Page 143 of 1395
Cylinder Head
Installation
Installthe cylinder head in the reverse order of removal:
1. Clean the cylinder head and block surfaces.
2. Clean the oil control orifice. Install the cylinder headgasket, dowel pins and the oil control orifice on thecylinder block. Always use a new cylinder head gas-ket.
CYLII{DER HEADGASKETR€place.
DOWEL PIN
O.RINGRoplace.
DOWELPIN
OIL CONTBOLORIFICEClean.
Apply clean engine oil to the bolt threads and underthe bolt heads.
4. Tighten the cylinder head bolts in two steps. In thefirst step tighten all bolts, in sequence, to about 29
N.m {3.0 kgf.m,22 lbf.ft); in the finat step, tighten inthe same sequence to 85 N.m (8.7 kgf.m,63 lbf.ft).
Use a beam-type torque wrench. When using a pre-
set-type torque wrench, be sure to tighten slowly
and do not overtighten.
lf a bolt makes any noise while you are torquing it,loosen the bolt, and retighten it from the 1st step.
CYLINDER HEAD BOLTS TOROUE SEOUENCE:
Tighten the intake manifold mounting bolts (see
page 6-21).
Install the exhaust manifold bracket. and tighten thenew self-locking nuts (see page 6-20).
6-30
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Page 144 of 1395
7.Place the rocker arms on the pivots and the valve
stems. Put the rocker arms in their original posi-
lrons.
lnstall the camshafts, then install the oil seals with
the open side (spring) facing in. Make sure that the
keyways on the camshafts are facing up and the No.
1 piston is at TDC.
Clean and dry the cylinder head mating surfaces.
Apply liquid gasket (P/N 08718 - 0001 or 08718 -
0OO3) to the head mating surfaces of the No. 1 and
No. 6 camshaft holders on both the intake and
exhaust side.
L
No. I
EXHAUST
II{TAKE
Apply liquid gasket to th€ shaded areas.
't't,
'10. lnstall the camshaft holders.
NOTE:
o "1" or "E' marks are stamped on the camshaft
holders.
. The arrows marked on the camshaft holders
should point at the timing belt.
Tighten each bolt in two steps to ensure that the
rockers do not bind on the valves.
Wipe off the excess liquid gasket from the No. 1 and
No. 6 camshaft holders with a shop towel,
Specified torque:
9.8 N.m (1.0 kgf.m, 7.2 lbf.ft)
Apply engine oil to the bolt ihreads.
I?,ITAKE
EXHAUST
(cont'd)
6-31
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Page 145 of 1395
Cylinder Head
Installation (cont'dl
'13. Align the marks on the cylinder head plug to thecylinder head upper surface, then install the cylin
der head plug in the end of the cylinder head.
CYLINOER HEADPLUGReplace.
lnstallthe back cover.
To set the camshafts at TDC position for the No. lpiston, align the holes in the camshafts with theholes in the No. l camshaft holders and insert 5.0mm pin punches in the holes. Install the keys into
the camshaft grooves.
37 N m (3.8 *gl.m, 27 lbt.tr)
9.8 N.m (1.0 kgtm,7.2|hrftl
Push the camshaft pulleys onto the camshafts. thentighten the retaining bolts to the torque specified.
6-32
14.
KEYS
I x 1.25 mm
6x1.0mm
Install the timing belt (see page 6-1 1).
Adjust the valve clearance (see page 6-3).
Thoroughly clean the head cover gasket and thegroove.
lnstall the head cover gasket in the groove of thecylinder head cover. Seat the head cover gasket in
the recesses for the camshaft first, then work it into
the groove around the outside edges. Make sure thehead cover gasket is seated securely in the corners
of the recesses with no gap.
17.
'18.
19.
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Page 146 of 1395
21.
22.
Check that the mating surfaces are clean and dry.
Apply liquid gasket, part No. 08718 - 0001 or 08718- 0003, to the head cover gasket at the eight corners
of the recesses.
NOTE:
. Do not install the parts if five minutes or more
have elapsed since applying liquid gasket.
Instead, reapply liquid gasket after removing old
residue.
. After assembly. wait at least 30 minutes before
filling the engine with oil.
Apply liquid gasket tothe shaded areas.
Hold the head cover gasket in the groove by placing
your fingers on the camshaft holder contacting sur-
faces (top of the semicirclesl.
Once the cylinder head cover is on the cylinder
head, slide the cover slightly back and forth to seat
the head cover gasket.
Inspect the cover washers. Replace any washer that
is damaged or dete(iorated.
23.
24.
25. Tighten the nuts in tvvo or three steps. In the final
step, tighten all nuts, in sequence. to 9.8 N.m (1.0
kgf.m, 7.2 lbf.ft).
Check that all tubes, hoses and connectors are
installed correctly.
26.
6-33
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Page 147 of 1395
Engine Block
Speciaf Tools .............7-2
lllustrated lndex ................................... 7-3
Flywheel and Drive Plate
Replacement ..,.,....7-5
Connecting Rod and Grankshaft
End Play .................7-6
Main Bearings
Cfearance ...............7 -7
Selection ................7-8
Connecting Rod Bearings
Clearance ...............7-8
Selection ................7-9
Pistons and Crankshaft
Removal .................7-9
Crankshaft
Inspection .............. 7-11
Pistons
fnspection ..............7-12
fnstaflation .............7-20
Cylinder Block
Inspection ..............7-13
Piston Pins
Removal ..,.......,,..... 7-14
Installation ............. 7-15
Inspection .............. 7-16
Connecting Rods
Selection ................7 -14
Piston Rings
End Gap .................7 -17
Ring-to-Groove Clearance ............... 7 -17
Replacement .........7-18
Alignment .............. 7-18
Crankshaft Oil Seal
lnstallation ............. 7-19
Crankshaft
lnstalfation .............7-20
Oil Seals
fnstalfation ....,..,.....7-23
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Page 150 of 1395
lllustrated Index (cont'd)
NOTE: New rod bearings
(see pages 7-91.
must be selected by matching connecting rod assembly and crankshaft identification markings
PISTON INSTALLANON DIRECTION:
Lubricate all internal parts with engine oil
during reassembly.EXHAUST
INTAKE
PISTON RINGSReplacement. page 7-18Measurdment, page 7-17Alignm€nt, page 7-18
PISTONInspection, page 7-12
l1\AAtr\
\9q9Q9e/
PISTON PINRemoval, page 7-14
Installation, page 7-15Inspection. page 7-16
ENGINC BLOCKCylinder bore inspection. pago 7-13
Warpage inspoction, Page 7-'13
CONNECTING ROD BEARING CAPlnstallation, page 7-20NOTE: Install the caps so thebearing recess is on thesame side as the recessin the rod.
CONNECTING ROD CAP8 x 0.75 mm31 N.m {3.2 kgl.m.23 tbf.ftl
CONNECTING
COiINECI'ING RODBEARINGSClearance, page 7-8
Solection. page 7-9
NUT
End play, page 7-6Selection, page 7-14
Inspect the top ot each cylinder borefor carbon build up or a ridgebelore removing the piston.
Remove the ridge if necessary, page 7-10Apply engine oil to the bolt threads.NOTE: After torquing each bearingcap, rotate the crankshaft to check forbinding.
7-4
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Page 156 of 1395
Pistons and Crankshaft
Removal (cont'dl
6. Remove the bolts. To prevent warpage, unscrew the
bolts in sequence 1/3 turn at a time; repeat the
sequence until all bolts are loosened.
Remove the rod caps/bearings and main caps/bear-
ings, Keep all caps/bearings in order
Lift the crankshaft out of the engine. being careful
not to damage the journals.
7.
7-10
9.
10.
Remove the upper bearing halves from the connecting
rods, and set them aside with their respective caps.
Reinstall the main caps and bearings on the engine
in proper order.
lf you can feel a ridge of metal or hard carbon
around the top of each cvlinder, remove it with a
ridge reamer. Follow the reamer manufacturer's
instructions. lf the ridge is not removed, it may
damage the pistons as they 8re pushed out.
12.
11.
14.
Use the wooden handle of a hammer to drive the
pistons out.
13.Reinstall the connecting rod bearings and caps after
removing each piston/connecting rod assembly.
To avoid mixup on reassembly, mark each piston/
connecting rod assembly with its cylinder number.
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it indi-
cates the rod bore size.
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Page 158 of 1395
PistonsI
Inspection
LCheck each piston for distortion or cracks.
Measure the piston diameter at distance A from the
bottom of the skirt.
A: '97 - 98 models 15 mm 10.5 inl'99 - 00 models 20 mm 10.8 inl
Piston Diameter:
Standard (New): 8:1.980 - txl.990 mm(3.3063 - 3.3067 inl
Service Limit: 83.970 mm {3.3059 inl
SKIRT DIAMETER
7-12
3. Calculate the difference between the cylinder bore
diameter (see page 7-13) and the piston diameter.
Piston-to-Cylinder Clearance:
Standard {New): 0.010 - 0.040 mm
{0.0004 - 0.0016 inl
Service Limit: 0.05 mm {0.002 in}
lf the clearance is near or exceeds the service limit,
inspect the piston and cylinder block for excessive
wear.
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