt
- Do not kink.
- Removing/installing and tensioning, refer to Timing Components.
19 Toothed Timing Belt Tensioner
20 Tensioner Nut
- Tighten to: 45 Nm (33 ft. lbs.).
21 Upper Toothed Timing Belt Guard
22 Toothed Timing Belt Guard
23 From Crankcase Breather


Part III: Cylinder Block Overview





LEGEND
1 Cylinder Block
2 Woodruff Key
- Check for tight fit.
3 O-ring
- Always replace.
4 Engine Ground (GND) Connection
5 Bolt
- Tighten to: 25 Nm (18 ft. lbs.).
6 Knock Sensor
7 Knock Sensor Bolt
- Tighten to: 25 Nm (18 ft. lbs.).
- Incorrect tightening torque can influence knock sensor function.
8 Ignition Distributor
9 Distributor Clamp Bolt
- Tighten to: 25 Nm (18 ft. lbs.).
10 Distributor Clamp
11 Gasket
- Always replace.
12 Oil Filter Bracket
13 Crankcase Breather
14 Oil Cooler
- Coat flange area with AMV 188 100 02, or equivalent, outside sealing ring.
- Ensure clearance to surrounding components.
- Replace if contaminated.
15 Oil Filter
- Loosen with strap wrench.
- Tighten by hand.
- Follow any manufacturers installation instructions on oil filter.
16 Tensioner Mounting Bolt
- Tighten to: 10 Nm (7 ft. lbs.).
17 Engine Speed (RPM) Sensor
18 Support Ring
19 Water Pump Mounting Studs And Bolts
- Tighten in two stages:
- 1st stage, tighten to: 20 Nm (15 ft. lbs.).
- 2nd stage, turn an additional: 90° (1/4 turn).
20 Tensioner Bracket Nut
- Tighten to: 30 Nm (22 ft. lbs.).
21 Tensioner
22 Bracket
23 Seal
- Always replace.
24 Tensioner Lever
25 Hammer Head Screw
26 Coolant (Water) Pump
27 Oil Pan
28 Oil Pan Bolt
- Tighten to: 20 Nm (15 ft. lbs.).
- Loosen or tighten bolts on flywheel side using tool wrench tool No. 3185, or equivalent.
29 Bracket
- For power steering pump.
30 Oil Pan Baffle With Gasket
- With gasket for oil pan.
- Replace if damaged.
- To remove, remove oil pump.