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Engine mechanism - Camshaft(4) Ensure whether the timing sprocket of VVT driver
will turn toward timing advance direction in de-
creasing the pressure of timing delay oil duct.
(5) When camshaft timing sprocket turns at max.
timing advance position, release the air pressure
in timing delay side oil duct, and then release the
air in timing advance side oil duct.
Hint: camshaft timing sprocket will turn only af-
ter the lock pin is released.
(d) Check the fixing state of max. delay position.
Ensure camshaft timing sprocket assembly is fixed at
max. delay position.11. Remove VVT driver assembly.(a) Clip the camshaft with a jaw vice, and ensure VVT driver
is locked tightly.
Warning: be careful not to damage camshaft.
(b) As shown in the diagram, seal 5 oil ducts of camshaft
journal with vinyl rubber cloth.
Hint: there are 2 advance side oil ducts in the
groove of camshaft, and clog one of them
with rubber block.
(c) In opposite side of the groove, respectively prick a hole
on vinyl rubber cloth of advance side oil duct surface
and delay side oil duct surface.
(d) Send in 2 oil ducts (advance side oil duct and delay
side oil duct) with the surface rubber cloth pricked
under the pressure of 150Kpa.
Warning:cover the oil ducts with cloth to avoid
oil injecting out in pushing.
(e) Ensure whether the timing sprocket of VVT driver will
turn toward timing advance direction in decreasing the
pressure of timing delay oil duct.
Hint: camshaft timing sprocket will turn toward
advance direction only after the lock pin is
released.
(f) When camshaft timing sprocket turns at max. timing
advance position, release the air pressure in timing
delay side oil duct, and then release the air in timing
advance side oil duct. Warning: if the air pressure in timing advance side oil duct is released earlier than that
in timing delay side oil duct, VVT driver assembly will move suddenly toward
delay side, and the lock pin will be damaged.
(c) Check rotating is smooth.
Besides max. delay position, turn VVT driver assembly within rotating rang and check rotating is
smooth.
Warning: Perform inspection with hands but not with
compressed air.55Delay side
oil ductAdvance
side oil
duct
Close
OpenClose
Open
Vinyl rubber cloth
Rubber block
Delay side
oil ductAdvance
side oil
ductDropping
pressure
Maintaining
pressure Delay side
oil ductAdvance
side oil
duct
Dropping
pressure
Maintaining
pressure Delay side
oil ductAdvance
side oil
duct
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Engine mechanism - CamshaftWarning: if the air pressure in timing advance side oil duct is released earlier than that in
timing delay side oil duct, VVT driver assembly will move suddenly toward
delay side.This will cause the damage of lock pin.
(g) Remove VVT drive fixed bolts.
Notes:
It is strictly forbidden to remove other 4 bolts.
Under the condition of repeating using camshaft
timing sprocket, release lock pin at first, and then
install sprocket.12. Install VVT driver assembly.
13. Install camshaft.Put VVT driver assembly together with intake camshaft.
(a) As shown in the diagram, gently make VVT assembly
hold camshaft and turn it toward left until straight pin is
inserted into groove.
Warning: it is strictly forbidden to turn camshaft
timing sprocket toward timing delay side
(toward right).
(b) Check there is no clearance between sprocket flange
and camshaft.
(c) Fix camshaft timing sprocket and then tighten flange
bolt.
Torque: 70 ±5N.m
(d) Check VVT driver assembly could move to timing
delay side and is locked at max. timing delay position.
(f) As shown in the diagram, align alignment mark with
timing mark on camshaft timing sprocket, and install
timing chain on the timing sprocket.
(g) Check forward mark and figure, and tighten bolts as
sequences shown in the diagram.
Torque: 13 ±0.78N.m
(h) Align alignment mark on the chain with timing mark on
camshaft timing sprocket, and place exhaust camshaft
in cylinder head.Straight pin
key
grooveFlange bolt
Straight pin56Timing remark
chain linkTiming mark
Timing remark chain link
Timing mark
Page 69 of 419
Engine mechanism - Camshaft(n) Install chain tensioner components.
(1) Check o-ring is clean, and buckle on the hook as
shown in the diagram.
(2) Coat engine oil on the chain tensioner, and then
install it.
Torque: 9 ±1.8N.m
Note:when installing the chain temsioner,
buckle on the hook again if plunger has
ejected.
(3) Turn crankshaft counterclockwise to separate the
hook from lock pin on the plunger.
(4) Turn crankshaft clockwise, and check the sliding
parts are blocked by plunger.
Hint: if the plunger does not eject, press the ten-
sion rail toward chain tensioner with
screwdriver or fingers to separate the hook
from lock pin and make the plunger eject.Pushing into
Turning Plunger
Pushing into58Lifting
Hook Pressing
in
Pin
PinHook Sepa-
rate
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Engine mechanism - Camshaft14. Adjust valve clearance.
15. Install cylinder head cover components.(a) Install gasket to cylinder head cover.
(b) Eliminate all old sealant (FIPG) materials.
(c) Coat sealant on position shown in the diagram.
Sealant: silicon rubber flange sealant 1596 (Kesaixin
1596).
Notes:Eliminate all oil on contact surface.After coating sealant, finish installation of cylinder
head cover within 3 minutes.After installing, do not refill engine oil within 2
minutes.
(d) Install cylinder head cover and harness bracket with 9
bolts, 2 oil seal washers and 2 nuts.
Evenly tighten bolts and nuts at several times.
Torque: nut: 29 ±5.8N.m
Bolt: 69 ±13.8N.m16. Install drive belt tensioner device.Torque: nut: 29 ±5.8N.m
Bolt: 69 ±13.8N.m17. Install right engine mounting assembly.Torque: 52N.m18. Check there is oil leakage.
59
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Engine mechanism - Crankshaft front oil seal assemblyReplacement1. Remove engine right bottom shield.
2. Remove drive belt.Slowly turn drive belt tensioner clockwise to loosen it. Then
remove drive belt and put back drive belt tensioner slowly and
gently.3. Remove right engine mounting assembly.(a) Remove PS oil pump reservoir and put it aside.
(b) Place wooden block between jack and engine, properly
place the jack, and then remove right engine mounting
assembly.4. remove damping pulley.(a) Remove pulley bolts with special tool.
(b) Remove damping pulley with special tool.Special
tool
Special
tool60Crankshaft front oil seal assembly
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Engine mechanism - Crankshaft front oil seal assembly5. Remove crankshaft front oil seal.(a) Cut oil seal lip with blade.
(b) Prize out oil seal with flat screwdriver whose sharp end is
winded with tape.
Note:check crankshaft is damaged after removing oil
seal, and repair with abrasive paper (#400) if it
is damaged.6. Install crankshaft front oil seal.(a) Coat a little MP grease on new oil seal lip.
Note: do not let oil seal lip contact with foreign
matters.
(b) Gently knock new oil seal in with special tool and hammer
until the seal surface is parallel and level with the end sur-
face edge of mounting hole.
Note: wipe off redundant grease on crankshaft.7. Install damping pulley.(a) Align the key groove on the pulley with the key on the
crankshaft, and slide pulley in.
(b) Install pulley bolts with special tool.
Torque: m8. Install right engine mounting assembly.Torque: 9. Check there is oil leakage.Cut
position
Prizing out
Special
tool61Special
tool
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Engine mechanism - Crankshaft rear oil seal assemblyReplacement1. Remove transmission assembly.
2. Remove clutch assembly and flywheel components.Fix crankshaft with special tool, remove clutch assembly at
first, and then remove flywheel components.3. Remove crankshaft rear oil seal.(a) Cut oil seal mouth with blade.
(b) Prize out oil seal with flathead screwdriver whose sharp
end is winded with tape.
Note: check crankshaft is damaged after removing oil
seal, and repair with abrasive paper (#400) if it is
damaged.4. Install crankshaft rear oil seal [4G18-1002130].(a) Coat a little MP grease on new oil seal lip.
Note: do not let oil seal lip contact with foreign
matters.
(b) Gently knock new oil seal in with special tool and hammer
until the seal surface is parallel and level with the end sur-
face edge of mounting hole.
Note: wipe off redundant grease on crankshaft.5. Install flywheel components and clutch assembly.(a) Fix crankshaft with special tool.
(b) Clean bolts and bolt holes.
(c) Coat bolts with adhesive.
Adhesive: thread locking adhesive 1234 (Kesaixin 1234)
(d) Install flywheel components.
As sequences shown in the diagram, tighten bolts at sev-
eral times.
Torque: (e) Install clutch assembly.6. Install transmission assembly.Special
tool
Cut
positionSpecial
tool62Crankshaft rear oil seal assembly
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Engine mechanism - Cylinder cover gasket componentsReplacement1. Take measures to prevent gasoline leaking.
2. Remove timing chain assembly.
3. Remove camshaft.As sequences shown in the diagram, evenly loosen at
several times, and remove 19 bearing cover bolts, and then
remove 9 bearing covers of intake camshaft and exhaust
camshaft.4. Remove cylinder head assembly.(a) Remove warm air water outlet pipe from cylinder head.
(b) As shown in the diagram, evenly loosen 10 cylinder head
bolts with 10mm dual hexagonal sleeves at several times,
and then remove 10 cylinder head bolts and plain washer.
Notes:Be careful not to let washer fall into cylinder head. Incorrect disassembling sequence will cause cylin-
der head warp or chap.5. Remove cylinder head gasket components
[4G18-1003160].
6. Install cylinder head gasket components.Put new cylinder head gasket on the cylinder body.
Notes:Pay attention to installation direction.Gently put down cylinder head to avoid damaging
cylinder head gasket.7. Install cylinder head assembly.Hint: Lock up cylinder head bolts as 2 steps.
(a) Coat a thin layer of engine oil at bolt thread and the bottom
of bolt head.
(b) As shown in the diagram, evenly tighten 10 cylinder head
bolts and plain washer with 10mm dual hexagonal sleeves
at several times.
Torque: 63Cylinder cover gasket components
