Page 16 of 65
3. Remove engine gussets and oil pan bolts.
+Remove bolts/nuts in numerical order shown in ®gure, alternat-
ing left and right ones toward the center.
4. Remove oil pump assembly.
Installation
Always install with new oil seal.
1. Install oil pump assembly.
Location Bolt length mm (in)
V120 (0.79)
V235 (1.38)
V345 (1.77)
V455 (2.17)
2. Install oil pan. Tighten bolts in the order shown in the ®gure.
+Always replace oil pan gaskets with new ones when reas-
sembling.
+Install oil pan gasket after cleaning the contacting surface.
+Oil pan bolts/nuts:
Bolt
:8-12Nzm (0.8 - 1.2 kg-m, 69 - 104 in-lb)
Nut
:10-14Nzm (1.0 - 1.4 kg-m, 87 - 122 in-lb)
3. Install engine gusset and oil pan guard.
SEM739B
SEM432C
SEM794F
SEM739BA
OIL PAN
Removal (Cont'd)
EM-15
Page 20 of 65
Installation
1. Con®rm that No. 1 cylinder is set at BDC on its expansion
stroke as follows:
Con®rm that crankshaft key is at the bottom.
2. Set timing belt.
a. Ensure timing belt, sprockets and pulleys are clean and
free from oil or water. Do not bend or twist timing belt too
much.
b. Align white lines on timing belt with matching mark on
camshaft sprocket, crankshaft sprocket and injection
pump pulley.
c. Point arrow on timing belt toward front.
SMA771B
TIMING BELT
EM-19
Page 22 of 65

VALVE OIL SEAL
1. Remove timing belts.
2. Remove camshaft sprocket and back covers.
3. Remove camshaft brackets by loosening bracket nuts from
center to outside in two or three stages.
4. Remove camshaft oil seals and camshaft.
5. Remove valve lifters and mark order No. on each lifter.
6. Replace valve oil seal according to the following procedure.
When replacing valve oil seal, set the corresponding piston at
TDC. Failure to do so causes the valve to drop into the cylin-
der.
1) Set No. 1 cylinder at TDC.
2) Remove valve springs and valve oil seals for No. 1 and No. 6
cylinders. Valve spring seats should not be removed.
3) Install new valve oil seals for No. 1 and No. 6 cylinders as
illustrated. Reinstall valve springs. (narrow pitch side toward
cylinder head)
4) Install valve spring retainers on intake valves and valve rotators
on exhaust valves, and remount valve assembly.
5) Set No. 2 cylinder at TDC.
6) Replace valve oil seals for No. 2 and No. 5 cylinders according
to steps 2) and 3).
7) Set No. 3 cylinder at TDC.
8) Replace valve oil seals for No. 3 and No. 4 cylinders according
to steps 2) and 3).
9) Install valve lifters in original positions.
SEM716B
SEM790F
SEM745B
SEM746B
OIL SEAL REPLACEMENT
EM-21
Page 39 of 65
Assembly
1. Install valve component parts.
Install valve spring with its narrow pitch side toward cylinder
head side.
a. When installing valve, apply engine oil on the valve stem
and lip of valve oil seal.
b. Check whether the valve face is free from foreign matter.
c. Install valve spring retainers on the intake side and valve
rotators on the exhaust side.
d. Valve rotators cannot be disassembled.
2. Set camshaft.
Set camshaft so that dowel pin faces up.
3. Install cam bracket caps so that front mark faces forward.
Cam bracket nut (Tighten in two or three stages):
:21-26Nzm
(2.1 - 2.7 kg-m, 15 - 20 ft-lb)
4. Apply engine oil to new oil seal and install it.
Installation
1. Install cylinder head gasket.
a. When replacing only cylinder head gasket, install same
grade gasket as the one formerly used.
b. When replacing or repairing cylinder block, cylinder head,
piston, connecting rod and crankshaft, select gasket as
follows:
SEM202
SEM731BB
SEM732B
SEM733B
CYLINDER HEAD
EM-38
Page 43 of 65

Adjusting
Adjust valve clearance while engine is cold.
1. Turn crankshaft. Position cam lobe upward on camshaft for
valve that must be adjusted.
2. Place Tool (A) around camshaft as shown in ®gure.
Before placing Tool (A), rotate notch toward center of cylinder
head. (See ®gure.) This will simplify shim removal later.
CAUTION:
Be careful not to damage cam surface with Tool (A).
3. Rotate Tool (A) (See ®gure.) so that valve lifter is pushed down.
4. Place Tool (B) between camshaft and valve lifter to retain valve
lifter.
CAUTION:
+Tool (B) must be placed as close to camshaft bracket as
possible.
+Be careful not to damage cam surface with Tool (B).
5. Remove Tool (A).
6. Remove adjusting shim using a small screwdriver and a mag-
netic ®nger.
7. Determine replacement adjusting shim size using the following
formula.
+Use a micrometer to determine thickness of removed shim.
+Calculate thickness of new adjusting shim so valve clearance
comes within speci®ed values.
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
S = Standard valve clearance
Unit: mm (in)
HOTIntake 0.28 - 0.38 (0.0110 - 0.0150)
Exhaust 0.32 - 0.42 (0.0126 - 0.0165)
COLDIntake 0.26 - 0.34 (0.0102 - 0.0134)
Exhaust 0.30 - 0.38 (0.0118 - 0.0150)
Intake:
N=R+[MþS]
Exhaust:
N=R+[MþS]
Shims are available in 15 sizes from 2.20 mm (0.0866 in) to 2.90
mm (0.1142 in), in steps of 0.05 mm (0.0020 in).
SEM636F
SEM637F
SEM638F
SEM145D
VALVE CLEARANCE
EM-42
Page 56 of 65

2. Install crankshaft and main bearing caps and tighten bolts to
the speci®ed torque.
+Apply new engine oil to the bolt thread and seat surface.
+Prior to tightening bearing cap bolts, shift crankshaft back
and forth to properly seat the bearing cap.
+Tighten bearing cap bolts gradually in two or three steps.
Start with center bearing and move outward as shown in
®gure.
+After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
3. Measure crankshaft end play.
Crankshaft end play:
Standard
0.050 - 0.18 mm (0.0020 - 0.0071 in)
Limit
0.30 mm (0.0118 in)
If beyond the limit, replace thrust bearing with a new one.
4. Install connecting rod bearings in connecting rods and connect-
ing rod caps.
+Con®rm that correct bearings are selected. Refer to ``Con-
necting rod bearing (Big end)'', EM-52.
+Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing.
+Apply new engine oil to bearing surfaces, bolt threads and
seating surfaces.
5. Install pistons with connecting rods.
a. Install them into corresponding cylinders with Tool.
+Make sure connecting rod does not scratch cylinder wall.
+Make sure connecting rod bolts do not scratch crankshaft
pin journals.
+Arrange so that front mark on piston head faces toward
front of engine.
+Apply new engine oil to piston rings and sliding surface of
piston.
b. Install connecting rod caps.
+Apply new engine oil to bolt threads and nut seating sur-
faces.
Tighten connecting rod cap nuts using the following procedure.
(1) Tighten to 14 to 16 Nzm
(1.4 to 1.6 kg-m, 10 to 12 ft-lb).
(2) Turn nuts 60 to 65É clockwise with an angle wrench. If
an angle wrench is not available, tighten nuts to 37 to
45 Nzm (3.8 to 4.6 kg-m, 27 to 33 ft-lb).
SEM801FA
SEM756B
SEM757B
SEM936A
SEM759B
CYLINDER BLOCK
Assembly (Cont'd)
EM-55