Special Tools

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

1. Remove the engine. Refer to Engine Replacement.
2. Remove the flywheel or flexible plate bolts.
3. Remove the flywheel or the flexible plate.



4. Remove the crankshaft rear oil seal.
5. Mount the engine assembly on the OTC 1726 .



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-key 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 camshaft 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 camshaft cover bolts.
22. Remove the camshaft cover washers.
23. Remove the camshaft cover and the camshaft cover gasket.




Important: 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.



29. Remove the rear timing belt cover bolts and cover.



30. Rotate the engine on OTC 1726  (1).



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



39. Remove the oil pump retaining bolts.
40. Remove the oil pump.



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



44. Mark the order of the crankshaft bearing caps.
45. Remove the crankshaft bearing cap bolts.
46. Remove the crankshaft bearing caps and the lower crankshaft bearings.
47. Remove the crankshaft.

Warning: Refer to Safety Glasses Warning in the Preface section.

48. 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 Mechanical Specifications.



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 Mechanical Specifications.




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

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

Caution: Refer to Fastener Caution in the Preface section.

10. Install the crankshaft bearing caps and the bolts.

Tighten
Tighten the crankshaft bearing cap bolts to 50 N·m (37 lb ft) plus 45 degrees and 15 degrees.




11. Remove the crankshaft bearing cap bolts and the caps.
12. Measure the width of the flattened plastic thread of the plastic gaging using the scale printed on the plastic gaging package. Plastic gaging is available for different tolerance ranges.
13. Inspect the bearing clearance of permissible tolerance ranges. Refer to Engine Mechanical Specifications.



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.

Tighten
Tighten the crankshaft bearing cap bolts to 50 N·m (37 lb ft) using a torque wrench. Use the J 45059 or the KM-470-B  (1) to tighten the crankshaft bearings another 45 degrees and 15 degrees.





Important: Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the plastic gaging 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 gaging (ductile plastic threads).
18. Cut the plastic gaging 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.

Tighten
Tighten the connecting rod bearing cap bolts to 35 N·m (26 lb ft) using a torque wrench. Use the J 45059 or the KM-470-B  (1) to tighten the connecting rod bearing cap bolts another 45 degrees plus 15 degrees.




20. Remove the connecting rod bearing caps.
21. Measure the width of the flattened plastic thread of the plastic gaging using the scale printed on the plastic gaging package. Plastic gage is available for different tolerance ranges.
22. Inspect the bearing clearance for permissible tolerance ranges. Refer to Engine Mechanical Specifications.



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

Tighten
Tighten the connecting rod bearing cap bolts to 35 N·m (26 lb ft) using a torque wrench. Use the J 45059 or the KM-470-B  (1) to tighten the connecting rod cap bolts another 45 degrees plus 15 degrees.




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

Tighten
Tighten the oil pump retaining bolts to 10 N·m (89 lb in).




27. Install the crankshaft bearing bridge and bolts.

Tighten
Tighten the crankshaft bearing bridge bolts to 20 N·m (15 lb ft) plus 45 degrees using J 45059 or the KM-470-B .

28. Install the crankshaft bearing bridge and oil pan scraper bolts.

Tighten
Tighten the crankshaft bearing bridge and oil scraper bolts to 20 N·m (15 lb ft) plus 45 degrees using J 45059 .

29. Install the oil suction pipe.
30. Install the oil suction pipe and support bracket bolts.

Tighten
Tighten the oil suction pipe bolts to 8 N·m (81 lb in) and oil suction pipe support bracket bolt to 6 N·m (53 lb in).




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

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




35. Rotate the engine on the OTC 1726  (1).



36. Install the rear timing belt cover.
37. Install the rear timing belt cover bolts.

Tighten
Tighten the rear timing belt cover bolts to 7 N·m (62 lb in).

38. Install the crankshaft gear and bolt.

Tighten
Tighten the crankshaft gear bolt to 145 N·m (107 lb ft) plus 30 degrees plus 15 degrees using J 45059 or the KM-470-B  (1).

39. Install the engine mount and retaining bolts.

Tighten
Tighten the engine mount retaining bolts to 45 N·m (33 lb ft).




40. Install the timing belt automatic tensioner.
41. Install the timing belt automatic tensioner bolts.

Tighten
Tighten the timing belt automatic tensioner bolts to 25 N·m (18 lb ft).

42. Install the timing belt idler pulley.
43. Install the timing belt idler pulley bolt and nut.

Tighten
Tighten the timing belt idler pulley nut to 25 N·m (18 lb ft).





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

44. Install the intake camshaft gear.
45. Install the intake camshaft gear bolt while holding the intake camshaft firmly in place.

Tighten
Tighten the intake camshaft gear bolt to 50 N·m (37 lb ft) plus 60 degrees and 15 degrees using J 45059 or the KM-470-B .

46. Install the exhaust camshaft gear.
47. Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place.

Tighten
Tighten the exhaust camshaft gear bolt to 50 N·m (37 lb ft) plus 60 degrees and 15 degrees using J 45059 or the KM-470-B .




48. Install the timing belt. Refer to Timing Belt Replacement.
49. Adjust the timing belt tension. Refer to Timing Belt Inspection.
50. 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.
51. Install the camshaft cover and the camshaft cover gasket.
52. Install the camshaft cover washers.
53. Install the camshaft cover bolts.

Tighten
Tighten the camshaft cover bolts to 8 N·m (71 lb in).




54. Connect the ignition wires to the spark plugs.
55. Install the spark plug cover.
56. Install the spark plug cover bolts.

Tighten
Tighten the spark plug cover bolts to 8 N·m (71 lb in).

57. Connect the breather tube to the camshaft cover.
58. Install the front timing belt cover.
59. Install the front timing belt cover bolts.

Tighten
Tighten the front timing belt cover bolts to 8 N·m (71 lb in).

60. Install the engine lifting device.
61. Remove the engine from the OTC 1726 .



62. Install a new crankshaft rear oil seal using J 36972 or the KM-635 .



63. Install the flywheel or flexible plate.
64. Install the flywheel or the flexible plate bolts.

Tighten
Tighten the flywheel bolts to 65 N·m (48 lb ft). Use the J 45059 or the KM-470-B  (1) to tighten the flywheel bolts another 30 degrees plus 15 degrees. For the automatic transmission, tighten the flexible plate bolts to 45 N·m (33 lb ft).

65. Install the engine. Refer to Engine Replacement.