Service Manual2004 2.0L DOHC ENGINE MECHANICAL file:///D:/MANUALES DE SERVICIO Y REPARACION POR MARC...

Tacuma-Rezzo

SECTION 1C2

2.0L DOHC ENGINE MECHANICAL

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact
with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK
unless otherwise noted.

DESCRIPTION AND OPERATION

CYLINDER HEAD AND GASKET
The cylinder head is made of an aluminum alloy. The cylinder head uses cross-flow intake and exhaust ports. A spark plug is located in the center of each
combustion chamber. The cylinder head houses the dual camshafts.

CRANKSHAFT
The crankshaft has eight integral weights which are cast with it for balancing. Oil holes run through the center of the crankshaft to supply oil to the connecting rods,
the bearings, the pistons, and the other components. The end thrust load is taken by the thrust washers installed at the center journal.

TIMING BELT
The timing belt coordinates the crankshaft and the dual overhead camshafts and keeps them synchronized. The timing belt also turns the coolant pump. The timing
belt and the pulleys are toothed so that there is no slippage between them. There are two idler pulleys. An automatic tensioner pulley maintains the timing belt's
correct tension. The timing belt is made of a tough reinforced rubber similar to that used on the serpentine drive belt. The timing belt requires no lubrication.

OIL PUMP
The oil pump draws engine oil from the oil pan and feeds it under pressure to the various parts of the engine. An oil strainer is mounted before the inlet of the oil
pump to remove impurities which could clog or damage the oil pump or other engine components. When the crankshaft rotates, the oil pump driven gear rotates.
This causes the space between the gears to constantly open and narrow, pulling oil in from the oil pan when the space opens and pumping the oil out to the engine
as it narrows.
At high engine speeds, the oil pump supplies a much higher amount of oil than required for lubrication of the engine. The oil pressure regulator prevents too much
oil from entering the engine lubrication passages. During normal oil supply, a coil spring and valve keep the bypass closed, directing all of the oil pumped to the
engine. When the amount of oil being pumped increases, the pressure becomes high enough to overcome the force of the spring. This opens the valve of the oil
pressure regulator, allowing the excess oil to flow through the valve and drain back to the oil pan.

OIL PAN
The engine oil pan is mounted to the bottom of the cylinder block. The engine oil pan houses the crankcase and is made of cast aluminum.
Engine oil is pumped from the oil pan by the oil pump. After it passes through the oil filter, it is fed through two paths to lubricate the cylinder block and cylinder
head.
In one path, the oil is pumped through oil passages in the crankshaft to the connecting rods, then to the pistons and cylinders. It then drains back to the oil pan. In
the second path, the oil is pumped through passages to the camshaft. The oil passes through the internal passageways in the camshafts to lubricate the valve
assemblies before draining back to the oil pan.

EXHAUST MANIFOLD
A single four-port, rear-takedown manifold is used with this engine. The manifold is designed to direct escaping exhaust gases out of the combustion chambers with
a minimum of back pressure. The oxygen sensor is mounted to the exhaust manifold.

INTAKE MANIFOLD
The intake manifold has four independent long ports and utilizes an inertial supercharging effect to improve engine torque at low and moderate speeds.

CAMSHAFTS
This engine is a dual overhead camshaft (DOHC) type, which means there are two camshafts. One camshaft operates the intake valves, and the other camshaft
operates the exhaust valves. The camshafts sit in journals on the top of the engine (in the cylinder head) and are held in place by camshaft caps. The camshaft
journals of the cylinder head are drilled for oil passages. Engine oil travels to the camshafts under pressure where it lubricates each camshaft journal. The oil
returns to the oil pan through drain holes in the cylinder head. The camshaft lobes are machined into the solid camshaft to precisely open and close the intake and
the exhaust valves the correct amount at the correct time. The camshaft lobes are oiled by splash action from pressurized oil escaping from the camshaft journals.

EXHAUST GAS RECIRCULATION VALVE

The exhaust gas recirculation (EGR) system is used to lower oxides of nitrogen (NOX) emission levels caused by high combustion temperature. The main element of
the system is the EGR valve operated by
The EGR valve feeds small amounts of exhaust gas into the intake manifold to decrease combustion temperature. The amount of exhaust gas recirculated is
controlled by variations in vacuum and exhaust back pressure. If too much exhaust gas enters, combustion will not take place. For this reason, very little exhaust
gas is allowed to pass through the valve, especially at idle.
The EGR valve is usually open under the following conditions:

Warm engine operation.

Above idle speed.

COMPONENT LOCATOR
UPPER END

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1. Spark Plug Cover

2. Oil Cap
3. Oil Cap Seal
4. Bolt
5. Bolt
6. Valve Cover
7. Valve Cover Gasket
8. Seal
9. Hydraulic Valve Lash Adjuster
10. Valve Key
11. Valve Spring Retainer
12. Valve Spring
13. Valve Stem Seal
14. Valve Spring Seat
15. Valve Guide
16. Valve Spring Seat
17. Intake Valve
18. Exhaust Valve
19. Bolt-Stud
20. Exhaust Manifold Gasket
21. Exhaust Manifold
22. Nut
23. Exhaust Manifold Heat Shield
24. Bolt
25. Oxygen Sensor Bracket
26. Oxygen Sensor
27. Clamp
28. Bolt-Stud
29. Nut
30. Bolt
31. Thermostat Housing
32. Thermostat Housing Seal
33. Thermostat Adapter Seal
34. Thermostat Adapter
35. Bolt
36. Bolt
37. Washer
38. Camshaft Gear
39. Camshaft Seal
40. Camshaft
41. Plug
42. Plug
43. Plug
44. Front Camshaft Cap
45. Bolt
46. Intermediate Camshaft Cap
47. Cylinder Head
48. Intake Manifold Bracket
49. Intake Manifold
50. Vacuum Connector
51. Bolt
52. MAP Sensor Wiring Harness
53. MAP Sensor
54. Intake Manifold Gasket
55. Throttle Body Gasket
56. Nut
57. IACU Motor
58. Screw
59. TP Sensor
60. Throttle Body
61. Nut

LOWER END

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1. Hose Clamp
2. Engine Ventilation Hose
3. Engine Ventilation Pipe
4. Oil Level Gauge Stick
5. Engine Ventilation Gasket
6. Piston Ring Set
7. Piston
8. Piston Pin
9. Connecting Rod
10. Bolt
11. Connecting Rod Bearing Set
12. Screw
13. Transmitter Disc
14. Woodruff Key
15. Crankshaft
16. Shaft Seal Ring
17. Flywheel(Manual Transaxle)
18. Bolt(Manual Transaxle)
19. Flexible Plate Spacer(Automatic Transaxle)
20. Flexible Plate(Automatic Transaxle)
21. Disc Reinforcing(Automatic Transaxle)
22. Bolt(Automatic Transaxle)
23. Crankshaft Bearing Set
24. Engine Block
25. CKP Sensor
26. Oil Pump Body Gasket
27. Cover
28. Gear
29. Oil Pump
30. Oil Pressure Switch
31. Plug
32. Crankshaft Front Seal
33. Crankshaft Gear
34. Bypass Valve
35. Oil Filter
36. Torsional Damper
37. Bolt
38. Oil Suction Pipe
39. Bolt
40. Bearing Bridge
41. Bolt

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42. Oil Pan Scraper

43. Oil Pan Gasket
44. Oil Pan
45. Bolt
46. Oil Pan Plug Insert
47. Bolt
48. Crankshaft Main Bearing Cap
49. Bolt
50. Bolt
51. Torque Roll Axis Cover
52. Front Tooth Belt Hood
53. Seal
54. Front Tooth Belt Gasket
55. Clip
56. Damper Ring
57. Bolt
58. Timing Belt Tensioner
59. Timing Belt
60. Guide Roller
61. Torque Roll Axis Support
62. Rear Tooth Belt Hood
63. CMP Sensor
64. Coolant Pump
65. Seal Ring

REPAIR INSTRUCTION
ON-VEHICLE SERVICE

VALVE COVER

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal and Installation Procedure

1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Disconnect the breather hoses from the valve cover.
4. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.
5. Disconnect the clip at the valve cover.
6. Remove the spark plug cover bolts and cover.
Installation Notice
Tightening Torque 8 Nm(71 lb-in)

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7. Disconnect the ignition wires at the spark plugs.

8. Remove the valve cover bolts.
Installation Notice
Tightening Torque 8 Nm(71 lb-in)
9. Remove the valve cover.
10. Remove the valve cover gasket from the valve cover.
11. Installation should follow the removal procedure in the reverse order.

CYLINDER HEAD AND GASKET

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Tools Required

J-42472 Timing Belt Adjuster

KM-470-B Angular Torque Gauge

Removal and Installation Procedure

1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine after it stalls for 10 seconds to rid the fuel system of fuel pressure.

3. Drain the engine coolant. Refer to Section 1D, Engine Cooling.

4. Disconnect the negative battery cable
5. Remove the air filter housing bolts and the air filter housing assembly.
6. Remove the air inlet duct bolts and air inlet duct
Installation Notice
Tightening Torque 8 Nm(71 lb-in)

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7. Disconnect the intake air temperature (IAT) sensor connector.

8. Disconnect the breather hose from the valve cover.
9. Remove the air intake tube from the throttle body.

10. Disconnect the camshaft position (CMP) sensor connector.

11. Disconnect the oxygen sensor connector.
12. Disconnect the engine coolant temperature (ECT) sensor connector.
13. Disconnect the coolant temperature gauge connector.
14. Disconnect the EGR valve connector.

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15. Remove the electronic ignition (EI) system ignition coil. Refer to Section 1F, Engine Controls.
16. Disconnect the heater inlet hose at the cylinder head.
17. Remove the coolant pipe bracket bolt.

18. Remove the fuel injector rail and fuel injectors as an assembly. Refer to Section 1F, Engine Controls.
19. Remove the generator-to-intake manifold support bracket bolts upper bracket bolts and support bracket.
Installation Notice
Tightening Torque 20 Nm(15 lb-in)
20. Remove the intake manifold-to-generator strap bracket bolt and loosen the bolt on the generator.
Installation Notice
Tightening Torque 20 Nm(15 lb-in)
21. Move the strap clear of the intake manifold.

22. Loosen the generator lower bracket-to-generator bolt.

23. Put out the generator backward
24. Disconnect the coolant hose from the throttle body.
25. Disconnect the coolant hose from the cylinder head.
26. Disconnect the upper radiator hose at the thermostat housing.

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27. Remove the forward engine mount. Refer to "Forward Engine Mount" in this section.
28. Disconnect the clips at the upper front timing belt cover.
29. Remove the torque roll axis cover bolt.
Installation Notice
Tightening Torque 6 Nm(53 lb-in)
30. Remove the torque roll axis cover.

31. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
32. Remove the right front wheel well splash shield. Refer to Section 9R, Body Front End.
33. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
34. Remove the crankshaft pulley bolts.
35. Remove the crankshaft pulley.
Installation Notice
Tightening Torque 20 Nm(15 lb-in)

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36. Remove front timing belt cover bolts.

Installation Notice
Tightening Torque 6 Nm(53 lb-in)
37. Remove the front timing belt cover.

38. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear
timing belt cover.
39. Remove the timing belt. Refer to "Timing Belt" in this section.

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40. Remove the exhaust manifold heat shield bolts and the exhaust manifold heat shield.
Installation Notice
1st stage: 13 Nm(10lb-ft):
. 9,10,6,5,8,7,2,1,3,4
2nd stage: 13 Nm(10lb-ft):
. 9,10,6,5,8,7,2,1,3,4
Tightening Torque
3rd stage: 13 Nm(10lb-ft):
. 9,10,6,5,8,7,2,1,3,4
4th stage: 13 Nm(10lb-ft):
9,10,6,5,8,7,2,1,3,4,9,10,6
41. Remove the exhaust manifold retaining nuts.
Installation Notice
Tightening Torque 15 Nm(11lb-ft)
42. Disconnect the exhaust manifold from the cylinder head.

43. Remove the intake manifold retaining nuts/bolt.

Installation Notice
Tightening Torque 22 Nm(16lb-ft)
44. Disconnect the intake manifold from the cylinder head.

45. Remove the valve cover. Refer to "Valve Cover" in this section.

Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

46. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
Installation Notice
50 Nm(37lb-ft)
Tightening Torque
+60 +15

47. Remove the intake camshaft gear.

48. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
Installation Notice
50 Nm(37lb-ft)
Tightening Torque
+60 +15
49. Remove the exhaust camshaft gear.

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50. Remove the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft bearing cap.
Installation Notice
Tightening Torque 8 Nm(71lb-ft)
51. Remove the intake/exhaust camshaft caps. Maintain the correct positions for installation.
52. Remove the intake/exhaust camshaft.

53. Loosen all of the cylinder head bolts gradually and in the sequence shown.
54. Remove the cylinder head bolts.
55. Remove the cylinder head and cylinder head gasket.

Notice : Prevent any engine oil or coolant from entering the cylinders when removing the cylinder heads.

Installation Notice
25 Nm(18lb-ft)
Tightening Torque
+90 +90 +90
56. Installation should follow the removal procedure in the reverse order.

Cleaning Procedure
1. Clean the gasket surfaces of the cylinder head and the engine block.
2. Make sure the gasket surfaces of the cylinder head and the engine block are free of nicks and heavy scratches.
3. Clean the cylinder head bolts.
4. Inspect the cylinder head for warpage. Refer to "Cylinder Head and Valve Train Components" in this section.

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CAMSHAFTS

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal and Installation Procedure

1. Remove the timing belt. Refer to "Timing Belt" in this section.

2. Remove the valve cover. Refer to "Valve Cover" in this section.

Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

3. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
Installation Notice
50 Nm(37lb-ft)
Tightening Torque
+60 +15
4. Remove the intake camshaft gear.
5. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
Installation Notice
50 Nm(37lb-ft)
Tightening Torque
+60 +15

6. Remove the exhaust camshaft gear.

7. Remove the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.
Installation Notice
Tightening Torque 8 Nm(71lb-ft)
8. Remove the intake/exhaust camshaft caps. Maintain the correct positions for installation.
9. Remove the intake/exhaust camshaft.
10. Installation should follow the removal procedure in the reverse order.

TIMING BELT CHECK AND ADJUST

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Tools Required

KM-470-B Angular Torque Gauge

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1. Disconnect the negative battery cable.

2. Remove the air filter housing bolts.
3. Remove the air filter housing assembly.

4. Disconnect the intake air temperature (IAT) sensor connector.

5. Remove the breather tube from the valve cover.
6. Remove the air intake tube from the throttle body.

7. Remove the forward engine mount. Refer to "Forward Engine Mount" in this section.
8. Disconnect the clips at the upper front timing belt cover.
9. Remove the torque roll axis cover bolt.
Installation Notice
Tightening Torque 6 Nm(53lb-ft)
10. Remove the torque roll axis cover.

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11. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
18. Remove the right front wheel splash shield. Refer to Section 9R, Body Front End.
12. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
13. Remove the crankshaft pulley bolts.
14. Remove the crankshaft pulley.
Installation Notice
Tightening Torque 20 Nm(15lb-ft)

15. Remove front timing belt cover bolts.

16. Remove the front timing belt cover.
Installation Notice
Tightening Torque 6 Nm(53lb-ft)

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17. Rotate the crankshaft at least one full turn clockwise using the crankshaft gear bolt
18. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.
19. Align the camshaft gear timing marks. Use the exhaust gear mark for the exhaust gear and the intake gear mark for the intake gear, since the gears are
interchangeable.

20. Loosen the automatic tentioner bolt. To tighten the belt tension, turn the hex-key tab counterclockwise.
21. Rotate the automatic tensioner hex-key tab clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned to the notch in the timing belt
automatic tensioner bracket.

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22. Tighten the automatic tentioner bolt.

Installation Notice
Tightening Torque 25 Nm(18lb-ft)
23. Rotate the crankshaft two full turns clockwise using the crankshaft gear bolt.
24. Check the automatic tensioner pointer.

25. When the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch on the timing belt automatic tensioner bracket, the belt is tensioner
correctly.
26. Installation should follow the removal procedure in the reverse order.

TIMING BELT

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Tools Required

KM-470-B Angular Torque Gauge

1. Disconnect the negative battery cable.
2. Remove the air filter housing bolts.
3. Remove the air filter housing assembly.

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4. Disconnect the intake air temperature (IAT) sensor connector.

5. Disconnect the breather hose from the valve cover.
6. Remove the air intake tube from the throttle body.

7. Remove the forward engine mount. Refer to "Forward Engine Mount" in this section.
8. Disconnect the clips at the upper front timing belt cover.
9. Remove the torque roll axis cover bolt.
Installation Notice
Tightening Torque 6 Nm(53lb-ft)
10. Remove the torque roll axis cover.

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11. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
18. Remove the right front wheel splash shield. Refer to Section 9R, Body Front End.
12. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
13. Remove the crankshaft pulley bolts.
14. Remove the crankshaft pulley.
Installation Notice
Tightening Torque 20 Nm(15lb-ft)

15. Remove front timing belt cover bolts.

16. Remove the front timing belt cover.
Installation Notice
Tightening Torque 6 Nm(53lb-ft)

17. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear
timing belt cover.

Notice : The camshaft gears must align with the notch on the camshaft cover or damage to the engine could result.

18. Align the camshaft gears with the notch on the camshaft cover

Important : Use the intake gear mark for the intake camshaft gear and the exhaust gear mark for the exhaust camshaft gear since both gears are
interchangeable.

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19. Loosen the automatic tensioner bolt. Turn the hex-key tab to relieve belt tension.
Installation Notice
Tightening Torque 25 Nm(18lb-ft)
20. Remove the timing belt.
21. Installation should follow the removal procedure in the reverse order.

ENGINE OIL PRESSURE INSPECTION PROCEDURE

Tools Required

KM-498-B Pressure Gauge

KM-135 Adapter
1. Remove the front, right-hand wheel well splash shield.
2. Disconnect the oil pressure switch connector.

3. Install the adapter KM-135 in place of the oil pressure switch.

Installation Notice
Tightening Torque 40 Nm(30lb-ft)
4. Connect the pressure gauge KM-498-B to the adapter
5. Start the engine and check the oil pressure at idle speed and engine temperature of 803C(1763F). The minimum oil pressure should be 30 kPa (8.88 psi)

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6. Turn the engine OFF and remove the oil pressure gauge and adapter.

OIL PUMP

Removal and Installation Procedure

1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to "Timing Belt" in this section.
3. Remove the rear timing belt cover. Refer to "Rear Timing Belt Cover" in this section.
4. Disconnect the oil pressure switch connector.

5. Remove the oil pan. Refer to "Oil Pan" in this section.

6. Remove the oil suction pipe bolts on the oil pump.
Installation Notice
Tightening Torque 8 Nm(71lb-in)
7. Remove the oil suction pipe support bracket bolts.
Installation Notice
Tightening Torque 20 Nm(15lb-ft) +45
8. Remove the oil suction pipe.

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9. Remove the oil pump retaining bolts.

Installation Notice
Tightening Torque 10 Nm(89lb-in)
10. Carefully separate the oil pump and gasket from the engine block and the oil pan.

Notice : Apply Loctite 242 to the oil pump bolts and room temperature vulcanizing (RTV) sealant to the new oil pump gasket.

11. Remove the oil pump.

Inspection Procedure
1. Clean the oil pump and the engine block gasket mating surfaces.
2. Remove the safety relief valve bolt.
3. Remove the safety relief valve and the spring.
4. Remove the oil pump-to-crankshaft seal.

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5. Remove the oil pump rear cover screws.

6. Remove the rear cover.

7. Clean the oil pump housing and all of the parts of the oil pump housing.
8. Inspect all of the parts for signs of wear. Refer to "Engine Specifications" in this section.
9. Coat all of the oil pump parts with clean engine and reinstall them.

Notice : Pack the oil pump gear cavity with petroleum jelly to ensure an oil pump prime, or engine damage could result.

10. Apply Loctite 242 to the rear cover bolts and install the rear oil pump cover with the bolts.
11. Install the safety relief valve, the spring, the washer, and the bolt.
Installation Notice
Tightening Torque 30 Nm(22lb-ft)
12. Installation should follow the removal procedure in the reverse order.

OIL PAN

Removal and Installation Procedure

1. Disconnect the negative battery cable.

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2. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
3. Remove the right front wheel well splash shield.
4. Drain the engine oil from the engine crankcase.
5. Remove the exhaust front pipe. Refer to Section 1G, Engine Exhaust.

6. Remove the reaction lower rod. Refer to "Reaction Lower Rod" in this section.
7. Remove the oil pan-to-transaxle housing retaining bolts.
Installation Notice
Tightening Torque 75 Nm(55lb-ft)
8. Remove the oil pan retaining bolts.
Installation Notice
Tightening Torque 10 Nm(89lb-in)
9. Remove the oil pan from the engine block.
10. Remove the oil pan gasket from the oil pan.
11. Installation should follow the removal procedure in the reverse order.

Cleaning Procedure
1. Clean the oil pan sealing surface.
2. Clean the engine block sealing surface.
3. Clean the oil pan retaining bolts.
4. Clean the oil pan attaching bolt holes in the engine block.

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ENGINE MOUNT, RIGHT SIDE

Tools Required

DW110-060 Engine Assembly Support Fixture

Removal and Installation Procedure

1. Remove the air filter housing bolts.
2. Remove the air filter housing assembly.

3. Support the engine assembly using the engine assembly support fixture DW110-160.

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4. Remove the reaction upper rod and the reaction upper rod bracket bolts.
Installation Notice
Tightening Torque 75 Nm(55lb-ft)
5. Remove the reaction upper rod and the reaction upper rod bracket.

6. Remove the engine mount bracket retaining bolt/nuts.

Installation Notice
Tightening Torque 60 Nm(44lb-ft)
1. Remove the engine mount bracket.

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2. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump
3. Remove the front timing belt cover bolts and the front timing belt cover.

4. Align the crankshaft pulley timing mark with the pointer, and the camshaft gears with the timing marks on the rear cover, by turning the crankshaft gear
bolt.
5. Loosen the timing belt automatic tensioner bolt.
6. Turn the hex-key tab to relieve belt tension.
7. Remove the timing belt.

8. Remove the timing belt idler pulley bolt/nut.

Installation Notice
Tightening Torque 25 Nm(18lb-ft)
9. Remove the timing belt idler pulleys.

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10. Remove the engine mount retaining bolts.

11. Remove the engine mount.
Installation Notice
Tightening Torque 55 Nm(44lb-ft)
12. Installation should follow the removal procedure in the reverse order.

REACTION LOWER ROD

Removal and Installation Procedure

1. Raise and suitably support the vehicle.
2. Remove the front fascia splash shield and engine under cover. Refer to Section 9N, Frame and Underbody.
3. Remove the reaction lower rod bracket bolt/nut.
4. Remove the reaction lower rod bracket.
Installation Notice
Tightening Torque 69 Nm(49lb-ft)

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5. Remove the reaction lower rod mount bolt.

6. Remove the reaction lower rod mount.
Installation Notice
Tightening Torque 69 Nm(49lb-ft)
7. Installation should follow the removal procedure in the reverse order.

INTAKE MAINFOLD

(Left Hand Drive Shown, Right Hand Drive Similar)

Removal and Installation Procedure

1. Remove the fuel pump fuse.
2. Start the engine. Crank the engine after it stalls for 10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the negative battery cable.
4. Remove the air filter housing bolts.
5. Remove the air filter housing assembly.

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6. Disconnect the manifold air temperature (MAT) sensor connector.

7. Disconnect the breather hose from the valve cover.
8. Remove the air intake tube from the throttle body.

9. Disconnect the throttle cable from the throttle body and the intake manifold.
10. Disconnect the vacuum hose at the fuel pressure regulator.

11. Remove the fuel injector rail and fuel injectors as an assembly. Refer to Section 1F, Engine Controls.
12. Remove the engine harness wire bracket bolts from the rear of the intake manifold.

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13. Remove the evaporative (EAP) emission canister purge solenoid bracket bolt and reposition the canister purge solenoid clear of the repair area.

14. Remove the alternator upper bracket bolts.

15. Remove the alternator upper bracket.

16. Disconnect the brake vacuum hose from the intake manifold.
17. Remove the ECM ground terminal bolt from the intake manifold.
18. Remove the intake manifold support bracket upper bolt to the intake manifold.
Installation Notice
Tightening Torque 20 Nm(15lb-ft)

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19. Remove the throttle body assembly. Refer to Section 1F, Engine Controls.
20. Remove the valve cover. Refer to "Valve Cover" in this section.
21. Remove the intake manifold retaining bolt/nuts in the sequence shown.
Installation Notice
Tightening Torque 22 Nm(16lb-ft)
22. Remove the intake manifold gasket.
23. Clean the sealing surfaces of the intake manifold and the cylinder head.
24. Installation should follow the removal procedure in the reverse order.

EXHAUST MANIFOLD

Removal and Installation Procedure

1. Disconnect the negative battery cable.
2. Remove the air inlet duct bolts.
3. Remove the air inlet duct assembly.

4. Disconnect the oxygen sensor connector.

5. Remove the exhaust manifold heat shield bolts.
6. Remove the exhaust manifold heat shield.
Installation Notice
Tightening Torque 15 Nm(11 lb-in)

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7. Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs.
Installation Notice
Tightening Torque 35 Nm(26 lb-in)
8. Remove the oxygen sensor.

9. Remove the exhaust manifold retaining nuts in the sequence shown.

10. Remove the exhaust manifold and exhaust manifold gasket
11. Clean the sealing surfaces of the exhaust manifold and the cylinder head.
Installation Notice
13 Nm (10lb-ft):
9,10,6,5,8,7,2,1,3,4
1st stage: 13 Nm (10lb-ft):
2nd stage: 9,10,6,5,8,7,2,1,3,4
Tightening Torque
3rd stage: 15 Nm (11lb-ft):
4th stage: 9,10,6,5,8,7,2,1,3,4
15 Nm (11lb-ft):
9,10,6,5,8,7,2,1,3,4,9,10,6

CAMSHAFT GEARS

Removal and Installation Procedure

1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to "Timing Belt" in this section.
3. Remove the valve cover. Refer to "Valve Cover" in this section.

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Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. Such damage can cause premature engine wear.

4. While holding the camshaft firmly in place, remove the camshaft gear retaining bolt.
Installation Notice
50 Nm(37 lb-in)
Tightening Torque
+60 +15
5. Remove the camshaft gear.
6. Installation should follow the removal procedure in the reverse order.

REAR TIMING BELT COVER

Removal and Installation Procedure

1. Remove the timing belt. Refer to "Timing Belt" in this section.

2. Remove the camshaft gears. Refer to "Camshaft Gear" in this section.
3. Remove the timing belt automatic tensioner bolt.
4. Remove the timing belt automatic tensioner.

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5. Remove the timing belt idler pulley bolt/nut.

Installation Notice
Tightening Torque 25 Nm (18lb-in)
6. Remove the timing belt idler pulleys.

7. Remove the engine mount retaining bolts

Installation Notice
Tightening Torque 55 Nm (41lb-in)
8. Remove the engine mount.

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9. Remove the crankshaft timing belt gear bolt.

Installation Notice
130 Nm (96lb-ft)
Tightening Torque
+45 +5
10. Remove the crankshaft timing belt gear.

11. Remove the rear timing belt cover screws/bolt.

12. Remove the rear timing belt cover.
13. Installation should follow the removal procedure in the reverse order.

ENGINE

Tools Required

KM-470-B Angular Torque Gauge

Removal and Installation Procedure

Important : On vehicles equipped with manual transaxle, the manual transaxle must be removed before the engine is removed. Refer to Section 5B,
Manual Transaxle.

1. Remove the fuel pump fuse.

2. Start the engine. After it stalls, crank the engine after it stalls for 10 seconds to rid the fuel system of fuel pressure.
3. Remove the air filter bolts and the air filter assembly.
4. Remove the air inlet duct bolts the air inlet duct.

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5. Disconnect the manifold intake temperature (IAT) sensor connector.

6. Disconnect the breather hose from the valve cover.
7. Disconnect the air intake tube from the throttle body.

8. Drain the engine coolant. Refer to Section 1D, Engine Cooling.

9. Discharge the air conditioning system, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.
10. Remove the battery and battery tray. Refer to Section 1E, Battery and Battery Tray.

11. Remove the fuse box cover.

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12. Remove the battery lead nut at the fuse box.

13. Disconnect the battery lead at the fuse box.
14. Disconnect the engine wiring harness connectors.

15. Remove the surge tank. Refer to Section 1D, Engine Coolant.
16. Disconnect the transaxle wiring harness connector from the transaxle case.
17. Disconnect the P/N switch connector from the transaxle case.

18. Disconnect the air breather hose from the transaxle case.

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19. Remove the clip from the selector lever connection on the transaxle case and disconnect the shift control cable from the selector lever connection.
20. Remove the clip from the shift control cable at the transaxle mount connection.
21. Disconnect the shift control cable from the transaxle mount.

22. Disconnect the breather hose at the valve cover.

23. Disconnect the throttle cable at the throttle body and the intake manifold.
24. Disconnect the fuel feed line at the fuel rail.
25. Disconnect the fuel return line at the fuel pressure regulator.

26. Disconnect the upper radiator hose at the thermostat housing.

27. Disconnect the power steering pressure hose and the power steering suction hose from the power steering pump. Refer to Section 6A, "Power Steering
System".
28. Disconnect the A/C compressor hose assembly and the connector from the compressor. Refer to Section 7B, Manual Control Heating, Ventilation, and Air
Conditioning System.

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29. Remove the front wheel. Refer to Section 2E, Tires and Wheels.
30. Remove the front wheel well splash shield. Refer to Section 9R, Body Font End.
31. Remove the front exhaust pipe. Refer to Section 1G, Engine Exhaust.

32. Disconnect the heater inlet hose at the heater core.

33. Disconnect the heater outer hose at the heater core.

34. Disconnect the vacuum line from the charcoal canister purge solenoid.
35. Disconnect the brake vacuum hose at the intake manifold.

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36. Disconnect the A/C compressor connector at the A/C compressor coil.
37. Disconnect the lower radiator hose at the coolant pipe.
38. Disconnect the fluid cooler inlet hose from the transaxle.
39. Disconnect the fluid cooler outlet hose from the transaxle.

40. Remove the right side engine mount and forward engine mount. Refer to "Forward Engine Mount" in this section.
41. Remove the cross member. Refer to Section 2C, Front Suspension.
42. Disconnect the drive axle assembly from the transaxle.

43. Using the power pack stand DW110-010, support the engine and transaxle.
44. Remove the right side engine mount. Refer to "Right Side Engine Mount" in this section.
45. Remove the transaxle mount. Refer to Section 5A, "Automatic Transaxle".
46. Slowly lift the vehicle.
47. Disconnect the engine assembly from the transaxle assembly. Refer to Section 5A, "Automatic Transaxle".
48. Installation should follow the removal procedure in the reverse order.

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PISTONS AND CONNECTING RODS

Tools Required

J-8037 Universal Piston Ring Compressor

J-8087 Cylinder Bore Check Gauge
KM-427 Piston Pin Service Set
KM 470-B Angular Torque Gauge

Removal and Installation Procedure

1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.
2. Remove the oil pan. Refer to "Oil Pan" in this section.
3. Remove the oil suction pipe bolts and support bracket bolts.
4. Remove the oil suction pipe.
5. Remove the engine block lower support and the splash shield bolts.
Installation Notice
Tightening Torque 20 Nm (20lb-ft)
6. Remove the engine block lower support and the splash shield.

7. Move the piston to the bottom of the piston stroke.

8. Mark the connecting rod cap for position.
9. Remove the connecting rod cap bolts.
Installation Notice
Tightening Torque 35 Nm (26lb-ft) +45 +15
10. Remove the connecting rod cap and the lower connecting rod bearing.
11. Remove the upper piston connecting rod bearing.
12. Ridge ream the cylinder wall.

Caution : Use care when handling the piston. Worn piston rings are sharp and may cause injury.

13. Remove the piston.

14. Use a piston ring expander tool to expand the piston rings.
15. Remove the piston rings.

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16. Remove the piston pin from the piston and connecting rod assembly using the piston pin service set KM-427.
17. Separate the piston from the connecting rod.

Inspection Procedure
1. Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted, replace the connecting rod.
2. Inspect the connecting rod bearings.
3. Inspect the connecting rod lower end for wear.
4. Inspect the connecting rod upper end for scoring.
5. Inspect the crankshaft rod bearing journal for wear. Refer to "Engine Specifications" in this section.
6. Inspect the piston for scoring, cracks, and wear.
7. Inspect the piston for taper using a micrometer.

8. Inspect the piston for fit to the connecting rod.

9. Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge. Refer to "Engine Specifications" in this section.
10. Inspect the bearing bore for concentricity and alignment using a bore gauge. Refer to "Engine Specifications" in this section. If the bearing bore is beyond
specifications, replace the engine block.
11. Inspect the engine block cylinder bore for wear, runout, ridging and taper using a bore gauge. Refer to "Engine Specifications" in this section.
12. Inspect the engine block cylinder bore for glazing. Lightly hone the cylinder bore as necessary.

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Installation Procedure

Important : For ease of installation of the piston pin, the connecting rod should be heated to 2803C. Heat the upper connecting rod only. Use
commercial thermocolor material to determine the correct temperature. When the thermocolor material changes from black to green, the temperature
is correct for installation.

1. Align the notch on the piston and the connecting rod so that the proper sides will be facing the front of the engine.
2. Install the piston pin guide through the piston and the connecting rod.
3. Coat the piston pin with clean oil.
4. Install the piston pin into the opposite side of the piston.
5. Install the piston pin into the piston and connecting rod assembly using the piston pin service set KM-427.

6. Select a set of new piston rings.

7. Measure the piston ring gap using a feeler gauge. Refer to "Engine Specifications" in this section.
8. Increase the piston ring gap by carefully filing off excess material if the piston ring gap is below specifications.

9. Measure the piston ring side clearance using a feeler gauge. Refer to "Engine Specifications" in this section.
10. If the piston ring is too thick, try another piston ring
11. If no piston ring can be found that fits to specifications, the piston ring may be ground to size with emery paper placed on a sheet of glass.

12. Install a piston oil ring, the expander, then the second piston oil ring to the bottom ring groove of the piston.
13. Install the second compression ring to the middle ring groove of the piston.
14. Install the top compression ring to the top ring groove of the piston.

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15. Use a piston ring expander to install the piston rings. Do not expand the piston rings beyond the expansion necessary for installation.
16. Stagger the piston oil rings, the oil ring rail gaps, the second compression ring, and the top compression ring in relation to the notch on the top of the piston.

17. Lubricate the cylinder wall and the piston rings with clean engine oil.
18. Install the piston using a ring compressor and a wood handle, guide the lower connecting rod end to prevent damaging the crankshaft journal.
19. Install the connecting rod cap and bearings. Refer to "Crankshaft Bearings and Connecting Rod Bearings - Gauging Plastic" in this section.

20. Install the connecting rod bearing cap bolts.

Installation Notice
Tightening Torque 35 Nm (26lb-ft) +45 +15
21. Install the engine block lower support bracket/ splash shield bolts.
Installation Notice
Tightening Torque 20 Nm (15lb-ft) +45

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22. Install the oil suction pipe.

23. Install the oil suction pipe bolts.
Installation Notice
Tightening Torque 20 Nm (15lb-ft) +45
24. Install the oil suction pipe support bracket.
25. Install the oil pan. Refer to "Oil Pan" in this section.
26. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.

UNIT REPAIR

CYLINDER HEAD AND VALVE TRAIN COMPONENTS

Tools Required

MKM-571-B Gauge
KM 340-0 Cutter Set
KM-340-7 Guide Drift
KM-340-13 Cutters
KM-340-26 Cutters
KM-348 Valve Spring Compressor
KM-653 Adapter

Disassembly Procedure
1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.
2. Remove the engine coolant temperature (ECT) sensor.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust manifold retaining nuts in the sequence shown.
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.
8. Remove the exhaust manifold studs.

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9. Remove the thermostat housing mounting bolts.

10. Remove the thermostat housing assembly.
11. Remove the fuel rail assembly. Refer to Section 1F, Engine Controls.
12. Remove the coolant bypass housing mounting bolts and the housing.

13. Remove the intake manifold retaining nuts and retaining bolt in the sequence shown.
14. Remove the intake manifold.
15. Remove the intake manifold gasket.

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16. Remove the direct ignition system (DIS) coil and the exhaust gas recirculation (EGR) mounting bracket bolts.
17. Remove the DIS ignition coil and the EGR mounting bracket and ignition wires.
18. Remove the intake manifold studs.
19. Remove the spark plugs.

20. Remove the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.

21. Remove the intake camshaft caps. Maintain the correct positions for installation.
22. Remove the intake camshaft.
23. Remove the intake valve tappet adjusters.
24. Remove the exhaust camshaft caps. Maintain the correct positions for installation.
25. Remove the exhaust camshaft.
26. Remove the exhaust valve tappet adjusters.

27. Compress the valve springs with the valve spring compressor KM-348 and the adapter KM-653.

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28. Remove the valve retainers.

29. Remove the valve spring compressor KM-348 and the adapter KM-653.
30. Remove the valve spring caps.
31. Remove the valve springs. Maintain the original position of the valve springs for installation.

32. Remove the valves. Maintain the original position of the valves for installation.
33. Remove the valve stem seals.

Cylinder Head Inspection

1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion, and blow-by.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder head using a feeler gauge and a straight edge.
5. Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be flat within 0.025 mm (0.00linch) maximum.

6. Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder head height should be 133.975 to 134.025 mm (5.274 to 5.276
inches). If the cylinder head height is less than 133.9 mm (5.271 inches), replace the cylinder head.
7. Inspect all threaded holes for damage.
8. Inspect valve seats for excessive wear and burned spots.

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Valve Inspection
1. Inspect the valve stem tip for wear.
2. Inspect the valve key grooves and the oil seal grooves for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be straight.
6. Inspect the valve face for grooving. If the groove is so deep that refacing the valve would result in a sharp edge, replace the valve.
7. Inspect the valve spring. If the valve spring ends are not parallel, replace the valve spring.
8. Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as required.

Cleaning Procedure
1. Clean the cylinder head.
2. Clean the valve guides.
3. Clean all of the threaded holes.
4. Clean the valves of carbon, oil, and varnish.

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Cylinder Head Overhaul

Valve Grind-in

1. Lubricate the valve seat using a fine-grained paste.

2. Lift the valve rhythmically from the seat with a commercially available valve grinding tool in order to distribute the paste.

3. Check the contact pattern on the valve head and in the cylinder head.
4. Clean the valves, the valve guides, and the cylinder head.

Valve Grind
1. Ensure that there are no crater line burns on the valve cone.
2. The valve may be reground only two times. Do not grind the valve stem end.
3. Ensure that the angle at the valve face is 45 degrees.
4. Inspect the assembly height of the intake valves and the exhaust valves.

Valve Guide - Ream

1. Measure the diameter of the valve guide using gauge MKM-571-B and a commercially available inside micrometer.

Important : Valve oversizes may already have been fitted in production.

2. An oversize service code is on the valve guide and the valve stem end. The following table gives the correct size, reamer, and production code for each service.
Production Service
Size Reamer
Code Code
Normal K
0.075 KM-805 1 K1

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Production Service
Size Reamer
Code Code
0.150 2 K2

3. Ream the valve guide from the upper side of the cylinder head to the next oversize.
4. After reaming, cross out the code and emboss the valve guide with the new code.

Valve Seat - Cut

1. Place the cylinder head on wooden blocks.
2. Cut the intake and the exhaust valve seats using the guide drift KM-340-7 as follows:
Valve seat - A 45-degree surface using the cutter KM-340-13.
Upper correction angle - A 30-degree surface using the cutter KM-340-13.
Lower correction angle - A 60-degree surface using the cutter KM-340-26.
3. Clean the chipping from the cylinder head.
4. Inspect the dimension for the valve seat width.
Intake: 1.2 to 1.4 mm (0.047 to 0.055 inch).
Exhaust: 1.4 to 1.8 mm (0.055 to 0.070 inch).
5. Inspect the assembly height of the intake valves and the exhaust valves. If the dimension is exceeded, install new valves. Inspect the assembly height of the
intake valves and the exhaust valves again. If the valve assembly height is still too large despite replacing the valves, replace the cylinder head.

Assembly Procedure
1. Coat the valve stems with engine oil.
2. Insert the valves in the cylinder head in their original positions.
3. Insert the valve spring seats.
4. Push the accompanying assembly sleeve onto the valve stem.
5. Insert the new valve stem seat.
6. Carefully drive the valve stem seal onto the stop with light taps.
7. Install the valve springs in their original positions.
8. Install the valve spring caps.

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9. Compress the valve springs with the valve spring compressor KM-348 and adapter KM-653.
10. Install the valve keys.
11. Remove the valve spring compressor KM-348 and adapter KM-653.

12. Lubricate the valve tappet adjusters with engine oil.

13. Install the valve lash adjusters.

14. Install the intake camshaft.

15. Install the intake camshaft bearing caps in their original positions.
16. Install the exhaust camshaft.
17. Install the exhaust camshaft bearing caps in their original positions.
18. Install the camshaft bearing cap bolts.
19. Tighten the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.
Installation Notice
Tightening Torque 8 Nm (71lb-in)

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20. Install the spark plugs.

Installation Notice
Tightening Torque 20 Nm (15lb-in)
21. Install the EI system ignition coil and EGR mounting bracket and bolts.
Installation Notice
Tightening Left Lower Side: 20 Nm (15lb-ft)
Torque Others: 30 Nm (22lb-ft)

22. Install the EI system ignition coil and EGR.

Installation Notice
Tightening Torque 8 Nm (71lb-in)

23. Install the intake manifold studs.

24. Install the intake manifold gasket.
25. Install the intake manifold.
26. Install the intake manifold retaining nuts and retaining bolt in the sequence shown.
Installation Notice
Tightening Torque 22 Nm (16lb-ft)

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27. Install the fuel rail assembly. Refer to Section 1F, Engine Controls.
28. Install the thermostat housing assembly.
29. Install the thermostat housing mounting bolts.
Installation Notice
Tightening Torque 15 Nm (11lb-ft)
30. Install the coolant bypass housing and mounting bolts.
Installation Notice
Tightening Torque 15 Nm (11lb-ft)

31. Install the exhaust manifold studs.

32. Install the exhaust manifold gasket.
33. Install the exhaust manifold.
34. Install the exhaust manifold retaining nuts in the sequence shown.
Installation Notice
13 Nm (10lb-ft):
9,10,6,5,8,7,2,1,3,4
1st stage: 13 Nm (10lb-ft)
2nd stage: 9,10,6,5,8,7,2,1,3,4
Tightening Torque
3rd stage: 15 Nm (11lb-ft)
4th stage: 9,10,6,5,8,7,2,1,3,4
15 Nm (11lb-ft)
9,10,6,5,8,7,2,1,3,4,9,10,6
35. Install the exhaust manifold heat shield.
36. Install the exhaust manifold heat shield bolts.
Installation Notice
Tightening Torque 15 Nm (11lb-ft)
37. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.

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CRANKSHAFT

Tools Required

KM-412 Engine Overhaul Stand

KM-470-B Angular Torque Gauge
J-36792 or KM-635 Crankshaft Rear Oil Seal Installer

Notice : Take extreme care to prevent any scratches, nicks, or damage to the camshafts.

Disassembly Procedure

1. Remove the engine. Refer to "Engine" in this section.

2. Remove the flywheel or flexible plate bolts.
3. Remove the flywheel or the flexible plate.

4. Remove the crankshaft rear oil seal.

5. Mounts the engine assembly on the engine stands KM-412.

6. Remove the front timing belt cover bolts.

7. Remove the front timing belt cover.
8. Remove the crankshaft pulley bolts.
9. Remove the crankshaft pulley.

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10. Loosen the timing belt automatic tensioner bolt.

11. Rotate the timing belt automatic tensioner hex-key clockwise to release the tension.
12. Remove the timing belt idler pulley bolt and nut.
13. Remove the timing belt idler pulleys.

14. Remove the timing belt.

15. Remove the engine mount retaining bolts.
16. Remove the engine mount.

17. Disconnect the breather tubes from the valve cover.

18. Remove the spark plug cover bolts.
19. Remove the spark plug cover.
20. Disconnect the ignition wires from the spark plugs.
21. Remove the valve cover bolts.
22. Remove the valve cover washers.
23. Remove the valve cover and the valve cover gasket.

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Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

24. While holding the intake camshaft firmly in place, remove the intake camshaft bolt.
25. Remove the intake camshaft gear.
26. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft bolt.
27. Remove the exhaust camshaft gear.

28. Remove the crankshaft timing belt gear bolt.

29. Remove the crankshaft timing belt gear.

30. Remove the rear timing belt cover screws/bolt.

31. Remove the rear timing belt cover.

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32. Rotate the engine on the engine overhaul stand KM-412.

33. Remove the oil pan retaining bolts.

34. Remove the oil pan.
35. Remove the oil suction pipe and support bracket bolts.
36. Remove the oil suction pipe.
37. Remove the crankshaft bearing bridge and oil pan scraper bolts.
38. Remove the oil pan scraper.
39. Remove the crankshaft bearing bridge bolts.
40. Remove the crankshaft bearing bridge.

41. Remove the oil pump retaining bolts.

42. Remove the oil pump.

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43. Mark the order of the connecting rod bearing caps.

44. Remove the connecting rod bearing cap bolts for all of the pistons.
45. Remove the connecting rod bearing caps and the lower connecting rod bearings.

46. Mark the order of the crankshaft bearing caps.

47. Remove the crankshaft bearing cap bolts.
48. Remove the crankshaft bearing caps and the lower crankshaft bearings.
49. Remove the crankshaft.
50. Clean the parts, as needed.

Assembly Procedure
1. Coat the crankshaft bearings with engine oil.
2. If replacing the crankshaft, transfer the pulse pickup sensor disc to the new crankshaft.

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3. Install the crankshaft.

4. Install the lower crankshaft bearings in the bearing caps.
5. Inspect the crankshaft end play with the crankshaft bearings installed.
6. Check for permissible crankshaft end play. Refer to "Engine Specifications" in this section.

7. With the crankshaft mounted on the front and rear crankshaft bearings, check the middle crankshaft journal for permissible out-of-round (runout). Refer to
"Engine Specifications" in this section.

Important : Grease the crankshaft journals and lubricate the crankshaft bearings slightly so that the plastic gauging thread does not tear when the
crankshaft bearing caps are removed.

8. Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging (ductile plastic threads).
9. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the crankshaft journals and the crankshaft bearings.
10. Install the crankshaft bearing caps and the bolts.
Installation Notice
Tightening Torque 50 Nm (37lb-ft)+ 45 + 15

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11. Remove the crankshaft bearing cap bolts and the caps.
12. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges)
13. Inspect the bearing clearance for permissible tolerance ranges. Refer to "Engine Specifications" in this section.

14. Apply a bead of adhesive sealing compound to the grooves of the crankshaft bearing caps.
15. Install the crankshaft bearing caps to the engine block.
16. Tighten the crankshaft bearing caps using new bolts.
Installation Notice
Tightening Torque 50 Nm (37lb-ft)+ 45 + 15

Important : Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the plastic gauging thread does not tear
when the connecting rod bearing caps are removed.

17. Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).
18. Cut the plastic gauging threads to the length of the connecting rod bearing width. Lay them axially between the connecting rod journals and the connecting
rod bearings.
19. Install the connecting rod bearing caps.
Installation Notice
Tightening Torque 35 Nm (26lb-ft)+ 45 + 15

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20. Remove the connecting rod bearing caps.

21. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges)
22. Inspect the bearing clearance for permissible tolerance ranges. Refer to "Engine Specifications" in this section.

23. Install the connecting rod bearing caps to the connecting rods.
24. Tighten the connecting rod bearing caps using new bolts.
Installation Notice
Tightening Torque 35 Nm (26lb-ft)+ 45 + 15

25. Install the oil pump.

26. Install the oil pump retaining bolts.
Installation Notice
Tightening Torque 10 Nm (89lb-in)

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27. Install the lower block support bracket and bolts.

Installation Notice
Tightening Torque 20 Nm (15lb-ft) +45
28. Install the lower block support bracket splash shield and bolts.
Installation Notice
Tightening Torque 20 Nm (15lb-ft) +45
29. Install the oil suction pipe.
30. Install the oil suction pipe on the oil pump bolts.
Installation Notice
Tightening Torque 8 Nm (71lb-in)
31. Install the oil suction pipe support bracket bolts.
Installation Notice
Tightening Torque 20 Nm (15lb-ft) +45

32. Coat the new oil pan gasket with sealant.

33. Install the oil pan gasket to the oil pan.
34. Install the oil pan.
35. Install the oil pan retaining bolts.
Installation Notice
Tightening Torque 20 Nm (15lb-ft)

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36. Rotate the engine on the engine overhaul stand KM-412.

37. Install the rear timing belt cover.

38. Install the rear timing belt cover bolts.
Installation Notice
Tightening Torque 10 Nm (89lb-in)
39. Install the crankshaft gear and bolt.
Installation Notice
Tightening Torque 130 Nm (96lb-ft) +40 +5
40. Install the engine mount and retaining bolts.
Installation Notice
Tightening Torque 60 Nm (44lb-ft)

41. Install the timing belt automatic tensioner.

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42. Install the timing belt automatic tensioner bolts.

Installation Notice
Tightening Torque 25 Nm (18lb-ft)
43. Install the timing belt idler pulleys.
44. Install the timing belt idler pulley bolt and nut.
Installation Notice
Tightening Torque 25 Nm (18lb-ft)

Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

45. Install the intake camshaft gear.

46. Install the intake camshaft gear bolt while holding the intake camshaft firmly in place.
Installation Notice
Tightening Torque 50 Nm (37lb-ft) + 60 +15
47. Install the exhaust camshaft gear.
48. Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place.
Installation Notice
Tightening Torque 50 Nm (37lb-ft) + 60 +15

49. Install the timing belt. Refer to "Timing Belt" in this section.
50. Adjust the timing belt tension. Refer to "Timing Belt Check and Adjust" in this section.
51. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear camshaft cover to cylinder head seal.
52. Install the valve cover and the valve cover gasket
53. Install the valve cover bolts.
54. Connect the ignition wires to the spark plugs.
55. Install the spark plug cover and bolts.
56. Connect the breather tube to the camshaft cover.

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57. Install the front timing belt cover.

58. Install the front timing belt cover bolts.
59. Install the engine lifting device.
60. Remove the engine from the engine overhaul stand KM-412.

61. Install a new crankshaft rear oil seal using installer J-36792 or KM-635.

62. Install the flywheel or flexible plate.

63. Install the flywheel or the flexible plate bolts.
Installation Notice
Tightening Torque (Flywheel Bolts) 60 Nm (48lb-ft) +30 +15
Tightening Torque (Flexible Plate Bolts) 65 Nm (48lb-ft)
64. Install the engine. Refer to "Engine" in this section.

CRANKSHAFT BEARINGS AND CONNECTING ROD BEARINGS - GAUGING PLASTIC

Tools Required

KM-470-B Angular Torque Gauge

Inspection Procedure - Crankshaft

1. Coat the crankshaft bearings with engine oil.
2. Install the upper crankshaft bearings into the engine block crankshaft journals.

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3. Install the lower crankshaft bearings into the crankshaft bearing caps.
4. Install the crankshaft.
5. Inspect the crankshaft end play with the crankshaft bearings installed.
6. Check for permissible crankshaft end play. Refer to "Engine Specifications" in this section.

7. With the crankshaft mounted on the front and rear crankshaft bearings, check the middle crankshaft journal for permissible out-of-round (runout). Refer to
"Engine Specifications" in this section.

Important : Grease the crankshaft journals and lubricate the crankshaft bearings slightly so that the plastic gauging thread does not tear when the
crankshaft bearing caps are removed.

8. Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging (ductile plastic threads).
9. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the crankshaft journals and the crankshaft bearings.

10. Install the crankshaft bearing caps.

11. Install the crankshaft bearing cap bolts.
Installation Notice
Tightening Torque 50 Nm (37lb-ft) +45 +15

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12. Remove the crankshaft bearing caps.

13. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
14. Inspect the bearing clearances for permissible tolerance ranges. Refer to "Engine Specifications" in this section.

Inspection Procedure - Connecting Rods

1. Coat the connecting rod bearings with engine oil.
2. Install the upper connecting rod bearings into the connecting rod journals.
3. Install the lower connecting rod bearings into the connecting rod journals.

Important : Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the plastic gauging thread does not tear
when the connecting rod bearing caps are removed.

4. Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).
5. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the connecting rod journals and the connecting rod bearings.

6. Install the connecting rod bearing caps.

7. Install the connecting rod bearing cap bolts.
Installation Notice
Tightening Torque 35 Nm (26lb-ft) +45 +15

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8. Remove the connecting rod bearing caps.

9. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
10. Inspect the bearing clearance for permissible tolerance ranges. Refer to "Engine Specifications" in this section.

SPECIFICATIONS
ENGINE SPECIFICATIONS

Application 2.0L DOHC

. General Data:
Engine Type 4 Cylinder (In-Line)
Displacement 1,998 cm (121 in)
Bore Stroke 86 86 mm (3.38in. 3.38in.)
Compressed Ratio 9.6:1
Firing Order 1-3-4-2
. Cylinder Bore:
85.975 ~ 86.025 mm
Diameter
(3.384 ~ 3.386 in.)
Out of Round (Maximum) 0.013 mm (0.0005 in.)
Cylinder Bore Taper (Maximum) 0.013 mm (0.0005 in.)
Piston Protusion 0.5 mm Max (0.019 in.)
Oversize (Measure Replacement Piston before Re-boring) Available in 0.50 mm to suit bore (0.019 in.)
Service Replacement Standard Bore 4 Piston, Pin, and Ring Assemblies Available
Block Face Distortion 0.5 mm Max (0.00197 in.)
. Piston:
85.955 ~ 86.485 mm
Diameter
(3.384 ~ 3.404 in.)
0.030 ~ 0.050 mm
Clearance to Bore
(0.00118 ~ 0.0020 in.)
0.5 mm Max
Piston Protusion
(0.019 in.)
Piston Taper 0.013 mm (0.0005 in.)
. Piston Rings:
0.20 ~ 0.35 mm
Ring, End Gap: Top Compression
(0.0079 ~ 0.0137 in.)
0.3 ~ 0.5 mm
Ring, End Gap, Second Compression
(0.011 ~ 0.019 in.)
0.25 ~ 0.76 mm
Oil
(0.0098 ~ 0.0299 in.)
. Piston Pin:
20.9970 ~ 20.9985 mm
Diameter
(0.82665 ~ 0.82671 in.)
1.0 mm (0.039 in.)
Pin OffSet
Towards Thrust Side
0.0035 ~ 0.0140 mm
Clearance: In Piston
(0.00013 ~ 0.00055 in.)
Clearance: In Rod Interference Fit in Rod
Length 61.5 mm (2.42 in.)
. Camshaft:
Lift - Intake 10.0 mm(0.39 in.)
Lift - Exhaust 10.0 mm(0.39 in.)
0.04 ~ 0.144 mm
Camshaft Cap to Bearing Journal Clearance
(0.0015 ~ 0.0056 in.)
42.455 ~ 43.470 mm
Bearing Journal OD
(1.6714 ~ 1.7114 in.)
. Crankshaft:
Main Journal -
57.974 ~ 57.995 mm
Diameter (All)
(2.2824 ~ 2.2832 in.)
Radial Runout (Shaft Support on No. 1 and No. 5 Bearings 0.03 ~ 0.061 mm
Measured at No. 3 Journal) (0.00118 ~ 0.00240 in.)
0.015 ~ 0.061 mm
Main Bearing Clearance (All)
(0.00059 ~ 0.00240 in.)

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Application 2.0L DOHC

0.070 ~ 0.302 mm
End Play
(0.0027 ~ 0.0118 in.)
0.25 and 0.5 mm
Service Oversize, Available in 2 sizes
(0.00098 and 0.019 in.)
. Connecting Rod Journal:
48.981 ~ 48.987 mm
Diameter (All)
(1.9283 ~ 1.9286 in.)
Out of Round (Maximum) 0.004 mm(0.00015 in.)
0.006 ~ 0.031 mm
Rod Bearing Play
(0.00023 ~ 0.00122 in.)
0.019 ~ 0.063 mm
(0.0007 ~ 0.0024 in.)
Rod Bearing Clearance
(Production 0.013 ~ 0.041 mm)
(0.0005 ~ 0.0016 in.)
. Cylinder Head:
Valve Stem Protrusion 39.8 mm Max (1.566 in.)
13.7 ~ 14.0 mm
Valve Guide Height
(0.53 ~ 0.55 in.)
134.0 0.025 mm
Overall Height
(5.275 ~ 0.0009 in.)
Minimum Overall Height After Machining 133.9 mm (5.271 in.)
. Valve System:
Valve Lash Compensators Hydraulic
Seat Runout (Maximum, All) 0.03 mm (0.001 in.)
Face Runout (Maximum, All) 0.03 mm (0.001 in.)
Valve Stem Diameter 5.970 ~ 5.955 mm
Intake (0.235 ~ 0.234 in.)
5.960 ~ 5.945 mm
Exhaust
(0.23464 ~ 0.2360 in.)
Valve Diameter 32 0.1 mm
Intake (1.2598 0.0039 in.)
29 0.1 mm
Exhaust
(1.1417 0.0039 in.)
Valve Seat Width 1.0 ~ 1.5 mm
Intake (0.039 ~ 0.059 in.)
1.7 ~ 2.2 mm
Exhaust
(0.066 ~ 0.086 in.)
Valve Face Angle 44
Valve Seat Angle 40
6.000 ~ 6.012 mm
Valve Guide Inside Diameter
(0.236 ~ 0.237 in.)
. Oil Pump:
0.10 ~ 0.20 mm
Gear Lash
(0.0040 ~ 0.008 in.)
0.11 ~ 0.19 mm
Outer Gear to Body
(0.0043 ~ 0.0074 in.)
0.11 ~ 0.24 mm
Outer Gear to Crescent
(0.0043 ~ 0.009 in.)
0.18 ~ 0.26 mm
Inner Gear to Crescent
(0.007 ~ 0.010 in.)
0.03 ~ 0.10 mm
End Clearance
(0.001 ~ 0.004 in.)
. Sealants and Adhesives:
Rear Main Bearing Cap GE p/n RTV 159
Camshaft Carrier-to-Cylinder head HN 1581 (Loctite 515)
Oil Pan Bolts HN 1256 (Loctite 542)
Oil Pump Bolts HN 1256 (Loctite 542)
Oil Pan Pickup Tube Bolts HN 1256 (Loctite 542)
Oil Gallery Plug HN 1256 (Loctite 542)
Coolant Jacket Caps and Plugs (Freeze Plugs) HN 1756 (Loctite 176)
Anti-seize Compound
Exhaust Manifold Studs/Nuts
(HMC Spec HN1325)

FASTENER TIGHTENING SPECIFICATIONS

Application Nm Lb-Ft Lb-in

A/C Compressor Hose Assembly Bolt 33 24 -
Air Filter Housing Bolts 8 - 71
Generator to Intake Manifold Strap Bracket Bolt 20 15 -
Generator-to-Intake Manifold Support Bracket Bolts 35 26 -
Automatic Tensioner Bolt 25 18 -
Camshaft Bearing Cap Bolts 8 - 71
Canister Purge Solenoid Bracket Bolt 5 - 44
Connecting Rod Cap Bearing Bolts 35 26
-
+45 +15 +45 +15
Coolant Bypass Housing Bolts 15 11 -
Coolant Pump Retaining Bolts 20 15 -
Coolant Temperature Sensor 25 18 -
Crankshaft Bearing Cap Bolts 50 37
-
+45 +15 +45
Crankshaft Position Sensor Retaining Bolts 13 - 115
Crankshaft Pulley Bolts 20 15 -

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Application Nm Lb-Ft Lb-in

Crankshaft Timing Belt Drive Gear Bolts 130 96
-
+40 +50 +40 +50
Cylinder Head Bolts 25 18
-
+90 +90 +90 +90 +90 +90
DIS Ignition Coil and EGR MOunting Bracket Bolts 25 18 -
Engine Block Lower Support Bracket/Splash Shield Bolts 35 26 -
Engine Mount Bolts 60 44 -
Engine Mount Bracket-to-Engine Mount Retaining Bolts 60 44 -
Engine Mount Bracket Retaining Bolts and Nut 60 44 -
Engine Mount Bracket-to-Engine Block Bolts 90 66 -
Engine Mount Bracket-to-Engine Block Nuts 90 66 -
Engine Mount Retaining Bolts 60 44 -
Engine to Intake Manifold Support Bracket 20 15 -
Exhaust Camshaft Gear Bolt 50 37
-
+60 +15 +60 +15
Exhaust Flex Pipe-to Catalytic Converter Retaining Nuts 30 22 -
Exhaust Flex Pipe-to-Exhaust Manifold Retaining Nuts 22 16 -
Exhaust Flex Pipe Spport Bracket Bolts 30 22 -
Exhaust Gas Recirculation Valve Bolts 20 15 -
Exhaust Manifold Heat Shield Bolts 15 11 -
Exhaust Manifold Retaining Nuts 15 11 -
Exhaust Support Bracket Bolts 30 22 -
Flexible Plate Bolts 65 48 -
Flywheel Bolts 65 48
-
+30 +15 +30 +15
Front Timing Belt Cover Bolts 6 - 53
Fuel Rail Retaining Bolts 25 18 -
Ignition Coil Mounting Bolts 10 - 89
Intake Camshaft Gear Bolt 50 37
-
+60 +15 +60 +15
Intake Manifold Retaining Nuts and Bolts 18 13 -
Intake Manifold Support Bracket Lower Bolts 20 15 -
Intake Manifold Support Bracket Upper Bolts 20 15 -
Oil Pan Drain Plug 35 26 -
Oil Pan Flange-to-Transaxle Bolts 40 30 -
Oil Pan Retaining Bolt 10 - 89
Oil Pump Retaining Bolts 10 - 89
Oil Pump Pickup Tube Bolts 8 - 71
Oil Pmp Pickup Tube Support Bracket Bolt 10 - 89
Oil Pump Rear Cover Bolt 6 - 53
Power Steering Hose Clamp Bolt 8 - 71
Rear Timing Belt Cover Bolts 6 - 53
Resonator Retaining Bolts 8 - 71
Spark Plug Cover Bolts 3 - 27
Spark Plugs 20 15 -
Thermostat Housing Mounting Bolts 15 11 -
Throttle Cable Bracket Bolts 8 - 71
Timing Belt Automatic Tensioner Bolt 25 18 -
Timing Belt Idler Pulley Nuts 25 18 -
Transaxle Bell Housing Bolts 75 55 -
Transaxle Torque Converter Bolts 60 44 -
Valve Cover Bolts 8 - 71

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

. KM-653 Adapter

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. KM-535 Installer

. KM-135 Adapter

. KM-805 Valve Guide Reamer

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. J-36972 Crankshaft Rear Oil Seal Installer

. MKM-571-B Gauge

. DW110-060 Engine Support Fixture

. KM-412 Engine Overhaul Stand

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. KM-348 Spring Compressor

. KM-635 Crankshaft Rear Oil Seal Installer

. KM-427 Piston Pin Service Set

. J-8037 Universal Piston Ring Compressor

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. KM-340-O Cutter Set

. KM-470-B Angular Torque Gauge

. J-8087 Cylinder Bore Check Gauge

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. KM-498-B Pressure Gauge

Copyright General Motors Daewoo Europe. All rights reserved

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