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5. When the repair work is completed, return the ignition switch to the
″LOCK ″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of al l control units using CONSULT-III.
Precaution for Procedure without Cowl Top CoverINFOID:0000000005930985
When performing the procedure after removing cowl top cover, cover
the lower end of windshield.
Precaution for Drain CoolantINFOID:0000000005930986
• Drain coolant when engine is cooled.
Precaution for Disconnecting Fuel PipingINFOID:0000000005930987
• Before starting work, make sure no fire or spark producing items are in the work area.
• Release fuel pressure before disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.
Precaution for Removal and DisassemblyINFOID:0000000005930988
• When instructed to use special service tools, use the spec ified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Cover openings of engine system with tape or the equiva lent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specif ied, do exactly as specified. Power tools may be used
where noted in the step.
Precaution for Inspection, Repair and ReplacementINFOID:0000000005930989
• Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and InstallationINFOID:0000000005930990
• Use torque wrench to tighten bolts or nuts to specification.
• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.
• Release air within route after draining coolant.
• Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure that there are no leaks at fuel line connections.
• After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage.
PIIB3706J
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PRECAUTIONS
Parts Requiring Angular Tightening
INFOID:0000000005930991
• Use an angle wrench for the final tightening of the following engine parts:
- Cylinder head bolts
- Camshaft sprocket (INT)
- Main bearing cap bolts
- Connecting rod cap nuts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular tightening)
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid GasketINFOID:0000000005930992
REMOVAL OF LIQUID GASKET SEALING
• After removing the bolts and nuts, separate the mating surface and remove the sealant using Tool.
CAUTION:
Be careful not to damage the mating surfaces.
• In areas where the cutter is difficult to use, use a plastic hammer to lightly tap (1) the cutter where the RTV Silicone Sealant is applied.
Use a plastic hammer to slide the cutter (2) by tapping on the side.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old Silicone RTV Sealant adhering to the gasket application surface and the mating surface.
• Remove the sealant completely from the groove of the gasketapplication surface, bolts, and bolt holes.
2. Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture, grease and foreign
materials.
3. Attach the sealant tube to the tube presser. Use Genuine Silicone RTV Sealant or equivalent. Refer to
GI-42, "
Recommended Chemical Product and Sealant".
4. Apply the sealant without breaks to the specified location using Tool.
• If there is a groove for the s ealant application, apply the seal-
ant to the groove.
• As for the bolt holes, normally apply the sealant inside the holes. If specified, it should be applied outside the holes. Make
sure to read the text of this manual.
• Within five minutes of the seal ant application, install the mat-
ing component.
• If the sealant protrudes, wipe it off immediately.
• Do not retighten after the installation. Tool number : KV10112100 (BT-8653-A)
Tool number : KV10111100 (J-37228)
WBIA0566E
PBIC0003E
Tool number WS39930000 ( – )
WBIA0567E
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• After 30 minutes or more have passed from the installation, fill
the engine with the specified oil and coolant. Refer to MA-14,
"Fluids and Lubricants".
CAUTION:
Follow all specific instruct ions in this manual.
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PREPARATION
PREPARATION
Special Service ToolINFOID:0000000005930993
The actual shapes of Kent-Moore tool
s may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name Description
K V 1 0 1111 0 0
(J-37228)
Seal cutter Removing steel oil pan and rear timing
chain case
KV10112100
(BT-8653-A)
Angle wrench Tightening bolts for bearing cap, cylinder
head, etc.
KV10107902
(J-38959)
Valve oil seal puller Removing valve oil seal
EM03470000
(J-8037)
Piston ring compressor Installing piston assembly into cylinder
bore
KV101092S0
(J-26336-B)
Valve spring compressor
1. KV10109210
(J-26336-B and J-26336-20)
Compressor
2. KV10109220
(—)
Adapter (M10)
3. KV10109230
(—)
Adapter (M8) Disassembling and assembling valve
mechanism
WS39930000
(—)
Tube presser Pressing the tube of liquid gasket
NT046
NT014
S-NT011
NT044
NT718
NT052
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ST16610001
(J-23907)
Pilot bushing puller
Removing crankshaft pilot bushing
KV11103000
( — )
Pulley puller Removing crankshaft pulley
KV991J0050
(J-44626)
Air fuel sensor Socket Loosening or tightening air fuel ratio sen-
sor
a: 22 mm (0.87 in)
KV10114400
(J-38365)
Heated oxygen sensor wrench Loosening or tightening rear heated oxy-
gen sensor
a: 22 mm (0.87 in)
KV11105210
(J-44716)
Stopper plate Securing drive plate and flywheel
KV10115600
(J-38958)
Valve oil seal drift Installing valve oil seal
Use side A.
a: 20 (0.79) dia
.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia .
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
KV10115801
(—)
Oil filter wrench Removing and installing oil filter
a: 64.3 mm (2.531 in)
Tool number
(Kent-Moore No.)
Tool name
Description
NT045
NT676
LBIA0444E
NT636
ZZA0009D
S-NT603
S-NT375
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PREPARATION
Commercial Service Tool
INFOID:0000000005930994
KV10109300
(—)
Pulley holder Removing and installing crankshaft pulley
K V 1 0 111 8 0 0
( — )
Valve guide drift Removing and installing valve guide
—
(J-48891 Removing and installing spark plug
Tool number
(Kent-Moore No.)
Tool name
Description
NT628
PBIC4012E
ALBIA0672GB
(Kent-Moore No.)
Tool name
Description
Power tool Loosening bolts and nuts
Valve seat cutter set Finishing valve seat dimensions
Piston ring expander Removing and installing piston ring
PBIC0190E
NT048
NT030
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Valve guide reamer
(1): Reaming valve guide inner hole
(2): Reaming hole for oversize valve guide
(J-43897-18)
(J-43897-12)
Oxygen sensor thread cleaner Reconditioning the exhaust system threads
before installing a new oxygen sensor (Use
with anti-seize lubricant shown below.)
a: J-43897-18 (18 mm dia.) for zirconia ox-
ygen sensor
b: J-43897-12 (12 mm dia.) for titania oxy-
gen sensor
Anti-seize lubricant (Permatex 133AR
or equivalent meeting MIL specifica-
tion MIL-A-907) Lubricating oxygen sensor thread cleaning
tool when reconditioning exhaust system
threads
E20 Torx® Socket
(J-45816) Removing and installing drive plate and fly-
wheel bolts
(Kent-Moore No.)
Tool name
Description
PBIC4013E
AEM488
AEM489
LBIA0285E
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NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting - Engine NoiseINFOID:0000000005930995
WBIA0769E
1. Piston pin noise 2. Piston slap noise3. Main bearing noise
4. Water pump noise 5. Timing chain and tensioner noise 6. Drive belt noise (stick/slipping)
7. Tappet noise 8. Camshaft bearing noise 9. Connecting rod noise
A. Rotational mechanism B. Water pumpC. Timing chain
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