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 upper and the lower front timing belt cover bolts.
7. Remove the upper and the lower front timing belt cover.



8. Slightly loosen the water pump retaining bolts.



9. Rotate the water pump using the J 42492-A to remove the tension from the timing belt.
10. Remove the spark plug cover bolts.



11. Disconnect the engine ventilation hoses from the camshaft cover.
12. Disconnect the oil filler cap.
13. Remove the spark plug cover bolts.
14. Remove the spark plug cover.
15. Remove the spark plug cover.
16. Remove the camshaft cover nuts.
17. Remove the camshaft cover washers.
18. Remove the camshaft cover and the camshaft cover gasket.




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

19. While holding the intake camshaft firmly in place, remove the intake camshaft bolt.
20. Remove the intake camshaft gear.
21. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft bolt.
22. Remove the exhaust camshaft gear.



23. Remove the timing belt automatic tensioner bolts.
24. Remove the timing belt automatic tensioner.
25. Remove the timing belt idler pulley bolt.
26. Remove the timing belt idler pulley.



27. Remove the crankshaft timing belt gear.
28. Remove the rear timing belt cover bolts.
29. Remove the rear timing belt cover.



30. Rotate the engine on the engine overhaul stand OTC 1726 .



31. Remove the oil pan retaining bolts.
32. Remove the oil pan.
33. Remove the oil suction pipe bolts.
34. Remove the oil suction pipe.



35. Remove the oil pump retaining bolts.
36. Remove the oil pump.



37. Mark the order of the connecting rod bearing caps.
38. Remove the connecting rod bearing cap bolts for all of the pistons.
39. Remove the connecting rod bearing caps and the lower connecting rod bearings.
40. Remove the upper connecting rod bearings.
41. Mark the order of the crankshaft bearing caps.
42. Remove the crankshaft bearing cap bolts.
43. Remove the crankshaft bearing caps and the lower crankshaft bearings.
44. Remove the crankshaft.
45. Remove the upper crankshaft bearings.

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

46. Clean the parts, as needed.

1. Coat the crankshaft bearings with the engine oil.
2. Install the upper crankshaft bearings in the engine block.



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 the 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 gauging 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 plus 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 for 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 using the J 45059 or the KM-470-B .

Tighten
Tighten the crankshaft bearing cap bolts to 50 N·m (37 lb ft) using a torque wrench. Tighten the crankshaft bearing 45 degrees plus 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 using the J 45059 or the KM-470-B .

Tighten
Tighten the connecting rod bearing cap bolts to 25 N·m (18 lb ft) using a torque wrench. Tighten the connecting rod bearing cap bolts 30 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 gaging 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 using the J 45059 or the KM-470-B .

Tighten
Tighten the connecting rod bearing cap bolts to 25 N·m (18 lb ft) using a torque wrench. Tighten the connecting rod cap bolts 30 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 oil suction pipe.
28. Install the oil suction pipe bolts.

Tighten
Tighten the oil suction pipe bolts to 10 N·m (89 lb in).




29. Coat the new oil pan gasket with sealant.
30. Install the oil pan gasket to the oil pan.
31. Install the oil pan.
32. Install the oil pan retaining bolts.

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




33. Rotate the engine on the engine overhaul stand OTC 1726 .



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

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




36. Install the crankshaft timing belt gear.
37. Install the timing belt automatic tensioner.
38. Install the timing belt automatic tensioner bolts.

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

39. Install the timing belt idler pulley.
40. Install the timing belt idler pulley bolt.

Tighten
Tighten the timing belt idler pulley bolt to 40 N·m (30 lb ft).





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

41. Install the intake camshaft gear.
42. Install the intake camshaft gear bolt while holding the intake camshaft firmly in place.

Tighten
Tighten the intake camshaft gear bolt to 67.5 N·m (49 lb ft).

43. Install the exhaust camshaft gear
44. Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place.

Tighten
Tighten the exhaust camshaft gear bolt to 67.5 N·m (49 lb ft).




45. Install the timing belt. Refer to Timing Belt Replacement.
46. Adjust the timing belt tension. Refer to Timing Belt Inspection.
47. 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.
48. Install the camshaft cover and the camshaft cover gasket.
49. Install the camshaft cover washers.
50. Install the camshaft cover nuts.

Tighten
Tighten the camshaft cover nuts to 10 N·m (89 lb in).




51. Connect the ignition wires to the spark plugs.
52. Connect the oil filler cap.
53. Connect the engine ventilation hose to the camshaft cover.
54. Install the upper and the lower front timing belt covers.
55. Install the upper and the lower front timing belt cover bolts.

Tighten
Tighten the upper and the lower front timing belt cover bolts to 10 N·m (89 lb in).




56. Install the engine lifting device.
57. Remove the engine from the engine overhaul stand OTC 1726 .



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



59. Install the flywheel or the flexible plate.
60. Install the flywheel or the flexible plate bolts using the J 45059 or the KM-470-B .

Tighten
Tighten the flywheel bolts to 35 N·m (25 lb ft). Tighten the flywheel bolts another 30 degrees plus 15 degrees. If the vehicle is equipped with an automatic transaxle, tighten the flexible plate bolts to 45 N·m (33 lb ft).

61. Install the engine. Refer to Engine Replacement.