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2014 brz en
PREPARATION MATERIALS PREPARATION MATERIALS
PP
ENGINE
ENGINE MECHANICAL
EM
COOLING
CO
PREPARATION MATERIALS
PREPARATION MATERIALS
ENGINE MECHANICAL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GREASE · OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PP PP-2
PP-5 PP-6
PP2
Preparation materials - ENGINE MECHANICAL
ENGINE MECHANICAL Preparationmaterials
SST
PP
Illustration
Tool number 18252AA000
Description Crankshaft socket
Remarks Used for turning the crankshaft.
ST18252AA000
18355AA000
Pulley wrench
· Used for removing and installing the crankshaft pulley.
· Used for removing and installing the water pump pulley.
· Used for removing and installing the intake cam sprocket, and exhaust cam sprocket.
ST18355AA000
18334AA030
Pulley wrench pin set
· Used for removing and installing the water pump pulley.
· Used for removing and installing the intake cam sprocket, and exhaust cam sprocket.
ST18334AA030
18270KA010
Socket
Used for removing and installing the intake cam sprocket, and exhaust cam sprocket.
ST18270KA010
Illustration
Preparation materials - ENGINE MECHANICAL
PP3
Tool number 18854AA000
Description Angle gauge
Remarks
· Used for tightening the cylinder head bolt. · Used for tightening the cylinder block bolt.
PP
ST18854AA000
18334AA000
Pulley wrench pin set
· Used for removing and installing the crankshaft pulley.
· Used for removing and installing the drive plate and ring gear SUB-ASSY, and flywheel SUBASSY.
ST18334AA000
18332AA20
Oil filer wrench
Used for removing and installing the oil filter.
ST18332AA020
398437700
Oil seal installer
Used for installing the timing chain or belt cover oil seal.
ST-398437700
PP4
Illustration
PP
Preparation materials - ENGINE MECHANICAL
Tool number 0920287002000
Description Remover and replacer
Remarks Used for removing and installing the valve spring.
ST0920287002000
499765700
Valve guide remover and installer
Used for removing and installing the valve guide bushing No. 2.
ST-499765700
18261AA010
Valve oil seal guide
Used for press-fitting the intake valve guide stem seal, and exhaust valve guide stem seal.
ST18261AA010
18270AA020
Socket
Used for removing and installing the connecting rod.
ST18270AA020
Illustration
Preparation materials - ENGINE MECHANICAL
PP5
Tool number 18671AA020
Description Oil seal guide
Remarks Used for installing the engine rear oil seal.
PP
ST18671AA020
18657AA030
Oil seal installer
Used for installing the engine rear oil seal.
ST18657AA030
GENERAL TOOL
Tool name Union nut wrench (19 mm) Deep socket wrench (19 mm) Deep socket wrench (24 mm) Socket hexagon (6 mm) Hex wrench (2.5 mm in diameter) Socket hexagon (5 mm) Oil pan seal cutter Straight hexagon (14 mm) Dial gauge Thickness gauge Micrometer Caliper Caliper gauge Valve seat cutter Right angle gauge Hand reamer Piston ring tool Straight edge ruler Cylinder gauge Connecting rod aligner Piston ring compressor
Remarks Used for removing and installing the engine water temperature sensor. Used for removing and installing the engine oil temperature sensor, and ventilation valve SUB-ASSY. Used for removing and installing the engine oil pressure switch ASSY. Used for removing and installing the pump drive case ASSY. Used for securing the chain tensioner No. 1. Used for removing and installing the chain guide. Used for removing the oil pan. Used for removing and installing the cylinder block plug. Used for measuring the camshaft and crankshaft. Used for various measurements. Used for measuring the valve clearance, camshaft, valve, piston, piston pin and crankshaft. Used for measuring the valve, valve spring, and valve guide bushing No. 2. Used for measuring the valve guide busing No. 2, valve shim, piston pin, and connecting rod. Used for correcting the valve seat seating surface. Used for measuring the valve spring. Used for grinding the valve guide bushing No. 2. Used for removing and installing the piston ring. Used for inspecting warpage. Used for measuring the cylinder liner. Used for measuring the connecting rod. Used for installing the piston onto the cylinder block.
PP6
GREASE · OTHER
Description Metal wire (approx. 1 mm in diameter) THREE BOND 1217G or equivalent
PP
Plastigauge THREE BOND 1324 or equivalent THREE BOND 1105 or equivalent Red dye Valve compound Protective tape
Preparation materials - ENGINE MECHANICAL
Part number
K0877Y0100
004403042 004403010
Used location
Chain tensioner No. 2
· Front camshaft cap, intake rear camshaft cap, and exhaust rear camshaft cap · Cam carrier · Cylinder head gasket No. 2 · Rocker cover, rocker cover LH · Timing chain or belt cover SUB-ASSY · Cylinder head plate RR · Vacuum pump ASSY · Oil pan upper · Oil pan · Pump drive case ASSY · Oil separator cover · Cylinder block
Camshaft, connecting rod, crankshaft
Engine oil pressure switch ASSY
Cylinder block tight plug No. 1
Valve
Valve
· Timing chain or belt cover oil seal · Timing chain or belt cover SUB-ASSY · Engine rear oil seal · Rocker cover · Cam carrier · Oil pan upper · Piston pin hole snap ring
ENGINE/HYBRID SYSTEM
ENGINE MECHANICAL
LIQUID GASKET APPLYING LOCATION (FA20)
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTIAL ENGINE ASSY (FA20)
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD ASSY (FA20)
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER BLOCK ASSY (FA20)
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EM-2
EM EM-4
EM-14 EM-34 EM-37
EM-78 EM-78 EM-82 EM-91
EM-101 EM-102 EM-107 EM-121
EM2
Engine mechanical - LIQUID GASKET APPLYING LOCATION (FA20)
LIQUID GASKET APPLYING LOCATION (FA20) Engine/hmyebcrhidasnyicsatelm
APPLICATION
1.
EM
Handling of liquid gasket <Caution> When removing liquid gasket, be careful not to let the gasket particles get inside of the engine. (1) Before applying liquid gasket, completely remove the old liquid gasket attached to the seal portion, bolt and bolt hole, and
wash the seal portion. (2) Clean oil, water, dust etc off from the mating surface of each part and the counter part using cloth etc. (3) Apply liquid gasket to the parts to be attached. (4) Observe the direction for the width application and avoid excessive or short application and always overlap the start and
end of application. (5) After assembly, be careful not to move the parts. (6) Install within 5 min. after applying. (7) After assembly, do not fill coolant, oil and start the engine within a determined time.
2. Application location and liquid gasket to be used
Number in figure 1 2 3 4 5 6 7 8 9 10 11 12 13 14
PCV valve × cylinder block
Liquid gasket applying location
Cylinder block (bank 1 side) × cylinder block (bank 2 side)
Cylinder block tight plug No. 1 × cylinder block
Cam carrier LH × pump drive case ASSY
Cylinder head gasket × cylinder block Cylinder head gasket × cylinder head
Cylinder head × cam carrier
Cam carrier × camshaft cap
Cam carrier and camshaft cap × cylinder head cover gasket
Cylinder block, cylinder head, cam carrier and rocker cover × chain cover
Engine oil pressure switch ASSY × chain cover
Cam carrier × vacuum pump ASSY*1 or cylinder head plate RR*2
Cam carrier × oil separator cover
Cylinder block × oil pan upper
Oil pan upper × oil pan
Liquid gasket to be used
THREE BOND 1324 or equivalent THREE BOND 1217G or equivalent
THREE BOND 1105 or equivalent
THREE BOND 1217G or equivalent THREE BOND 1217G or equivalent
THREE BOND 1217G or equivalent
THREE BOND 1217G or equivalent THREE BOND 1217G or equivalent
THREE BOND 1217G or equivalent
THREE BOND 1324 or equivalent THREE BOND 1217G or equivalent
THREE BOND 1217G or equivalent
THREE BOND 1217G or equivalent THREE BOND 1217G or equivalent
*1: Transmission A/T *2: Transmission M/T
Engine mechanical - LIQUID GASKET APPLYING LOCATION (FA20)
3. Liquid gasket applying location
EM3
EM
A280649J01
EM4
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
PARTIAL ENGINE ASSY (FA20) Engine/hmyebcrhidasnyicsatelm
EXPLODED VIEW
EM
6.4 {65,4.7}
Camshaft position sensor (bank 1 intake side)
O-ring
Camshaft position sensor (bank 2 intake side)
6.4 {65,4.7}
O-ring
O-ring
Camshaft position sensor (bank 1 exhaust side)
6.4 {65,4.7}
Camshaft position sensor (bank 2 exhaust side)
O-ring
N m {kgf cm}{ft lbf} : Specified torque Non-reusable parts
6.4 {65,4.7}
ME-06965
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM5
Engine hanger No. 2
23 {235,17.0}
PCV valve
21 {214,15.5}
x2
EM
24 {245,17.7}
Knock control sensor Gasket
6.4 {65,4.7}
24 {245,17.7}
Knock control sensor
Crank position sensor
18 {184,13.3}
E.F.I. water temperature sensor
N m {kgf cm}{ft lbf} : Specified torque Non-reusable parts Locking part
x4
17 {173,12.5}
Spark plug
ME-07448
EM6
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
Camshaft timing oil control valve ASSY (bank 1 intake side)
EM
O-ring
x2
6.4 {65,4.7}
Back-up ring
O-ring Back-up ring
x2
6.4 {65,4.7}
O-ring
Camshaft timing oil control valve ASSY (bank 1 exhaust side)
Camshaft timing oil control valve ASSY (bank 2 intake side)
x2
6.4 {65,4.7}
x2
6.4 {65,4.7}
N m {kgf cm}{ft lbf} : Specified torque
Back-up ring
O-ring Back-up ring Camshaft timing oil control valve ASSY (bank 2 exhaust side)
Non-reusable parts
ME-06967
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
Water pipe ASSY
6.4 {65,4.7}
x4
Water by-pass hose No. 1
6.4 {65,4.7}
PCV hose connector
x3 O-ring
x2
O-ring x2
EM7
EM
Gasket Engine water pump ASSY
x3
14 {143,10.3}
x5
6.4 {65,4.7}
Water pump pulley
N m {kgf cm}{ft lbf} : Specified torque Non-reusable parts
Thermostat Gasket
Thermostat cover
x2
6.4 {65,4.7}
ME-07822
EM8
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM
Oil level gauge
O-ring
Oil level gauge guide
6.4 {65,4.7}
x3 O-ring
O-ring
14 {143,10.3}
Oil filter
45 {459,33.2}
Oil filter union
Oil filler cap O-ring
Chain cover
First time: 20 {204,14.8}
Second time: Further-tighten 90°
x5
Gasket
25 {255,18.4}
x27
10 {102,7.4}
18 {184,13.3}
Engine oil temperature sensor
18 {184,13.3}
Engine oil pressure switch ASSY
Chain cover oil seal Crankshaft pulley boss O-ring Crankshaft pulley
N m {kgf cm}{ft lbf} : Specified torque
Non-reusable parts
Locking part
ME-07823
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM9
EM
6.4 {65,4.7}
x4
O-ring
x3
Baffle plate
90 {918,66.4}
Cylinder block plug
10 {102,7.4}
x2 Stud bolt
O-ring
x3
18 {184,13.3}
x10
18 {184,13.3}
Oil pan upper
6.4 {65,4.7}
x2
Oil pan
Oil strainer SUB-ASSY
Seal ring x2
N m {kgf cm}{ft lbf} : Specified torque Non-reusable parts
6.4 {65,4.7}
x11
Gasket
42 {428,31.0}
Drain plug
ME-07824
EM10
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM
Transmission M/T:
x3
16 {163,11.8}
Cylinder head plate RR
Transmission A/T:
O-ring
x3
16 {163,11.8}
Vacuum pump ASSY
N m {kgf cm}{ft lbf} : Specified torque
Non-reusable parts
ME-06968
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM11
18 {184,13.3}
x3
Intake cam sprocket RH
EM
18 {184,13.3}
Exhaust cam sprocket RH
x3 Chain tensioner No.2
O-ring
6.4 {65,4.7}
Chain guide
6.4 {65,4.7}
x2
Chain tension lever
18 {184,13.3}
x3 Intake cam sprocket LH
Timing chain
Crankshaft sprocket
Timing chain
Chain tension lever
6.4 {65,4.7}
x2
18 {184,13.3}
x3
Exhaust cam sprocket LH
Chain tensioner No.1
6.4 {65,4.7}
Chain guide
N m {kgf cm}{ft lbf} : Specified torque
Non-reusable parts
ME-07825
EM12
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM
Bank 1:
Rocker cover
6.4 {65,4.7}
x2
Injector driver bracket
Transmission A/T:
31 {316,22.9} 6.4 {65,4.7}
x2 x2 Gasket
x8
6.4 {65,4.7}
Intake center camshaft cap RH
Camshaft oil field pipe SUB-ASSY
Exhaust center camshaft cap RH
Rocker cover gasket
Intake rear camshaft cap RH
Transmission M/T:
25 {255,18.4}
Hole plug Gasket
Cam carrier
x9 x2
First time: 18 {18.4,13.3} Second time: Loosen 180° Third time: 18 {18.4,13.3}
Oil control valve filter RH
Oil spacer RH
18 {184,13.3}
x12
Exhaust rear camshaft cap RH
First time: 20 {204,14.8}
Second time: 100 {1020,73.8}
Third time: Loosen 360°
Fourth time: 20 {204,14.8} Fifth time: 42 {428,31.0}
Front camshaft cap RH
Sixth time: Further-tighten 100°
Seventh time: Further-tighten 100° (Center: 2) Further-tighten 50° (Except for center)
Cylinder head bolt x6
Intake camshaft RH
Exhaust camshaft RH
x2
6.4 {65,4.7}
x8 x8 x8
x2
Valve shim x2
Roller rocker arm Roller rocker arm pivot Cylinder head SUB-ASSY
Spark plug tube gasket
O-ring N m {kgf cm}{ft lbf} : Specified torque
Non-reusable parts
Cylinder head gasket
ME-07826
Bank 2:
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
Cylinder head gasket No. 2
Spark plug tube gasket LH
Pump drive case ASSY
EM13
19 {194,14.0}
x3
EM
Cylinder head LH
Cam carrier LH
First time: 20 {204,14.8}
Second time: 100 {1020,73.8}
Third time: Loosen 360°
Fourth time: 20 {204,14.8}
Fifth time: 42 {428,31.0}
Sixth time: Further-tighten 100°
Seventh time: Further-tighten 100° (Center: 2) Further-tighten 50° (Except for center)
Cylinder head bolt
x2 x2
O-ring
Roller rocker arm pivot
x2 Oil control valve filter LH x8
x6
x8
x9
x8
Valve shim
x2
6.4 {65,4.7}
Roller rocker arm
Oil spacer LH First time: 18 {18.4,13.3}
Intake camshaft LH
Intake center camshaft cap LH
Intake rear camshaft cap LH
Second time: Loosen 180° Third time: 18 {18.4,13.3}
Exhaust rear camshaft cap LH
Exhaust camshaft LH
Front camshaft cap LH
Exhaust center cam shaft cap LH
x13
18 {184,13.3}
N m {kgf cm}{ft lbf} : Specified torque Non-reusable parts
Rocker cover gasket No. 2
Rocker cover LH
x8
6.4 {65,4.7}
ME-07827
EM14
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
DISASSEMBLY
1. Removal of oil filler cap (1) Remove the oil filler cap.
2. Removal of oil filter (1) Using SST, remove the oil filter. SST 18332AA020
EM
3. Removal of oil filter union (1) Remove the oil filter union.
A281050
4. Removal of engine water temperature sensor (1) Remove the engine water temperature sensor and gasket.
A280837
5. Removal of knock control sensor (1) Remove the two bolts to remove the two knock control sensors.
A280838
6. Removal of crank position sensor (1) Remove the bolt to remove the crank position sensor.
A280839
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM15
7. Removal of camshaft position sensor (1) Remove the bolt to remove the camshaft position sensor (bank 1 intake side). (2) Remove the O-ring from the camshaft position sensor.
A280840
EM
(3) Remove the bolt to remove the camshaft position sensor (bank 1 exhaust side).
(4) Remove the O-ring from the camshaft position sensor.
A280841
(5) Remove the bolt to remove the camshaft position sensor (bank 2 intake side).
(6) Remove the O-ring from the camshaft position sensor.
A280842
(7) Remove the bolt to remove the camshaft position sensor (bank 2 exhaust side).
(8) Remove the O-ring from the camshaft position sensor.
A280843
8. Removal of camshaft timing oil control valve ASSY (1) Remove the two bolts to remove the camshaft timing oil control valve ASSY (bank 1 intake side).
A280844
EM16
EM
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(2) Remove the O-ring from the camshaft timing oil control valve
ASSY.
Captions in illustration
*1 O-ring
*2 Back-up ring
(3) Remove the back-up ring from the camshaft timing oil control valve
ASSY.
A276534J01
(4) Remove the two bolts to remove the camshaft timing oil control valve ASSY (bank 1 exhaust side).
(5) Remove the O-ring from the camshaft timing oil control valve ASSY.
(6) Remove the back-up ring from the camshaft timing oil control valve ASSY.
A280845
(7) Remove the two bolts to remove the camshaft timing oil control valve ASSY (bank 2 intake side).
(8) Remove the O-ring from the camshaft timing oil control valve ASSY.
(9) Remove the back-up ring from the camshaft timing oil control valve ASSY.
A280846
(10) Remove the two bolts to remove the camshaft timing oil control valve ASSY (bank 2 exhaust side).
(11) Remove the O-ring from the camshaft timing oil control valve ASSY.
(12) Remove the back-up ring from the camshaft timing oil control valve ASSY.
A280847
9. Removal of engine oil temperature sensor (1) Remove the engine oil temperature sensor. <Caution> Catch the engine oil using cloth to prevent it from splashing.
A280848
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM17
10. Removal of engine oil pressure switch ASSY (1) Removal the engine oil pressure switch ASSY. <Caution> Catch the engine oil using cloth to prevent it from splashing.
ME-06590
EM
11. Removal of PCV hose connector (1) Remove the three bolts to remove the PCV hose connector. (2) Slide the hose clamp to disconnect the water by-pass hose No. 1 from the water pipe ASSY. (3) Slide the hose clamp to disconnect the water by-pass hose No. 1 from the PCV hose connector.
A280851
(4) Remove the two O-rings from the PCV hose connector.
A279577
12. Removal of vacuum pump ASSY (transmission A/T) (1) Remove the three bolts to remove the vacuum pump ASSY from the cam carrier RH. (2) Remove the O-ring from the vacuum pump ASSY.
C260987
13. Removal of cylinder head plate RR (transmission M/T) (1) Remove the three bolts to remove the cylinder head plate RR from the cam carrier RH.
C260986
EM18
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
14. Removal of oil level gauge guide (1) Remove the oil level gauge. (2) Remove the bolt to remove the oil level gauge guide. (3) Remove the O-ring from the oil level gauge guide.
EM
LU-02942
15. Removal of transmission oil cooler hose No. 3 (transmission A/T) (1) Slide the hose clamp to remove the transmission oil cooler hose No. 3. 16. Removal of water pipe ASSY (1) Slide the hose clamp to remove the water by-pass hose No. 3. (2) Remove the four bolts to remove the water pipe ASSY.
A279573
(3) Remove the two O-rings from cylinder block (bank 1 side and bank 2 side).
A280856
17. Removal of PCV valve (1) Remove the PCV valve from the cylinder block (bank 1 side).
A278795
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM19
18. Removal of pump drive case ASSY (1) Remove the three bolts to remove the pump drive case ASSY.
A278730
19. Removal of water pump pulley
556
(1) Fix the water pump pulley using SST.
SST 18355AA000, 18334AA030
(2) Remove the three bolts to remove the water pump pulley.
EM
556 556
CO-03030
20. Removal of engine water pump ASSY (1) Remove the five bolts to remove the engine water pump ASSY and gasket.
A279726
21. Removal of thermostat cover (1) Remove the two bolts to remove the thermostat cover.
A281051
22. Removal of thermostat (1) Remove the thermostat. (2) Remove the gasket from the thermostat.
EM20 556
EM
D 556 C
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
556
ME-06537
23. Removal of crankshaft pulley (1) Fix the crankshaft pulley using SST. SST 18355AA000, 18334AA000 Captions in illustration
*a Hold *b Rotate
(2) Remove the crankshaft pulley set bolt to remove the crankshaft pulley.
(3) Remove the O-ring from the crankshaft pulley boss. (4) Remove the crankshaft pulley boss.
A276039
24. Removal of chain cover oil seal (1) Remove the chain cover oil seal using a flat tip screwdriver wrapped with protective tape etc. Captions in illustration
*1 Protective tape
<Caution>
Make sure that there is no flaw in the crankshaft and chain cover oil
seal fitting portion.
<Reference>
A276038J01
When flaw is found in the crankshaft, correct the crankshaft using abrasive paper (No. 400).
25. Removal of chain cover (1) Remove the 32 bolts.
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM21
EM
ME-06633
(2) Remove the chain cover at the rib position shown in the figure using a flat tip screwdriver wrapped with protective tape.
Captions in illustration
*1
Protective tape
-
-
<Caution> Do not damage the chain cover, cylinder head, camshaft timing gear and cylinder block.
ME-06634
EM22
(3) Remove the four O-rings.
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM
26. Removal of the timing chain (bank 1 side) (1) Install the SST to the crankshaft. SST 18252AA000
C
A281482
(2) Using SST and by turning the crankshaft, align the alignment marks of the crankshaft sprocket, intake cam sprocket RH, and exhaust cam sprocket RH. Captions in illustration
*a Alignment mark *b Key
<Reference> At this time, the crankshaft sprocket key points downward.
D
C
q
A279525J01
(3) Push down the chain tension lever as shown in the figure, and insert a 2.5 mm {0.098 in} dia. hex wrench into the hole of the chain tensioner No. 1 and stopper plate to secure the plunger.
A279526
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM23
(4) Remove the two bolts to remove the chain tensioner No. 1.
A279527
(5) Remove the chain tension lever.
(6) Remove the bolt, and remove the chain guide.
EM
A279528
(7) Remove the timing chain.
<Caution> Under the condition that the timing chain is detached, the valve heads contact each other and valve stem may bend. Do not turn the intake camshaft RH and exhaust camshaft RH to the outside of range of zero-lift (in range where it can be turned lightly by hand). <Reference>
Organize disassembled parts by their installation positions.
27. Removal of the timing chain (bank 2 side)
(1) Install the SST to the crankshaft.
q
SST 18252AA000 (2) Using SST and by turning the crankshaft, align the alignment
marks of the crankshaft sprocket, intake cam sprocket LH, and
exhaust cam sprocket LH.
q
Captions in illustration
*1 Key
*2 Alignment mark
A279529J01
EM24
EM
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(3) Push up the chain tension lever as shown in the figure, and insert a piece of metal wire (approx. 1 mm {0.039 in} in dia.) into the hole of the chain tensioner No. 2 and stopper plate to secure the plunger.
A279530
(4) Remove the two bolts to remove the chain tensioner No. 2. (5) Remove the chain tension lever.
A279531
(6) Remove the O-ring from cylinder block (bank 2 side).
A279532 A279533
(7) Remove the bolt, and remove the chain guide. (8) Remove the timing chain.
<Caution> · Under the condition that the timing chain is detached, the valve
heads contact each other and valve stem may bend. Do not turn the exhaust camshaft LH to the outside of range of zero-lift (in range where it can be turned lightly by hand). · At this time, No. 1 piston and No. 4 piston is in vicinity of TDC. If the intake camshaft LH is turned, the valve and the piston may contact and valve stem may bend. Do not turn the intake camshaft LH. <Reference> Organize disassembled parts by their installation positions.
q
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM25
28. Operation for prevention of piston and valve from damage (1) Using SST and by turning the crankshaft approximately 200° clockwise, align the alignment marks of crankshaft sprocket to the positions as shown in the figure. Captions in illustration
*1 Alignment mark
A279534J01
SST 18252AA000
EM <Caution>
Never turn counterclockwise except to fine-adjust the alignment mark because the valve and piston may contact.
(2) Using SST and by turning the intake cam sprocket LH by
approximately 180°, align the alignment marks of intake cam
sprocket LH to the positions (zero-lift position) as shown in the
556
figure. Captions in illustration
*1 Alignment mark
SST 18355AA000, 18334AA030
<Caution>
After this work, when the intake valve and exhaust valve lift at the
same time, the valve heads may contact each other and valve stem
may bend. Do not turn the intake camshaft LH and exhaust camshaft
LH to the outside of range of zero-lift (in range where it can be turned
556
lightly by hand). (3) Remove SST from the crankshaft.
ME-06631
29. Removal of crankshaft sprocket (1) Remove the crankshaft sprocket.
556 556
A279563
30. Removal of intake cam sprocket RH (1) Fix the intake cam sprocket RH using SST to remove the three bolts. SST 18355AA000, 18334AA030, 18270KA010 (2) Remove the intake cam sprocket RH.
556
ME-06528
EM26
556
EM
556
556
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
31. Removal of exhaust cam sprocket RH
(1) Fix the exhaust cam sprocket RH using SST to remove the three
bolts.
556
SST 18355AA000, 18334AA030, 18270KA010
(2) Remove the exhaust cam sprocket RH.
556
ME-06529
32. Removal of intake cam sprocket LH
556
(1) Fix the intake cam sprocket LH using SST to remove the three
bolts.
SST 18355AA000, 18334AA030, 18270KA010 (2) Remove the intake cam sprocket LH.
556
ME-06530
556 556
33. Removal of exhaust cam sprocket LH (1) Fix the exhaust cam sprocket LH using SST to remove the three bolts. SST 18355AA000, 18334AA030, 18270KA010 (2) Remove the exhaust cam sprocket LH.
556
ME-06531
34. Removal of rocker cover (1) Move the engine stand to face the bank 1 side upward. (2) Remove the two bolts to remove the injector driver bracket.
A283322
(3) Remove the 8 bolts.
A283323
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM27
(4) Remove the rocker cover using a flat tip screwdriver wrapped with protective tape. <Caution> Do not damage the cam carrier, cam cap and rocker cover.
(5) Remove the rocker cover gasket. (6) Remove the two spark plug tube gaskets. <Caution> When removing the gasket using scraper, use special care not to damage the cam lobe of camshaft.
EM
A283324
35. Removal of cam carrier RH
<Caution>
Do not remove the intake and exhaust camshafts initially, because it may cause the deformation of cam carrier.
(1) By loosening equally in the order as shown in the figure, remove the 9 bolts.
A283325J01
(2) Remove the cam carrier RH using a flat tip screwdriver wrapped with protective tape. <Caution> Do not damage the cylinder head and cam carrier. (3) Remove the two O-rings and eight sets of roller rocker arm from cylinder head SUB-ASSY. <Reference> Organize disassembled parts by their installation positions.
A278733
(4) Remove the eight valve shims and eight roller rocker arm pivots from the cylinder head SUB-ASSY. <Reference> Organize disassembled parts by their installation positions.
A278734
EM28
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM
36. Removal of cylinder head SUB-ASSY (1) Loosen the six cylinder head bolts equally in the order as shown in the figure. (2) While tapping the cylinder head SUB-ASSY with a plastic hammer, separate it from cylinder block. (3) Remove the cylinder head SUB-ASSY. <Caution> Be careful not to scratch the mating surfaces of cylinder head and cylinder block.
A278735J01
37. Removal of cylinder head gasket (1) Remove the cylinder head gasket.
38. Removal of rocker cover LH (1) Move the engine stand to face the bank 2 side upward. (2) Remove the 8 bolts.
A279567
(3) Remove the rocker cover LH using a flat tip screwdriver wrapped with protective tape. <Caution> Do not damage the cam carrier, cam cap and rocker cover.
(4) Remove the rocker cover gasket No. 2. (5) Remove the two spark plug tube gaskets. <Caution> When removing the gasket using scraper, use special care not to damage the cam lobe of camshaft.
A279568
39. Removal of cam carrier LH <Caution> Do not remove the intake and exhaust camshafts initially, because it may cause the deformation of cam carrier.
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM29
(1) By loosening equally in the order as shown in the figure, remove
the 9 bolts.
A283326J01
EM
(2) Remove the cam carrier LH using a flat tip screwdriver wrapped with protective tape. <Caution> Do not damage the cylinder head and cam carrier. (3) Remove the two O-rings and eight sets of roller rocker arm from cylinder head LH. <Reference> Organize disassembled parts by their installation positions.
A278737
(4) Remove the eight valve shims and eight roller rocker arm pivots from the cylinder head LH. <Reference> Organize disassembled parts by their installation positions.
A278738
ME-06503
41. Removal of cylinder head gasket No. 2 (1) Remove the cylinder head gasket No. 2.
42. Removal of spark plug (1) Remove the four spark plugs.
40. Removal of cylinder head LH (1) Loosen the six cylinder head bolts equally in the order as shown in the figure. (2) While tapping the cylinder head LH with a plastic hammer, separate it from cylinder block. (3) Remove the cylinder head LH. <Caution> Be careful not to scratch the mating surfaces of cylinder head and cylinder block.
EM30
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
43. Removal of engine hanger No. 2 (1) Remove the two bolts to remove the engine hanger No. 2 from cylinder block (bank 1 side).
EM
A279574
44. Removal of oil pan (1) Remove the drain plug and gasket.
(2) Remove the 11 bolts.
A278797
(3) Remove the oil pan using an oil pan seal cutter. <Caution> Do not damage the fitting surface of the oil pan upper and flange portion of the oil pan.
A120816
(4) Remove the two seal rings from the oil pan.
A279593
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM31
45. Removal of oil strainer SUB-ASSY (1) Remove the two bolts to remove the oil strainer SUB-ASSY. (2) Remove the O-ring.
A278798
EM
46. Removal of oil pan upper (1) Remove the 13 bolts. (2) Remove the oil pan upper using a flat tip screwdriver wrapped with protective tape. <Caution> Do not damage the fitting surfaces of the cylinder block and oil pan upper.
A281037
(3) Remove the three O-rings from cylinder block.
A278741
(4) Remove the four bolts to remove the oil pan baffle plate No. 1 from the oil pan upper.
A279598
(5) Remove the two stud bolts from the oil pan upper.
A279592
EM32
EM
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
47. Removal of camshaft cap (bank 1 side) (1) Loosen the 12 bolts equally and slowly in order as shown in the figure to remove the front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH. <Reference> Organize disassembled parts by their installation positions.
A278744J01
48. Removal of camshaft (bank 1 side) (1) Remove the intake camshaft RH and exhaust camshaft RH from the cam carrier RH.
A278745
49. Removal of oil control valve filter RH (1) Remove the two oil control valve filters RH from the cam carrier RH.
A278746
50. Removal of oil spacer RH (1) Remove the two bolts to remove the oil spacer RH.
A279590
51. Removal of camshaft oil field pipe SUB-ASSY (transmission A/T) (1) Remove the two union bolts and bolt to remove the camshaft oil field pipe SUB-ASSY and two gaskets from the cam carrier RH.
A278793
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM33
52. Removal of hole plug (transmission M/T) (1) Remove the hole plug and gasket from the cam carrier RH.
A278792
EM
53. Removal of camshaft cap (bank 2 side)
(1) Loosen the 13 bolts equally and slowly in order as shown in the
figure to remove the front camshaft cap LH, intake center camshaft
cap LH, intake rear camshaft cap LH, exhaust center camshaft cap
LH and exhaust rear camshaft cap LH.
<Reference>
Organize disassembled parts by their installation positions.
A278747J01
54. Removal of camshaft (bank 2 side) (1) Remove the intake camshaft LH and exhaust camshaft LH from the cam carrier LH.
A278748
55. Removal of oil control valve filter LH (1) Remove the two oil control valve filters LH from the cam carrier LH.
A278789
56. Removal of oil spacer LH (1) Remove the two bolts to remove the oil spacer LH.
A279591
EM34
INSPECTION
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
1. Inspection of roller rocker arm (1) Make sure that the roller turns smoothly by hand. <Reference> Replace the roller rocker arm if catch is found.
EM
A125485
2. Inspection of timing chain (1) Check that the timing chain has no deformation, cracks or other damages. <Reference> Replace the timing chain if faulty.
3. Inspection of camshaft timing gear (1) Check the camshaft timing gear teeth for abnormal wear and scratches. <Reference> Replace the camshaft timing gear if faulty.
4. Inspection of crankshaft sprocket (1) Check the crankshaft sprocket teeth for abnormal wear and scratches. <Reference> Replace the crankshaft sprocket if faulty. (2) Check that there is no free play between the crankshaft sprocket and key. <Reference> Replace the crankshaft sprocket or key if faulty.
5. Inspection of chain tension lever (1) Check that the chain tension lever has no deformation, cracks or other damages.
6. Inspection of chain guide No.1 (1) Check that the chain guide No.1 has no deformation, cracks or other damages.
7. Inspection of chain tensioner (1) Check that the chain tensioner has no deformation, cracks or other damages. (2) Make sure that the plunger moves smoothly by pushing with it unlocked. <Reference> If not, replace the chain tensioner.
A279536
(3) Make sure that the plunger does not move by pushing with the cam locked. 8. Inspection of cam carrier
(1) Visually check the oil control valve filter of cam carrier, and if clogging is found, replace with a new part. (2) Check the cam carrier journal for damage and wear.
<Reference> Replace the camshaft SUB-ASSY if faulty.
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM35
9. Inspection of camshaft
(1) Check the camshaft journals for damage and wear.
<Reference>
Replace the camshaft if faulty.
(2) Check the cam surface condition of camshaft.
<Reference>
· If slight fault is found, correct it using abrasive paper (No. 400).
· Replace the camshaft if uneven wear is found. (3) Runout test
EM
(a)Set the camshaft on a V-block.
(b)Using a dial gauge, check the camshaft runout.
Service limit:
0.020 mm {0.00079 in}
<Reference>
· Measurement should be performed at a temperature of
20°C {68°F}.
· If it exceeds the limit, replace the camshaft.
C #
$
A278753
(4) Height test (a)Measure the height of the cam using micrometer. Standard value (intake)
D %
Measurement location A B
Standard value 40.82 to 40.92 mm {1.6083 to 1.6110 in}
34.0 mm {1.3386 in}
Standard value (exhaust)
Measurement location A B
Standard value 40.72 to 40.82 mm {1.6031 to 1.6071 in}
34.0 mm {1.3386 in}
Standard value (fuel pump drive cam)
ME-06619
Measurement location C
Standard value 40.55 to 40.65 mm {1.5965 to 1.6004 in}
Captions in illustration
*a Valve drive cam *b Fuel pump drive cam
<Reference> · Measurement should be performed at a temperature of
20°C {68°F}. · If it is not within the specified value, replace the camshaft. (5) Outer diameter check (a)Check the journal outer diameter using micrometer. Standard value: 25.946 to 25.963 mm
{1.02149 to 1.02216 in} <Reference> · Measurement should be performed at a temperature of
20°C {68°F}. · If it is not within specified value, check the oil clearance.
A278755
EM36
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM
A278760
10. Camshaft thrust clearance check (1) Using a dial gauge, check the thrust clearance of the camshaft. Standard value: 0.068 to 0.116 mm {0.00027 to 0.00457 in} <Reference> · Measurement should be performed at a temperature of 20°C {68°F}. · Set the dial gauge at end surface of camshaft. · If it is not within the specified value or if uneven wear is found, replace each camshaft cap and cam carrier as a set. If necessary replace the camshaft.
11. Camshaft oil clearance check <Reference> Measurement should be performed at a temperature of 20°C {68°F}. (1) Remove the gasket from cam carrier and front camshaft cap, intake rear camshaft cap and exhaust rear camshaft cap. (2) Clean each camshaft cap and cam carrier journal. (3) Set the camshaft to the cam carrier. (4) Place a plastigauge across the journals of each camshaft and set the camshaft caps. (5) Tighten each bolt in order as shown in the figure, tighten the front camshaft cap, intake center camshaft cap, intake rear camshaft cap, exhaust center camshaft cap and exhaust rear camshaft cap.
C
D
A281476J01
Captions in illustration
*a
Bank 1
*b
Bank 2
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
(6) Loosen each bolt equally and slowly in order as shown in the figure to remove the bolts of the front camshaft cap, intake center camshaft cap, intake rear camshaft cap, exhaust center camshaft cap and exhaust rear camshaft cap.
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM37
C
D
Captions in illustration
*a
Bank 1
EM
A281476J02
*b
Bank 2
(7) Obtain the camshaft oil clearance at the widest point of plastigauge on each journal. Standard value: 0.037 to 0.072 mm {0.00146 to 0.00283 in} <Reference> If it is not within the specified value, replace each camshaft cap and cam carrier as a set. If necessary replace the camshaft.
A278791
(8) Remove the plastigauge properly.
ASSEMBLY
1. Installation of oil spacer LH (1) Install the oil spacer LH with two bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A279591
EM38
EM
##
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
#
#
2. Installation of oil control valve filter LH (1) Install two new oil control valve filters LH to the cam carrier LH. Captions in illustration
*a 0 to 0.5 mm {0 to 0.0197 in} (from the end surface of cam carrier LH)
#
#
C
A278751J01
3. Installation of camshaft (bank 2 side) (1) Apply engine oil to the cam carrier LH journal.
(2) Install the intake camshaft LH and exhaust camshaft LH to the cam carrier LH.
A278748
4. Installation of camshaft cap (bank 2 side) (1) Apply THREE BOND 1217G or equivalent to the mating surface of front camshaft cap LH, intake rear camshaft cap LH and exhaust rear camshaft cap LH as shown in the figure.
%% $
$
&
&
&
& $ $
&
% %
& & & % %
OO
KP
& & ##
OO
KP
&
&
##
## C
D
$$ OO
KP
E
H
H
%% OO
KP &&
C
F
G
H
H
Captions in illustration
*1
Front camshaft cap LH
*3
Exhaust rear camshaft cap LH
*a
1.0 mm {0.0394 in} or less
*c
2.5 to 3.5 mm {0.0984 to 0.1378 in} in dia.
*e
1.5 to 2.5 mm {0.0591 to 0.0984 in} in dia.
ME-06942
*2
Intake rear camshaft cap LH
-
-
*b
3.0 to 4.0 mm {0.1181 to 0.1575 in} in dia.
*d
2.5 to 4.0 mm {0.0984 to 0.1575 in} in dia.
*f
Groove
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM39
<Caution>
· Clean and degrease the fitting surface.
· Do not apply liquid gasket excessively to avoid engine seizure.
· Do not apply liquid gasket to the intake center camshaft cap LH and exhaust center camshaft cap LH.
· Install within 5 min. after applying liquid gasket.
(2) Apply engine oil to the journals of each camshaft cap and set the cam carrier LH.
(3) Tighten 13 bolts in order as shown in the figure, install the front
camshaft cap LH, intake center camshaft cap LH, intake rear
EM camshaft cap LH, exhaust center camshaft cap LH and exhaust
rear camshaft cap LH.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
A278747J02
5. Installation of hole plug (transmission M/T) (1) Using a new gasket, install the hole plug to the cam carrier RH.
Standard value: T=25N·m {225kgf·cm} {18.4 ft·lbf}
A278792
6. Installation of camshaft oil field pipe SUB-ASSY (transmission A/T) (1) Using two new gaskets, temporarily tighten the camshaft oil field pipe SUB-ASSY with the two union bolts and bolt. (2) Tighten the two union bolts to specified torque.
Standard value: T=31N·m {316kgf·cm} {22.9 ft·lbf}
A278793
(3) Tighten the bolt to specified torque.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
EM40
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
7. Installation of oil spacer RH (1) Install the oil spacer RH with two bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
EM
#
#
#
#
A279590
8. Installation of oil control valve filter RH (1) Install two new oil control valve filters RH to the cam carrier RH as shown in the figure. Captions in illustration
*a 0 to 0.5 mm {0 to 0.0197 in} (from the end surface of cam carrier RH)
##
C
A278749J01
9. Installation of camshaft (bank 1 side) (1) Apply engine oil to the cam carrier RH journal.
(2) Install the intake camshaft RH and exhaust camshaft RH to the cam carrier RH.
A278745
10. Installation of camshaft cap (bank 1 side) (1) Apply THREE BOND 1217G or equivalent to the mating surface of front camshaft cap RH, intake rear camshaft cap RH and exhaust rear camshaft cap RH as shown in the figure.
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM41
OO
KP
#
#
%
%
OO
KP %
##
$$
$
OO
KP
D
$
C
E
G
G
%%
D
F
EM
%
##
$$
Captions in illustration
*1
Front camshaft cap RH
*3
Exhaust rear camshaft cap RH
*a
2.5 to 4.0 mm {0.0984 to 0.1575 in} in diameter
*c
3.0 to 4.0 mm {0.1181 to 0.1575 in} in diameter
*e
Groove
G
ME-06943
*2
Intake rear camshaft cap RH
-
-
*b
1.0 mm {0.0394 in} or less
*d
1.5 to 2.5 mm {0.0591 to 0.0984 in} in diameter
-
-
<Caution> · Clean and degrease the fitting surface. · Do not apply liquid gasket excessively to avoid engine seizure. · Do not apply liquid gasket to the intake center camshaft cap RH and exhaust center camshaft cap RH. · Install within 5 min. after applying liquid gasket. (2) Apply engine oil to the journals of each camshaft cap and set to the cam carrier RH.
(3) Tighten 12 bolts in order as shown in the figure, install the front
camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
A278744J02
EM42
EM
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
11. Installation of oil pan upper (1) Install the two stud bolts to the oil pan upper.
Standard value: T=10N·m {102kgf·cm} {7.4 ft·lbf}
Stud bolt height (A): 70.0 mm {2.756 in}
#
A280854J01
(2) Install the baffle plate No. 1 to the oil pan upper with four bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
C D
A279598
OO
KP
(3) Apply THREE BOND 1217G or equivalent to the mating surface of the oil pan upper as shown in the figure. Captions in illustration
*a THREE BOND 1217G or equivalent
*b 4.0 to 6.0 mm {0.158 to 0.236 in} in diameter
*c Groove
<Caution> · Clean and degrease the fitting surface. · Install within 5 min. after applying liquid gasket. · Apply liquid gasket 1.5 mm {0.0591 in} outside from the groove of
the oil pan upper. However, application of liquid gasket around the bolt hole is allowed.
E
ME-06961
(4) Install three new O-rings to the cylinder block.
A278741
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM43
A279588J03
(5) Tighten 13 bolts (A and B) in order as shown in the figure, and install the oil pan upper to the cylinder block.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
Captions in illustration
Bolt A
Bolt B
EM
12. Installation of oil strainer SUB-ASSY (1) Install a new O-ring.
Bolt type Bolt A Bolt B
Bolt length (except for head) 25 mm {0.984 in} 75 mm {2.953 in}
<Reference> After tightening, if the liquid gasket is squeezed out in the seal surface area of the chain cover, completely remove any liquid gasket that is squeezed out.
(2) Install the oil strainer SUB-ASSY to the oil pan with two bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A278798
13. Installation of oil pan (1) Install the two new oil pan seal rings to the oil pan.
A279593J01
EM44
OO
KP
EM
C
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(2) Apply THREE BOND 1217G or equivalent to the mating surface of the oil pan of the oil pan upper as shown in the figure. Captions in illustration
*a THREE BOND 1217G or equivalent *b 4.0 to 6.0 mm {0.158 to 0.236 in} in diameter
<Caution> · Clean and degrease the fitting surface. · Install within 5 min. after applying liquid gasket.
D
ME-06962
(3) Tighten 11 bolts in order as shown in the figure, and install the oil pan.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A278797J01
14. Installation of engine hanger No. 2 (1) Install the engine hanger No. 2 to the cylinder block (bank 1 side) with two bolts.
Standard value: T=21N·m {214kgf·cm} {15.5 ft·lbf}
A279574
15. Installation of cylinder head gasket No. 2 (1) Move the engine stand to face the bank 2 side upward. (2) Clean the bolt holes in the cylinder block (bank 2 side). <Caution> To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc. (3) Apply THREE BOND 1217G or equivalent to the mating surface of the new cylinder head gasket No. 2 as shown in the figure.
##
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
##
EM45
##
C
# #
# #
D E
EM
A278764J02
Captions in illustration
*a
0 to 1.0 mm {0 to 0.039 in}
*c
Gasket end
*b
2.0 to 4.0 mm {0.079 to 0.158 in} in diameter
-
-
<Caution> · Clean and degrease the fitting surface. · Install within 5 min. after applying liquid gasket. (4) Install the cylinder head gasket No. 2.
16. Installation of cylinder head LH
(1) Clean the cylinder head bolt threads and apply sufficient engine oil to the washer and cylinder head bolt threads.
(2) Set the cylinder head LH to the cylinder block (bank 2 side).
(3) Tighten the six cylinder head bolts in the order as shown in the figure.
Standard value: T=20N·m {204kgf·cm} {14.8 ft·lbf}
ME-06502
(4) Further-tighten the six cylinder head bolts in the same order.
Standard value: T=100N·m {102kgf·cm} {73.8 ft·lbf}
<Caution>
If the bolt makes stick-slip sound during tightening, clean the bolt holes and the fitting surface and wait until it dries, and then
repeat the process from the procedure of application of gasket.
<Reference>
If the processes are resumed, the cylinder head gasket can be reused.
(5) Loosen the six cylinder head bolts by 360° in the order as shown in
the figure.
ME-06503
EM46
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(6) Tighten the six cylinder head bolts in the order as shown in the figure.
Standard value: T=20N·m {204kgf·cm} {14.8 ft·lbf}
EM
ME-06502
(7) Further-tighten the six cylinder head bolts in the same order.
Standard value: T=42N·m {428kgf·cm} {31.0 ft·lbf}
(8) Further-tighten the six cylinder head bolts by 100° in the order as
C
shown in the figure using SST. SST 18854AA000
Captions in illustration
*a Temporary bolt
<Reference>
556
As necessary, attach the temporary bolt to fix SST.
ME-06505
(9) Further-tighten the two cylinder head bolts by 100° in the order as shown in the figure using SST. SST 18854AA000
556
ME-06641
(10) Further-tighten the four cylinder head bolts by 50° in the order as shown in the figure using SST. SST 18854AA000
556
ME-06506
17. Installation of cam carrier LH (1) Apply engine oil to the valve shim and the roller rocker arm pivot, and install to the cylinder head LH.
A278738
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM47
(2) Apply engine oil to the eight sets of the roller rocker arm and two new O-rings, and install to the cylinder head LH.
(3) Apply THREE BOND 1217G or equivalent to the mating surface of the cam carrier LH as shown in the figure.
A278737
EM
##
E
F
C
$$ F
C
OO
G
KP
Captions in illustration
*a
Groove
*c
1.0 mm {0.0394 in} or less
*e
-0.5 to 0.5 mm {-0.0197 to 0.0197 in}
D
D
#
$
#
OO
KP
$
ME-06979
*b
Range B-B
*d
2.5 to 3.5 mm {0.098 to 0.138 in} in diameter
-
-
<Caution>
· Clean and degrease the fitting surface.
· Do not apply liquid gasket excessively.
· Install within 5 min. after applying liquid gasket.
· Completely remove any liquid gasket that is squeezed out on the
fitting surface of the chain cover.
(4) Tighten nine bolts in order as shown in the figure, and install the
cam carrier LH.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
A283326J02
EM48
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
<Reference> Set the intake camshaft LH and the exhaust camshaft LH to the zero-lift position.
EM
A278759
(5) Loosen the three bolts by 180° in the order as shown in the figure.
A283328J01
(6) Tighten the three bolts in the order as shown in the figure.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
A283328J02
(7) Loosen the three bolts by 180° in the order as shown in the figure.
A283328J03
(8) Tighten the three bolts in the order as shown in the figure.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
A283328J04
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM49
(9) Loosen the three bolts by 180° in the order as shown in the figure.
A283328J05
EM
(10) Tighten the three bolts in the order as shown in the figure.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
<Reference> After tightening, if the liquid gasket is squeezed out in the seal surface area of the chain cover, completely remove any liquid gasket that is squeezed out.
A283328J06
18. Cam clearance check (bank 2 side) <Caution> Under the condition that the timing chain (bank 2 side) is detached, the valve heads contact each other and valve stem may bend. Do not turn the intake camshaft LH and exhaust camshaft LH to the outside of range of zero-lift (in range where it can be turned lightly by hand). (1) Measure the roller surface of cam base circle and roller rocker arm using thickness gauge.
A281473
Standard value (when cold): 0.10 to 0.16 mm {0.0039 to 0.0063 in} (intake side) 0.21 to 0.27 mm {0.0083 to 0.0106 in} (exhaust side)
<Reference> · For cam clearance inspection, adjust the cam base circle position so that the thickness gauge can be inserted easily
by hand turning the camshaft to be measured. · If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. 19. Cam clearance adjustment (bank 2 side) (1) Remove the cam carrier LH. (2) Remove the roller rocker arm. (3) Remove the valve shim.
EM50
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(4) Measure the thickness of the removed valve shim using micrometer.
EM
A281710
(5) Calculate the thickness of the valve shim so that the cam clearance is within the specified range.
Standard value: Intake side: (Selected shim thickness) = (removed shim thickness) + [(measured clearance) 0.13 mm {0.0051 in}] × 1.54
Exhaust side: (Selected shim thickness) = (removed shim thickness) + [(measured clearance) 0.24 mm {0.0094 in}] × 1.69
(6) Apply engine oil to the inner circle area of the selected valve shim, and install to the valve.
<Caution> Make sure that the valve shim turns smoothly after inserting. (7) Install the roller rocker arm. (8) Install the cam carrier LH.
20. Installation of rocker cover LH
C
(1) Apply a light coat of engine oil to the two new spark plug tube
gaskets, and insert them up to the spark plug tube end.
Captions in illustration
*a Spark plug tube end
(2) Install the new rocker cover gasket No. 2 to the rocker cover LH.
# C
#
# C
#
D
A279571J01
#
$
C
C %
#
(3) Apply THREE BOND 1217G or equivalent to the mating surface of the rocker cover LH as shown in the figure.
Application area A B C
Application length 10.0 mm {0.394 in} or more 18.8 mm {0.740 in} or more 63.0 mm {2.480 in} or more
Captions in illustration
*a Arch starting point *b 2.0 to 4.0 mm {0.079 to 0.158 in} in diameter
A279572J02
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM51
(4) Set the rocker cover LH, and tighten the eight bolts in the order as shown in the figure.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
ME-06507
EM
21. Installation of cylinder head gasket (1) Move the engine stand to face the bank 1 side upward. (2) Clean the bolt holes in the cylinder block (bank 1 side). <Caution> To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc. (3) Apply THREE BOND 1217G or equivalent to the both surfaces of the new cylinder head gasket as shown in the figure.
## ##
## ##
##
C D
E
A278761J02
Captions in illustration
*a
0 to 1.0 mm {0 to 0.039 in}
*c
Gasket end
*b
2.0 to 4.0 mm {0.79 to 0.158 in} in diameter
-
-
<Caution> · Clean and degrease the fitting surface. · Install within 5 min. after applying liquid gasket. (4) Attach the cylinder head gasket.
22. Installation of cylinder head SUB-ASSY
(1) Clean the cylinder head bolt threads and apply sufficient engine oil to the washer and cylinder head bolt threads.
(2) Set the cylinder head SUB-ASSY to the cylinder block (bank 1 side).
(3) Tighten the six cylinder head bolts in the order as shown in the
figure.
Standard value: T=20N·m {204kgf·cm} {14.8 ft·lbf}
A278735J02
(4) Further-tighten the six cylinder head bolts in the same order.
Standard value: T=100N·m {102kgf·cm} {73.8 ft·lbf}
<Caution> If the bolt makes stick-slip sound during tightening, clean the bolt holes and the fitting surface and wait until it dries, and then repeat the process from the procedure of application of gasket. <Reference> If the processes are resumed, the cylinder head gasket can be reused.
EM52
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(5) Loosen the six cylinder head bolts by 360° in the order as shown in the figure.
EM
A278735J01
(6) Tighten the six cylinder head bolts in the order as shown in the figure.
Standard value: T=20N·m {204kgf·cm} {14.8 ft·lbf}
A278735J02
(7) Further-tighten the six cylinder head bolts in the same order.
Standard value: T=42N·m {428kgf·cm} {31.0 ft·lbf}
(8) Further-tighten the six cylinder head bolts by 100° in the order as
shown in the figure using SST. SST 18854AA000 Captions in illustration
*a Temporary bolt
556
<Reference> As necessary, attach the temporary bolt to fix SST.
C
ME-06642
(9) Further-tighten the two cylinder head bolts by 100° in the order as shown in the figure using SST. SST 18854AA000
556
ME-06643
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM53
(10) Further-tighten the four cylinder head bolts by 50° in the order as shown in the figure using SST. SST 18854AA000
556
EM
ME-06644
23. Installation of cam carrier RH (1) Apply engine oil to the valve shim and the roller rocker arm pivot, and install to the cylinder head SUB-ASSY.
A278734
(2) Apply engine oil to the eight sets of the roller rocker arm and two new O-rings, and install to the cylinder head SUB-ASSY.
(3) Apply THREE BOND 1217G or equivalent to the mating surface of the cam carrier RH as shown in the figure.
A278733
C
#
OO
#
KP
Captions in illustration
*a
Range B-B
*c
2.5 to 3.5 mm {0.098 to 0.138 in} in diameter
*e
Groove end
##
D E
$
G
OO
KP
$
$$
F
E C
OO
G
KP
*b
0 to 1.0 mm {0 to 0.0394 in}
*d
-0.5 to 0.5 mm {-0.0197 to 0.0197 in}
-
-
<Caution> · Clean and degrease the fitting surface. · Do not apply liquid gasket excessively.
ME-06980
EM54
EM
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
· Install within 5 min. after applying liquid gasket.
· Completely remove any liquid gasket that is squeezed out on the
fitting surface of the chain cover.
(4) Tighten nine bolts in order as shown in the figure, and install the
cam carrier RH.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
A283325J02
<Reference> Set the intake camshaft RH and the exhaust camshaft RH to the zero-lift position.
A278757
(5) Loosen the three bolts by 180° in the order as shown in the figure.
A283330J01
(6) Tighten the three bolts in the order as shown in the figure.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
A283330J02
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM55
(7) Loosen the three bolts by 180° in the order as shown in the figure.
A283330J03
(8) Tighten the three bolts in the order as shown in the figure.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
EM
A283330J04
(9) Loosen the three bolts by 180° in the order as shown in the figure.
A283330J05
(10) Tighten the three bolts in the order as shown in the figure.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
<Reference>
After tightening, if the liquid gasket is squeezed out in the seal
surface area of the chain cover, completely remove any liquid
gasket that is squeezed out.
A283330J06
24. Cam clearance check (bank 1 side) <Caution> Under the condition that the timing chain (bank 1 side) is detached, the valve heads contact each other and valve stem may bend. Do not turn the intake camshaft RH and exhaust camshaft RH to the outside of range of zero-lift (in range where it can be turned lightly by hand).
EM56
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(1) Measure the roller surface of cam base circle and roller rocker arm using thickness gauge.
EM
A281474
Standard value (when cold): 0.10 to 0.16 mm {0.0039 to 0.0063 in} (intake side) 0.21 to 0.27 mm {0.0083 to 0.0106 in} (exhaust side)
<Reference> · For cam clearance inspection, adjust the cam base circle position so that the thickness gauge can be inserted easily
by hand turning the camshaft to be measured. · If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on.
25. Cam clearance adjustment (bank 1 side) (1) Remove the cam carrier RH. (2) Remove the roller rocker arm. (3) Remove the valve shim.
(4) Measure the thickness of the removed valve shim using micrometer.
A281710
(5) Calculate the thickness of the valve shim so that the cam clearance is within the specified range.
Standard value: Intake side: (Selected shim thickness) = (removed shim thickness) + [(measured clearance) - 0.13
mm {0.0051 in}] × 1.54
Exhaust side: (Selected shim thickness) = (removed shim thickness) + [(measured clearance) - 0.24 mm {0.0094 in}] × 1.69 (6) Apply engine oil to the inner circle area of the selected valve shim, and install to the valve.
<Caution> Make sure that the valve shim turns smoothly after inserting. (7) Install the roller rocker arm.
(8) Install the cam carrier RH.
26. Installation of rocker cover
(1) Apply a light coat of engine oil to the two new spark plug tube
C
gaskets, and insert them up to the spark plug tube end.
Captions in illustration
*a Spark plug tube end
(2) Install the rocker cover gasket to the new rocker cover.
A279569J01
C $#
D %#
C
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM57
(3) Apply THREE BOND 1217G or equivalent to the mating surface of the rocker cover as shown in the figure.
# C
#
# C
#
Application area A B C
Application length 10.0 mm {0.394 in} or more 68.0 mm {2.677 in} or more 70.7 mm {2.784 in} or more
Captions in illustration
*a Arch starting point *b 2.0 to 4.0 mm {0.079 to 0.158 in} in diameter
EM
A279570J01
(4) Set the rocker cover, and tighten the eight bolts in the order as shown in the figure.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A283323J01
(5) Install the injector driver bracket using two bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A283322
27. Installation of spark plug (1) Install the four spark plugs.
Standard value: T=17N·m {173kgf·cm} {12.5 ft·lbf}
EM58
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
28. Installation of exhaust cam sprocket LH
<Caution>
Before installation, check that there is no foreign matter on the exhaust cam sprocket LH and exhaust camshaft LH.
(1) Install the exhaust cam sprocket LH by aligning the knock hole of
the exhaust cam sprocket LH and the knock pin of the exhaust
camshaft LH.
Captions in illustration
EM
*1 Knock hole *2 Knock pin
A279561J01
556 556
(2) Fix the exhaust cam sprocket LH using SST and tighten the three bolts. SST 18355AA000, 18334AA030, 18270KA010
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
556
ME-06532
29. Installation of intake cam sprocket LH
<Caution> Before installation, check that there is no foreign matter on the intake cam sprocket LH and intake camshaft LH.
(1) Install the intake cam sprocket LH by aligning the knock hole of the
intake cam sprocket LH and the knock pin of the intake camshaft
LH.
Captions in illustration
*1 Knock hole
*2 Knock pin
A279559J01
556 556
(2) Fix the intake cam sprocket LH using SST and tighten the three bolts. SST 18355AA000, 18334AA030, 18270KA010
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
556
ME-06533
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM59
30. Installation of exhaust cam sprocket RH
<Caution>
Before installation, check that there is no foreign matter on the exhaust cam sprocket RH and exhaust camshaft RH.
(1) Install the exhaust cam sprocket RH by aligning the knock hole of
the exhaust cam sprocket RH and the knock pin of the exhaust
camshaft RH.
Captions in illustration
*1 Knock hole *2 Knock pin
EM
556 556
A279557J01
(2) Fix the exhaust cam sprocket RH using SST and tighten the three bolts. SST 18355AA000, 18334AA030, 18270KA010
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
556
ME-06534
31. Installation of intake cam sprocket RH <Caution> Before installation, check that there is no foreign matter on the intake cam sprocket RH and intake camshaft RH. (1) Install the intake cam sprocket RH by aligning the knock hole of the intake cam sprocket RH and the knock pin of the intake camshaft RH. Captions in illustration
*1 Knock hole
*2 Knock pin
556 556
A279555J01
(2) Fix the intake cam sprocket RH using SST and tighten the three bolts. SST 18355AA000, 18334AA030, 18270KA010
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
556
ME-06535
EM60
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
32. Installation of crankshaft sprocket (1) Install the crankshaft sprocket.
EM
A279563
33. Installation of timing chain (bank 2 side)
<Caution>
Be careful that the foreign matter is not into or onto the assembled component during installation.
<Reference>
Apply engine oil to all component parts of the timing chain.
(1) Install the SST to the crankshaft.
SST 18252AA000
(2) Move the link plate in the direction of arrow to press in the plunger.
Captions in illustration
*1 Link plate
*2 Plunger
q
A279536J01
(3) Insert a piece of metal wire (approx. 1 mm {0.0394 in} dia.) into the
stopper pin hole to secure the plunger. <Reference>
If the stopper pin hole on the link plate and the stopper pin hole on
the chain tensioner are not aligned, check that the first notch of
plunger rack is engaged with the stopper tooth. If not engaged,
retract the plunger a little so that the first notch of plunger rack is
engaged with the stopper tooth.
Captions in illustration
A279537J01
*1 First notch of rack *2 Stopper tooth
(4) Check that the crankshaft sprocket is located at the position shown in the figure. If not aligned, turn the crankshaft to align the crankshaft sprocket alignment mark to the position shown in the figure. Captions in illustration
*1 Alignment mark
<Caution> Perform properly to avoid contact of the valve and piston.
A279534J02
q
(7) Remove SST.
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM61
(5) Using SST and by turning the intake cam sprocket LH, align the
alignment mark to the position as shown in the figure.
SST 18355AA000, 18334AA030
556
<Caution>
The intake valve and exhaust valve contact each other and valve stem
may bend. Do not turn the exhaust camshaft LH.
Captions in illustration
*1 Alignment mark
EM
556
ME-06591 ME-06549
(6) Using SST and by turning the crankshaft approximately 200° counterclockwise, align the crankshaft sprocket key to the position as shown in the figure. SST 18252AA000 <Caution> Never turn clockwise because the valve and piston may contact. However, turning clockwise is allowed in case of fine adjustment after aligning the crankshaft sprocket key to the position shown in the figure. Captions in illustration
*1 Key
q
A279540J01
(8) Using SST and by turning the exhaust cam sprocket LH, align the alignment mark to the position as shown in the figure. SST 18355AA000, 18334AA030 <Caution> To prevent valve damage, turn the exhaust cam sprocket LH only within the range of zero-lift (in range where it can be turned lightly by hand). Captions in illustration
*1 Alignment mark
EM62
E C
EM
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
D F
(9) Align the mark plate (blue) of the timing chain to the alignment mark of the crankshaft sprocket. Captions in illustration
*a Alignment mark *b Timing mark *c Mark plate (blue) *d Mark plate (pink)
D
F
A279541J02
(10) Align the mark plate (pink) of the timing chain to the timing mark of the intake cam sprocket LH. (11) Align the mark (pink) of the timing chain to the timing mark of the exhaust cam sprocket LH. (12) Apply engine oil to the sliding surface of the chain guide bolt. (13) Install the chain guide with the bolt.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
(14) Install a new O-ring to the cylinder block (bank 2 side).
A279532
(15) Install the chain tension lever.
A279531
(16) Tighten the two bolts to install the chain tensioner No. 2.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM63
(17) Make sure that the timing chain is securely installed.
E
Captions in illustration
*a Alignment mark
C
*b Timing mark
*c Mark plate (blue)
D F
*d Mark plate (pink)
(a)Align the mark (blue) of the timing chain to the alignment mark
EM of the crankshaft sprocket.
(b)Align the mark (pink) of the timing chain to the timing mark of
D
the intake cam sprocket LH.
(c)Align the mark (pink) of the timing chain to the timing mark of
the exhaust cam sprocket LH.
F
A279542J02
(18) Pull out the wire from the chain tensioner No. 2.
<Reference>
Pull out the piece of metal wire, while pushing up the chain tension lever to push in the plunger of the chain tensioner No.
2.
(19) Install the SST to the crankshaft.
SST 18252AA000
(20) Turn the crankshaft clockwise, and make sure that there is no abnormal condition.
<Caution> Always perform this check.
34. Installation of timing chain (bank 1 side)
<Caution> Be careful that the foreign matter is not into or onto the assembled component during installation. <Reference>
Apply engine oil to all component parts of the timing chain.
(1) Move the link plate in the direction of arrow to press in the plunger.
Captions in illustration
*1 Link plate
*2 Plunger
A279544J01
(2) Insert a dia. 2.5 mm {0.098 in} hex wrench into the stopper pin hole
to fix the plunger.
Captions in illustration
*1 First notch of rack
*2 Stopper tooth
A279545J01
<Reference> If the stopper pin hole on the link plate and the stopper pin hole on the chain tensioner are not aligned, check that the first notch of plunger rack is engaged with the stopper tooth. If not engaged, retract the plunger a little so that the first notch of plunger rack is engaged with the stopper tooth.
EM64
EM
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(3) Using SST and by turning the crankshaft, align the alignment mark
of the crankshaft sprocket, intake cam sprocket LH and exhaust
cam sprocket LH.
Captions in illustration
*1 Alignment mark
<Reference> When the mark is aligned to the position shown in the figure, the crankshaft sprocket key points downward.
q
F D
A279546J02 A279547J02
(4) Using SST, align the alignment mark of the intake cam sprocket RH and exhaust cam sprocket RH to the position as shown in the figure. SST 18355AA000, 18334AA030 <Caution> To prevent valve damage, turn the intake cam sprocket RH and exhaust cam sprocket RH only within the range of zero-lift (in range where it can be turned lightly by hand). Captions in illustration
*1 Alignment mark
(5) Align the mark plate (blue) of the timing chain to the alignment mark of the crankshaft sprocket. Captions in illustration
*a Alignment mark *b Timing mark *c Mark plate (blue) *d Mark plate (pink)
F D
C
E
A279548J01
(6) Align the mark plate (pink) of the timing chain to the timing mark of the intake cam sprocket RH. (7) Align the mark plate (pink) of the timing chain to the timing mark of the exhaust cam sprocket RH. (8) Apply engine oil to the sliding surface of the chain guide bolt. (9) Install the chain guide with the bolt.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(10) Install the chain tension lever.
EM65
A279527
EM
(11) Tighten the two bolts to install the chain tensioner No. 1.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
F C
(12) Make sure that the timing chain is securely installed. Captions in illustration
*a Alignment mark
D E
*b Timing mark *c Mark plate (blue)
*d Mark plate (pink)
F D
(a)Align the mark plate (blue) of the timing chain to the alignment mark of the crankshaft sprocket.
(b)Align the mark plate (pink) of the timing chain to the timing mark of the intake cam sprocket RH.
(c)Align the mark plate (pink) of the timing chain to the timing mark of the exhaust cam sprocket RH.
A279549J01
(13) Pull out the hex wrench from the chain tensioner No. 1. (14) Turn the crankshaft clockwise, and make sure that there is no abnormal condition.
<Caution> Always perform this check. (15) Remove SST from the crankshaft. 35. Installation of chain cover (1) Apply a little coat of engine oil to four new O-rings and install to the engine. (2) Before applying liquid gasket, completely remove the old sealing material attached to the sealing portion. (3) If there is a gap at the position shown in the figure, fill in the THREE BOND 1217G or equivalent.
EM66
EM
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(4) Apply THREE BOND 1217G or equivalent to the chain cover at the position shown in the figure.
A281483
*a 14.5 mm {0.571 in} 17.5 mm {0.689 in}
A
A
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
24.5 mm {0.965 in}
*c 127 mm {5.000 in}
18.5 mm {0.728 in}
316.2 mm {12.449 in}
C C
EM67
EM
B B
D D
A - A (*a) *e *f
B - B (*b) *g
*e
<Caution> · Clean and degrease the fitting surface. · Install within 5 min. after applying liquid gasket. Captions in illustration
*a
Range A
*b
*c
Range B
*d
*e
3.5 to 4.5 mm {0.138 to 0.177 in} in diameter
*f
*g
12 mm {0.472 in} in diameter
*h
*i
0.5 mm {0.0197 in}
-
(5) Temporarily install the chain cover using 32 bolts. (6) Tighten the 32 bolts in the order as shown in the figure.
C - C (*c) *e *h
D - D (*d)
*e *i
LU-03003
Boss (five locations) Other than ranges A and B 2 mm {0.079 in} 2.5 mm {0.098 in} -
EM68
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM
Captions in illustration
Bolt A
Bolt B
A281484J01
Bolt C
Bolt D
Standard value: Bolt A, B
T=10N·m {102kgf·cm} {7.4 ft·lbf}
Bolt C, D
T=25N·m {255kgf·cm} {18.4 ft·lbf}
36. Installation of chain cover oil seal
556
(1) Apply a little coat of engine oil to the inside and outside of the new
oil seal.
<Caution>
· Do not foul the lip.
· Do not attach engine oil to the dust seal portion.
(2) Using SST, hammer in the chain cover oil seal evenly so that it is
aligned to the end surface of the chain cover.
SST 398437700
<Caution>
ME-06639
· Do not hammer in the oil seal obliquely.
· Be careful not to deform the oil seal.
<Reference>
The depth at which the chain cover oil seal is hammered in is
allowed within 0 to 1.0 mm {0 to 0.0394 in} from the end surface of
the chain cover.
37. Installation of crankshaft pulley (1) Install the crankshaft pulley boss. (2) Install a new O-ring to the crankshaft pulley boss.
C
556
556 D
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM69
(3) Install so that the knock hole of the crankshaft pulley and the knock pin of the crankshaft pulley boss match. Captions in illustration
*1 Knock hole *2 Knock pin *a Rotate *b Hold
EM
556
ME-06538
(4) Apply engine oil to the washer and bolt threads of the crankshaft pulley set bolt.
(5) Use the SST to lock the crankshaft pulley, and tighten the crankshaft pulley set bolt.
SST 18355AA000, 18334AA000
Standard value: T=20N·m {204kgf·cm} {14.8 ft·lbf}
(6) As shown in the figure, using a marker, draw a reference line (A)
on the crankshaft pulley set bolt and end line (B) on the crank
pulley at the same level of the line marked on the crankshaft pulley
set bolt head portion.
Captions in illustration
*a Reference line (A)
*b End line (B)
D
<Reference>
C
Lines are marked at an interval of 90° on the crankshaft pulley set
A281493J01
bolt head portion.
(7) Use SST to lock the crankshaft pulley, and further-tighten the
crankshaft pulley set bolt by 90° to the angle where reference line
556
(A) and end line (B) are aligned.
SST 18355AA000, 18334AA000
Captions in illustration
*a Reference line (A)
*b End line (B)
556
C D
556
ME-06638
38. Installation of thermostat (1) Install a new gasket to the thermostat.
EM70
EM
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
39. Installation of thermostat cover (1) Set the thermostat to the oil pan upper, and install the thermostat cover with two bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A281051
40. Installation of engine water pump ASSY (1) Using a new gasket, install the water pump ASSY with five bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A279726
41. Installation of water pump pulley (1) Temporarily- tighten the three bolts to the water pump pulley. (2) Fix the water pump pulley using SST. SST 18355AA000, 18334AA030
556
556 556
CO-03051
(3) Tighten the three bolts.
Standard value: T=14N·m {143kgf·cm} {10.3 ft·lbf}
#
C
42. Installation of pump drive case ASSY (1) Apply THREE BOND 1217G or equivalent to the pump drive case ASSY as shown in the figure. Captions in illustration
*A Cross section A - A
#
#
*1 THREE BOND 1217G or equivalent
D
*a Application area of liquid gasket: within 1 mm {0.039 in} from edge
*b Diameter of liquid gasket: 2 to 4 mm {0.079 to 0.158 in}
A281430J01
<Caution> · Clean and degrease the fitting surface. · Install within 5 min. after applying liquid gasket.
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM71
(2) Tighten the three bolts to install the pump drive case ASSY.
Standard value: T=19N·m {194kgf·cm} {14.0 ft·lbf}
A278730
43. Installation of PCV valve (1) Apply THREE BOND 1324 or equivalent to the PCV valve.
EM
A092670J01
(2) Install the PCV valve to the cylinder head block.
Standard value: T=23N·m {235kgf·cm} {17.0 ft·lbf}
A278795
44. Installation of water pipe ASSY (1) Install two new O-rings to the cylinder block.
A280856
(2) Install the water pipe ASSY with four bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A279573
EM72
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
45. Installation of oil level gauge guide (1) Install a new O-ring to the oil level gauge guide. (2) Apply engine oil to the O-ring and install the oil level gauge guide with a bolt.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
(3) Install the oil level gauge.
EM
C #
##
46. Installation of cylinder head plate RR (transmission M/T) (1) Apply THREE BOND 1217G or equivalent to the cam carrier RH as shown in the figure. Captions in illustration
*a 2.0 to 4.0 mm {0.079 to 0.158 in} in diameter
*b 1.0 mm {0.0394 in} or less
*c Groove
D
E
<Caution> · Clean and degrease the fitting surface.
#
A279600J01
· Install within 5 min. after applying liquid gasket.
(2) Install the cylinder head plate RR with three bolts.
Standard value: T=16N·m {163kgf·cm} {11.8 ft·lbf}
A278731
C #
##
47. Installation of vacuum pump ASSY (transmission A/T) (1) Apply THREE BOND 1217G or equivalent to the cam carrier RH as shown in the figure. Captions in illustration
*a 2.0 to 4.0 mm {0.079 to 0.158 in} in diameter *b 1.0 mm {0.0394 in} or less *c Groove
D
E
<Caution> · Clean and degrease the fitting surface.
#
A279600J01
· Install within 5 min. after applying liquid gasket.
(2) Install a new O-ring.
(3) Tighten the three bolts to install the vacuum pump ASSY.
Standard value: T=16N·m {163kgf·cm} {11.8 ft·lbf}
C260987
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
48. Installation of PCV hose connector (1) Install two new O-rings to the PCV hose connector.
EM73
A279577
EM
(2) Connect the water by-pass hose No. 1 to the PCV hose connector and water pipe ASSY using hose clamp.
(3) Install the PCV hose connector with three bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A280851
49. Installation of engine oil pressure switch ASSY (1) Degrease the threads of the engine oil pressure switch ASSY. (2) Apply THREE BOND 1324 or equivalent to the threads. <Caution> Do not attach THREE BOND 1324 or equivalent to the oil hole. Captions in illustration
*1 THREE BOND 1324 or equivalent
LU-02948
(3) Install the engine oil pressure switch ASSY.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
<Caution> After assembly, do not start the engine within one hour.
ME-06590
50. Installation of engine oil temperature sensor (1) Install a new gasket to the engine oil temperature sensor.
EM74
EM
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(2) Install the engine oil temperature sensor.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
A280848
A276534J01
51. Installation of camshaft timing oil control valve ASSY (1) Install the back-up ring to the camshaft timing oil control valve ASSY (bank 2 exhaust side). Captions in illustration
*1 O-ring *2 Back-up ring
(2) Install a new O-ring to the camshaft timing oil control valve ASSY (bank 2 exhaust side).
(3) Apply engine oil to O-ring.
(4) Install the camshaft timing oil control valve ASSY (bank 2 exhaust side) using two bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
(5) Install the back-up ring to the camshaft timing oil control valve ASSY (bank 2 intake side).
(6) Install a new O-ring to the camshaft timing oil control valve ASSY (bank 2 intake side).
(7) Apply engine oil to O-ring.
A280847
(8) Install the camshaft timing oil control valve ASSY (bank 2 intake side) using two bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
(9) Install the back-up ring to the camshaft timing oil control valve ASSY (bank 1 exhaust side).
(10) Install a new O-ring to the camshaft timing oil control valve ASSY (bank 1 exhaust side).
(11) Apply engine oil to O-ring.
A280846
(12) Install the camshaft timing oil control valve ASSY (bank 1 exhaust side) using two bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
(13) Install the back-up ring to the camshaft timing oil control valve ASSY (bank 1 intake side).
(14) Install a new O-ring to the camshaft timing oil control valve ASSY (bank 1 intake side).
(15) Apply engine oil to O-ring.
A280845
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM75
(16) Install the camshaft timing oil control valve ASSY (bank 1 intake side) using two bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A280844
EM
52. Installation of camshaft position sensor (1) Install a new O-ring to the camshaft position sensor (bank 2 exhaust side). (2) Apply engine oil to O-ring. (3) Install the camshaft position sensor (bank 2 exhaust side) using a bolt.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A280843
(4) Install a new O-ring to the camshaft position sensor (bank 2 intake side). (5) Apply engine oil to O-ring.
(6) Install the camshaft position sensor (bank 2 intake side) using a bolt.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A280842
(7) Install a new O-ring to the camshaft position sensor (bank 1 exhaust side). (8) Apply engine oil to O-ring.
(9) Install the camshaft position sensor (bank 1 exhaust side) using a bolt.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A280841
(10) Install a new O-ring to the camshaft position sensor (bank 1 intake side). (11) Apply engine oil to O-ring.
EM76
EM
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
(12) Install the camshaft position sensor (bank 1 intake side) using a bolt.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A280840
53. Installation of crank position sensor (1) Install the crank position sensor using a bolt.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
q q
A280839
54. Installation of knock control sensor (1) Install the two knock control sensors in the direction shown in the figure using two bolts.
Standard value: T=24N·m {245kgf·cm} {17.7 ft·lbf}
Captions in illustration
Engine front
q
q
A281038J01
A280837
55. Installation of engine water temperature sensor (1) Install the engine water temperature sensor, using a new gasket.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
<Caution> · When a torque wrench extended with a union nut wrench is used,
the actual tightening torque becomes over-torque if the part is tightened until the torque wrench reading reaches the specified tightening torque. · This manual only indicates the specified tightening torque. If using an SST or extension, it is necessary to use the following formula to calculate the proper torque wrench reading.
Engine mechanical - PARTIAL ENGINE ASSY (FA20)
EM77
56. Installation of oil filter union (1) Install the oil filter union.
Standard value: T=45N·m {459kgf·cm} {33.2 ft·lbf}
A281050
57. Installation of oil filter
(1) Apply a little coat of engine oil to the seal rubber portion of a new oil filter. (2) Tighten the oil filter by hand.
<Caution> Be careful not to damage the seal rubber of the oil filter. (3) Using SST, tighten the oil filter.
SST 18332AA020 Standard value: Specified tightening torque
T=14N·m {143kgf·cm} {10.3 ft·lbf}
When using SST, calculate the following formula. Calculation T2 = L2/(L1 + L2) × T1
T1
14 N·m {143 kgf·cm, 10.3 ft·lbf}
T2
Tightening torque
L1
SST length (0.080 m {3.150 in})
L2
Torque wrench length (m (in))
<Reference> · This torque is valid when SST and a torque wrench are aligned. · Install SST and a torque wrench so that they are aligned.
58. Installation of oil filler cap (1) Install the oil filler cap.
EM
EM78
Engine mechanical - CYLINDER HEAD ASSY (FA20)
CYLINDER HEAD ASSY (FA20) Engine/hmyebcrhidasnyicsatelm
EXPLODED VIEW
EM
Exhaust valve
Cylinder head
Intake valve guide bushing No. 2
Valve spring seat
Valve stem oil seal
Intake valve
Valve spring
Valve spring retainer
6.4 {65,4.7}
Chain cover mount bolt
Valve spring retainer lock
18 {184,13.3}
Stud bolt
x3 Valve spring seat
Exhaust valve Guide bushing No. 2
Valve spring retainer
Valve stem oil seal
Valve spring
Valve spring retainer lock
N m {kgf cm}{ft lbf} : Specified torque
DISASSEMBLY
Non-reusable parts
ME-06971
1. Removal of chain cover mount bolt (1) Remove the chain cover mount bolt from the cylinder head.
A278767
Engine mechanical - CYLINDER HEAD ASSY (FA20)
2. Removal of stud bolt
<Reference>
Replace the stud bolt if deformed or damaged in the threaded portion.
(1) Remove the six stud bolts from the cylinder head.
C
Captions in illustration
*a Bank 1
*b Bank 2
EM79
EM
D
A278768J01
3. Removal of intake valve
<Caution>
During work, place a cloth, etc. to avoid scratching the mating surface of the cylinder head.
<Reference>
· Mark each part to prevent confusion.
· Organize disassembled parts by their installation positions.
(1) Compress the valve spring and remove the valve spring retainer
lock using SST.
556
SST 0920287002000
ME-06552
(2) Remove the valve, valve spring retainer, valve spring and valve spring seat.
4. Removal of exhaust valve <WARNING> · Metal sodium is included in the exhaust valve. Pay special attention to dealing and disposal of metal sodium because it is strong alkaline enough to cause a high chemical reaction. · Do not disassemble because metal sodium may cause vision loss, burn and fire due to chemical reaction. · It is safe as long as metal sodium is sealed in exhaust valve and not exposed to the air. · If exhaust valve is broken, remove the exhaust valve and dispose of the metal sodium. (Perform the pre-disposal process and disposal process.) · Do not break the exhaust valve intentionally to retrieve the metal sodium.
EM80
Engine mechanical - CYLINDER HEAD ASSY (FA20)
· To identify the exhaust valve including metal sodium, refer to its engraved mark. Captions in illustration
*a Engraved mark (identification: E2H·FA20 engine)
'*
EM
C
ME-06632
<Caution> During work, place a cloth, etc. to avoid scratching the mating surface of the cylinder head. <Reference> · Mark each part to prevent confusion. · Organize disassembled parts by their installation positions.
(1) Compress the valve spring and remove the valve spring retainer lock using SST. SST 0920287002000
556
ME-06553
(2) Remove the valve, valve spring retainer, valve spring and valve spring seat. 5. Removal of valve stem oil seal (1) Remove the eight valve stem oil seals. <Caution> · During work, place a cloth, etc. to avoid scratching the mating surface of the cylinder head. · Use special care not to damage the cylinder head and guide during work.
A278770
6. Removal of intake valve guide bushing No. 2 (1) Place the cylinder head on a wooden piece etc facing the combustion chamber upward.
Engine mechanical - CYLINDER HEAD ASSY (FA20)
EM81
(2) Using SST and a hammer, punch out intake valve guide bushing No. 2. SST 499765700 <Caution> · Place a wooden piece wrapped with a cloth to stabilize the cylinder head before work. · Use special care not to damage the cylinder head during work.
EM
556
ME-06554
7. Removal of exhaust valve guide bushing No. 2 (1) Place the cylinder head on a wooden piece etc facing the combustion chamber upward. (2) Using SST and a hammer, punch out exhaust valve guide bushing No. 2. SST 499765700 <Caution> · Place a wooden piece wrapped with a cloth to stabilize the cylinder head before work. · Use special care not to damage the cylinder head during work.
556
ME-06555
8. Disposal of exhaust valve <WARNING> · Metal sodium is included in the exhaust valve. Pay special attention to dealing and disposal of metal sodium because it is strong alkaline enough to cause a high chemical reaction. · Do not disassemble because metal sodium may cause vision loss, burn and fire due to chemical reaction. · It is safe as long as metal sodium is sealed in exhaust valve and not exposed to the air. · If exhaust valve is broken, remove the exhaust valve and dispose of the metal sodium. (Perform the pre-disposal process and disposal process.) · Do not break the exhaust valve intentionally to retrieve the metal sodium.
EM82
Engine mechanical - CYLINDER HEAD ASSY (FA20)
· To identify the exhaust valve including metal sodium, refer to its engraved mark. Captions in illustration
*a Engraved mark (identification: E2H·FA20 engine)
'*
EM
C
ME-06632
<Caution> <Pre-disposal process> · When industrial waste disposal process turns out to be dissolution, the process can be performed. · If exhaust valve is broken, remove from the cylinder head and dispose in the same method of general steel after performing the
process. · When performing the process, observe the followings.
(a) Prepare an extinguisher at hand. (b) Wear protective goggles. (c) Wear rubber gloves. <Disposal process> 1. Wearing rubber gloves, remove the broken exhaust valve from the cylinder head. 2. Prepare a large container (bucket or oil tin etc.) in a well ventilated place, and fill the container with over 10 liter of water.
3. Put in the broken exhaust valve longitudinally using a large tweezers or pliers. <Caution> · Let the broken exhaust valve completely sunken. · Keep fire away from the container because hydrogen gas generates due to chemical reaction. · Stay away at least 2 to 3 m {6.6 to 9.8 ft} from the container because of an intense chemical reaction.
ME-06635
4. After chemical reaction finishes (after the elapse of four to five hours), take out the exhaust valve using a large tweezers or pliers carefully, and dispose in the same disposal method as other parts. <Caution> · For disposal of chemically-reacted liquid waste (sodium hydroxide), follow all government and local regulations concerning disposal of liquid waste. · If chemically-reacted liquid waste (sodium hydroxide) touches skin, wash it off immediately with a sufficient amount of water.
INSPECTION
1. Inspection of cylinder head (1) Visually check that there are no cracks, scratches or other damage. (2) Use liquid penetrant testing (red check) on the important sections to check for fissures. (3) Check that there are no marks of gas leaking or water leaking on gasket attachment surface. (4) Check the warping of the cylinder head mating surface that mates with cylinder block at the locations shown in the figure using a straight edge and thickness gauge.
Engine mechanical - CYLINDER HEAD ASSY (FA20)
EM83
C
EM
D
A278772J01
Captions in illustration
*a
Bank 1
*b
Bank 2
Limit: 0.035 mm {0.00138 in} Grinding limit of cylinder head: 98.4 mm {3.874 in} or less Standard value for cylinder head height: 98.5 mm {3.878 in} <Reference> · Measurement should be performed at a temperature of 20°C {68°F}. · If there is warpage on the cylinder head mating surface, the cylinder head bolt tightening torque and angle tightening
may be improper. When installing the cylinder head, make sure that tightening to specified torque and angle tightening are performed precisely according to the operation procedures. · If it exceeds the limit, correct the surface by grinding it with a surface grinder or replace the cylinder head. · When the cylinder head is replaced, lap each valve.
2. Inspection of intake valve (1) Check the valve flange and stem for damage, wear or deformation.
EM84
Engine mechanical - CYLINDER HEAD ASSY (FA20)
(2) Using a caliper, measure the whole length of the valve. Captions in illustration
*a Overall length
Standard value: 103.3 mm {4.067 in} C
EM
A121380J12
(3) Using a caliper, measure the thickness of the valve head. Captions in illustration
*a Thickness
Standard value: 0.8 to 1.2 mm {0.0315 to 0.0472 in}
<Reference>
· It is possible to differentiate between the intake valve and the
exhaust valve by their overall length.
· If it is not within the specified value, replace the valve with a
C
new part.
A121379J06
· When the valve is replaced, lap the valve.
A121381
(4) Check the valve stem outer diameter using micrometer. Standard value: 5.455 to 5.470 mm {0.2148 to 0.2154 in} <Reference> · Measurement should be performed at a temperature of 20°C {68°F}. · Measure the outer diameter of the valve stem at the six locations as shown in the figure, and read the value of most worn location. · If it is not within the specified value, replace the valve with a new part. · When the valve is replaced, lap the valve.
3. Inspection of exhaust valve (1) Check the valve flange and stem for damage, wear or deformation. (2) Using a caliper, measure the whole length of the valve. Captions in illustration
*a Overall length
Standard value: 95.1 mm {3.744 in}
C
A121380J12
Engine mechanical - CYLINDER HEAD ASSY (FA20)
EM85
(3) Using a caliper, measure the thickness of the valve head. Captions in illustration
*a Thickness
Standard value: 1.0 to 1.4 mm {0.039 to 0.055 in}
<Reference>
· It is possible to differentiate between the intake valve and the
exhaust valve by their overall length.
C
EM · If it is not within the specified value, replace the valve with a new part.
A121379J06
· When the valve is replaced, lap the valve.
(4) Check the valve stem outer diameter using micrometer. Standard value: 5.445 to 5.460 mm {0.21437 to 0.21496 in}
<Reference> · Measurement should be performed at a temperature of 20°C
{68°F}.
· Measure the outer diameter of the valve stem at the six locations as shown in the figure, and read the value of most worn location.
A121381
· If it is not within the specified value, replace the valve with a new part.
· When the valve is replaced, lap the valve.
4. Inspection of valve guide bushing oil clearance (1) Using a caliper gauge, measure the inner diameter of valve guide bushing. Standard value: 5.500 to 5.512 mm {0.21654 to 0.21701 in}
<Reference> · Measurement should be performed at a temperature of 20°C
{68°F}.
· Measure the inner diameter of the valve guide bushing at the six locations as shown in the figure, and read the value of most worn location.
· If it is not within the standard value, replace the valve guide bushing.
(2) Calculate the oil clearance between valve and valve guide bushing. Standard value (intake): 0.030 to 0.057 mm {0.00118 to 0.00224 in}
Standard value (exhaust): 0.040 to 0.067 mm {0.00157 to 0.00264 in}
<Reference>
A278774
· Oil clearance = valve guide bushing inner dia. - Valve stem outer dia.
· If the clearance between valve and valve guide bushing exceeds the standard, replace the valve or valve guide, whichever shows the greater amount of wear or damage.
· When the valve is replaced, lap the valve.
5. Inspection of valve shim clearance (1) Visually check the valve shim for any damage.
EM86
Engine mechanical - CYLINDER HEAD ASSY (FA20)
EM
(2) Measure the valve stem end outer diameter using micrometer.
Standard value (intake): 5.455 to 5.470 mm
{0.21476 to 0.21535 in}
Standard value (exhaust): 5.445 to 5.460 mm
{0.21437 to 0.21496 in}
<Reference>
· Measurement should be performed at a temperature of 20°C
{68°F}.
· Measure the outer diameter of the valve stem end at the two
A278794
locations as shown in the figure, and read the value of most worn location.
· If it is not within the specified value, replace the valve with a
new part.
· When the valve is replaced, lap the valve.
(3) Using a caliper gauge, measure the inner diameter of valve shim.
Standard value: 5.500 to 5.560 mm {0.21654 to 0.21890 in}
<Reference>
· Measurement should be performed at a temperature of 20°C
{68°F}.
· Measure the inner diameter of the valve shim at the two
locations as shown in the figure, and read the value of most
worn location.
· If it is not within the standard value, replace the valve shim.
A278780
· If the valve shim has to be replaced, check the cam clearance and replace with the suitable valve shim.
(4) Calculate the clearance between valve and valve shim.
Standard value (intake): 0.030 to 0.105 mm {0.00118 to 0.00413 in}
Standard value (exhaust): 0.040 to 0.115 mm {0.00157 to 0.00453 in}
<Reference>
· Valve shim clearance = Valve shim inner dia. - Valve stem end outer dia.
· If it exceeds the standard, replace the valve or valve shim, whichever shows the greater amount of wear or damage.
· When the valve is replaced, lap the valve.
· If the valve shim has to be replaced, check the cam clearance and replace with the suitable valve shim.
6. Inspection of intake valve seat (1) Check the valve seat for damage and deformation. (2) Clean the valve and valve seat. (3) Apply a thin coat of engine oil to the valve stem, and apply red dye evenly on the valve face. Captions in illustration
*a Valve stem
*b Valve face
C D
A278781J01
(4) Slowly insert the valve applied with red dye into the valve guide bushing, lightly press the valve against the valve seat without turning the valve, and then slowly pull out the valve.
(5) Check the seating width of valve seat as shown in the figure, using a caliper gauge.
Engine mechanical - CYLINDER HEAD ASSY (FA20)
EM87
C
D
EM
#
q q q
A279579J01
Captions in illustration
*a
Bank 1
*b
Bank 2
Standard (A):
0.8 to 1.6 mm {0.032 to 0.063 in} (face at 90° in the figure)
<Reference>
· Check the seating width between valve and valve seat by measuring the width of red dye on the seating surface of
valve seat.
· If the seating width between valve and valve seat is not within standard, correct the seating surface of valve seat
using the valve seat cutter.
· When the red dye does not appear seamlessly on the valve seat seating surface, lap the valve.
· When the red dye does not appear seamlessly on the valve seat seating surface even after lapping the valve, correct
the valve seat seating surface using the valve seat cutter.
(6) Wipe off the red dye on the valve and valve seat completely.
EM88
C
EM
Engine mechanical - CYLINDER HEAD ASSY (FA20)
(7) Apply a thin coat of engine oil to the valve stem, and apply red dye evenly on the valve and valve seat seating surface. Captions in illustration
*a Valve stem *b Seating surface
D
A279580J01
(8) Slowly insert the valve into the valve guide bushing, lightly press the valve against the valve seat without turning the valve, and then slowly pull out the valve. (9) Check the seating position between valve and valve seat. Captions in illustration
*a Seating position
C
A281044J01
(10) After inspection, wipe off the red dye completely.
Standard (Seating position between valve and valve seat): Center all around the valve
<Reference> · Check the seating position between valve and valve seat by
checking the position of red dye on the valve face. · If the seating position between valve and valve seat is not at
the center of valve face, correct the seating surface of valve seat using the valve seat cutter.
7. Inspection of exhaust valve seat (1) Check the valve seat for damage and deformation. (2) Clean the valve and valve seat. (3) Apply a thin coat of engine oil to the valve stem, and apply red dye evenly on the valve face. Captions in illustration
*a Valve stem
*b Valve face
C D
A278781J01
(4) Slowly insert the valve applied with red dye into the valve guide bushing, lightly press the valve against the valve seat without turning the valve, and then slowly pull out the valve.
(5) Check the seating width of valve seat as shown in the figure, using a caliper gauge.
Engine mechanical - CYLINDER HEAD ASSY (FA20)
C
D
EM89
EM
#
q q q
A279603J01
Captions in illustration
*a
Bank 1
*b
Bank 2
Standard (A):
1.1 to 1.7 mm {0.043 to 0.067 in} (face at 90° in the figure)
<Reference>
· Check the seating width between valve and valve seat by measuring the width of red dye on the seating surface of
valve seat.
· If the seating width between valve and valve seat is not within standard, correct the seating surface of valve seat
using the valve seat cutter.
· When the red dye does not appear seamlessly on the valve seat seating surface, lap the valve.
· When the red dye does not appear seamlessly on the valve seat seating surface even after lapping the valve, correct
the valve seat seating surface using the valve seat cutter.
(6) Wipe off the red dye on the valve and valve seat completely.
EM90
C
EM
Engine mechanical - CYLINDER HEAD ASSY (FA20)
(7) Apply a thin coat of engine oil to the valve stem, and apply red dye evenly on the valve and valve seat seating surface. Captions in illustration
*a Valve stem *b Seating surface
D
A279604J01
(8) Slowly insert the valve into the valve guide bushing, lightly press the valve against the valve seat without turning the valve, and then slowly pull out the valve. (9) Check the seating position between valve and valve seat. Captions in illustration
*a Seating position
C
A281045J01
(10) After inspection, wipe off the red dye completely.
Standard (Seating position between valve and valve seat): Center all around the valve
<Reference> · Check the seating position between valve and valve seat by
checking the position of red dye on the valve face. · If the seating position between valve and valve seat is not at
the center of valve face, correct the seating surface of valve seat using the valve seat cutter.
8. Inspection of valve spring (1) Check the valve spring for damage and deformation. (2) Using a caliper, measure the free length of the valve spring. Standard value: 41.06 mm {1.617 in} <Reference> · Measurement should be performed at a temperature of 20°C {68°F}. · If it is not within the specified value, replace the valve spring.
A051437
(3) Using a valve spring tester, measure the load/length of the valve spring. Standard value: 182 to 210N/33.0mm {1.299in} 552 to 610N/22.0mm {0.866in} <Reference> · Measurement should be performed at a temperature of 20°C {68°F}. · If it is not within the specified value, replace the valve spring.
Engine mechanical - CYLINDER HEAD ASSY (FA20)
EM91
(4) Using a right angle gauge and caliper, measure the squareness of
C
the spring.
Limit (a):
2.5° (1.8 mm) {0.0710 in} or less
<Reference>
· Measurement should be performed at a temperature of 20°C
{68°F}.
· To check the squareness of the valve spring, stand the valve
EM spring on a flat table and check its deflection at the top of the
valve spring using a right angle gauge.
A146307J05
· If it is not within the specified value, replace the valve spring.
ASSEMBLY
1. Installation of intake valve guide bushing No. 2
(1) Before installing the valve guide bushing, make sure that neither scratches nor damages exist on the inner surface of
valve guide bushing installation holes of cylinder head.
(2) Draw a reference line for insert on the new valve guide bushing at
the position shown in the figure using a marker.
OO
KP
Captions in illustration
*a Reference line for insert
C
<Reference>
A reference line for insert is used as a guide when tapping-in the
valve guide bushing.
ME-06982
(3) Place the cylinder head on a wooden piece etc facing the combustion chamber downward. (4) Apply an enough coat of engine oil to the valve guide bushing, and set the valve guide bushing on the cylinder head.
(5) Using SST and a hammer, tap in the valve guide bushing down to the reference line for insert. SST 499765700 <Caution> · During work, place a cloth, etc. to avoid scratching the mating surface of the cylinder head. · Use special care not to damage the cylinder head during work.
556
ME-06556
EM92
EM
C
Engine mechanical - CYLINDER HEAD ASSY (FA20)
(6) While measuring the protrusion amount shown in the figure using a caliper gauge, tap in the valve guide bushing within the range of the standard. Captions in illustration
*a Protrusion amount
Specified protrusion amount: 11.4 to 11.8 mm {0.449 to 0.466 in} <Caution> · During work, place a cloth, etc. to avoid scratching the mating
surface of the cylinder head. · Use special care not to damage the cylinder head during work. <Reference> Be careful not to tap-in excessively by repeating the steps of Tapping-in several times Measurement Tapping-in several times Measurement when installing the valve guide bushing.
A278778J01
(7) Place the cylinder head on a wooden piece etc facing the combustion chamber upward.
<Caution>
· Place a wooden piece wrapped with a cloth to stabilize the cylinder head before work.
· Use special care not to damage the cylinder head during work.
(8) Using a hand reamer and pin vise, grind the inner surface of the
valve guide bushing so that the oil clearance is within the specified
value.
Standard value: 5.500 to 5.512 mm {0.21654 to 0.21701 in}
(20°C {68°F})
<Caution>
By widening the hole slowly and evenly using a hand reamer, grind so
that it is within the specified value.
<Reference>
· Apply engine oil to a hand reamer.
· If the inner surface of valve guide bushing is damaged, the
edge of the hand reamer should be slightly ground with an
abrasive sheet (No. 400).
· If the inner surface of valve guide bushing becomes lustrous
and the hand reamer does not chip, use a new hand reamer or
A281465
remedy the hand reamer.
(9) After reaming, clean the valve guide bushing to remove chips.
(10) Using a caliper gauge, measure the inner diameter of valve guide bushing to calculate the oil clearance between the
valve and valve guide bushing.
(11) Check the seating width between valve and valve seat.
2. Installation of exhaust valve guide bushing No. 2 (1) Before installing the valve guide bushing, make sure that neither scratches nor damages exist on the inner surface of
valve guide bushing installation holes of cylinder head.
(2) Draw a reference line for insert on the new valve guide bushing at
OO
KP
the position shown in the figure using a marker. Captions in illustration
C
*a Reference line for insert
<Reference>
A reference line for insert is used as a guide when tapping-in the
valve guide bushing.
ME-06983
(3) Place the cylinder head on a wooden piece etc facing the combustion chamber downward.
Engine mechanical - CYLINDER HEAD ASSY (FA20)
EM93
(4) Apply an enough coat of engine oil to the valve guide bushing, and set the valve guide bushing on the cylinder head.
(5) Using SST and a hammer, tap in the valve guide bushing down to
the reference line for insert.
SST 499765700
556
<Caution>
· During work, place a cloth, etc. to avoid scratching the mating
surface of the cylinder head.
· Use special care not to damage the cylinder head during work.
EM
ME-06557
(6) While measuring the protrusion amount shown in the figure using a caliper gauge, tap in the valve guide bushing within the range of the standard. Captions in illustration
*a Protrusion amount
Specified protrusion amount: 11.4 to 11.8 mm {0.449 to 0.466 in}
<Caution>
· During work, place a cloth, etc. to avoid scratching the mating
surface of the cylinder head.
· Use special care not to damage the cylinder head during work.
C
<Reference>
Be careful not to tap-in excessively by repeating the steps of
Tapping-in several times Measurement Tapping-in several
times Measurement when installing the valve guide bushing.
A279607J01
(7) Place the cylinder head on a wooden piece etc facing the combustion chamber upward.
<Caution>
· Place a wooden piece wrapped with a cloth to stabilize the cylinder head before work.
· Use special care not to damage the cylinder head during work.
(8) Using a hand reamer and pin vise, grind the inner surface of the
valve guide bushing so that the oil clearance is within the specified
value.
Standard value: 5.500 to 5.512 mm {0.21654 to 0.21701 in}
(20°C {68°F})
<Caution>
By widening the hole slowly and evenly using a hand reamer, grind so
that it is within the specified value.
<Reference>
A278779
· Apply engine oil to a hand reamer. · If the inner surface of valve guide bushing is damaged, the
edge of the hand reamer should be slightly ground with an
abrasive sheet (No. 400).
· If the inner surface of valve guide bushing becomes lustrous
and the hand reamer does not chip, use a new hand reamer or
remedy the hand reamer.
(9) After reaming, clean the valve guide bushing to remove chips.
EM94
Engine mechanical - CYLINDER HEAD ASSY (FA20)
(10) Using a caliper gauge, measure the inner diameter of valve guide bushing to calculate the oil clearance between the valve and valve guide bushing.
(11) Check the seating width between valve and valve seat.
3.
EM
Correction of intake valve seat <Caution> · Always perform cutting while checking the valve seating position and width. · Cut with a care to avoid any steps, and release force gradually towards end.
(1) Using a cutter head with 45°, cut so that the seating width is wider than the specified value.
q q
q
A278782J01
(2) Lap the valve. (3) Check the seating position between valve and valve seat.
<Reference> This procedure is necessary to select a seat cutter to be used in the following step. (4) Using the 30° or 75° seat cutter, correct the valve seat so that the seating width between valve and valve seat becomes the standard value.
Engine mechanical - CYLINDER HEAD ASSY (FA20)
EM95
#
$
%
EM
q q q
q q q
q q q
A279608J01
<Caution> · Always perform cutting while checking the valve seating position and width. · Cut with a care to avoid any steps, and release force gradually towards end. <Reference> Select a proper valve seat cutter according to the following table.
Seating position between valve and valve seat A in the figure B in the figure C in the figure
Seat cutter selection
When the seating position of valve face is high, grind the surface using the 30° seat cutter until seating width between valve and valve seat becomes the standard value.
When the seating position of valve face is low, grind the surface using the 75° seat cutter until seating width between valve and valve seat becomes the standard value.
When the seating position of valve face is at center, grind the surface evenly using the 30° and 75° seat cutters until seating width between valve and valve seat becomes the standard value.
(5) Lap the valve.
4. Correction of exhaust valve seat <Caution> · Always perform cutting while checking the valve seating position and width. · Cut with a care to avoid any steps, and release force gradually towards end.
EM96
EM
q q q
Engine mechanical - CYLINDER HEAD ASSY (FA20)
(1) Using a cutter head with 45°, cut so that the seating width is wider than the specified value.
A279605J01
(2) Lap the valve. (3) Check the seating position between valve and valve seat.
<Reference> This procedure is necessary to select a seat cutter to be used in the following step. (4) Using the 30° or 60° seat cutter, correct the valve seat so that the seating width between valve and valve seat becomes the standard value.
#
$
%
q q q
q q q
<Caution> · Always perform cutting while checking the valve seating position and width. · Cut with a care to avoid any steps, and release force gradually towards end. <Reference> Select a proper valve seat cutter according to the following table.
q q q
A279608J02
Engine mechanical - CYLINDER HEAD ASSY (FA20)
EM97
Seating position between valve and valve seat A in the figure B in the figure C in the figure
Seat cutter selection
When the seating position of valve face is high, grind the surface using the 30° seat cutter until seating width between valve and valve seat becomes the standard value.
When the seating position of valve face is low, grind the surface using the 60° seat cutter until seating width between valve and valve seat becomes the standard value.
When the seating position of valve face is at center, grind the surface evenly using the 30° and 60° seat cutters until seating width between valve and valve seat becomes the standard value.
(5) Lap the valve.
5. Lapping of valve
EM
(1) Apply a thin coat of engine oil to the valve stem, and apply a small
amount of valve compound evenly on the valve face.
Captions in illustration
*a Valve stem
*b Valve face
C
C E F
D
A278781J01
D
<Reference> · Be careful not to put the valve compound more than necessary. · To avoid damaging the valve guide bushing and valve stem, be
careful not to let the valve compound contact the valve stem. (2) Slowly insert the valve applied with the valve compound into the
valve guide bushing, and lap the seating surface between valve and valve seat. <Reference> · First, lift the valve and strike it against the valve seat twice, and
then slightly turn the valve once. Repeat these steps as one set. · To prevent the seating width between valve and valve seat from exceeding the standard value, be careful not to keep turning the valve while pressing it against the valve seat during lapping. · Be careful not to lift the valve too far during lapping in order to prevent the valve from coming off the valve guide bushing. (3) Wipe off the valve compound on the valve and valve seat completely after lapping. <Caution> Be careful not to leave any valve compound in order to avoid malfunction. (4) Check the seating width and seating position between valve and valve seat.
6. Installation of intake valve stem oil seal (1) Apply engine oil to the tip of the new intake valve stem oil seal. Captions in illustration
*a Intake side
*b Exhaust side
*c Grey
*d Light green
ME-07209
<Caution> · Be careful with the identification colors of valve stem oil seal. · Wrong assembly between intake side and exhaust side will cause
trouble.
EM98
EM 556
Engine mechanical - CYLINDER HEAD ASSY (FA20)
(2) Using SST, press in the intake valve stem oil seal fully into the valve guide bushing by hand. SST 18261AA010 <Caution> · During work, place a cloth, etc. to avoid scratching the mating surface of the cylinder head. · When installing the valve oil seal, press the SST with hands to install it and never drive the SST with a plastic hammer, otherwise the valve oil seal can be damaged. · Do not install the oil seal obliquely.
1-
0)
556
A281043J01
7. Installation of exhaust valve stem oil seal
(1) Using SST, press in the exhaust valve stem oil seal fully into the valve guide bushing by hand.
SST 18261AA010
<Caution>
· During work, place a cloth, etc. to avoid scratching the mating surface of the cylinder head.
· When installing the valve oil seal, press the SST with hands to install it and never drive the SST with a plastic hammer,
otherwise the valve oil seal can be damaged.
· Do not install the oil seal obliquely.
8. Installation of intake valve
<Caution>
· During work, place a cloth, etc. to avoid scratching the mating surface of the cylinder head.
· Install the valve spring with its narrow side facing to the cylinder head.
(1) Set the valve spring seat, valve spring and valve spring retainer onto the cylinder head.
(2) Apply engine oil to the valve stem of each valve and insert the valve into valve guide bushing.
<Caution>
When inserting the valve into valve guide bushing, use special care not to damage the oil seal lip.
(3) Using SST, compress the valve spring and install the valve spring
retainer lock applied with engine oil.
556
SST 0920287002000
ME-06552
(4) Using a plastic hammer, tap the tip of the valve stem slightly to settle the valve spring. <Caution> Do not strike the valve spring retainer.
A279609
Engine mechanical - CYLINDER HEAD ASSY (FA20)
EM99
9. Installation of exhaust valve <Caution> · During work, place a cloth, etc. to avoid scratching the mating surface of the cylinder head. · Install the valve spring with its narrow side facing to the cylinder head. (1) Set the valve spring seat, valve spring and valve spring retainer onto the cylinder head. (2) Apply engine oil to the valve stem of each valve and insert the valve into valve guide bushing. <Caution> When inserting the valve into valve guide bushing, use special care not to damage the oil seal lip.
EM (3) Using SST, compress the valve spring and install the valve spring retainer lock applied with engine oil. SST 0920287002000
556
ME-06553
(4) Using a plastic hammer, tap the tip of the valve stem slightly to settle the valve spring. <Caution> Do not strike the valve spring retainer.
A279610
10. Installation of stud bolt
C
(1) Install the six stud bolts onto the cylinder head.
Standard value: T=18N·m {184kgf·cm} {13.3 ft·lbf}
Captions in illustration
*a Bank 1
*b Bank 2
D
A278768J02
EM100
EM
Engine mechanical - CYLINDER HEAD ASSY (FA20)
11. Installation of chain cover mount bolt (1) Install the chain cover mount bolt to the cylinder head LH.
Standard value: T=6.4N·m {65kgf·cm} {4.7 ft·lbf}
A278767
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
CYLINDER BLOCK ASSY (FA20) Engine/hmyebcrhidasnyicsatelm
EXPLODED VIEW
EM101
Connecting rod cap Connecting rod bearing
Crankshaft Connecting rod bearing
Connecting rod ASSY
x2
First time: 10 {102,7.4} Second time: 25 {255,18.4} Third time: Further-tighten 92.5°
Connecting rod cap bolt
Cylinder block (bank 1 side)
Piston
Piston pin hole snap ring
Crankshaft Timing gear key
Piston pin hole snap ring
Piston pin
Piston ring set
Oil ring side rail
Oil ring expander
Oil ring side rail
Compression ring No. 2 Compression ring No. 1
EM
Crankshaft bearing No. 5
No. 1, No. 3 crankshaft bearing
No. 2, No. 4 crankshaft bearing
Cylinder block (bank 2 side)
N m {kgf cm}{ft lbf} : Specified torque
Non-reusable parts
ME-06972
EM102
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM
First time: 35 {357,25.8} Second time: Loosen 180°
Third time: 35 {357,25.8}
Fourth time: Loosen 180° Fifth time: 17 {173,12.5}
25 {255,18.4}
Sixth time:
Further-tighten 60°
x5 Washer
x10 x10
37 {377,27.3}
Cylinder block tight plug No. 1
6.4 {65,4.7}
x7
6.4 {65,4.7}
Crankshaft sensor holder ASSY
Oil separator cover
Engine rear oil seal
37 {377,27.3}
x2
Cylinder block tight plug No. 1
O-ring
Cylinder block plate
N m {kgf cm}{ft lbf} : Specified torque Non-reusable parts
x5
6.4 {65,4.7}
DISASSEMBLY
1. Removal of piston with connecting rod (1) Mark each connecting rod cap and piston with a cylinder number. (2) Turn the crankshaft to the position where the connecting rod cap bolt can be removed.
37 {377,27.3}
Cylinder block tight plug No. 1
ME-06973
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM103
(3) Using SST, remove the connecting rod cap bolt to remove the connecting rod cap. SST 18270AA020
EM
A279369
(4) Turn the crankshaft to separate the crankshaft pin and connecting
rod large end.
Captions in illustration
*1 Connecting rod
*2 Crankshaft pin
A279370J01
<Reference> When removing the piston with connecting rod No. 1 and No. 3, turn the crankshaft clockwise, on the other hand, when removing the piston with connecting rod No. 2 and No. 4, turn the crankshaft counter clockwise.
(5) Push the connecting rod in the direction of the arrow, and remove the piston along with the connecting rod from the cylinder block.
A279371
2. Removal of cylinder block SUB-ASSY (bank 1 side) <Caution> Be careful not to scratch the mating surface of cylinder block during work. (1) Move the engine stand so that bank 1 side faces upward. (2) Remove the five bolts shown in the figure.
A279375
EM104
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
(3) Loosen the ten cylinder block mounting bolts in the order as shown in the figure.
EM
A279376J01
(4) Remove the 10 bolts to remove the cylinder block (bank 1 side). <Caution> Lift the cylinder block (bank 1 side) slightly, and make sure that the crankshaft is remaining in the cylinder block (bank 2 side). If the cylinder block (bank 1 side) is lifted without care, the crankshaft may be lifted along and fall off from the cylinder block (bank 1 side). 3. Removal of crankshaft (1) Remove the crankshaft from the cylinder block (bank 2 side).
A279379
4. Removal of engine rear oil seal (1) Remove the engine rear oil seal.
5. Removal of O-ring (1) Remove the O-ring from the cylinder block (bank 2 side).
A279377
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM105
C
D
6. Removal of crankshaft bearing
(1) Remove the 10 crankshaft bearings from the cylinder block (bank 1 side and bank 2 side).
Captions in illustration
*1 No. 1, No. 3 crankshaft bearing
*2 No. 2, No. 4 crankshaft bearing
*3 Crankshaft bearing No. 5
*a Bank 1 *b Bank 2
EM
<Reference> · Organize disassembled parts by their installation positions. · Remove the bearing by pressing at the opposite side of the
locking lip.
A279378J01
7. Removal of oil separator cover (1) Remove the 7 bolts to remove the oil separator cover from the cylinder block (bank 1 side).
A279366
8. Removal of cylinder block SUB-ASSY (bank 2 side) (1) Remover the bolt to remove the engine stand from the cylinder block (bank 2 side). 9. Removal of cylinder block plate (1) Remove the 5 bolts to remove the cylinder bock plate from the cylinder block (bank 2 side).
A279368
EM106
EM
C D
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
10. Removal of crankshaft sensor holder ASSY (1) Remove the two bolts to remove the crankshaft sensor holder ASSY from the cylinder block (bank 2 side).
A278796
11. Removal of cylinder block tight plug No. 1 (1) Remove the three cylinder tight plugs No. 1 from the cylinder block (bank 1 side and bank 2 side). Captions in illustration
*a Bank 1 *b Bank 2
A278799J01
12. Removal of connecting rod bearing (1) Remove the connecting rod bearing from connecting rod and connecting rod cap. <Reference> Organize disassembled parts by their installation positions.
13. Removal of piston ring set <Reference> Organize disassembled parts by their installation positions. (1) Remove compression ring No. 1 and then, compression ring No. 2 in numerical order, using piston ring tool.
A094743
(2) Remove the oil rings in the order of oil ring side rail (upper), oil ring side rail (lower), oil ring expander by hand.
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM107
14. Removal of piston with pin (1) Remove either one of the piston pin hole snap rings from the piston using a flat tip screwdriver wrapped with protective tape. Captions in illustration
*1 Protective tape
<Reference>
Be careful not damage the piston and piston pin, by wrapping the
tip of flat tip screwdriver with tape. (2) Remove the piston pin from the piston.
EM
A283333J01
(3) Remove the other piston pin hole snap ring from the piston using a
flat tip screwdriver wrapped with protective tape.
<Reference>
Be careful not damage the piston and piston pin, by wrapping the
tip of flat tip screwdriver with tape.
INSPECTION
1. Inspection of cylinder block SUB-ASSY
(1) Visually inspect to make sure that there are no cracks, scratches or other damage.
(2) Use liquid penetrant testing (red check) on the important sections to check for fissures.
(3) Check that there are no traces of gas leaking or water leaking on the gasket attachment surface.
(4) Check the oil passages for clogging.
2. Inspection of cylinder block warpage
(1) Check for warpage of mating surfaces of the cylinder block and cylinder head using a straight edge and thickness gauge.
Service limit:
0.025 mm {0.00098in}
EM108
C
EM
D
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
A280641J01
Captions in illustration
*a
Bank 1
*b
Bank 2
<Reference> · Measurement should be performed at a temperature of 20°C {68°F}. · If it exceeds the limit, correct the surface by grinding it with a surface grinder or replace the cylinder block.
Grinding limit of cylinder block: 204.9mm {8.067in} Standard value for cylinder block height: 205.0mm {8.071in}
3. Inspection of cylinder liner (1) Measure the inner diameter of each cylinder at the positions shown in the figure, using a cylinder gauge to obtain the taper and out-of-roundness.
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
#
*
$
*
* *
EM109
EM
A279400J01
Standard value
Inner diameter A Inner diameter B
Service limit
86.005 to 86.015mm {3.38602 to 3.38641in} 85.995 to 86.005mm {3.38562 to 3.38602in}
Taper Out-of-roundness
Measuring point
0.030mm {0.00118in} 0.010mm {0.00039in}
H1
10.0mm {0.394in}
H2
45.0mm {1.772in}
H3
80.0mm {3.150in}
H4
115.0mm {4.528in}
<Reference>
· Measurement should be performed at a temperature of 20°C {68°F}.
· Measure the inner diameter of each cylinder liner in both the thrust and piston pin directions at the heights as shown
in the figure.
· If it is not within the standard, perform boring and honing, or replace the cylinder block and piston as a set.
· The cylinder bore size mark is stamped on the upper face of
C D
the cylinder block.
0Q 0Q 0Q 0Q 0Q
G H E F
A279399J01
Captions in illustration
*a Main journal size mark *b Cylinder block (bank 1/bank 2) combination mark *c Cylinder bore size mark No. 1 *d Cylinder bore size mark No. 2 *e Cylinder bore size mark No. 3 *f Cylinder bore size mark No. 4
EM110
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
4. Inspection of piston outer diameter
(1) Set a micrometer at 39.4 mm {1.551 in} from the upper face of piston skirt, and then measure the diameter at a right angle to the
OO
KP
pin hole. Standard value
Grade A
85.985 to 85.995mm {3.38523 to 3.38562in}
Grade B
85.975 to 85.985mm {3.38484 to 3.38523in}
EM
0.25mm {0.0098in} oversize 0.50mm {0.0197in} oversize
86.225 to 86.245mm {3.39468 to 3.39547in} 86.475 to 86.495mm {3.40452 to 3.40531in}
ME-06984
<Reference> · Measurement should be performed at a temperature of 20°C
{68°F}.
· Measure the outer diameter of each piston in thrust direction at
the height as shown in the figure.
· If it is not within the specified value, replace the piston.
· Standard sized pistons are classified into two grades, (A) and
(B). These grades should be used as guide lines in selecting a
standard piston.
· If the piston is replaced, check the clearance between cylinder
liner and piston and select a suitable sized piston.
5. Inspection of piston oil clearance
(1) Calculate the oil clearance from the inner diameter of cylinder liner and the outer diameter of piston.
Standard value: 0.010 to 0.030mm {0.00039 to 0.00118in} <Reference>
· Oil clearance = Cylinder maximum inner dia. - Piston outer dia.
· If it is not within the standard, perform boring and honing, or replace the cylinder block and piston as a set.
6. Correction of cylinder liner
(1) If any of the inner diameter, taper, out-of-roundness or clearance between cylinder liner and piston is out of standard or if
there is any damage on the cylinder liner, rebore it to replace with an oversize piston.
Boring limit:
86.505 mm {3.40570in} (inner diameter of cylinder liner)
<Reference>
· When any of the cylinder liner needs reboring, all other cylinder liners must be bored at the same time, and replaced with oversize pistons.
· If the inner diameter of cylinder liner exceeds the limit after boring and honing, replace the cylinder block and piston
as a set.
· Immediately after reboring, the inner diameter of cylinder liner may differ from its real diameter due to temperature rise. Thus, when measuring the inner diameter of cylinder liner, wait until it has cooled to a temperature of 20°C {68°F}.
7. Inspection of piston with pin
(1) Check the piston and piston pin for wear or crack.
(2) Check the piston hole snap ring for distortion or wear. (3) Check the piston ring groove for damage.
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
(4) Check the groove for burr. Captions in illustration
*1 Groove
<Reference> If the burr is found, remove the burr from groove.
EM111
A279402J01
EM
(5) Check that the piston pin can be inserted into the piston with a thumb. <Reference> Inspection should be performed at a temperature of 20°C {68°F}.
8. Inspection of connecting rod small end bushing (1) Check that the connecting rod small end bushing is not damaged.
A279403
9. Inspection of piston pin oil clearance (1) Using a caliper gauge, measure the inner diameter of piston pin hole. <Reference> · Measurement should be performed at a temperature of 20°C {68°F}. · Measure the inner diameter of the piston pin hole at the four locations as shown in the figure, and read the value of most worn location. · Record the measured value.
OO
KP
OO
KP
(2) Check the piston pin outer diameter at the position shown in the figure using a micrometer. <Reference> · Measurement should be performed at a temperature of 20°C {68°F}. · Measure the outer diameter of the piston pin at the four locations as shown in the figure, and read the value of most worn location. · Record the measured value.
ME-06985
A281040
(3) Using a caliper gauge, measure the inner diameter of connecting rod bushing. <Reference> · Measurement should be performed at a temperature of 20°C {68°F}. · Measure the inner diameter of the connecting rod bushing at the two locations as shown in the figure, and read the value of most worn location. · Record the measured value.
(4) Calculate the clearance between piston and piston pin. Standard value: 0.004 to 0.008mm {0.00016 to 0.00031in} <Reference> · Oil clearance = Piston pin hole inner dia. - Piston pin outer dia. · If it is not within the standard, replace the piston and piston pin as a set.
(5) Calculate the clearance between piston pin and connecting rod bushing.
EM112
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
Standard value: 0.006 to 0.026mm {0.00024 to 0.00102in} <Reference> · Oil clearance = Connecting rod bushing inner dia. - Piston pin
outer dia. · If the clearance between piston pin and connecting rod bushing
is not within the standard, replace the connecting rod and piston pin as a set.
EM 10. Inspection of piston ring (1) Make sure the piston ring is not broken or damaged. <Reference> · If damaged, replace the piston ring. · Use piston ring with same size as piston when replacing piston ring.
11. Inspection of ring closed gap (1) Using the piston, set the piston ring into cylinder liner at a right angle. Captions in illustration
*1 Piston ring
<Reference> Press down into the cylinder liner until the ring gets in down to the crown of the piston.
ME-06585
(2) Measure the closed gap of the piston ring using a thickness gauge. Standard value
A279405
No. 1 No. 2
Oil
0.20 to 0.25mm {0.00784 to 0.00984in} 0.60 to 0.70mm {0.02362 to 0.02756in} 0.10 to 0.35mm {0.00394 to 0.01378in}
<Reference> · Measurement should be performed at a temperature of 20°C
{68°F}. · If it is not within the standard value, replace the piston ring. · Use piston ring with same size as piston when replacing piston
ring.
12. Inspection of clearance piston ring and ring groove (1) Fit the piston ring straight into the piston ring groove, then check the clearance between piston ring and piston using a thickness gauge. Standard value
A279515
No. 1 No. 2
0.030 to 0.080mm {0.00118 to 0.00315in} 0.030 to 0.070mm {0.00118 to 0.00276in}
<Reference> · Measurement should be performed at a temperature of 20°C
{68°F}. · Before inspecting the clearance, clean the piston ring groove
and piston ring. · If it is not within the standard value, replace the piston ring.
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM113
· Use piston ring with same size as piston when replacing piston ring.
13. Inspection of connecting rod ASSY (1) Check that the large or small end thrust surface of each connecting rod is not damaged. (2) Check each connecting rod bearing for scar, peeling, seizure, melting or wear, etc. (3) Check for bend using a connecting rod aligner. Limit (per a length of 100 mm {3.937 in}): 0.10mm {0.0039in}
EM <Reference>
· Measurement should be performed at a temperature of 20°C {68°F}.
· If it exceeds the limit, replace the connecting rod.
ME-06586
(4) Check for twist using a connecting rod aligner. Limit (per a length of 100 mm {3.937 in}): 0.10mm {0.0039in} <Reference> · Measurement should be performed at a temperature of 20°C {68°F}. · If it exceeds the limit, replace the connecting rod.
ME-06587
14. Inspection of connecting rod thrust clearance (1) Clean the connecting rod bearing and crank pin and apply engine oil to the crank pin.<*1> (2) With the claw aligned in position, assemble the connecting rod bearing with the connecting rod and connecting rod cap. Captions in illustration
*a Claw position
C
A281479J01
EM114
EM
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
(3) Check the identification symbol, and set the connecting rod, connecting rod cap and connecting rod cap bolt. Captions in illustration
*1 Identification symbol
<Reference> · Measurement should be performed at a temperature of 20°C
{68°F}. · Each connecting rod has its own mating cap.
A281041J01
(4) Apply engine oil to the bolt threads.
556
(5) Using SST, tighten the connecting rod cap bolts in the order as shown in the figure. SST 18270AA020
Standard value: T=10N·m {102kgf·cm} {7.4ft·lbf}
<Caution> · Make sure to hold the crankshaft securely during work. · When holding the crankshaft, be careful not to damage the
crankshaft.
ME-06649
(6) Further tighten the connecting rod cap bolts.<*2>
Standard value: T=25N·m {255kgf·cm} {18.4ft·lbf}
<Caution> · Make sure to hold the crankshaft securely during work. · When holding the crankshaft, be careful not to damage the crankshaft. (7) Using steps <*1> through <*2>, assemble the piston with connecting rod No. 2, No.3 and No. 4 as well as No. 1.
556
556
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM115
(8) Further-tighten the connecting rod cap bolts No. 1 through No. 4 by 92.5° in the order as shown in the figure using SST. SST 18270AA020, 18854AA000 <Caution> · Make sure to hold the crankshaft securely during work. · When holding the crankshaft, be careful not to damage the crankshaft.
ME-06646
EM
(9) Check the thrust clearance of each connecting rod using a thickness gauge. Standard value: 0.070 to 0.330mm {0.00276 to 0.01299in} <Reference> · If it is not within the standard value, replace the connecting rod. · Measure the thrust clearance of each connecting rod at several points, and replace the connecting rod if there is uneven wear.
A279519
15. Inspection of connecting rod bearing oil clearance (1) Remove the connecting rod bearing.<*1> (2) Set the connecting rod bearing to the connecting rod and connecting rod cap. (3) Place the plastigauge to the axial direction of crankshaft pin, and then, check the identification symbol, and set the connecting rod, connecting rod cap and connecting rod cap bolt. Captions in illustration
*1 Identification symbol
<Reference> · Measurement should be performed at a temperature of 20°C
{68°F}. · Each connecting rod has its own mating cap.
A281041J01
(4) Apply engine oil to the bolt threads.
EM116
EM
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
(5) Using SST, tighten the connecting rod cap bolts in the order as
shown in the figure.
SST 18270AA020
Standard value: T=10N·m {102kgf·cm} {7.4ft·lbf}
<Caution>
· Do not turn the crankshaft during measuring.
· Make sure to hold the crankshaft securely during work.
· When holding the crankshaft, be careful not to damage the
crankshaft.
556
ME-06649
(6) Further tighten the connecting rod cap bolts.<*2>
Standard value: T=25N·m {255kgf·cm} {18.4ft·lbf}
<Caution> · Do not turn the crankshaft during measuring. · Make sure to hold the crankshaft securely during work. · When holding the crankshaft, be careful not to damage the crankshaft. (7) Using steps <*1> through <*2>, assemble the piston with connecting rod No. 2, No.3 and No. 4 as well as No. 1.
(8) Further-tighten the connecting rod cap bolts No. 1 through No. 4 by
92.5° in the order as shown in the figure using SST.
SST 18270AA020, 18854AA000
556
<Caution> · Do not turn the crankshaft during measuring. · Make sure to hold the crankshaft securely during work. · When holding the crankshaft, be careful not to damage the
crankshaft.
556
ME-06646
A279521
(9) Remove the bearing cap to measure the widest point of the plastigauge. Standard value: 0.025 to 0.055mm {0.00098 to 0.00217in} <Caution> Completely remove the plastigauge after measuring. <Reference> · If it is not within the standard value, replace the connecting rod bearing. · Measure the outer diameter of crank pin using micrometer, and select the suitable size connecting rod bearing when replacing the connecting rod bearing.
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM117
Standard value
Bearing Standard 0.03 mm (0.0012 in.) Undersize 0.05 mm (0.0020 in.) Undersize 0.25 mm (0.0098 in.) Undersize
Bearing size (Thickness at center) 1.492 to 1.508 mm (0.05874 to 0.05937 in.) 1.511 to 1.515 mm (0.05949 to 0.05965 in.) 1.521 to 1.525 mm (0.05988 to 0.06004 in.) 1.621 to 1.625 mm (0.06382 to 0.06398 in.)
Outer diameter of crank pin 49.976 to 50.000 mm (1.96756 to 1.96850 in.) 49.946 to 49.970 mm (1.96637 to 1.96732 in.) 49.926 to 49.950 mm (1.96559 to 1.96653 in.) 49.726 to 49.750 mm (1.95771 to 1.95866 in.)
16. Inspection of crankshaft
(1) Clean the crankshaft completely, and check it for cracks using liquid penetrant testing (red check). (2) Using a dial gauge, check the crankshaft bend.
EM
Service limit:
0.035mm {0.00138in}
<Reference>
· Measurement should be performed at a temperature of 20°C
{68°F}.
· If a suitable V-block is not available, using just crankshaft
bearings No. 1 and No. 5, position the crankshaft on cylinder
block. Then, measure the crankshaft bend using a dial gauge.
· If it exceeds the limit, grind to correct the crankshaft journal or
A279522
replace the crankshaft.
(3) Measure the outer diameter of the crank pin and journal using a micrometer to calculate the taper and out-of-roundness. Limit (pin)
Taper Out-of-roundness
0.006mm {0.00024in} 0.005mm {0.00020in}
Limit (journal)
Taper Out-of-roundness
0.006mm {0.00024in} 0.005mm {0.00020in}
Grinding limit
Pin Journal
47.726mm {1.87897in} 67.735mm {2.6673in}
Standard value
Bearing
Standard
0.03 mm (0.0012 in.) Undersize
0.05 mm (0.0020 in.) Undersize
0.25 mm (0.0098 in.) Undersize
Connecting rod bearing thickness (at center)
1.492 to 1.508 mm (0.05874 to 0.05937 in.)
1.511 to 1.515 mm (0.05949 to 0.05965 in.)
1.521 to 1.525 mm (0.05988 to 0.06004 in.)
1.621 to 1.625 mm (0.06382 to 0.06398 in.)
A279523
<Reference> · Measurement should be performed at a temperature of 20°C
{68°F}. · If it is not within the standard, replace the connecting rod
bearing or crankshaft bearing, and grind to correct the crank pin or journal, or replace the crankshaft as required. · Select the suitable size connecting rod bearing or crankshaft bearing when replacing the connecting rod bearing or crankshaft bearing. · When grinding to correct the crank journal or crank pin, finish them to the suitable dimensions as shown in the table below according to the undersize bearing to be used.
Crank pin outer diameter
49.976 to 50.000 mm (1.96756 to 1.96850 in.)
49.946 to 49.970 mm (1.96637 to 1.96732 in.)
49.926 to 49.950 mm (1.96559 to 1.96653 in.)
49.726 to 49.750 mm (1.95771 to 1.95866 in.)
Crank shaft bearing thickness (at center)
No. 1 to No. 4
No. 5
2.495 to 2.513 mm
2.493 to 2.511 mm
(0.09823 to 0.09894 in.) (0.09815 to 0.09886 in.)
2.519 to 2.522 mm
2.517 to 2.520 mm
(0.09917 to 0.09929 in.) (0.09909 to 0.09921 in.)
2.529 to 2.532 mm
2.527 to 2.530 mm
(0.09957 to 0.09968 in.) (0.09949 to 0.09961 in.)
2.629 to 2.632 mm
2.627 to 2.630 mm
(0.10350 to 0.10362 in.) (0.10342 to 0.10354 in.)
Crankshaft journal diameter
67.985 to 68.009 mm (2.67657 to 2.67751 in.)
67.955 to 67.979 mm (2.67539 to 2.67633 in.)
67.935 to 67.959 mm (2.67460 to 2.67555 in.)
67.735 to 67.759 mm (2.66673 to 2.66767 in.)
EM118
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
17. Inspection of crankshaft bearing
(1) Check the crankshaft bearing for scar, peeling, seizure, melting or wear, etc.
18. Inspection of crankshaft thrust clearance
(1) Use a thickness gauge to check the thrust clearance of crankshaft
at crankshaft bearing No. 5.
Standard value: 0.130 to 0.308mm {0.00512 to 0.01213in}
<Reference>
EM
If it is not within the standard value, replace crankshaft bearing No. 5.
A279524
19. Inspection of crankshaft oil clearance (1) Remove the gasket from cylinder block.
(2) Clean each crankshaft bearing and crankshaft journal.
C
(3) Set each crankshaft bearing to the cylinder block. Captions in illustration
*1 Crankshaft bearing No. 1, No. 3 (with groove)
*2 Crankshaft bearing No. 2, No. 4 (without groove)
*3 Crankshaft bearing No. 5
*a Bank 1
*b Bank 2
D
<Caution> · Be careful not to scratch the mating surface of cylinder block
during work. · Because journal bearings No. 1 and No. 3 differ from No. 2 and No.
4, confirm at assembly.
A279378J01
(4) Set the crankshaft to the cylinder block (bank 2 side). (5) Set a plastigauge to the axial direction of the crankshaft journal. (6) Set the cylinder block (bank 1 side) to the cylinder block (bank 2 side). (7) Apply engine oil to the washers and cylinder block mounting bolt threads.
<Caution> To prevent mixture of engine oil into the water jacket, do not apply a large amount.
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM119
(8) Tighten the ten mounting bolts in the order as shown in the figure.
Standard value: T=35N·m {357kgf·cm} {25.8ft·lbf}
<Caution> When tightening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
A279376J02
EM
(9) Loosen the ten mounting bolts by 180° in the order as shown in the figure. <Caution> When loosening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
A279376J01
(10) Tighten the ten mounting bolts in the order as shown in the figure.
Standard value: T=35N·m {357kgf·cm} {25.8ft·lbf}
<Caution> When tightening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
A279376J02
(11) Loosen the four mounting bolts by 180° in the order as shown in the figure. <Caution> When loosening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
A283331J01
(12) Tighten the four mounting bolts in the order as shown in the figure.
Standard value: T=17N·m {173kgf·cm} {12.5ft·lbf}
<Caution> When tightening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
A283331J02
EM120
C
EM
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
556
ME-06645
(13) Further-tighten the four mounting bolts by 60° in the order as shown in the figure using SST. SST 18854AA000 Captions in illustration
*a temporary bolt
<Caution> When tightening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block. <Reference> As necessary, attach the temporary bolt to fix SST. (14) Loosen the six mounting bolts by 180° in the order as shown in the figure. <Caution> When loosening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
A283332J01
(15) Tighten the six mounting bolts in the order as shown in the figure.
Standard value: T=17N·m {173kgf·cm} {12.5ft·lbf}
<Caution> When tightening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
A283332J02
C
556
ME-06647
(16) Further-tighten the six mounting bolts by 60° in the order as shown in the figure using SST. SST 18854AA000 Captions in illustration
*a temporary bolt
<Caution> When tightening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block. <Reference> As necessary, attach the temporary bolt to fix SST. (17) Loosen the ten cylinder block mounting bolts in the order as shown in the figure.
A279376J01
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM121
(18) Remove the 10 bolts to remove the cylinder block (bank 1 side)
<Caution> Lift the cylinder block (bank 1 side) slightly, and make sure that the crankshaft is remaining in the cylinder block (bank 2 side). If the cylinder block (bank 1 side) is lifted without care, the crankshaft may be lifted along and fall off from the cylinder block (bank 1 side).
(19) Measure the widest point of the plastigauge.
Standard value: 0.013 to 0.031mm {0.00051 to 0.00122 in}
<Caution> Completely remove the plastigauge after measuring. <Reference>
EM
· If it is not within the standard, replace the crankshaft bearing,
and grind to correct the crankshaft journal or replace the
crankshaft as required.
· Select the crankshaft bearing of suitable size according to the
A279521
table below when replacing crankshaft bearing. · When grinding to correct the crankshaft journal, finish them to
the suitable dimensions as shown in the table below according
to the undersize bearing to be used.
Standard value
Bearing
Connecting rod bearing Crank pin outer diameter
thickness (at center)
Crank shaft bearing thickness (at center)
No. 1 to No. 4
No. 5
Crankshaft journal diameter
Standard
1.492 to 1.508 mm
49.976 to 50.000 mm
2.495 to 2.513 mm
2.493 to 2.511 mm
67.985 to 68.009 mm
(0.05874 to 0.05937 in.) (1.96756 to 1.96850 in.) (0.09823 to 0.09894 in.) (0.09815 to 0.09886 in.) (2.67657 to 2.67751 in.)
0.03 mm (0.0012 in.)
1.511 to 1.515 mm
49.946 to 49.970 mm
2.519 to 2.522 mm
2.517 to 2.520 mm
67.955 to 67.979 mm
Undersize
(0.05949 to 0.05965 in.) (1.96637 to 1.96734 in.) (0.09917 to 0.09929 in.) (0.09909 to 0.09921 in.) (2.67539 to 2.67633 in.)
0.05 mm (0.0020 in.)
1.521 to 1.525 mm
49.926 to 49.950 mm
2.529 to 2.532 mm
2.527 to 2.530 mm
67.935 to 67.959 mm
Undersize
(0.05988 to 0.06004 in.) (1.96559 to 1.96653 in.) (0.09957 to 0.09968 in.) (0.09949 to 0.09961 in.) (2.67460 to 2.67555 in.)
0.25 mm (0.0098 in.)
1.621 to 1.625 mm
49.726 to 49.750 mm
2.629 to 2.632 mm
2.627 to 2.630 mm
67.735 to 67.759 mm
Undersize
(0.06382 to 0.06398 in.) (1.95771 to 1.95866 in.) (0.10350 to 0.10362 in.) (0.10342 to 0.10354 in.) (2.66673 to 2.66767 in.)
ASSEMBLY
1. Installation of cylinder block tight plug No. 1
<Caution> · During the work, stabilize the cylinder block by placing it on a wooden piece wrapped with cloth etc, in this case be careful not to
contact the knock pin with the wooden piece. · Be careful not to scratch the mating surface of cylinder block during work.
(1) Apply THREE BOND 1105 or equivalent to the threaded portions
of three cylinder block tight plug No. 1s and install to cylinder block
C
(bank 1 side and bank 2 side).
Captions in illustration
*a Bank 1
*b Bank 2
Standard value: T=37N·m {377kgf·cm} {27.3ft·lbf}
<Caution>
D
Before applying liquid gasket, degrease the thread holes of the
cylinder block and main gallery plug.
A279611J01
EM122
EM
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
2. Installation of crankshaft sensor holder ASSY (1) Install the crankshaft sensor holder ASSY to the cylinder block (bank 2 side) with two bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7ft·lbf}
A278796
3. Installation of cylinder block plate (1) Install the cylinder block plate to the cylinder block (bank 2 side) with five bolts.
Standard value: T=6.4N·m {65kgf·cm} {4.7ft·lbf}
A279368
4. Installation of oil separator cover (1) Apply THREE BOND 1217G or equivalent to the mating surface of the new oil separator cover. Captions in illustration
*a Dia. 3.0 to 5.0mm {0.138 to 0.197in}
C
A279367J01
<Caution> · Clean and degrease the fitting surface. · Install within 5 min. after applying liquid gasket.
(2) Tighten seven bolts in order as shown in the figure, and install the oil separator cover to the cylinder block (bank 1 side).
Standard value: T=6.4N·m {65kgf·cm} {4.7ft·lbf}
A279366
5. Installation of O-ring (1) Install a new O-ring to the cylinder block (bank 2 side).
A279377
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM123
C
D
6. Installation of crankshaft bearing
(1) Apply engine oil to the ten crankshaft bearing and install to cylinder block (bank 1 side and bank 2 side).
Captions in illustration
*1 Crankshaft bearing No. 1, No. 3 (with groove)
*2 Crankshaft bearing No. 2, No. 4 (without groove)
*3 Crankshaft bearing No. 5
*a Bank 1 *b Bank 2
EM
<Caution> · Be careful not to scratch the mating surface of cylinder block
during work. · Because journal bearings No. 1 and No. 3 differ from No. 2 and No.
4, confirm at assembly.
A279378J01
7. Installation of crankshaft (1) Apply engine oil to the crankshaft journal, and set to the cylinder block (bank 2 side).
A279379
8. Installation of cylinder block SUB-ASSY (bank 1 side) (1) Apply THREE BOND 1217G or equivalent to the mating surface of the cylinder block (bank 1 side) as shown in the figure.
OO
KP D
C
E # #
D
Captions in illustration
*a
Dia. 3.5 to 4.5mm {0.138 to 0.177in}
*c
Range A-A
*e
Dia. 2.7 to 3.7mm {0.106 to 0.146in}
*g
2.0mm {0.079in}
F ##
F $
% %
$ OO
$$
$
KP
$
I
%%
G J H J H J
ME-06986
*b
Dia. 0.5 to 1.5mm {0.0197 to 0.0591in}
*d
Within 1.0mm {0.039in}
*f
Dia. 3.5 to 4.5mm {0.138 to 0.177in}
*h
Groove
EM124
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM
<Caution>
· Do not let the gasket overflow to the oil passage and crankshaft bearing portions, because the engine seizure may result.
· Clean and degrease the fitting surface.
· Install within 5 min. after applying liquid gasket.
(2) Install the cylinder block (bank 1 side) to the cylinder block (bank 2 side).
(3) Apply engine oil to the washers and cylinder block mounting bolt threads.
<Caution>
To prevent mixture of engine oil into the water jacket, do not apply a large amount.
(4) Tighten the ten mounting bolts in the order as shown in the figure.
Standard value: T=35N·m {357kgf·cm} {25.8ft·lbf}
<Caution> When tightening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the
joint accuracy of the cylinder block.
A279376J02
(5) Loosen the ten mounting bolts by 180° in the order as shown in the figure. <Caution> When loosening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
A279376J01
(6) Tighten the ten mounting bolts in the order as shown in the figure.
Standard value: T=35N·m {357kgf·cm} {25.8ft·lbf}
<Caution> When tightening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
A279376J02
(7) Loosen the four bolts by 180° in the order as shown in the figure. <Caution> When loosening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
A283331J01
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM125
(8) Tighten the four mounting bolts in the order as shown in the figure.
Standard value: T=17N·m {173kgf·cm} {12.5ft·lbf}
<Caution> When tightening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
A283331J02
EM
(9) Further-tighten the four mounting bolts by 60° in the order as
shown in the figure using SST.
SST 18854AA000
556
Captions in illustration
*a temporary bolt
C
<Caution>
When tightening the mounting bolts, hold the cylinder block (bank 2
side) while not holding the cylinder block (bank 1 side) to ensure the
joint accuracy of the cylinder block.
ME-06645
<Reference> As necessary, attach the temporary bolt to fix SST.
(10) Loosen the six mounting bolts by 180° in the order as shown in the
figure. <Caution> When loosening the mounting bolts, hold the cylinder block (bank 2
side) while not holding the cylinder block (bank 1 side) to ensure the
joint accuracy of the cylinder block.
A283332J01
(11) Tighten the six mounting bolts in the order as shown in the figure.
Standard value: T=17N·m {173kgf·cm} {12.5ft·lbf}
<Caution> When tightening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block.
C
A283332J02
556
ME-06647
(12) Further-tighten the six mounting bolts by 60° in the order as shown in the figure using SST. SST 18854AA000 Captions in illustration
*a temporary bolt
<Caution> When tightening the mounting bolts, hold the cylinder block (bank 2 side) while not holding the cylinder block (bank 1 side) to ensure the joint accuracy of the cylinder block. <Reference> As necessary, attach the temporary bolt to fix SST.
EM126
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
EM
(13) Install the five bolts shown in the figure.
Standard value: T=25N·m {255kgf·cm} {18.4ft·lbf}
<Reference> After tightening, if the gasket is squeezed out in the seal surface area of the oil pan upper, completely remove any gasket that is squeezed out. However, gasket in the groove should not be removed.
A279375
9. Installation of engine rear oil seal
(1) Apply a little coat of engine oil to the inside and outside of the new engine rear oil seal.
(2) Using SST, strike in the engine rear oil seal equally flush with the
end surface of the cylinder block.
SST 18671AA020, 18657AA030
<Caution>
· Do not hammer in the engine rear oil seal obliquely.
· Wipe off the oil attached to the crankshaft.
· Do not hammer in the engine rear oil seal too deep.
<Reference>
556
The strike amount of the engine rear oil seal is allowed within 0 to -
556
1.0 mm {0 to 0.039 in} from the end surface of the cylinder block.
ME-06589
10. Installation of cylinder block SUB-ASSY (1) Mount the cylinder block SUB-ASSY onto the engine stand.
11. Installation of piston with pin (1) Install the piston pin hole snap ring to one side of the piston using a screwdriver wrapped with protective tape. Captions in illustration
*1 Protective tape
C
A281475J01
<Reference> · Make sure the piston pin hole snap ring is firmly inserted into
the groove. · After installing the piston pin hole snap ring, turn the piston pin
hole snap ring so that the end and cutout portion of the hole snap ring do not match. Captions in illustration
*1 Piston pin hole snap ring
*a OK
*b NG
D
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Engine mechanical - CYLINDER BLOCK ASSY (FA20)
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(2) Set the piston to the connecting rod. Captions in illustration
*1 Front mark *a Bank 1 *b Bank 2
<Reference>
Align the front mark of piston and the connecting rod direction
correctly as shown in the figure. (3) Apply engine oil to the piston pin, and attach the piston pin.
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(4) Install the piston pin hole snap ring to the piston using a screwdriver wrapped with protective tape. Captions in illustration
*1 Protective tape
<Reference> · Make sure the piston pin hole snap ring is firmly inserted into
the groove. · After installing the piston pin hole snap ring, turn the piston pin
hole snap ring so that the end and cutout portion of the hole snap ring do not match.
Captions in illustration
*1 Piston pin hole snap ring *a OK *b NG
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12. Installation of piston ring set (1) Install the oil ring in the order of oil ring expander, side rail (lower) and oil ring side rail (upper) by hand. <Reference> Oil ring consists of oil ring side rail (upper), oil ring expander and oil ring side rail (lower). (2) Set the oil ring expander gap to the position (B) in the figure.
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Engine mechanical - CYLINDER BLOCK ASSY (FA20)
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(3) Engage the lower turn stopper of the oil ring side rail (lower) in the oil notch of the coated piston skirt cutout at the position (A) in the figure and engage the upper turn stopper to the oil ring expander. Captions in illustration
*1 Front mark *2 Oil ring side rail (lower) *3 Oil ring expander *4 Cutout portion *a 0 to 20°
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(4) Align the oil ring side rail (upper) gap to position (C) (0 to 20°) in the figure and engage the upper turn stopper to the oil
ring expander.
(5) Using a piston ring tool, install compression ring No. 2 and then, compression ring No. 1in numerical order with a
stamped mark upward.
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(6) Set the gap of compression ring No. 1 to the position (A) or (B) in the figure.
<Reference>
Either (A) or (B) is good for compression ring No. 1 if it points in the
piston pin direction.
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(7) Set the gap of compression ring No. 2 to the position (A) or (B), 180° opposite side of compression ring No. 1, in the figure.
(8) Check that the positions of piston ring and oil ring gap are properly adjusted. 13. Installation of piston with connecting rod
(1) Move the engine stand to face the oil pan side of the cylinder block upward. (2) With the claw aligned in position, assemble the connecting rod bearing with the connecting rod and connecting rod cap. <*a> Captions in illustration
*a Claw position
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(3) Check that the positions of piston ring and oil ring gap are properly adjusted. (4) Apply engine oil to the outer circumference of each piston, crank pin, and in the cylinder block.
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
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(5) Turn the crankshaft so that the crankshaft pin position comes to TDC. Captions in illustration
*1 Crankshaft pin
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(6) Compress the piston ring using piston ring compressor, and insert the piston with connecting rod into the cylinder block by tapping the piston crown using the handle of a plastic hammer etc. <Caution> · Be careful not to damage the cylinder liner and crankshaft pin by the connecting rod large end. · Do not apply strong impact when inserting the piston with connecting rod to prevent connecting rod bearing from falling off. <Reference> Face the piston front mark towards the front of the engine.
(7) Apply engine oil to the connecting rod cap seat and the connecting rod cap bolt threads. (8) Turn the crankshaft so that the crank pin and the large end of connecting rod are positioned as shown in the figure, while pressing the piston crown, and then install the connecting rod cap using the connecting rod cap bolt. Captions in illustration
*1 Connecting rod
*2 Crankshaft pin
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Engine mechanical - CYLINDER BLOCK ASSY (FA20)
<Reference> · Each connecting rod has its own mating cap. Make sure that
they are assembled correctly by checking their identification symbols. Captions in illustration
*1 Identification symbol
· Use a new connecting rod cap bolt. · When installing piston with connecting rod No. 1 and No. 3,
turn the crankshaft counter-clockwise, on the other hand, when installing the piston with connecting rod No. 2 and No. 4, turn the crankshaft clockwise.
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(9) Using SST, tighten the two connecting rod cap bolts in the order as shown in the figure. SST 18270AA020 Captions in illustration
*a Cylinder No. 1, No. 4 *b Cylinder No. 2, No. 3
Standard value: T=10N·m {102kgf·cm} {7.4ft·lbf}
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(10) Further-tighten the two bolts in the same order.<*2>
Standard value: T=25N·m {255kgf·cm} {18.4ft·lbf}
(11) Using steps <*1> through <*2>, assemble the piston with connecting rod No. 2, No.3 and No. 4 as well as No. 1.
Engine mechanical - CYLINDER BLOCK ASSY (FA20)
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(12) Further-tighten the connecting rod cap bolts No. 1 through No. 4 by
556 C
92.5° in the order as shown in the figure using SST. SST 18270AA020, 18854AA000 Captions in illustration
*a Cylinder No. 1, No. 4
*b Cylinder No. 2, No. 3
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*c temporary bolt
<Reference> As necessary, attach the temporary bolt to fix SST.
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(13) Make sure that the crankshaft turns smoothly.
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Engine mechanical - CYLINDER BLOCK ASSY (FA20)
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ENGINE/HYBRID SYSTEM
COOLING
WATER PUMP (FA20)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO-2
CO
CO2
WATER PUMP (FA20) ECnogoilnineg/hybrid system
INSPECTION
CO
Cooling - WATER PUMP (FA20)
1. Inspection of engine water pump ASSY (1) Make sure that the bearing has no noise and catch. <Reference> If noise or catch is noted, replace the engine water pump ASSY. (2) Make sure the impeller is not abnormally deformed or damaged. <Reference> If the impeller is abnormally deformed or damaged, replace the engine water pump ASSY.
CO-03080
