Page 3849 of 5135
A56697
A56698
A56699
A09518
A09519
Hexagon
Wrench
(8mm)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
18. REMOVE OIL PAN SUB±ASSY
(a) Remove the 19 bolts and 3 nuts.
(b) Using a screwdriver, remove the oil pan by prying the por-
tions between the cylinder block and No. 1 oil pan.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and No. 1 oil pan.
19. REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Remove the oil pump by prying a screwdriver between the
oil pump and main bearing cap.
(c) Remove the gasket.
20. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.
21. REMOVE OIL CHECK VALVE SUB±ASSY
(a) Using hexagon wrench (8mm), remove the pressure
valve and gasket.
Page 3850 of 5135
A09619
SST
A09620
B07976
A56700
SST
14±8
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
22. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB±ASSY
23. REMOVE CAMSHAFT OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
24. INSTALL CAMSHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the camshaft oil seal retainer edge.
SST 09223±46011
25. REMOVE CRANKSHAFT SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
26. INSTALL CRANKSHAFT SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump edge.
SST 09316±60011 (09316±00011, 09316±00021)
Page 3851 of 5135
A09449
SST
A09451
A09555
Measuring Point
16 mm (0.63 in.)
P12477
Seal Packing
A09522
Upper
Front
60
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±9
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
27. REMOVE ENGINE REAR OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
28. INSTALL ENGINE REAR OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the rear oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
29. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard outside diameter:
10.75 ± 11.00 mm (0.4232 ± 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
30. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB±ASSY
(a) Apply seal packing 2 or 3 threads.
Seal packing: Part No. 08826±00100 or equivalent
(b) Install the drain union.
Torque: 29 Nm (291 kgfcm, 21 ftlbf)
HINT:
After applying the specified torque, if the drain pipe of the drain
union is not at the position shown in the illustration, rotate the
drain union further clockwise and make the drain pipe face
downward.
Page 3852 of 5135
A09519
Hexagon
Wrench
(8mm)
A09476
Seal Width
2 ± 3 mm
A56701
Seal Width
2 ± 4 mm
Seal
PackingNew Gasket
14±10
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
31. INSTALL OIL CHECK VALVE SUB±ASSY
(a) Using hexagon wrench (8mm), install a new gasket and
the pressure valve.
Torque: 30 Nm (310 kgfcm, 22 ftlbf)
32. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:
Install a nozzle that has been cut to a 2 ± 3 mm (0.08
± 0.12 in.) opening.
Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil seal retainer with 6 bolts. Uniformly tighten
the bolt in several passes.
Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
33. INSTALL OIL PUMP ASSY
(a) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:
Avoid applying an excessive amount to the surface.
Install a nozzle that has been cut to a 2 ± 4 mm (0.08
± 0.16 in.) opening
Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install a new gasket to the oil pump.
Page 3853 of 5135
B08024
A57099
A56702
A56703
Seal Width
4 ± 7 mm AB
B A
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±11
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Pour in 0.5 cm3 (0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(d) Apply engine oil to the cylinder block side where it con-
tacts with the oil pump driven rotor.
(e) Install the oil pump with the 9 bolts.
Torque: 31 Nm (320 kgfcm, 23 ftlbf)
(f) Measure the oil pump rotating torque
(1) Check that the pump rotates smoothly without ab-
normal noise.
(2) Using a torque wrench, check the pump rotating
torque.
Rotating torque: 3.0 Nm (30 kgfcm, 26 in.lbf) or less
34. INSTALL OIL PAN SUB±ASSY
(a) Apply seal packing to the No. 1 oil pan as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:
Install a nozzle that has been cut to a 4 ± 7 mm (0.16
± 0.28 in.) opening.
Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil pan with 19 bolts and 3 nuts.
Torque:
11 Nm (112 kgfcm, 8 ftlbf) for 10 mm head bolt and
nut
21 Nm (210 kgfcm, 15 ftlbf) for 12 mm head bolt
42 Nm (429 kgfcm, 31 ftlbf) for 14 mm head bolt
Page 3854 of 5135
A56696
A56704
Seal Width
4 ± 7 mmBA
A
B
A56706
Front
Measuring Point
A57100
Measuring Tip
Protrusion 14±12
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
35. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 bolts
and 2 nuts.
Torque:
21 Nm (210 kgfcm, 15 ftlbf) for bolt
13 Nm (135 kgfcm, 10 ftlbf) for nut
36. INSTALL OIL PAN SUB±ASSY NO.2
(a) Apply a seal packing to the oil pan as shown in the illustra-
tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:
Install a nozzle that has been cut to a 4 ± 7 mm (0.16
± 0.28 in.) opening.
Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil pan with 16 bolts and 3 nuts. Uniformly tight-
en the bolts and nuts in several passes.
Torque: 12 Nm (120 kgfcm, 9 ftlbf)
37. INSTALL CYLINDER HEAD SUB±ASSY
(a) Check piston protrusions for each cylinder.
(1) Find where the piston head protrudes most by slow-
ly turning the crankshaft clockwise and counter-
clockwise.
(2) Measure each cylinder at 2 places as shown in the
illustration, marking a total of 8 measurements.
(3) For the piston protrusion valve of each cylinder, use
the average of the 2 measurements of each cylin-
der.
Protrusion: 0.165 ± 0.425 mm (0.0065 ± 0.0168 in.)
Page 3855 of 5135
A
B
C
D
E
A09570
Front
A56055
A09564
1
18 2 3
4 56
78 9 (A)
10 11
12 1314
1516 17(B)
(A) (A) (A) (A)(A) (A)
(A)
(B) (B) (B) (B)
(B) (B) (B) (B) (B)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±13
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(b) Select a new cylinder head gasket.
HINT:
There are 5 sizes of new cylinder head gaskets, marked ºAº,
ºBº, ºCº, ºDº, or ºEº according.
New installed cylinder head gasket thickness:
A0.85 ± 0.95 mm (0.0335 ± 0.0374 in.)
B0.90 ± 1.00 mm (0.0354 ± 0.0394 in.)
C0.95 ± 1.05 mm (0.0374 ± 0.0413 in.)
D1.00 ± 1.10 mm (0.0394 ± 0.0433 in.)
E1.05 ± 1.15 mm (0.0413 ± 0.0453 in.)
(1) Select the largest piston protrusion value from the
measurements made, then select a new appropri-
ate gasket according to the table below.
Piston protrusion mm (in.)Gasket size
0.165 ± 0.220 (0.0065 ± 0.0087)Use A
0.220 ± 0.270 (0.0087 ± 0.0106)Use B
0.270 ± 0.320 (0.0106 ± 0.0126)Use C
0.320 ± 0.370 (0.0126 ± 0.0146)Use D
0.370 ± 0.425 (0.0146 ± 0.0167)Use E
(c) Place a new cylinder head gasket in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(d) Place the cylinder head in position on the cylinder head
gasket.
(e) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 4 progressive steps
(steps (3), (5), (6) and (7)).
(1) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts and plate
washers.
(2) Install the plate washer to the cylinder head bolt.
(3) Install and uniformly tighten the 18 cylinder head
bolts and plate washers in several passes in the se-
quence shown.
Torque: 45 Nm (460 kgfcm, 33 ftlbf)
HINT:
Each bolt length is indicated in the illustration.
Bolt length:
(A)160 mm (6.30 in.)
(B)104 mm (4.09 in.)
If any of the cylinder head bolt does not meet the torque specifi-
cation, replace the cylinder head bolts.
Page 3856 of 5135
9090
909090
90
A09565
Front
Painted
Mark
A09624
A09625
A09626
Alignment Mark
A09601
Seal Packing
14±14
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(4) Mark the front of the cylinder head bolt with paint.
(5) Retighten the cylinder head bolts additional 90 in
the numerical order shown.
(6) Retighten the cylinder head bolts additional 90 in
the numerical order shown.
(7) Retighten the cylinder head bolts additional 90 in
the numerical order shown.
(8) Check that the painted mark is at the intake man-
ifold side now.
38. INSTALL CAMSHAFT SUB±ASSY, NO.1
(a) Place the camshaft carrier in position on the cylinder
head.
(b) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(c) Place the intake camshaft on top of the camshaft carrier
as shown in the illustration so that the No. 3 and No. 4 of
cylinder cam lobes face downward.
39. INSTALL CAMSHAFT SUB±ASSY, NO.2
(a) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(b) Engage the exhaust camshaft gear to the intake cam-
shaft gear by matching the alignment marks on each
gear.
(c) Roll down the exhaust camshaft onto the bearing journals
while engaging gears with each other.
(d) Install the camshaft bearing caps.
(1) Remove any old packing (FIPG) material from the
No.5 camshaft bearing cap.
(2) Apply seal packing to the No. 5 camshaft bearing
cap as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent