Pajero Dakar 2010 11

GENERAL INFORMATION
Item Specification
Total displacement mL 3,200
Bore × Stroke mm 98.5 × 105
Compression ratio 17
Combustion chamber Direct injection type
Camshaft arrangement DOHC
Number of valve Inlet 8
Exhaust 8
Valve timing Inlet Opening BTDC 13°
Closing ABDC 31°
Exhaust Opening BBDC 60°
Closing ATDC 12°
Fuel system Common rail fuel injection
Rocker arm Double roller type
REMOVAL AND INSTALLATION
Removal steps
<<A>> >>E<< 1. Cylinder head bolt
>>E<< 2. Cylinder head bolt washer
>>E<< 3. Cylinder head assembly
>>D<< 4. Cylinder head gasket
>>C<< 5. Valve spring retainer lock
<> 6. Valve spring retainer
>>B<< 7. Valve spring
8. Intake valve
>>C<< 9. Valve spring retainer lock
<> 10. Valve spring retainer
12. Exhaust valve
>>A<< 13. Valve stem seal
14. Valve spring seat
17. Intake valve guide
18. Exhaust valve guide
19. Intake valve seat
20. Exhaust valve seat
21. Cylinder head
REMOVAL SERVICE POINTS
<<A>> CYLINDER HEAD BOLTS REMOVAL
Using a 14 mm - 12 points socket wrench, loosen the cylinder head bolts. Loosen each bolt evenly, little by little, by two or
three steps.
caution provide
one punch mark on the head of the cylinder head bolt each time the bolt is tightened. Replace the bolt that
already has five punch marks (the evidence of having been tightened five times)
<> VALVE SPRING RETAINER LOCK REMOVAL
1.Set special tool Valve spring compressor (MD999597) as illustrated to compress the valve spring. Remove the retainer
lock.
2.Relieve the spring tension and remove the valve, retainer, spring, etc. Store removed valves, springs, and other parts,
tagged to indicate their cylinder no. and location for assembly.
INSTALLATION SERVICE POINTS
>>A<< VALVE STEM SEAL INSTALLATION
1.Install the valve spring seat.

2.The special tool Valve stem seal installer (MH063609) must be used to install the valve stem seal. Improper installation
could result in oil consumption through valve guide.
caution Do not reuse removed valve stem seals.
>>B<< VALVE SPRING INSTALLATION
Direct the valve spring end with identification colour toward the spring retainer.
>>C<< VALVE SPRING RETAINER LOCK INSTALLATION
caution The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and
damage, the stem seal.
Compress the valve spring using the special tool Valve spring compressor (MD999597), them install the retainer lock.
>>D<< CYLINDER HEAD GASKET INSTALLATION
1.In case any of the cylinder block, piston, connecting rod and crankshaft has not been replaced, install the gasket of the same
rank as before which can be identified by the rank shown in the illustration at left.
2.In case any of the cylinder block, piston, connecting rod and crankshaft have been replaced, reselect and install the gasket
in accordance with the following procedure.
(1) With each piston held at the top dead centre, measure its protrusion from the upper block surface at the locations shown in
the illustration at left (total of eight locations). Be sure to take measurements on the crankshaft centre line.
(2) Using the average of the eight measurements, select the gasket rank (A, B, C or D) in accordance with the table given
below. If, however, the maximum protrusion at any one location exceeds the protrusion tolerance shown for any rank in the
following table, use the gasket one rank higher that rank.
Piston projection Cylinder head gasket
Crankcase identification mark Maximum piston projection mark mm Type bysize Tightened thickness mm
A -0.165 - -0.205 A (1 notch) 0.66 - 0.74
B -0.124 - -0.164 B (2 notch) 0.71 - 0.79
C -0.083 - -0.123 C (3 notch) 0.76 - 0.84
D -0.042 - -0.082 D (4 notch) 0.81 - 0.89
If the piston projection exceeds the tolerance, replace the piston, connecting rod, crankshaft or cylinder block
note
and check again.
>>E<< CYLINDER HEAD BOLT / CYLINDER HEAD BOLT WASHER / CYLINDER

HEAD ASSEMBLY INSTALLATION
1.Apply a coat of specified sealant to the upper surface of the front plate that joins the cylinder head gasket.
Specified sealant:
Three bond 1207F or equivalent
2.
Before installing the cylinder head bolt, check the number of punch marks on its head. (the
caution bolt is reusable if it is four or less.) the number of punch marks corresponds to that to times
the bolt has been tightened to the plastic area. if the bolt has five punch marks, replace it.
Set the cylinder head bolt washer with its shear droop toward the bolt head.
3.Apply engine oil to the bolt threads and washers.
note Using a 14 mm - 12 points socket wrench.
4.Tighten the bolts again to a torque of 49 ± 5 N·m in the indicated sequence. After that, confirm all bolts are reached to the
specified torque, and then go to the next process.
5.Make paint marks on each bolt’s head and on the cylinder head.
6.
If the tightening angle is smaller than 90°, proper fastening performance could not be
caution assured. Be sure to respect that angle.
If the bolt is tightened to an angle greater than the specified angle, loosen the bolt
completely and then retighten it beginning with the first step.
Turn the bolts 90° in the tightening direction and in the indicated sequence.
7.Give another 90° turn in the tightening direction to each bolt, making sure that the paint mark on the bolt head and that on the
cylinder head are on the same line.
Removal steps
<<A>> >>D<< 1. Cylinder head bolt
2. Cylinder head bolt washer
3. Cylinder head assembly
>>C<< 4. Cylinder head gasket
<> >>B<< 5. Valve spring retainer lock
6. Valve spring retainer
7. Valve spring
8. Intake valve
<> >>B<< 9. Valve spring retainer lock
11. Valve spring
12. Exhaust valve
14. Spring seat
16. Spring seat
17. Intake valve guide
20. Intake valve seat
21. Cylinder head
<<A>> CYLINDER HEAD BOLTS REMOVAL
Using a 14 mm - 12 points socket wrench, loosen the cylinder head bolt. Loosen each bolt evenly, little by little, by two or three
steps.
caution provide one punch mark on the head of the cylinder head bolt each time the bolt is tightened. replace the bolt that
already has five punch marks (the evidence of having been tightened five times)
<> VALVE SPRING RETAINER LOCK REMOVAL
1.Set special tool Valve spring compressor (MD998772) as illustrated to compress the valve spring. Remove the retainer
lock.
2.Relieve the spring tension and remove the valve, retainer, spring, etc. Store removed valves, springs, and other parts,
tagged to indicate their cylinder no. and location for assembly.
caution Do not reuse removed valve stem seals.

1.Install the valve spring seat.
2.The special tool Valve stem seal installer (MD998775) must be used to install the valve stem seal. Improper installation
could result in oil consumption through valve guide.
>>B<< VALVE SPRING RETAINER LOCK INSTALLATION
caution The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and
damage, the stem seal.
Compress the valve spring using the special tool Valve spring compressor (MD998772), them install the retainer lock.
>>C<< CYLINDER HEAD GASKET INSTALLATION
1.In case any of the cylinder block, piston, connecting rod and crankshaft has not been replaced, install the gasket of the same
rank as before which can be identified by the identification tab shown in the illustration at left.
2.In case any of the cylinder block, piston, connecting rod and crankshaft have been replaced, reselect and install the gasket
in accordance with the following procedure.
(1) With each piston held at the top dead center, measure its protrusion from the upper block surface at the locations shown in
the illustration at left (total of eight locations). Be sure to take measurements on the crankshaft center line.
(2) Using the average of the eight measurements, select the gasket rank (A, B or C) in accordance with the table given
below. If, however, the maximum protrusion at any one location exceeds the protrusion tolerance shown for any rank in the
following table, use the gasket one rank higher that rank.
<Except High power>

Rank Average value of piston Protrusion tolerance for Thickness of selected gasket Identification
protrusions mm each rank mm (when tightened) mm tab
A 0.06 - 0.12 0.17 0.95 ± 0.04 Non-equipped
B 0.12 - 0.18 0.23 1.00 ± 0.04
C 0.18 - 0.24 - 1.05 ± 0.04
<High power>
Rank Average value of piston Protrusion tolerance for Thickness of selected gasket Identification
protrusions mm each rank mm (when tightened) mm tab
A 0.16 - 0.22 0.17 1.07 ± 0.04 Equipped
B 0.22 - 0.28 0.23 1.12 ± 0.04
C 0.28 - 0.34 - 1.17 ± 0.04
If the piston projection exceeds the tolerance, replace the piston, connecting rod, crankshaft or cylinder block
note
and check again.
>>D<< CYLINDER HEAD BOLT INSTALLATION
Before installing the cylinder head bolt, check the number of punch marks on its head. (the bolt is reusable if it is
caution four or less.) the number of punch marks corresponds to that to times the bolt has been tightened to the plastic
area. if the bolt has five punch marks, replace it.
1.Set the cylinder head bolt washer with its shear droop toward the bolt head.
2.Apply engine oil to the bolt threads and washers.
note Using a 14 mm - 12 points socket wrench.
3.Tighten the bolts to 78 ± 2 N·m in the indicated sequence.

4.Loosen all the bolts completely.
5.Tighten the bolts again to a torque of 29 ± 2 N·m in the indicated sequence. After that, confirm all bolts are reached to the
specified torque, and then go to the next process.
6.Make paint marks on each bolt’s head and on the cylinder head.
When the tightening angle is smaller than the specified tightening angle, the appropriate tightening
caution capacity cannot be secured.
When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the
beginning again according to the procedure.
7.Turn the bolts 90° in the tightening direction and in the indicated sequence.
8.Give another 90° turn in the tightening direction to each bolt, making sure that the paint mark on the bolt head and that on the
cylinder head are on the same line.
Removal steps
>>D<< 1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
<<A>> >>C<< 4. Retainer lock
7. Inlet valve
<<A>> >>C<< 8. Retainer lock
11. Exhaust valve
<> >>A<< 12. Valve stem seal
<> >>A<< 14. Valve stem seal
16. Inlet valve guide
18. Inlet valve seat
20. Cylinder head
<<A>> RETAINER LOCK REMOVAL
1.Using special tool Valve spring compressor (MD998735), compress the spring.
2.Remove the retainer locks.
<> VALVE STEM SEAL REMOVAL
Using the special tool Valve stem seal plier (MB992085), nip the valve stem seal and remove it.
1.Install the valve spring seat to the valve guide.
Valve stem seals for inlet valves and for exhaust valves are different. Be sure to install the correct ones.
Valve stem seal identification colour.
caution
Inlet: Grey
Exhaust: Grey green
2.
caution Always use the special tool to install the valve stem seal. Improperly installed valve stem
seals may leak oil.
Do not strike the valve stem seal strongly because it might be damaged.
Using special tool Valve stem seal installer (MB992182), install a new stem seal to the valve guide.
note After install, check the special tool does not stick to the valve spring sheet. Put the valve
spring sheet in position.
>>B<< VALVE SPRING INSTALLATION
Install the valve spring end with its identification colour toward the spring retainer.
Identification colour
Inlet: White
Exhaust: Blue
>>C<< RETAINER LOCK INSTALLATION
Using special tool Valve spring compressor (MD998735), compress the valve spring and insert the retainer lock into
position.
>>D<< CYLINDER HEAD BOLT INSTALLATION
1.Check in the following procedure before reusing the cylinder head bolt.
(1) Measure the outside diameter "A".
(2) Measure the smallest outside diameter "B" within the range "X" shown in the illustration.
(3) If the difference of outside diameter of thread exceeds the limit, replace the cylinder head bolt.
Limit: 0.1mm
2.
caution Attach the head bolt washer in the direction shown in the figure.
Tighten the bolts in the illustrated sequence two or three rounds.
Tightening torque: 45 ± 2 N·m
3.
When the tightening angle is smaller than the specified tightening angle, the
caution appropriate tightening capacity cannot be secured.
When the tightening angle is larger than the specified tightening angle, remove the
bolt to start from the beginning again according to the procedure.
Using the special tool Angle gauge (MB991614), tighten the cylinder head bolt another 150°.
INSPECTION
CYLINDER HEAD
1.Check the cylinder head gasket surface for flatness by using a straight edge and feeler gauge.
Standard value: Less than 0.03 mm
Limit: 0.05 mm
2.If the service limit is exceeded, correct to meet the specification.
Grinding limit: *0.15 mm
* Includes combined with cylinder block grinding.

*If the service limit is exceeded, correct to meet the specification.
Cylinder head height (specification when new):
120 mm
VALVE
1.Check the valve seat contact. Valve seat contact should be uniform at the centre of the valve face. If incorrect, reface using a
valve refacer.
2.If the margin is below the limit, replace the valve.
Standard value:
Inlet 1.0 mm
Exhaust 1.2 mm
Minimum limit:
Inlet 0.5 mm
Exhaust 0.7 mm
3.Measure the valve’s total length. If the measurement is less than the limit, replace the valve.
Standard value:
Inlet 111.84 mm
Exhaust 114.04 mm
Minimum limit:
Inlet 111.34 mm
Exhaust 113.54 mm
VALVE SPRING
1.Measure the free height of the spring. If it is less than the limit, replace.
Standard value:
Inlet 63.77 mm
Exhaust 59.90 mm
Minimum limit:
Inlet 62.77 mm
Exhaust 58.90 mm
2.Measure the squareness of the spring. If it exceeds the limit, replace.
Standard value: 2° or less
Limit: 4°
VALVE GUIDE
Measure the clearance between the valve guide and valve stem. If it exceeds the limit, replace the valve guide or valve, or both.
Standard value:
Inlet 0.020 - 0.047 mm
Exhaust 0.035 - 0.062 mm
Limit:
Inlet 0.10 mm
Exhaust 0.15 mm
VALVE GUIDE REPLACEMENT PROCEDURE
1.Using a press, remove the valve guide toward the cylinder block.
2.
caution Do not install a valve guide of the same size again.
Rebore the valve guide hole of the cylinder head so that it fits the press-fitted oversize valve guide.
Valve guide hole diameters
0.05 oversize: 11.050 - 11.068 mm
3.Press-fit the valve guide until it projects by the specified amount.

Standard value: 16.7 - 17.3 mm
note When press-fitting the valve guide, work from the cylinder head top surface.
note Pay attention to the difference in length of the valve guides. [Inlet side: 45.5 mm; exhaust side:
52.5 mm]
note After installing the valve guides, insert new valves in them to check for smooth operation.
VALVE SEAT
Assemble the valve, then measure the contact width. If the measurement exceeds the specified limit, replace the valve seat.
VALVE SEAT REPLACEMENT PROCEDURE
1.Cut the valve seat from the inside to thin the wall thickness. Then, remove the valve seat.
2.Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter.
Inlet seat ring hole diameters
0.3 oversize: 36.300 - 36.325 mm
Exhaust seat ring hole diameters
0.3 oversize: 32.300 - 32.325 mm
3.Before fitting the valve seat, either heat the cylinder head up to approximately 250°C or cool the valve seat in liquid nitrogen,
to prevent the cylinder head bore from galling.
4.Using a valve seat cutter, correct the valve seat to the specified width and angle.
See "VALVE SEAT RECONDITIONING PROCEDURE" on the previous page.
VALVE SEAT RECONDITIONING PROCEDURE
1.Before correcting the valve seat, check for clearance between the valve guide and valve and, if necessary, replace the valve
guide.
2.Using the seat grinder, correct to obtain the specified seat width and angle.
3.After correcting the valve seat, lap the valve and valve seat using lapping compound. Then, check the valve stem projection.
INSPECTION
CYLINDER HEAD
Check the cylinder head gasket surface for flatness by using a straightedge in the directions of illustration.
Standard value: 0.03 mm
Limit: 0.2 mm
VALVE
1.Check the valve face for correct contact. If incorrect, reface using valve refacer. Valve seat contact should be maintained
uniform at the center of valve face.
2.If the margin is smaller than the service limit, replace the valve.
Standard value:
Intake: 1.3 mm
Exhaust: 1.5 mm
Limit:
Intake: 0.8 mm
Exhaust: 1.0 mm
3.Measure the valves total length. If the measurement is less than the limit, replace the valve.
Standard value:
Intake: 107.58 mm
Exhaust: 107.98 mm
Limit:
Intake: 107.08 mm
Exhaust: 107.48 mm
VALVE SPRING
1.Measure the free height of spring and if it is smaller than the limit, replace.
Limit: 53.3 mm
2.Measure the squareness of the spring and, if the limit is exceeded, replace.
Limit: Max. 4°
VALVE GUIDE
Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or
both.
Standard value:
Intake: 0.020 - 0.047 mm
Exhaust: 0.035 - 0.062 mm
Limit:
Intake: 0.10 mm
Exhaust: 0.15 mm
VALVE SEAT
guide.
3.After correction, valve and valve seat should be lapped with a lapping compound.
1.Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the valve seat.
2.Rebore the valve seat hole in cylinder head to the oversize valve seat diameter.
Intake valve seat hole diameter:
0.30 O.S.: 33.300 - 33.325 mm
Exhaust valve seat hole diameter:
0.30 O.S.: 29.300 - 29.321 mm
3.When the valve sheet is a press fit, engine oil is applied to the valve sheet or the cylinder head not to damage the inside
diameter of the cylinder head.
4.Using valve seat cutter, correct the valve seat to the specified width and angle.
See "VALVE SEAT RECONDITIONING PROCEDURE."
1.Force out the valve guide toward the cylinder block using a press.
caution Do not use a replacement valve guide of the same size as the removed one.
2.Machine the valve guide hole in the cylinder head to the size matched to the selected oversize valve guide.
Valve guide hole diameter:
0.05 O.S.: 11.050 - 11.068 mm
note Do not install a valve guide of the same size again.

3.Press-fit the valve guide until it remains protruded above the cylinder head by the amount indicated in the illustration.
Protrusion: 18.3 - 18.9 mm
note Press the valve guide from above the cylinder head.
The valve guides for the intake valves are different in length from those for the exhaust valves
note (45.2 mm for intake valves; 48.2 mm for exhaust valves)
4.After installing the valve guide, insert a new valve in it to check for smooth movement.
INSPECTION
CYLINDER HEAD
Check the cylinder head gasket surface for flatness by using a straightedge in the directions of illustration.
Limit: 0.2 mm
VALVE
1.Check the valve face for correct contact. If incorrect, reface using valve refacer. Valve seat contact should be maintained
uniform at the centre of valve face.
2.If the margin is smaller than the service limit, replace the valve.
Limit: 0.5 mm
3.Measure the valves total length. If the measurement is less than the limit, replace the valve.
Standard value:
Intake: 115.4 mm
Exhaust: 115.4 mm
Limit:
Intake: 114.9 mm
Exhaust: 114.9 mm
VALVE SPRING
1.Measure the free height of spring and if it is smaller than the limit, replace.
Limit: 50.3 mm
2.Measure the squareness of the spring and, if the limit is exceeded, replace.
Limit: Max. 4°
VALVE GUIDE
Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or
both.
Standard value:
Intake: 0.025 - 0.058 mm
Exhaust: 0.050 - 0.088 mm
Limit:
Intake: 0.10 mm
Exhaust: 0.15 mm
VALVE SEAT
caution If the variation in the width exceeds 0.2 mm even if the contact width is within the standard value, replace or
correct the valve sheet.
guide.
Standard value: 43.25° - 43.75°
3.After correction, valve and valve seat should be lapped with a lapping compound.
4.Assemble the valve, then measure the contact width.
1.Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the valve seat.
2.Rebore the valve seat hole in cylinder head to the oversize valve seat diameter.
Intake valve seat hole diameter:
0.30 O.S.: 35.300 - 35.325 mm
Exhaust valve seat hole diameter:
0.30 O.S.: 33.300 - 33.325 mm
3.Before fitting the valve seat, either heat the cylinder head up to approximately 250°C or engine oil is applied to the valve
sheet or the cylinder head not to damage the inside diameter of the cylinder head.
4.Using valve seat cutter, correct the valve seat to the specified width and angle.
See "VALVE SEAT RECONDITIONING PROCEDURE."
1.Force out the valve guide toward the cylinder block using a press.
caution Do not use a replacement valve guide of the same size as the removed one.
2.Machine the valve guide hole in the cylinder head to the size matched to the selected oversize valve guide.
Valve guide hole diameter:
0.05 O.S.: 12.050 - 12.068 mm
note Do not install a valve guide of the same size again.

3.Press-fit the valve guide until it remains protruded above the cylinder head by the amount indicated in the illustration.
Protrusion: 17.0 - 17.5 mm
note Press the valve guide from above the cylinder head.
The valve guides for the intake valves are different in length from those for the exhaust valves
note
(54 mm for intake valves; 47 mm for exhaust valves)
4.After installing the valve guide, insert a new valve in it to check for smooth movement.
INSPECTION
CYLINDER HEAD
1.Check the cylinder head gasket surface for flatness by using a straight edge and feeler gauge.
Limit: 0.2 mm
2.If it exceeds the limit, correct to meet specification.
* Includes combined with cylinder block grinding.

Cylinder head height (Specification when new): 120 mm
VALVE
1.Check the valve seat contact. Valve seat contact should be uniform at the centre of the valve face. If incorrect, reface using a
valve refacer.
2.If the margin is below the limit, replace the valve.
Standard value:
<Intake> 1.0 mm
<Exhaust> 1.2 mm
Limit:
<Intake> 0.5 mm
<Exhaust> 0.7 mm
3.Measure the valve’s total length. If the measurement is less than the limit, replace the valve.
Standard value:
<Intake> 112.30 mm
<Exhaust> 114.11 mm
Limit:
<Intake> 111.80 mm
<Exhaust> 113.61 mm
VALVE SPRING
1.Measure the free height of the spring. If it is less than the limit, replace.
Limit: 50.0 mm
2.Measure the squareness of the spring. If it exceeds the limit, replace.
Limit: 4°
VALVE GUIDE
Measure the clearance between the valve guide and valve stem. If it exceeds the limit, replace the valve guide or valve, or both.
Standard value:
<Intake> 0.02 - 0.05 mm
<Exhaust> 0.04 - 0.07 mm
Limit:
<Intake> 0.10 mm
<Exhaust> 0.15 mm
VALVE SEAT
If the variation in the width exceeds 0.2 mm even if the contact width is within the standard value, replace or
caution correct the valve sheet.
guide.
3.After correcting the valve seat, lap the valve and valve seat using lapping compound. Then, check the valve stem projection.
1.Cut the valve seat from the inside to thin the wall thickness. Then, remove the valve seat.
2.Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter.
Intake seat ring hole diameters
0.3 oversize: 34.30 - 34.33 mm
Exhaust seat ring hole diameters
0.3 oversize: 31.80 - 31.83 mm
3.When the valve sheet is a press fit, engine oil is applied to the valve sheet or the cylinder head not to damage the inside
diameter of the cylinder head.
4.Using a valve seat cutter, correct the valve seat to the specified width and angle.
See "VALVE SEAT RECONDITIONING PROCEDURE" on the previous page.
1.Remove the snap ring from the exhaust valve guide.

2.Using a press, remove the valve guide toward the cylinder block.
3.
caution Do not install a valve guide of the same size again.
Rebore the valve guide hole of the cylinder head so that it fits the press-fitted oversize valve guide.
Valve guide hole diameters
0.05 oversize 11.05 - 11.07 mm
4.Install the new snap ring into the groove of exhaust valve guide.
5.Press-fit the valve guide until it protrudes 14.0 mm from the cylinder head top surface as shown in the illustration.
note When press-fitting the valve guide, work from the cylinder head top surface.
note Pay attention to the difference in length of the valve guides. (Intake side: 45.5 mm; exhaust
side: 50.5 mm)
note After installing the valve guides, insert new valves in them to check for smooth operation.
Removal steps
>>M<< 1. Oil filter
<<A>> >>L<< 2. Oil pressure switch <Except High power>
>>K<< 3. Oil pressure switch <High power>
4. O-ring
>>J<< 5. Oil cooler
6. O-ring
7. Heat protector <Except High power>
8. Oil filter bracket
9. Oil filter bracket gasket
10. Oil drain plug
>>I<< 11. Oil drain plug gasket
<> >>H<< 12. Oil pan
>>H<< 13. Oil pan gasket*
14. Oil screen
15. Oil screen gasket
16. Stiffener
17. Front upper case
18. Front upper case gasket
>>G<< 19. Front upper case oil seal
20. Plug cap
21. O-ring
<<C>> >>F<< 22. Flange bolt
23. Front lower case
24. Front lower case gasket
>>E<< 25. Crankshaft front oil seal
>>D<< 26. Balancer shaft oil seal
27. Plug
28. Relief spring
29. Relief plunger
30. Oil pump cover
<<D>> >>C<< 31. Inner rotor
<<D>> >>C<< 32. Outer rotor
33. Balancer shaft gear cover
>>B<< 34. Balancer shaft driven gear
>>B<< 35. Balancer shaft drive gear
36. Balancer shaft, left
37. Balancer shaft, right
<<E>> >>A<< 38. Balancer shaft bearing
note *:Use either an oil pan gasket or a sealant for installing the oil pan.
<<A>> OIL PRESSURE SWITCH REMOVAL
Using special tool Oil pressure switch socket wrench (MD998012), removal the oil pressure switch.
<> OIL PAN REMOVAL
1.Knock the special tool Oil pan sealer cutter (MD998727) deeply between the oil pan and the cylinder block.
2.Hitting the side of the special tool Oil pan sealer cutter (MD998727), slide the special tool along the oil pan to remove it.
<<C>> FLANGE BOLT REMOVAL
1.Remove the plug on the right side of cylinder block.

2.Insert a Phillips screwdriver into the plug hole to lock the silent shaft in position.
3.Remove the flange bolt.
<<D>> OUTER ROTOR / INNER ROTOR REMOVAL
Put alignment marks on the outer and inner rotors for reference in reassembly.
<<E>> BALANCER SHAFT BEARING REMOVAL
1.Install the special tool Bearing installer stopper (MD998380) to the cylinder block. This is used to hold the special tool.
2.Pull out the rear bearing from the cylinder block using the special tool Balancer shaft bearing puller (MD998251).
>>A<< BALANCER SHAFT BEARING INSTALLATION
Using the special tools, press-fit the bearing into the cylinder block.
Before press-fitting the bearing, apply an ample amount of engine oil to the bearing surfaces as well as bearing hole in the
cylinder block.
Balance shaft bearing installer (MD998250)

Bearing installer stopper (MD998380)
>>B<< BALANCER SHAFT DRIVE GEAR / BALANCER SHAFT DRIVEN GEAR

INSTALLATION
1.Apply engine oil to the balancer shaft drive and driven gears.
2.Install the balancer shaft drive and driven gears to the front lower case. Make sure that the alignment marks are in line.
>>C<< INNER ROTOR / OUTER ROTOR INSTALLATION
Install the outer rotor in the same direction as before noting the mark put at the time of removal. Apply engine oil to the entire
rotor surface.
>>D<< OIL SEAL INSTALLATION
1.Apply engine oil to the oil seal outer surface.

2.Using the special tool Balancer shaft drive gear oil seal guide (MD998385), drive in with a socket wrench.
>>E<< CRANKSHAFT FRONT OIL SEAL INSTALLATION
1.Attach the special tool Crankshaft front oil seal guide (MD998383) to the crankshaft and apply engine oil to the outer
surface of the tool.
2.Using the special tool Crankshaft front oil seal installer (MD998382), install the front oil seal into the front lower case.
>>F<< FLANGE BOLT INSTALLATION
1.Insert a Phillips screwdriver into the plug hole to block the balancer shaft.
2.Install the flange bolt and tighten to the specification.
3.Remove the screwdriver and install the plug.
>>G<< FRONT UPPER CASE OIL SEAL INSTALLATION
Apply engine oil to the oil seal outer surface and drive in with a socket wrench.
>>H<< OIL PAN / OIL PAN GASKET INSTALLATION
Use either an oil pan gasket or a sealant for installing the oil pan. Install the oil pan in accordance with the following
procedure respectively.
<SEALANT>
1.Clean both mating surfaces of oil pan and cylinder block.
2.Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan flange.
Specified sealant:
Three bond 1217G or equivalent
3.The oil pan should be installed in 15 minutes after the application of sealant.
<GASKET>
>>I<< OIL DRAIN PLUG GASKET INSTALLATION
Replace the gasket with a new one and install it in the direction shown in the illustration.
>>J<< OIL COOLER SWITCH INSTALLATION
Position the tab as shown in the illustration.
>>K<< OIL PRESSURE SWITCH INSTALLATION
caution Use care not to allow the sealant to plug the oil passage.
Apply sealant to the threads of the switch.
Specified sealant:
>>L<< OIL PRESSURE SWITCH INSTALLATION

This area shall be free from oil (antirust oil etc.) for switch output shall be adversely affected
caution
.
1.
Apply sealant to the threads of the switch.
Specified sealant:
2.Using special tool Oil pressure switch socket wrench (MD998012), tighten the oil pressure switch to the specified torque.
>>M<< OIL FILTER INSTALLATION
1.Clean the filter mounting surface of the oil filter bracket.

2.Apply engine oil to the O-ring of the oil filter.
3.Using general service tool Oil filter wrench, Install the oil filter to the bracket and tighten it to the specified torque.
4.If a torque wrench cannot be used use the following procedure.
(1) Screw in the oil filter until its o-ring contacts the oil filter bracket.
(2) Tighten the oil filter 3/4 turn.
Removal steps
<<A>> >>F<< 1. Oil pressure switch
>>E<< 2. Oil filter
5. Drain plug
>>D<< 6. Drain plug gasket
7. Cover
<> >>C<< 8. Oil pan
9. Baffle plate
10. Oil screen
11. Oil screen gasket
12. Relief plug
13. Relief spring
14. Relief plunger
>>B<< 15. Crankshaft oil seal
16. Oil pump case
17. Oil pump case gasket
18. Oil pump cover
<<C>> >>A<< 19. Oil pump outer rotor
<<C>> >>A<< 20 Oil pump inner rotor
Using special tool Oil pressure switch socket wrench (MD998012), removal the oil pressure switch.
<> OIL PAN REMOVAL
1.Remove the bolts A shown in the illustration first.

2.Remove all other bolts.
3.
caution Do not use a scraper or special tool to remove the oil pan.
Remove the oil pan.
4.Thread the bolt into the illustrated bolt hole to remove the oil pan.
<<C>> OIL PUMP OUTER ROTOR / OIL PUMP INNER ROTOR REMOVAL
Make alignment dots on the outer and inner rotors for assembly.
>>A<< OIL PUMP INNER ROTOR / OIL PUMP OUTER ROTOR INSTALLATION
Apply engine oil to the rotors. Then, install the rotors ensuring that the alignment dots made at disassembly are properly
aligned.
>>B<< CRANKSHAFT OIL SEAL INSTALLATION
1.Install the guide of special tool Crankshaft front oil seal installer (MD998717) to the front end of the crankshaft.
2.Apply engine oil to the lip area of a new oil seal and push it in until it contacts the oil pump case.
3.Using special tool Crankshaft front oil seal installer (MD998717), press-fit the oil seal into the oil pump case.
>>C<< OIL PAN INSTALLATION
1.Clean the gasket surfaces of the cylinder block and upper oil pan.
2.Apply a 4 mm diameter bead of sealant to the oil pan. Be sure to install the oil pan quickly while the sealant is wet (within 15
minutes).
Specified sealant:
3.
caution When installing the upper oil pan, be sure not to expel the sealant from the oil pan flange at
portion A in the illustration.
Tighten the upper oil pan bolts in the sequence shown to specified torque of 9.0 ± 3.0 N·m.
4.After installation, keep the sealed area away from the oil and coolant for approximately one hour.
>>D<< DRAIN PLUG GASKET INSTALLATION
1.Clean the installation surface of the filter bracket.

3.Screw the oil filter on until the O-ring contacts the bracket. Then tighten 3/4 turn (14 ± 2 N·m)
>>E<< OIL FILTER INSTALLATION
caution If the gasket is installed in the wrong direction, oil leaks will be occurred.
Install the drain plug gasket as illustrated.
>>F<< OIL PRESSURE SWITCH INSTALLATION
caution This area shall be free from oil (antirust oil etc.) for switch output shall be adversely affected
.
1.
Keep the end of threaded portion clear of sealant.
caution Avoid an overtightening.
Apply sealant to the oil pressure switch threads.
Specified sealant:
Three bond 1215, Three bond 1212D or equivalent
2.Using special tool Oil pressure switch socket wrench (MD998012), tighten the oil pressure switch to the specified torque
of 10 ± 2 N·m.
Removal steps
1. Drain plug
2. Drain plug gasket
>>G<< 3. Oil filter
>>F<< 4. Oil pressure switch
<<A>> >>E<< 7. Oil pan
8. Oil screen
>>D<< 9. Oil screen gasket
>>C<< 10. Bearing cap bolt
>>C<< 11. Beam
>>C<< 12. Right plate
>>C<< 13. Left plate
14. Relief plug
15. Relief spring
16. Relief plunger
>>B<< 17. Crankshaft front oil seal
>>A<< 18. Oil pump case
19. O-ring
20. Oil pump cover
21. Oil pump outer rotor
22. Oil pump inner rotor
REMOVAL SERVICE POINT
<<A>> OIL PAN REMOVAL
1.Remove the bolts A shown in the illustration first.

2.Remove all other bolts.
caution Do not use a scraper or special tool to remove the oil pan.
3.Thread the M10 × 1.25 pitch bolt into the illustrated bolt hole to remove the oil pan.
>>A<< OIL PUMP CASE INSTALLATION
1.
Carefully work so that the rests of the liquid gasket cannot enter to the oil passage or water
caution passage.
Remove all the rests of the liquid gasket on the oil pump case and the cylinder block.
2.Degrease and clean the plane where the liquid gasket is applied and the both sides of the chamfered areas where the liquid
gasket collects.
3.After degreasing and cleaning the plane and the both sides, always spray compressed air into the oil passage and the
water passage. Check that the oil passage and the water passage are free of foreign materials such as liquid gasket.
4.As shown in the illustration, apply a 2.0 ± 0.5 mm diameter bead of sealant to the area on the oil pump case.
Specified sealant:
5.After checking that the o-ring is installed, install the oil pump case to the cylinder block.
6.Tighten the oil pump case to the specified torque.
>>B<< CRANKSHAFT OIL SEAL INSTALLATION
Using special tool Crankshaft front oil seal installer (MD998382), press-fit the oil seal into the oil pump case.
>>C<< BEAM / BEARING CAP BOLT INSTALLATION
1.Before installing the bearing cap bolt, check the bolt screw head is not damaged. If the screw head extremely gets
damaged, replace it with a new bolt. The standard length of the new bolt measured from under the head is as follows:
2.
caution When the beam is removed and installed, never loosen the tightening bolts of the crankshaft
bearing cap.
Put the right and left plates on the crankshaft bearing, Temporarily tighten bolt.
3.Put the beam on them, Temporarily tighten bolt.
4.Tighten the beam bolts to the specified torque in the tightening sequence shown.
5.
Using the special tool Angle gauge (MB991614), tighten the beam bolt (M9) 60° in accordance with the tightening order.
6.Tighten the plate bolts to the specified torque in the tightening sequence shown.
>>D<< OIL SCREEN GASKET INSTALLATION
Install the oil screen gasket so that the tab is positioned as shown in the illustration.
>>E<< OIL PAN INSTALLATION
1.Completely remove liquid gasket adhering to the cylinder block and oil pan.
2.Degrease the cylinder block and oil pan.
3.Apply a 2.5 ± 0.5 mm diameter bead of sealant to the oil pan. Be sure to install the oil pan quickly while the sealant is wet.
Specified sealant:
note Install the oil pan within 15 minutes after applying liquid gasket.
Then wait at least one hour. Never start the engine or let engine oil or coolant touch the
note adhesion surface during that time.
4.Tighten the upper oil pan bolts.
Tightening torque: 9.5 ± 2.5 N·m
5.After installation, keep the sealed area away from the oil and coolant for approximately one hour.
>>F<< OIL PRESSURE SWITCH INSTALLATION
The threaded part tip of the switch must be clear of the sealant.
1.Completely remove existing sealant from the oil pressure switch and the switch mounting hole on the oil pump case.
2.Apply sealant to the threaded part of the oil pressure switch as shown.
Specified sealant:
Three bond 1212D, Three bond 1215 or equivalent
3.Install the oil pressure switch to the oil pump case by tightening to a specified torque.
>>G<< OIL FILTER INSTALLATION
1.Clean the filter mounting surface on the front case.

3.
caution If the filter is tightened by hand only, it will be insufficiently torqued, resulting in oil leaks.
Screw the oil filter in and tighten the oil filter to the specified torque using a commercially available special tool oil filter
wrench (MB991396) or general tool from where the O-ring has come into contact with the oil filter mounting surface.
Tightening torque:
MD332687, MD365876 16 ± 4 N·m <approx. 1 turn>
MD360935 14 ± 2 N·m <approx. 3/4 of a turn>
INSPECTION
FRONT LOWER CASE
1.The front case parts must be free from damage and cracks.
2.Install the oil pump rotor or gear into the front case and make sure that the rotor or gear turns smoothly with no excessive
play in it.
3.The front case and oil pump cover surfaces in contact with the pump rotor or gear side face must be free from ridge wear.
BALANCER SHAFT
1.Check oil holes must be free from clogging.

2.Check journal for size, damage, and contact with bearing. If defects are evident, replace the balancer shaft, bearing, or
front case assembly.
3.Check the balancer shaft oil clearance. If wear is excessive, replace the balancer shaft bearing, balancer shaft or front case
assembly.
Standard value
Front:
Right 0.02 - 0.05 mm
Left 0.02 - 0.06 mm
Rear: 0.06 - 0.10 mm
OIL PUMP
1.Install the inner and outer rotors in the front case.

2.Check the tip clearance using a thickness gauge.
3.Check the side clearance using a straight edge and a thickness gauge.
4.Check the body clearance using a thickness gauge.

Limit: 0.35 mm
INSPECTION
OIL PUMP
1.Check the tip clearance.

2.Check the side clearance.

3.Check the body clearance.

Limit: 0.35 mm
Removal steps
>>G<< 1. Connecting rod bolt
<<A>> >>F<< 2. Connecting rod cap
>>D<< 3. Connecting rod bearing, lower
>>E<< 4. Piston and connecting rod assembly
>>D<< 5. Connecting rod bearing, upper
>>C<< 6. Piston ring no.1
>>C<< 7. Piston ring no.2
>>B<< 8. Oil ring
<> >>A<< 9. Piston pin
10. Piston
11. Connecting rod
<<A>> CONNECTING ROD CAP REMOVAL
1.Mark the cylinder number on the side of the connecting rod big end for correct reassembly.
2.Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.
<> PISTON PIN REMOVAL
1.The special tool Piston pin setting tool (MD998780) consists of the elements shown in the illustration.
2.When removing the piston pin, the special tool Guide D (MB991659) is also used.
3.Insert Push rod, into the piston from the front mark side, then attach Guide D, to the push rod.
4.Place the piston and connecting rod assembly on Base, with the front mark facing up.
5.Use a press to remove the piston pin.
note Keep the disassembled pistons, piston pins and connecting rods per cylinder.
>>A<< PISTON PIN INSTALLATION

1.When replacing the piston, note the cylinder bore size mark on the cylinder block as illustrated, and select a piston
according to the flowing table.
Cylinder bore size mark Piston size mark
A A
B B
note The piston size mark shows on the top of the piston.
2.Insert the push rod into the piston pin and install the guide A.
3.Align the front mark of the piston with that of the connecting rod. Align the piston with the connecting rod.
4.Apply engine oil to the outer circumference of the piston pin.
5.Insert the piston pin guide A installed at step 2 into the pin hole from the front mark of the piston.
6.Screw the guide B into A until the clearance "L" reaches 3.75 mm between A and B.
7.Place the piston and connecting rod assembly onto Base, with the front marks facing up.
8.Install the piston pin using a press. If the required press force is less than the standard value, replace the piston and piston
pin assembly or the connecting rod, or both.
Standard value: 5,000 - 15,000 N
9.Check that the piston moves smoothly.
>>B<< OIL RING INSTALLATION
1.Fit the oil ring spacer into the piston ring groove.
note The side rails and spacer may be installed in either direction.
caution Do not use any piston ring expander when installing the side rail. If will break the side rail.
2.Install the upper side rail.

To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into the position by
finger. See illustration.
3.Install the lower side rail in the same procedure as described in step 2.
4.Make sure that the side rails move smoothly in both directions.
>>C<< PISTON RING NO.2 / PISTON RING NO.1 INSTALLATION
To prevent wrong installation, check the identification mark of each piston ring. The identification mark is stamped near the
ring gap:
Identification mark
Number 1 ring: 1T
Number 2 ring: 2T
>>D<< CONNECTING ROD BEARING INSTALLATION
1.If the connecting rod bearing is replaced, select based on the identification mark of crankshaft (illustrated) and the table
shown below.
2.Every connecting rod bearing is identified by the paint mark at the illustrated location.
Crankshaft pin identification Bearing identification
mark colour
1 Black
2 Purple
3 Green
3.Install the selected bearing in the big end and in the cap of the connecting rod.
>>E<< PISTON AND CONNECTING ROD INSTALLATION
1.Liberally coat the circumference of the piston, piston ring, and oil ring with engine oil.
2.Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration.
3.Rotate the crankshaft so that the crank pin is on the centre of the cylinder bore.
4.Insert the piston and connecting rod assembly into the cylinder with the front mark on the piston crown pointing to the timing
belt side.
5.Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.
>>F<< CONNECTING ROD CAP INSTALLATION
1.Verifying the mark made during disassembly, install the bearing cap to the connecting rod. If the connecting rod is new with
no index mark, make sure that the bearing locking notches are on the same side as shown.
2.Make sure that the connecting rod big end side clearance meets the specification.
Limit: 0.4 mm
>>G<< CONNECTING ROD CAP BOLT INSTALLATION
1.Check in the following procedure before reusing the connecting rod bolt.
(1) Measure the outside diameter "A."
(2) Measure the smallest outside diameter "B" within the range "X" shown in the illustration.
(3) If the difference of outside diameter of thread exceeds the limit, replace the connecting rod bolt.
Limit: 0.1 mm
2.Apply engine oil to the threaded portion and seating face of the bolt.
3.To correctly install the cap, loosely install the bolts with fingers.
4.Alternately, tighten the bolts in several steps to the specified torque of 20 N·m.
5.Make a paint mark on the head of each bolt.
6.
Put another paint mark on the bolt head at 90° in the tightening direction from the first paint mark.
7.Tighten the bolt 90°. The paint mark on the connecting rod should be aligned with the paint mark on the bolt.
Removal steps
>>E<< 1. Connecting rod cap nut
<<A>> >>E<< 2. Connecting rod cap
3. Connecting rod bearing
<> >>D<< 4. Piston and connecting rod assembly
>>C<< 6. Piston ring No. 1
>>C<< 7. Piston ring No. 2
>>B<< 8. Oil ring
>>A<< 9. Snap ring
>>A<< 10. Piston pin
>>A<< 11. Piston
>>A<< 12. Snap ring
13. Bolt
>>A<< 14. Connecting rod
Mark the cylinder number on the side of the connecting rod big end for correct reassembly.
<> PISTON AND CONNECTING ROD ASSEMBLY REMOVAL
1.Not to damage the crank pin, attach a special tool Bolt guide (MB992010), to the connecting rod bolt.
2.Remove the piston and connecting rod assembly from the cylinder block.
>>A<< CONNECTING ROD / SNAP RING / PISTON PIN / PISTON

INSTALLATION
1.When replacing the piston pin, read off the cylinder bore size mark on the cylinder block as illustrated, and select a piston
according to the following table.
Cylinder bore size Piston size mark
A A
B None
C C
2.Set the snap ring into one side of the piston pin hole.
3.With the front mark of the connecting rod and that of the piston located on the same side, insert the piston pin.
It is difficult to fit the piston pin into the piston when they have a different temperature,
note Therefore, fit the piston pin into the piston when they have the same temperature.
4.Set the snap ring into the other side of the piston pin hole.
5.Check that the piston moves smoothly.

Install the expander coil and oil ring in the piston ring groove.
>>C<< PISTON RING NO. 1 / PISTON RING NO. 2 INSTALLATION
Use a piston ring expander to install the No.1 and No.2 piston rings. The ring identification mark should face upwards.
Identification marks
No. 1 ring: 1R
No. 2 ring: 2R
>>D<< PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION
1.Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring.
2.Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the figure.
3.Rotate crankshaft so that crank pin is on center of cylinder bore.
5.Use suitable thread protectors on connecting rod bolts before inserting piston and connecting rod assembly into cylinder
block. Care must be taken not to nick crank pin.
6.Using a suitable piston ring compressor tool, install piston and connecting rod assembly into cylinder block.
caution Insert with the front mark on the piston head directed toward the engine front (timing belt side).
>>E<< CONNECTING ROD CAP / CONNECTING ROD CAP NUT

INSTALLATION
no index mark, make sure that the bearing locking notches come on the same side as shown.
2.The connecting rod cap bolts and nuts are tightened using the torque-to-yield method. For this reason, each bolt to be
reused must be checked for elongation before installation. Whether or not the bolt has been elongated can be determined by
running a nut with fingers through all the threads of the bolt. If the nut does not turn smoothly over all the threads, the bolt has
been elongated and must be replaced.
3.Apply engine oil to the threads and bearing surface of each nut before installation.
4.Finger-tighten the nuts on the bolts, then tighten the nuts alternately and repeatedly to install the cap properly.
5.Tighten the nuts to a torque of 27 ± 2 N·m.
6.Using the special tool Angle gauge (MB991614), tighten the connecting rod cap nut in the illustrated sequence by a
further 90° to 94°.
7.Make sure that connecting rod big end side clearance meets the specification.
Limit: 0.40 mm
Removal steps
1. Connecting rod cap nut
<<A>> >>G<< 2. Connecting rod cap
>>F<< 4. Piston and connecting rod assembly
>>E<< 5. Connecting rod bearing
>>D<< 6. Piston ring No.1
>>D<< 7. Piston ring No.2
>>C<< 8. Oil ring
9. Snap ring
>>B<< 10. Piston pin
>>B<< 11. Piston
>>B<< 12. Connecting rod
13. Bolt
<> >>A<< 14. Connecting rod bush
<<A>> CONNECTING ROD CAP INSTALLATION
Mark the cylinder number on the side of the connecting rod big end for correct reassembly.
<> CONNECTING ROD BUSH REMOVAL
Use the special tool to remove the connecting rod bush.

Component parts of special tool Connecting Rod Bush Puller Kit (MH062575).
1.Secure the connecting rod to the base with the bracket and plate.
2.Attach the collar onto the puller as shown, under a press ram load of approximately 49,035 N.
>>A<< CONNECTING ROD BUSH INSTALLATION
Use the special tool Connecting rod bush puller Kit (MH062575) to install the connecting rod bush.
1.Apply a thin coat of engine oil to the outside surface of the connecting rod bush and the bush fitting hole in the connecting
rod.
2.Set the collar, connecting rod bush and collar on the puller as shown and secure them with the nut.
3.Aligning the oil hole, press-fit the connecting rod bush into the connecting rod slowly under a press ram load of
approximately 49,035 N.
4.After press-fitting, ream the connecting rod bush for the specified push-to-piston pin clearance.
Limit: 0.1 mm
caution After reaming, insert the piston pin into the connecting rod bush to ensure that it smoothly
moves with little play.
>>B<< CONNECTING ROD / PISTON PIN / PISTON INSTALLATION

1.When replacing the piston pin, read off the cylinder bore size mark on the cylinder block as illustrated, and select a piston
according to the following table.
Cylinder bore size Piston size mark
A A
B B
C C
2.Mate the piston with the connecting rod.

3.Line up the front marks and insert the piston pin. The piston pin must be smoothly pressed by hand into position. Replace the
piston pin if there is an excessive play.
>>C<< OIL RING INSTALLATION
Install the expander coil and oil ring in the piston ring groove.
>>D<< PISTON RING NO. 1 / PISTON RING NO. 2 INSTALLATION
Use a piston ring expander to install the No.1 and No.2 piston rings.
The ring identification mark should face upwards.
Identification mark
No. 1 ring: 1T
No. 2 ring: 2T
>>E<< CONNECTING ROD BEARING INSTALLATION
The connecting rod bearing to be used must have an appropriate thickness that matches the big end I.D. of the connecting
rod and the pin O.D. of the crankshaft assembly. There are two methods available for selecting an appropriate bearing.
<Selection bymeasurement>
1.Measure the big end I.D. of the connecting rod (with connecting rod bearing removed) and the pin O.D. of the crankshaft
assembly.
Before measuring the big end O.D. of the connecting rod, tighten the nut to a specified
caution
torque.
2.Select connecting rod bearing shells having the thickness that matches the respective measured values from the table
below. Install the selected connecting rod bearing shells with their lug fitted in the mating groove of the connecting rod.
caution The upper connecting rod bearing shell has an oil hole, while the lower connecting rod
bearing shell has no oil hole. Be careful not to install them in wrong place.
Crankshaft Connecting Compatible connecting rod bearing

pin O.D. rod big end identification colour (Figures in
I.D. brackets are sheet thicknesses)
53.980 - 58.010 - None (1.992 - 1.996 mm)
53.988 mm 58.019 mm
58.000 - Blue (1.988 - 1.992 mm)
58.010 mm
53.971 - 58.010 - Yellow (1.996 - 2.000 mm)
53.980 mm 58.019 mm
58.000 - None (1.992 - 1.996 mm)
58.010 mm
<Selection byidentification colour>

Select appropriate connecting rod bearings through the combination of the big end I.D. identification colour marked on each
connecting rod and the appropriate pin O.D. identification colour on the crankshaft assembly as shown in the table below.
Identification colour on Identification Compatible
crankshaft (Shown in colour on connecting rod
brackets is identification connecting bearing
mark) rod identification
colour
None (1) None Blue
Blue None
Blue (2) None None
Blue Yellow
The crankshaft assembly has additional pin O.D. identification marks ("1" or "2") stamped at as shown. The 4 marks apply to
No.1 pin, No.2 pin and so forth sequentially from the engine front to rear.
>>F<< PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION
1.Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring.
2.Arrange the piston ring and oil ring gaps (expander coil and spacer) as shown in the figure.
3.Rotate crankshaft so that crank pin is on centre of cylinder bore.
4.Use suitable thread protectors on connecting rod bolts before inserting piston and connecting rod assembly into cylinder
block. Care must be taken not to nick crank pin.
5.Using a suitable piston ring compressor tool, install piston and connecting rod assembly into cylinder block.
Insert with the front mark on the piston head directed toward the engine front (timing belt
caution
side).
>>G<< CONNECTING ROD CAP INSTALLATION
no index mark, make sure that the bearing locking notches come on the same side as shown.
2.Make sure that connecting rod big end side clearance meets the specification.
Limit: 0.60 mm
3.The connecting rod cap bolts and nuts are tightened using the torque-to-yield method. For this reason, each bolt to be
reused must be checked for elongation before installation.
Whether or not the bolt has been elongated can be determined by running a nut with fingers through all the threads of the bolt.
If the nut does not turn smoothly over all the threads, the bolt has been elongated and must be replaced.
4.Apply engine oil to the threads and bearing surface of each nut before installation.
5.Finger-tighten the nuts on the bolts, then tighten the nuts alternately and repeatedly to install the cap properly.
6.Tighten the nuts to a torque of 50 N·m.
7.Make a paint mark on the head of each nut.
8.
appropriate tightening capacity cannot be secured.
caution
Make a paint mark on the bolt at a point 90° away from the paint mark made on the nut in the tightening direction.
9.Turn the nut 90° to bring the mark on the nut into alignment with that on the bolt.
Removal steps
>>G<< 1. Connecting rod cap nut
<<A>> >>F<< 2. Connecting rod cap
>>D<< 3. Connecting rod bearing, lower
<> >>E<< 4. Piston and connecting rod assembly
>>D<< 5. Connecting rod bearing, upper
>>C<< 6. Piston ring No.1
>>C<< 7. Piston ring No.2
>>B<< 8. Oil ring
9. Snap ring
<<C>> >>A<< 10. Piston pin
11. Snap ring
12. Piston
13. Connecting rod
14. Bolt
1.Mark the cylinder number on the side of the connecting rod big end for correct reassembly.
2.Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.
<> PISTON AND CONNECTING ROD ASSEMBLY REMOVAL
2.Remove the piston and connecting rod assembly from the cylinder block.
<<C>> PISTON PIN REMOVAL
1.Remove the snap rings.

2.
The clearance between the piston and the piston pin is an almost tight fit at room
caution temperature. Therefore, be sure the heat the piston before pulling out the piston pin. In
addition, note that the piston is hot after heating.
3.Heat the piston approximately 70°C and pull out the piston pin.
>>A<< PISTON PIN INSTALLATION
1.When replacing a piston, check the cylinder bore size mark stamped at the indicated location on the cylinder block and
select an appropriate replacement piston using the following table.
Cylinder bore size mark Piston size mark
I A
II No mark
III C
note The piston size mark is located on the piston top surface.
2.Set the snap ring into one side of the piston pin hole.
3.
Apply ample coat of engine oil to the periphery of the piston pin and the hole of the connecting
caution rod small end. The clearance between the piston and the piston pin is an almost tight fit at
room temperature. Therefore, be sure to heat the piston before inserting the piston pin. In
addition, note that the piston is hot after heating.
Heat the piston to approximately 70°C.
4.With the front mark of the connecting rod and that of the piston located on the same side, insert the piston pin.
5.Set the snap ring into the other side of the piston pin hole.
1.Fit the oil ring spacer into the piston ring groove.
note The side rails and spacer may be installed in either direction.
2.
caution Do not use any piston ring expander when installing the side rail.
Install the upper side rail.
To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into the position by
finger. See illustration.
Use of a ring expander to expand the side rail end gap can break the side rail, unlike other piston rings.
3.Install the lower side rail in the same procedure as described in step 2.
Spacer and side rail sizes are colour-coded as follows:
note To install a side rail, fit one end of the rail into the groove, then press the rest of the rail into
position by hand as shown.
4.Make sure that the side rails move smoothly in either direction.
>>C<< PISTON RING NO.2 / PISTON RING NO.1 INSTALLATION
Using a piston ring expander, fit the No.2 and then No.1 piston ring into position. The ring end is provided with the
identification mark.
Identification mark
No.1 ring: 1T
No.2 ring: 2T
>>D<< CONNECTING ROD BEARING INSTALLATION
1.Measure the crankshaft pin diameter and confirm its classification from the following table. In the case of a crankshaft
supplied as a service part, identification colours/marks of its pins are painted/stamped at the positions shown in the
illustration.
Crankshaft pin outside diameter Connecting rod bearing
Identification colour Size mm Identification colour
Yellow 54.994 - 55.000 Pink
None 54.988 - 54.994 Red
White 54.982 - 54.988 Green
2.From the following table, select a bearing whose size is appropriate for the crankshaft pin outside the diameter. If the
crankshaft pin outside diameter Identification colour is "yellow," for example, select a bearing whose Identification colour is
"pink."
If there is no Identification colour paint on the crankshaft, measure the pin outside diameter and select bearing appropriate for
the measured value.
3.Install the selected bearing in the big end and in the cap of the connecting rod.
>>E<< PISTON AND CONNECTING ROD INSTALLATION
1.Liberally coat the circumference of the piston, piston ring, and oil ring with engine oil.
2.Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration.
3.Rotate the crankshaft so that the crank pin is on the centre of the cylinder bore.
5.Insert the piston and connecting rod assembly into the cylinder with the front mark on the piston crown pointing to the timing
belt side.
6.Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.
>>F<< CONNECTING ROD CAP INSTALLATION
no index mark, make sure that the bearing locking notches are on the same side as shown.
2.Make sure that the connecting rod big end side clearance meets the specification.
Limit: 0.4 mm
>>G<< CONNECTING ROD CAP NUT INSTALLATION
1.The connecting rod bolts should be examined before reuse. If the bolt threads are damaged, the bolt should be replaced.
Hand-thread the nut to the full length of the bolt threads. If the nut does not run down smoothly, the bolt should be replaced.
2.Before installation of each nut, apply engine oil to the threaded portion and bearing surface of the nut.
3.Loosely tighten each nut to the bolt.
4.Then tighten the nuts alternately to a torque of 27 ± 2 N·m to install the cap properly.
5.Make a paint mark on the head of each nut.
6.
Make a paint mark on the bolt end at the position 90° (1/4 turn) to 94° from the paint mark made on the nut in the direction of
tightening the nut.
7.Turn the nut further 90° (1/4 turn) to 94°and make sure that the paint marks on the nut and bolt are aligned.
INSPECTION
PISTON RING
1.Check for side clearance. If the limit is exceeded, replace the ring or piston, or both.
note In cases of keystone type, measure the ring to groove clearance as shown.
Standard value:
No. 1: 0.11 - 0.16 mm
No. 2: 0.07 - 0.10 mm
Oil: 0.03 - 0.06 mm
Limit:
No. 1: 0.20 mm
No. 2: 0.15 mm
Oil: 0.10 mm
2.Insert the piston ring into cylinder bore. Force it down with a piston, its crown being in contact with the ring, to correctly
position it at right angles to the cylinder wall. Then, measure the end gap with a free gauge. If the end gap is excessive,
replace piston ring.
Standard value:
No. 1: 0.20 - 0.30 mm
No. 2: 0.20 - 0.30 mm
Oil: 0.30 - 0.50 mm
Limit: 0.8 mm
CRANKSHAFT PIN OIL CLEARANCE (PLASTIGAGE METHOD)
1.Wipe off oil from the crankshaft pin and connecting rod bearing.
2.Cut a piece of plastigage whose length is equivalent to the width of the bearing and place it on the crankshaft pin in parallel
with its axis.
3.Install the connecting rod cap carefully and tighten the nuts according to INSTALLATION SERVICE POINTS.
4.Remove the nuts, then plastigage remove the connecting rod cap carefully.
5.Measure the largest width of the crushed plastigage using the ruler printed on the bag of the plastigage.
Limit: 0.1 mm
INSPECTION
PISTON RING
1.Check for side clearance. If the limit is exceeded, replace the ring or piston, or both.
note In cases of keystone type, measure the ring to groove clearance as shown.
Standard value:
No. 1: 0.07 - 0.10 mm
No. 2: 0.05 - 0.06 mm
Oil: 0.02 - 0.06 mm
Limit:
No. 1: 0.15 mm
No. 2: 0.15 mm
Oil: 0.10 mm
2.Insert the piston ring into cylinder bore. Force it down with a piston, its crown being in contact with the ring, to correctly
position it at right angles to the cylinder wall. Then, measure the end gap with a thickness gauge. If the end gap is excessive,
replace piston ring.
Item Standard value mm Limit mm
No.1 Except High power 0.30 - 0.45 0.8
High power 0.20 - 0.30 0.8
No.2 Except High power 0.30 - 0.45 0.8
High power 0.20 - 0.35 0.8
Oil 0.25 - 0.45 0.8
1.Wipe off oil from the crankshaft pin and connecting rod bearing.
2.Cut a piece of plastigage whose length is equivalent to the width of the bearing and place it on the crankshaft pin in parallel
with its axis.
3.Install the connecting rod cap carefully and tighten the nuts according to INSTALLATION SERVICE POINTS >>E<< .
4.Remove the nuts, then remove the connecting rod cap carefully.
5.Measure the largest width of the crushed plastigage using the ruler printed on the bag of the plastigage.
Limit: 0.1 mm
INSPECTION
PISTON RING
1.Check for side clearance.

If the limit is exceeded, replace the ring or piston, or both.
Standard value:
No.1: 0.03 - 0.07 mm
No.2: 0.02 - 0.06 mm
Limit:
No.1, No.2: 0.1 mm
2.Install the piston ring into the cylinder bore. Force the ring down with a piston, the piston crown being in contact with the
ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a feeler gauge.
note If the end gap is excessive, replace the piston ring.
Standard value:
No.1 ring: 0.30 - 0.45 mm
No.2 ring: 0.45 - 0.60 mm
Oil ring: 0.10 - 0.35 mm
Limit:
No.1, No.2 ring: 0.8 mm
Oil ring: 1.0 mm
1.Remove oil from the crankshaft pin and connecting rod bearing.
2.Cut the plastigage to the same length as the width of bearing and place it on crankshaft pin in parallel with its axis.
3.Install the connecting rod cap carefully and tighten the nuts to the specified torque. (See "Connecting rod cap nut
tightening" procedure.)
4.Carefully remove the connecting rod cap.
5.Measure the width of the plastigage at its widest part by using a scale printed on its package.
Limit: 0.1 mm
INSPECTION
PISTON RING
1.Check the piston ring for damage, excessive wear, and breakage. Replace if defects are evident. If the piston has been
replaced with a new one, the piston rings must also be replaced with new ones.
2.Check for clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or piston, or both.
Standard value:
Number 1: 0.04 - 0.08 mm
Number 2: 0.03 - 0.07 mm
Limit: 0.1 mm
3.Insert the piston ring into the cylinder bore. Force the ring down with a piston, the piston crown being in contact with the
ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a feeler gauge.
If the ring gap is excessive, replace the piston ring.
Standard value:
Number 1: 0.18 - 0.33 mm
Number 2: 0.28 - 0.48 mm
Oil: 0.10 - 0.60 mm
Limit:
Number 1: 0.4 mm
Number 2: 0.6 mm
Oil: 0.8 mm
CRANKSHAFT PIN OIL CLEARANCE <PLASTIGAGE METHOD>
The crankshaft oil clearance can be measured easily by using plastigage method, as follows:
1.Remove oil from the crankshaft pin and the bearing inner surface.
2.Cut plastigage to the same length as the width of the bearing and place it on the pin in parallel with its axis.
3.Install the connecting rod cap carefully and tighten the nuts to the specified torque.
4.Carefully remove the connecting rod cap.
5.Measure the width of the smashed plastigage at its widest section by using a scale printed on the plastigage bag.
Limit: 0.1 mm
caution On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown in the illustration. The balance of the flexible flywheel is adjusted in an assembled
condition. Removing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting in damage.
Removal steps
<<A>> >>I<< 1. Flywheel bolt <M/T>
2. Ball bearing <M/T>
3. Flywheel plate <M/T>
4. Flexible flywheel <M/T>
5. Crankshaft plate <M/T>
<<A>> >>I<< 6. Drive plate bolt <A/T>
7. Adapter plate <A/T>
8. Drive plate <A/T>
9. Crankshaft adapter <A/T>
10. Bell housing cover
11. Rear plate
>>H<< 12. Rear oil seal case assembly
>>G<< 13. Rear oil seal
14. Rear oil seal case
15. Engine Support bracket right
16. Engine Support bracket left
>>F<< 17. Front plate
<> >>E<< 18. Crankshaft gear
>>E<< 19. Crankshaft key
<<C>> >>D<< 20. Rear bearing
<<C>> >>D<< 21. Rear bearing
>>C<< 22. Crank case lower
23. O-ring
>>B<< 24. Thrust bearing lower
>>B<< 25. Crankshaft bearing lower
26. Crankshaft
>>B<< 27. Thrust bearing upper
>>B<< 28. Crankshaft bearing upper
29. Check valve
>>A<< 30. Oil jet
31. Crank case upper
<<A>> FLYWHEEL BOLT/ DRIVE PLATE BOLT REMOVAL
1.Using the special tool flywheel stopper (MB991883) to secure the flexible flywheel or drive plate.
2.Remove the flywheel bolts of drive plate bolts.
<> CRANKSHAFT GEAR REMOVAL
Using the special tool Crankshaft front oil seal installer (MH062469), remove the crankshaft gear in the following manner.
caution Apply engine oil to the sling surface of plate and puller.
<<C>> REAR BEARING REMOVAL
Using the special tool Balance shaft bush remover (MH062490), remove the rear bearing in the following manner.
caution Apply engine oil to the sling surface of plate and puller.
1.Set the tools as shown by passing the remover, through the rear bearing while tilting it as shown.
2.Pull the puller to bring the washer into contact with the remover.
3.Secure the plate to the crankcase using bolt.

The securing position of the plate is different between when removing the left-hand and right-
caution hand rear bearing. Be sure to secure it in right places.
4.Tighten the nut further to remove the rear bearing.
>>A<< OIL JET INSTALLATION
Install the oil jet in such a way that its pin is located at the illustrated position.
>>B<< THRUST BEARING / CRANKSHAFT BEARING INSTALLATION
When the bearing needs replacing, select a proper bearing by the following procedure.
1.Measure the crankshaft journal diameter and confirm its classification from the following table. In the case of a crankshaft
supplied as a service part, identification colours/marks of its journals and painted at the positions shown in the illustration.
If the crankshaft is machined to an undersized, bearings for undersized crankshaft should be
note
used and therefore the following selection procedure is unnecessary.
2.The cylinder block bearing bore diameter identification marks are stamped at the position shown in the illustration from front
to rear beginning at No. 1.
Crankshaft Crankcase Main bearing

Identification Journal O.D. Size I.D. mm Identification Journal Plate thickness Oil clearance
mm mark No. mm mm
1 (None) 67.970 - 67.978 A 72.010 - Black No.1,2,4,5 1.992 - 1.996 0.040 - 0.065
72.019
No.3 1.972 - 1.976 0.080 - 0.105
B 72.000 - Blue No.1,2,4,5 1.988 - 1.992 0.038 - 0.064
72.010
No.3 1.968 - 1.972 0.078 - 0.104
2 (Blue) 67.961 - 67.970 A 72.010 - Yellow No.1,2,4,5 1.996 - 2.000 0.040 - 0.066
72.019
No.3 1.976 - 1.980 0.080 - 0.106
B 72.000 - Black No.1,2,4,5 1.992 - 1.996 0.038 - 0.065
72.010 No.3 1.972 - 1.976 0.078 - 0.105
3.Select proper bearings from the above table on the basis of the identification data confirmed under Items (1) and (2).
4.Crankshaft bearing
(1) Install the bearings having an oil groove to the cylinder block.
The No. 3 bearing integrated with thrust bearing has no
note
oil groove.
(2) Install the bearings having no oil groove to the bearing cap.
5.Install the thrust plates and to crankshaft assembly at number 5 journal only. Install all halves of the thrust plates with the oil
groove oriented outward.
If any oversize thrust plates are to be used, be sure to use an upper thrust plate and lower
caution thrust plate of the same size at one side. However, using the same size upper (or lower)
thrust bearings on both sides is not necessary.
>>C<< CRANK CASE LOWER INSTALLATION
Before installing the lower crankcase assembly, check the head of the main cap bolt for punch marks. The
caution number of punch marks corresponds to the number of times the bolt has been tightened to the plastic area (Bolts
with two or less punch marks are reusable). If there are three, replace the main cap bolt.
1.Apply 2 mm thick bead of specified sealant to the fitting surface of the upper crankcase assembly as shown.
Specified sealant:
caution Apply sealant evenly, not broken or oversupplied.

Use care not to let the applied sealant slip out of place during installation.
2.Apply a thin cost of engine oil to the threaded part and seating surface of each main cap bolt then tighten the bolts to a
torque of 20 N·m in the sequence of the numbers shown (1 - 10).
3.After tightening, give the bolts an additional 90° turn.
4.Then, give the bolts another 90° turn to tighten them completely.
5.Following the main cap bolts, tighten the bolts to the specified torque 25 N·m in the sequence of the numbers shown (11 -
26)
6.After installing the lower crankcase assembly, check the following:
a. Smooth rotation of crankshaft assembly

b. Make sure that the crankshaft turns smoothly and the end play is correct. If the end play exceeds the limit, replace the
crankshaft bearings.
Limit: 0.4 mm
>>D<< REAR BEARING INSTALLATION
Using the special tool Balance shaft bush installer (MH062717), install the rear bearing in the following manner.
caution Apply engine oil to the sliding surfaces of the installer and plate.
1.Fit the rear bearing onto the installer from the non-chamfered side. At this time, align the oil hole with the alignment mark "-
" on the installer.
Align the oil hole of the left- hand bush with the "L" line of the installer and the oil hole of the right-hand rear bearing with the
"R" line.
Before installing the rear bearing onto the installer apply chassis grease to the inside
caution
surface of the rear bearing so that the oil hole dose not slip out of position.
2.Secure the plate to the crankcase using bolt as shown.
Note that the securing position of the plate is different between the left-hand balance
caution shaft rear bearing and the right-hand rear bearing.
Prior to securing the plate check that the installer is correctly positioned with respect to
the rear bearing.
3.Line up alignment mark "-" on the installer and the alignment mark "-" on the alignment mark plate.
4.Screw the nut onto the installer up to its alignment mark "-" to predetermine the press-fitting depth of the rear bearing.
5.Strike on the installer until the nut positively contacts the washer to press-fit the rear bearing into the crankcase.
6.Check that the oil hole of the rear bearing shaft bush is in alignment with the oil hole in the crankcase.
>>E<< CRANKSHAFT GEAR INSTALLATION

1.Before installing, heat the crankshaft gear to approximately 100°C with a piston heater or the like.
caution Use care not to be burned.
2.Align the notch in the crankshaft gear with the key of the crankshaft then install the crankshaft gear onto the crankshaft by
tapping on the end face lightly with a plastic hammer.
>>F<< FRONT PLATE INSTALLATION
Apply a 2 mm thick bead of the specified sealant to the lower crank case assembly and upper crankcase assembly where
indicated in the illustration.
Specified sealant:
Apply the sealant evenly, not broken or oversupplied.

caution
Use care not to let the applied sealant slip out of place during illustration.
The bolt that holds the front plate is also used to secure the timing gear case is installed.
>>G<< REAR OIL SEAL INSTALLATION
Press and fit the rear oil seal into the rear oil seal case shown in the illustration.
>>H<< REAR OIL SEAL CASE ASSEMBLY INSTALLATION
1.Apply a bead of FIPG to the surface of the rear oil seal case as shown in the drawing.
Specified sealant:
note Be sure to install the case quickly while the sealant is wet (within 15 minutes).
2.Install the rear oil seal into the cylinder block after applying an appropriate amount of engine oil to the entire circumference
of its lip portion.
3.Install the rear oil seal case by tightening its bolts to 10 ± 2 N·m.
note After installation, keep the sealed area away from the oil for approximately one hour.
>>I<< FLYWHEEL BOLT/ DRIVE PLATE BOLT INSTALLATION
1.Using special tool flywheel stopper (MB991883) to secure the drive plate of flexible flywheel.
2.Tighten the flywheel bolts and drive plate bolts to the specified torque.
Tightening torque
M/T: 132 ± 5 N·m
A/T: 135 ± 5 N·m
caution On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown in the illustration. The balance of the flexible flywheel is adjusted in an assembled
condition. Removing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting in damage.
Removal steps
1. Flywheel bolt (M/T-2WD)
2. Ball bearing (M/T-2WD)
3. Flywheel (M/T-2WD)
4. Flywheel bolt (M/T-4WD)
5. Ball bearing (M/T-4WD)
6. Adapter (M/T-4WD)
7. Flexible flywheel (M/T-4WD)
8. Crankshaft adapter (M/T-4WD)
9. Drive plate bolt (A/T)
10. Adapter plate (A/T)
11. Drive plate (A/T)
12. Crankshaft adapter (A/T)
13. Rear plate
14. Bell housing cover
>>E<< 15. Oil seal case
>>D<< 16. Oil seal
>>C<< 17. Bearing cap bolt
>>C<< 18. Bearing cap
>>C<< 19. Bearing cap No.3
>>C<< 20. Bearing cap No.4
>>B<< 21. Crankshaft bearing, lower
22. Crankshaft
>>B<< 23. Crankshaft bearing, upper
>>B<< 24. Crankshaft thrust bearing
>>A<< 25. Check valve
>>A<< 26. Oil jet
27. Engine support bracket, right
28. Engine support bracket, left
29. Cylinder block
>>A<< OIL JET INSTALLATION
There are two types of oil jets installed.

one for No.1 and 3 and the other for N0.2 and 4.
Make sure that the correct one is installed with correct direction as shown.
>>B<< CRANKSHAFT BEARING INSTALLATION

1.When the bearing needs replacing, select a proper bearing by the following procedure.
note If the crankshaft is machined to an undersized, bearings for undersized crankshaft should be
used and therefore the following selection procedure is unnecessary.
(1) Measure the crankshaft journal diameter and confirm its classification from the following table. In the case of a crankshaft
supplied as a service part, identification colors and marks of its journals and painted at the positions shown in the illustration.
(2) The cylinder block bore diameter identification marks are stamped at the position shown in the illustration from front to
rear beginning at No.1.
(3) Select proper bearings from the below table on the basis of the identification data confirmed under Items (1) and (2).
Example
a. If the measured value of a crankshaft journal outer diameter is 65.997 mm, the journal is classified as "1" or "Yellow" in
the table. In case the crankshaft is also replaced by a spare part, check the identification colors of the journals painted
on the new crankshaft.
b. Next, check the cylinder block bearing bore identification mark stamped on the cylinder block. If it is "A" read the
"Bearing identification mark" column to find the identification mark of the bearing to be used. In this case, it is "1" or
"Green"
Combination of crankshaft journal diameter and cylinder block bearing bore diameter Bearing
Crankshaft journal Classification Cylinder block bearing bore diameter identification mark
Identification color or mark O.D. mm identification mark
Using both ID (mark and color)
or either one
1 Yellow 65.994 - A 1 or Green
66.000
B 2 or Yellow
C 3 or None
2 None 65.988 - A 2 or Yellow
65.994 B 3 or None
C 4 or Blue
3 White 65.982 - A 3 or None
65.988 B 4 or Blue
C 5 or Red
2.Crankshaft bearing
(1) Install the bearings having an oil groove to the cylinder block.
note The No. 3 bearing integrated with thrust bearing has no

oil groove.
(2) Install the bearings having no oil groove to the bearing cap.
3.Crankshaft thrust bearing installation

(1) Install the two thrust bearing in the number 3 bearing bore in the cylinder block. For easier installation, apply engine oil to
the bearings; this will help hold them in position.
(2) The thrust bearings must be installed with their groove side toward the crankshaft web.
>>C<< BEARING CAP / BEARING CAP BOLT INSTALLATION
1.Install according to the front mark and cap No.

2.Apply engine oil to the threaded portion and seating face of the bolt.
3.Tighten the bearing cap bolts in the illustrated sequence to 40 ± 2 N·m.
4.Using the special tool Angle gauge (MB991614), tighten the bearing cap bolts in the illustrated sequence by a further 35°
to 39°.
5.After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end play
exceeds the limit, replace crankshaft bearings.
Limit: 0.45 mm

1.Apply oil to oil seal lips.
2.Using the special tool Oil seal installer (MD992147), Press and fit the oil seal into the oil seal case to have the dimension
shown in the illustration.
>>E<< OIL SEAL CASE INSTALLATION
1.Remove completely old FIPG remaining on the rear oil seal case and cylinder block.
2.Apply a bead of FIPG to the surface of the rear oil seal case as shown in the drawing.
Specified sealant:
note Be sure to install the case quickly while the sealant is wet (within 15 minutes).
3.Install the oil seal into the cylinder block after applying an appropriate amount of engine oil to the entire circumference of its
lip portion.
4.Install the rear oil seal case by tightening its bolts to 11 ± 1 N·m.
note After installation, keep the sealed area away from the oil for approximately one hour.
removal steps
<<A>> >>G<< 1. Drive plate bolt <A/T>
2. Adapter plate <A/T>
3. Drive plate <A/T>
4. Crankshaft adaptor <A/T>
<<A>> >>G<< 5. Flywheel bolt <M/T>
6. Flywheel <M/T>
7. Ball bearing <M/T>
8. Rear plate
>>F<< 9. Oil seal case
>>E<< 10. Crankshaft rear oil seal
>>D<< 11. Bearing cap bolt
>>D<< 12. Bearing cap
>>B<< 13. Crankshaft bearing, lower
14. Crankshaft
>>C<< 15. Thrust bearing
17. Detonation sensor
>>A<< 18. Detonation sensor bracket
19. Cylinder block
<<A>> DRIVE PLATE BOLT / FLYWHEEL BOLT REMOVAL
1.Using the special tool Flywheel stopper (MD998781), hold the drive plate or flywheel in place.
2.Remove the drive plate bolts or flywheel bolts.
>>A<< DETONATION SENSOR BRACKET INSTALLATION
Check that the bracket is in proper contact with the cylinder block boss and tighten to the specified torque of 28 ± 2 N·m in the
order shown.
>>B<< CRANKSHAFT BEARING INSTALLATION
1.Measure the crankshaft journal diameter and confirm its classification from the following table. In the case of a crankshaft
supplied as a service part, identification colours/marks of its journals are painted/stamped at the positions shown in the
illustration.
2.The cylinder block bearing bore diameter identification marks are stamped at the position shown in the illustration from left
to right, beginning at No.1.
Crankshaft journal outside diameter Cylinder block bearing bore Crankshaft bearing
Identification colour Size mm Identification mark Identification colour
Yellow 63.994 - 64.000 I Pink
II Red
III Green
None 63.988 - 63.994 I Red
II Green
III Black
White 63.982 - 63.988 I Green
II Black
III Brown
3.From the following table, select a bearing whose size is appropriate for the crankshaft journal outside diameter. If the
crankshaft journal outside diameter ID colour is "yellow" and the cylinder block bearing bore ID mark is "III," for example,
select a bearing whose ID colour is "green."
If there is no ID colour paint on the crankshaft, measure the journal outside diameter and select a bearing appropriate for the
measured valve.
4.Install bearings with a groove to the cylinder block.

5.Install the bearings having no groove to the bearing cap.
>>C<< CRANKSHAFT THRUST BEARING INSTALLATION
1.Install the thrust bearing in the No.3 bearing bore in the cylinder block and in the bearing cap. For easier installation, apply
engine oil to the bearings; this will help hold them in position.
2.The thrust bearings must be installed with their groove toward the crankshaft web.
>>D<< BEARING CAP / BEARING BOLT INSTALLATION
1.Attach the bearing cap on the cylinder block as shown in the illustration.
2.Tighten the bearing cap bolts to specified torque of 74 ± 4 N·m in the sequence shown in the illustration.
3.Check that the crankshaft rotates smoothly.
4.Check the end play. If it exceeds the limit value, replace the thrust bearing.
Limit: 0.4 mm
>>E<< CRANKSHAFT REAR OIL SEAL INSTALLATION
Using special tool Crankshaft rear oil seal installer (MD998718), press-fit a new crankshaft rear oil seal into the oil seal
case.
>>F<< OIL SEAL CASE INSTALLATION
1.Remove completely old FIPG remaining on the rear oil seal case and cylinder block.
2.Apply the sealant to the oil seal case.
Specified sealant:
3.Apply a small amount of engine oil to the entire circumference of the oil seal lip section, and place the oil seal case on the
cylinder block.
note Install the oil seal case within 15 minutes after applying liquid gasket.
note adhesion surface during that time.
>>G<< DRIVE PLATE BOLT / FLYWHEEL BOLT INSTALLATION
1.Using the special tool Flywheel stopper (MD998781) secure the drive plate or flywheel.
2.Tighten the drive plate bolt or flywheel bolt to the specified torque of 74 ± 2 N·m.
Removal steps
<<A>> >>H<< 1. Drive plate bolt
2. Adapter plate
3. Drive plate
4. Crankshaft adapter
5. Rear plate
>>G<< 6. Crankshaft rear oil seal
>>F<< 7. Oil seal case
>>E<< 8. Bearing cap bolt
<> >>E<< 9. Bearing cap
>>D<< 10. Crankshaft bearing, lower
11. Crankshaft
>>C<< 12. Thrust bearing
>>A<< 14. Crankshaft sensing ring
17. Bank stiffener
18. Bank stiffener gasket
19. Cylinder block
<<A>> DRIVE PLATE BOLT REMOVAL
1.Using special tool Flywheel stopper (MD998781), hold the drive plate.
2.Remove the drive plate bolt.
<> BEARING CAP REMOVAL
Using indelible ink, show the front mark and the cap No. on the bearing cap if they cannot be seen.
>>A<< CRANKSHAFT SENSING RING INSTALLATION
1.Apply the engine oil to the thread portions and the sealed portions on the installation bolts.
2.In accordance with the tightening order shown in the illustration, tighten the crankshaft sensing ring to the specified torque.
>>B<< CRANKSHAFT BEARING UPPER INSTALLATION

1.If the upper crankshaft bearing is replaced, select based on the identification mark of cylinder block (illustrated) and the
table shown below.
Crankshaft journal (Upper) Crankshaft bearing
Identification mark Identification mark
Number 1 and 4 journal
1 1
2 2
3 3
0 0
1 1
2 2
2.The upper crankshaft bearing has the identification mark on the location shown in the illustration.
3.Install the upper selected crankshaft bearing.
>>C<< CRANKSHAFT THRUST BEARING INSTALLATION
1.Install the thrust bearing in the No.3 bearing bore in the cylinder block and in the bearing cap. For easier installation, apply
engine oil to the bearings; this will help hold them in position.
2.The thrust bearings must be installed with their groove toward the crankshaft web.
>>D<< CRANKSHAFT BEARING LOWER INSTALLATION
1.If the lower crankshaft bearing is replaced, select based on the identification mark of crankshaft (illustrated) and the table
shown below.
Crankshaft journal (Lower) Crankshaft bearing
Identification mark Identification mark
0 0
1 1
2 2
3 3
4 4
2.The lower crankshaft bearing has the identification mark on the location shown in the illustration.
3.Install the lower selected crankshaft bearing.
>>E<< BEARING CAP / BEARING CAP BOLT INSTALLATION
1.Before installing the bearing cap bolt, check the bolt screw head is not damaged. If the screw head extremely gets
damaged, replace it with a new bolt. The standard length of the new bolt measured from under the head is as follows:
2.Attach the bearing cap on the cylinder block as shown in the illustration.
3.Tighten the bearing cap bolts to specified torque in the sequence shown in the illustration.
4.Make a paint mark on the head of each bolt.
5.
Make a paint mark on the bearing cap 90° from the paint mark made on the bolt, in the direction of tightening the bolt.
6.Turn each bolt 90° in the tightening sequence specified in step 2, and make sure that the paint marks on the bolt and cap
are aligned.
7.Check that the crankshaft rotates smoothly.
8.Check the end play. If it exceeds the limit value, replace the thrust bearing.
Limit: 0.3 mm
>>F<< CRANKSHAFT REAR OIL SEAL INSTALLATION
Using special tools Handle (MB992075) and Crankshaft rear oil seal installer (MB992183), press-fit a new crankshaft rear
oil seal into the oil seal case.
note Put the edge position in place as shown in the illustration.
>>G<< OIL SEAL CASE INSTALLATION
1.Completely remove liquid gasket adhering to the oil seal case and cylinder block.
2.Degrease the oil seal case and cylinder block.
3.Apply a 2.5 ± 0.5 mm diameter bead of sealant to the oil seal case.
Specified sealant:
4.Apply a small amount of engine oil to the entire circumference of the oil seal lip section, and place the oil seal case on the
cylinder block.
note Install the oil seal case within 15 minutes after applying liquid gasket.
note
adhesion surface during that time.
>>H<< DRIVE PLATE BOLT INSTALLATION
1.Cleanly remove sealant, oil and dust on the drive plate bolt, the drive plate and the threaded portions of the crankshaft.
2.Apply oil to the drive plate and the seating surface of the drive plate bolt.
3.Apply oil to the threaded hole of the crankshaft
4.Apply sealant to the thread portions of the drive plate bolt.
Specified sealant:
Three bond 2403 or equivalent
6.Tighten drive plate bolt or flywheel bolt to temporary torque of 20 ± 2 N·m in the order shown to illustration.
7.Tighten drive plate bolt or flywheel bolt to specified torque of 76 ± 4 N·m in the order shown in the illustration.
INSPECTION
CYLINDER BLOCK
1.Using a straightedge and free gauge, check the block top surface for warpage. Make sure that the surface is free from
gasket chips and other objects.
Limit: 0.1 mm
2.If the distortion is excessive, replace the cylinder block.
3.Check cylinder walls for scratches and seizure. If defects are evident, correct (bored to oversize) or replace.
4.Using cylinder gauge, measure the cylinder bore, and cylindricity. If worn badly, correct cylinder to an oversize and replace
piston and piston rings. Measurement points are shown in illustration.
Standard value
Cylinder I.D.: 87.6 mm

Cylindricity: 0.015 mm
CRANKSHAFT OIL CLEARANCE (PLASTIGAGE METHOD)
The crankshaft oil clearance can be measured easily by using a plastigage, as follows:
1.Remove oil and grease and any other foreign matters from crankshaft journal and bearing inner surface.
2.Install the crankshaft.
3.Cut the plastigage to the same length as the width of bearing and place it on journal in parallel with its axis.
4.Gently place the crankshaft bearing cap over it and tighten the bolts to the specified torque.
5.Remove the bolts and gently remove the crankshaft bearing cap.
Standard value:
0.018 - 0.038 mm
0.024 - 0.044 mm
Limit: 0.1 mm
INSPECTION
OIL JET / CHECK VALVE
The inspection procedure for this oil jet is the same as for the conventional oil jet.
The crankshaft oil clearance can be measured easily by using a plastigage, as follows.
Limit: 0.1 mm
CYLINDER BLOCK
1.Using a straightedge and thickness gauge, check the block top surface for warpage. Make sure that the surface is free
from gasket chips and other objects.
Limit: 0.1 mm
3.Check cylinder walls for scratches and size. If defects are evident, correct (bored to oversize) or replace.
Standard value:
Cylinder I.D. 91.10 - 91.13 mm
Cylindricity0.02 mm
INSPECTION
The crankshaft oil clearance can be measured easily by using a plastigage, as follows:
Standard value:
<No.1, 2, 4, 5> 0.04 - 0.06 mm
<No.3> 0.08 - 0.10 mm
Limit: 0.15 mm
CYLINDER BLOCK
1.Using a straightedge and free gauge, check the block top surface for warpage. Make sure that the surface is free from
gasket chips and other objects.
Limit: 0.15 mm
3.Check cylinder walls for scratches and seizure. If defects are evident, correct (bored to oversize) or replace.
Standard value:
Cylinder I.D.: 98.50 - 98.53 mm
Cylindricity0.015 mm
INSPECTION
CRANKSHAFT JOURNAL OIL CLEARANCE <PLASTIGAGE METHOD>
1.Remove oil from the crankshaft journal and crankshaft bearing inner surface.
3.Cut plastigage to the same length as the width of the bearing and place it on the journal in parallel with its axis.
4.Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque of 74 ± 4 N·m.
5.Carefully remove the crankshaft bearing cap.
Limit: 0.1 mm
CRANKSHAFT REAR OIL SEAL
1.Check the oil seal lip for wear and damage.

2.Check the rubber for deterioration or hardening.
3.Check the oil seal case for cracks and damage.
CYLINDER BLOCK
1.Visually check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident,
correct, or replace.
2.Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from
gasket chips and other foreign matter.
Limit: 0.1 mm
3.If the distortion is excessive, correct within the allowable limit or replace.
*Includes/combined with cylinder head grinding.
Cylinder block height (when new): 227.9 - 228.1 mm
4.Check the cylinder walls for scratches and seizure. If defects are evident, correct (bored to an oversize) or replace.
5.Using a cylinder gauge, measure the cylinder bore and cylindricality. If worn badly, correct by boring the cylinders to an
oversize and replace pistons and piston rings. Measure at the points shown in the illustration.
Standard value
Cylinder Inside Diameter: 93.0 mm
Cylindricality: 0.01 mm
REMOVAL STEPS
REMOVAL STEPS
Removal steps
1. Heater return pipe
2. O-ring
3. Thermostat cover
>>A<< 4. Thermostat
5. Thermostat case
6. O-ring
7. By-pass pipe
8. O-ring
9. Water pump
10. O-ring
>>A<< THERMOSTAT INSTALLATION
Install the thermostat respecting the shown angle and being careful not to tear off or damage its rubber ring.
caution Never adhere oils and greases on the rubber ring of the thermostat.
<Except High power>

Removal steps
1. Water hose
2. Water pipe "A"
3. Water hose
4. Water hose
>>E<< 5. Water pipe
>>E<< 6. O-ring
7. Water hose
8. Water pipe "D"
9. Joint
>>D<< 10. Front upper case stiffener
11. Water hose
12. Water hose
>>C<< 13. Coolant temperature gauge unit
>>B<< 14. Coolant temperature sensor
15. Water outlet fitting
16. Water outlet fitting gasket
17. Water inlet fitting
>>A<< 18. Thermostat
19. Plate
20. Gasket
21. Water pump
22. Water pump gasket
<High power>
Removal steps
1. Water hose
>>E<< 2. Water pipe
>>E<< 3. O-ring
4. Water hose
5. Water pipe "D"
6. Joint
>>D<< 7. Front upper case stiffener
8. Water hose
9. Water hose
>>C<< 10. Coolant temperature gauge unit
>>A<< 15. Thermostat
16. Plate
17. Gasket
18. Water pump
19. Water pump gasket
>>A<< THERMOSTAT INSTALLATION
1.Check that the rubber ring is undamaged and seated correctly in the thermostat flange.
2.Install the thermostat as shown in the illustration.
>>B<< COOLANT TEMPERATURE SENSOR INSTALLATION

When reusing the sensor, apply the specified sealant to the threads.
Specified sealant:
Three bond 1324N, LOCTITE 262 or equivalent
>>C<< COOLANT TEMPERATURE GAUGE UNIT INSTALLATION
Apply the specified sealant to the threads.

Specified sealant:
>>D<< FRONT UPPER CASE STIFFENER INSTALLATION
1.Temporarily tighten the front upper case stiffener with bolts.

2.Tighten to the specified torque of 50 ± 5 N·m Bolt "A" located at the front upper case side.
3.Next, tighten to the specified torque of 50 ± 5 N·m Bolt "B" located at the cylinder block side.
>>E<< WATER PIPE / O-RING INSTALLATION
caution Keep the O-ring free of oil or grease.

1.Attach a new O-ring to each end of the water pipe.
2.Wet the O-ring with water.
3.Insert the rear end of the pipe into the thermostat housing.
Removal steps
>>E<< 1. Coolant temperature gauge unit
>>D<< 2. Coolant temperature sensor
>>A<< 5. Water outlet pipe
>>A<< 6. O-ring
7. Water hose
>>C<< 9. Thermostat
10. Thermostat case
11. Thermostat case gasket
12. Fitting
13. Fitting gasket
14. Water hose
15. Water passage
>>B<< 16. Water passage gasket
17. Water hose
18. Water hose <except RUSSIA>
>>A<< 19. Water pipe
>>A<< 20. O-ring
>>A<< O-RING / WATER PIPE INSTALLATION

Wet the O-ring (with water) to ease assembly.
>>B<< WATER PASSAGE GASKET INSTALLATION
Install water passage gasket so that its side drop comes to the engine inside as shown in the illustration.
>>C<< THERMOSTAT INSTALLATION
Install the thermostat in the thermostat case with its jiggle valve located at the top position.
>>D<< COOLANT TEMPERATURE SENSOR INSTALLATION
Specified sealant:
>>E< COOLANT TEMPERATURE GAUGE UNIT INSTALLATION

Apply the specified sealant to the threads.
Specified sealant:
Removal steps
1. Water hose
2. Water hose
3. Water hose
>>I<< 4. Coolant temperature gauge unit
>>H<< 5. Coolant temperature sensor
8. Water outlet pipe
9. O-ring
>>G<< 11. Thermostat
12. Thermostat case
13. Thermostat case gasket
14. Water passage
>>F<< 15. Water passage gasket
16. Water passage gasket
>>E<< 17. Water pipe
>>E<< 18. O-ring
>>D<< 19. Oil pipe
>>C<< 20. Oil feeder control valve (OCV)
21. O-ring
>>B<< 22. Taper plug
>>A<< 23. Oil feeder control valve housing
>>A<< 24. Oil feeder control valve housing gasket
>>A<< OIL FEEDER CONTROL VALVE HOUSING / GASKET INSTALLATION
caution Oil passage shall be free from foreign matters.

Shall confirm fully that matching plane and such are free from foreign matters.
1.Install the oil feeder control valve housing gasket so that the protuberant is positioned as shown in the illustration.
2.Tighten the oil feeder control valve housing to the specified torque.
>>B<< TAPER PLUG INSTALLATION
1.Apply sealant to the threads of the taper plug.
Specified sealant:
2.Install the taper plug to the oil feeder control valve housing.
>>C<< OIL FEEDER CONTROL VALVE (OCV) INSTALLATION
caution Never re-use the O-ring.

Before installing O-ring, wind sealing tape around the oil passages cut-out area of oil feeder control
valve, to prevent damage. If the O-ring is damaged, it can cause an oil leak.
1.Apply a small amount of engine oil to the O-ring and then install it to the oil feeder control valve.
2.Install the oil feeder control valve to the cylinder head.
3.Tighten the oil feeder control valve.
>>D<< OIL PIPE INSTALLATION
1.Temporarily tighten the eye bolts on the both ends of the oil pipe.
2.Temporarily tighten the flange bolt on the clamp.
3.Tighten the eye bolts on the both ends of the oil pipe to the specified torque.
4.Tighten the flange bolt on the clamp to the specified torque.
>>E<< WATER PIPE / O-RING INSTALLATION

1.Wet the O-ring (with water) to ease assembly.
2.Install the water pipe into the bank stiffener.
>>F<< WATER PASSAGE GASKET INSTALLATION
Install the water passage gasket so that the tab is positioned as shown in the illustration.
>>G<< THERMOSTAT INSTALLATION
Install the thermostat in the thermostat case with its jiggle valve located at the top position.
>>H<< COOLANT TEMPERATURE SENSOR INSTALLATION
Apply sealant to the coolant temperature sensor.

Specified sealant:
Three bond 1324, LOCTITE 262 or equivalent
>>I<< COOLANT TEMPERATURE GAUGE UNIT INSTALLATION
Apply sealant to the coolant temperature gauge unit.

Specified sealant:
<Except High power>

Removal steps
1. Engine hanger
>>C<< 2. Eyebolt (Oil pipe)
>>C<< 3. Gasket
>>C<< 5. Gasket
>>C<< 6. Oil pipe
7. Eyebolt (Water pipe)
8. Gasket
9. Water pipe "C"
10. Eyebolt (Water pipe)
11. Gasket
12. Water pipe "B"
13. Oil return pipe
14. Oil return pipe gasket
>>B<< 15. Oil return pipe gasket
16. Turbocharger
>>A<< 17. Turbocharger gasket
18. Exhaust manifold heat protector
19. Engine hanger
20. Exhaust manifold
21. Exhaust manifold gasket
<High power>
Removal steps
1. Engine hanger
>>C<< 3. Gasket
>>C<< 5. Gasket
>>C<< 6. Oil pipe
7. Heat protector
8. Heat protector bracket
9. Water hose
10. Water hose
11. Turbocharger water pipe
>>D<< 12. Turbocharger water pipe gasket
13. Vacuum pipe and hose
14. Connector bracket
15. E-VRV
16. Oil return hose
17. Oil return pipe
18. Oil return pipe gasket
19. Turbocharger heat protector
20. Turbocharger
>>A<< 21. Turbocharger gasket
22. Exhaust manifold heat protector A
23. Exhaust manifold heat protector B
24. Engine hanger
>>A<< TURBOCHARGER GASKET INSTALLATION

Position the projection as shown in the illustration.
>>B<< OIL RETURN PIPE GASKET INSTALLATION
>>C<< EYE BOLT / GASKET / OIL PIPE INSTALLATION
1.Temporarily tighten the oil pipe with eye bolt.

note At this time, always install the gasket.
2.Tighten the eye bolt temporarily tightened to the specified torque of 17 ± 2 N·m.
note Ensure there is neither torsion nor camber.
3.Tighten the flange bolt to the specified torque of 24 ± 3 N·m.
>>D<< TURBOCHARGER WATER PIPE GASKET INSTALLATION

Removal steps
1. Engine hanger
2. Cover
3. Catalytic converter front
4. Gasket
5. Turbocharger heat protector
6. Turbocharger water inlet pipe
7. Vacuum pipe assembly
8. Vacuum hose
9. Turbocharger water outlet pipe
10. EGR water outlet pipe
11. O-ring
12. Oil pipe assembly
13. Oil return hose
>>B<< 14. Oil return pipe
>>B<< 15. Oil return pipe gasket
16. Turbocharger assembly
17. Turbocharger inlet gasket
>>A<< 18. Exhaust manifold heat protector
20. EGR cooler bracket
>>A<< EXHAUST MANIFOLD HEAT PROTECTOR INSTALLATION
Install the exhaust manifold heat protector onto the exhaust manifold by hand.
Install the exhaust manifold heat protector onto the exhaust manifold by tightening it to 14 ± 1 N·m.
>>B<< OIL RETURN PIPE / OIL RETURN PIPE GASKET INSTALLATION
Install the oil return pipe gasket in such a way that its projection is located at the illustrated position.
Removal steps
<<A>> >>G<< 1. Balance shaft RH gear
2. Thrust spacer
3. Oil pump assembly
4. O-ring
5. O-ring
6. O-ring
7. Plug
8. Relief spring
9. Steel ball
10. Oil pump cover
11. Driven gear assembly
12. Oil pump body and gear assembly
13. Woodruff key
14. Counter balance right shaft
>>F<< 15. Idler LH gear assembly
16. Idler LH gear
<> >>E<< 17. Idler LH gear bushing
18. Idler A shaft
<<C>> >>D<< 19. Balance shaft LH gear
20. Thrust spacer
21. Thrust LH plate assembly
22. O-ring
23. Woodruff key
24. Counter balance left shaft
>>C<< 25. Idler gear assembly
26. Idler gear
<<D>> >>B<< 27. Idler gear bushing
28. Idler shaft assembly
<<E>> >>A<< 29. Camshaft bolt
<<E>> >>A<< 30. Camshaft sprocket
PRE-REMOVAL INSPECTION
BACKLASH OF EACH GEAR

Measure backlash between gears, pair by pair, at three or more point. If the reading exceeds the specified standard value,
replace defective part.
Standard value:
Balance shaft gear RH and oil pump gear
0.040 - 0.192 mm
Oil pump gear and crankshaft gear
0.098 - 0.158 mm
Crankshaft gear and idler gear
0.082 - 0.142 mm
Idler gear LH and idler gear
0.040 - 0.196 mm
Idler gear LH and balance shaft gear LH
0.040 - 0.222 mm
Idler gear and idler B gear
0.096 - 0.156 mm
END PLAY
If the reading exceeds the specified standard value, replace defective part.
Standard value:
Balance shaft LH, RH
0.09 - 0.24 mm
Idler gear and sprocket assembly
0.05 - 0.20 mm
Idler gear LH assembly
0.05 - 0.20 mm
Limit: 0.3 mm
<<A>> BALANCER SHAFT RH GEAR REMOVAL
1.Using the bar, hold the balance shaft drive gear RH.
2.Remove the balance shaft drive gear RH bolt.
<> IDLER LH GEAR BUSHING REMOVAL
Using the special tool Idler gear bush puller (MH062463), remove the balance shaft bush.
<<C>> BALANCER SHAFT LH GEAR REMOVAL
1.Using the bar, hold the balance shaft drive gear LH.
2.Remove the balance shaft drive gear LH bolt.
<<D>> IDLER GEAR BUSHING REMOVAL
Using the special tool Idler sprocket bush puller (MH062462), remove the idler gear bush.
<<E>> CAMSHAFT BOLT / CAMSHAFT SPROCKET REMOVAL
When removing the bolt be sure to lock the camshaft by holding the hexagonal part A with a proper wrench.
Do not use the timing chain b for the locking.
caution The bolt is inversely threaded. The arrow mark on its head B indicates its turning direction when tightened.
To remove, turn the bolt in the reverse direction.
The camshaft sprocket a and timing chain b must be meshed in a fixed position. Do not remove the timing
chain from the camshaft sprockets unless absolutely necessary.
>>A<< CAMSHAFT SPROCKET / CAMSHAFT BOLT INSTALLATION
caution The bolt is inversely threaded. The arrow mark on its head B indicates its tuning direction when tightened.
>>B<< IDLER GEAR BUSHING INSTALLATION
Using the special tool Idler sprocket bush puller (MH062462), press-fit the idler gear bushing into the idler gear from the
side showing the match marks "0."
>>C<< IDLER GEAR ASSEMBLY INSTALLATION
Install the idler gear and sprocket assembly onto the idler shaft while aligning the mark "1" with that on the crankshaft gear.
>>D<< BALANCER SHAFT LH GEAR INSTALLATION

1.Assemble the parts shown in the illustration to the balance shaft LH.
Be sure that the washer and thrust spacer face in correct direction as shown. Install the balance shaft LH with the side
showing the match mark "0" outward.
2.Insert the completed balance shaft LH assembly into the crankcase assembly and set it in position with the dowel pin on the
crankcase assembly.
Do not rotate the balance shaft LH assembly during insertion into the crankcase
assembly.
caution
This may cause the O-ring to be slipped out of place.
Insert the balance shaft LH assembly using care not to damage the inner surface of the
rear bearing in the crankcase.
>>E<< IDLER LH GEAR BUSHING INSTALLATION
Using the special tool Idler gear bush puller (MH062463), press-fit the balance shaft idler bushing into the balance shaft
idler gear from the side showing the match marks "3" and "0."
>>F<< IDLER LH GEAR ASSEMBLY INSTALLATION
Install the idler gear LH assembly onto the idler shaft. At this time, be sure to align the match marks "3" and "0" on the idler
gear with the corresponding match marks on the idler gear and sprocket assembly and the balance shaft gear LH.
>>G<< BALANCER SHAFT RH GEAR INSTALLATION
1.Assemble the parts shown in the illustration to the balance shaft RH.
Be sure to install the washer and thrust spacer in the direction shown in the illustration, and install the balance shaft gear RH
with its mating mark "0" aligned with the mating mark "6" on the oil pump gear.
2.Insert the completed balance shaft RH assembly into the crankcase assembly while aligning the mating marks "5" on the oil
pump gear and the crankshaft gear, and set the shaft assembly in position with the dowel pin on the crankcase assembly.
Insert the balance shaft RH assembly using care not to damage the inner surface of the rear
caution
bearing in the crankcase.
3.After the timing gear are installed in position, check that all the rotary parts smoothly rotate.
INSPECTION
IDLER LH GEAR BUSHING / IDLER A SHAFT
If the idler LH gear bushing to idler A shaft clearance exceeds the limit, replace the defective parts.

Limit: 0.10 mm
IDLER GEAR BUSHING / IDLER SHAFT ASSEMBLY
If the idler gear bushing to idler shaft assembly clearance exceeds the limit, replace the defective parts.

Limit: 0.10 mm
OIL PUMP
1.Shaft to oil pump body and cover clearances.

in either case, if the measurement exceeds the specified service limit, replace oil assembly.

Limit: 0.15 mm
2.Difference between gear height and oil pump body depth.

If the difference exceeds the specified service limit, replace defective part.

Limit: 0.15 mm
3.Gear tooth crest to oil pump body clearance.

If clearance exceeds the specified service limit, replace defective part.

Limit: 0.27 mm
REAR BEARING
Measure the clearance between rear bearing and balance shaft. If the reading exceeds the specified limit, replace the
defective parts
Removal steps
<<A>> >>D<< 1. Oil pressure switch
2. Oil pipe assembly
3. Fuel supply pump holder bracket
<> 4. Fuel supply pump pipe assembly
>>C<< 5. Fuel supply pump assembly and holder
6. Suction control valve kit *1
7. Fuel supply pump holder gasket
<<C>> >>B<< 8. Fuel supply pump gear
<<C>> >>B<< 9. Idler gear B assembly
10. Idler shaft A
11. Fuel supply pump holder
12. Fuel supply pump assembly
13. O-ring
>>A<< 14. Fuel pipe bracket
15. Fuel return hose
<<D>> >>A<< 16. Fuel injection pipe No.1
<<E>> >>A<< 20. Common rail assembly
>>A<< 21. Fuel return pipe assembly
caution *1: Unless replaced, do not remove the sensor.
Using special tool Oil pressure switch socket wrench (MB992118), removal the oil pressure switch.
<> FUEL SUPPLY PUMP PIPE REMOVAL
When removing the fuel supply pump pipe, the fuel pressure in the fuel line is high. Thus, wait for 3 minutes or
caution longer after the engine stops, and cover the fuel supply pump pipe with a rag or similar materials to prevent the
fuel splash, and then disconnect the fuel supply pump pipe.
<<C>> FUEL SUPPLY PUMP GEAR / IDLER GEAR B ASSEMBLY REMOVAL
1.Using the special tool Supply pump gear stopper (MB992096), hold the fuel supply pump gear and idler gear B.
2.Remove the hold the fuel supply pump gear nut and idler gear B bolt.
3.Using the special tool Side bearing puller (MB990810), remove the fuel supply pump gear.
<<D>> FUEL INJECTION PIPE REMOVAL
Using special tool fuel injection pipe wrench (MB992188), remove the fuel injection pipe.
<<E>> COMMON RAIL ASSEMBLY REMOVAL

When operating, do not support the common rail assembly by holding the pressure limiter and the rail
caution pressure sensor at both ends.
Pay attention not to let foreign materials and dust get into the common rail assembly when the common rail
assembly is reused.
>>A<< FUEL RETURN PIPE ASSEMBLY / COMMON RAIL ASSEMBLY / FUEL

INJECTION PIPE ASSEMBLY / FUEL RETURN HOSE / FUEL PIPE BRACKET
INSTALLATION
1.
The reinstallation histories of the removed injection pipe and supply pump pipe are up
to five times. To count how many times the injection pipe and supply pump is reinstalled,
record the number of the reinstallation histories on the service booklet by adding this
latest number of the histories, which is usually "1," to the previous one. Use a new
injection pipe and supply pump when the total reinstallation history numbers reach five
times, or when the supply pump or common rail is replaced. In this case, record "a new
injection pipe and supply pump, the number of the reinstallation histories is zero" on the
service booklet.
caution If a fuel leak is present in the fuel injection pipe and fuel injection pipe set once, do not
reuse it and replace with a new one.
If the fuel injector assembly, common rail assembly or supply pump assembly is
replaced, the contact surface (seal surface) between the fuel injection pipe and fuel
injection pipe set, and the other side component is changed, do not reuse the fuel
injection pipe and fuel supply pump pipe and replace with a new one.
When the injection pipe and supply pump is reinstalled, confirm there is no foreign
material on the seal surface or in the pipe and then install it not to deviate from the axis,
fitting the seal surface.
Install the fuel return pipe assembly onto the cylinder head by hand.
2.Install the fuel return pipe assembly onto the cylinder head by tightening it to 20 ± 2 N·m.
3.
When operating, do not support the common rail assembly by holding the pressure
caution limiter and the rail pressure sensor at both ends.
Before the installation, make sure that there is no foreign object or rust to the thread
and to the high-pressure pipe sheet surface.
Temporarily fix the common rail assembly.

4.Align the fuel injection pipe centre axis with the other side components (fuel injector assembly and common rail assembly)
centre axis to install the fuel injection pipe. Then, tighten the flare nut temporarily until the tip of pipe (seal surface) contacts
with the other side components.
note When the fuel injection pipe is installed, tighten the flare nut while shaking the pipe lightly to
align the centre axis of both components.
5.Tighten the fuel pipe assembly to the specified torque of 35 ± 5 N·m at injector assembly.
6.Using special tool Fuel injection pipe wrench (MB992188), install injection pipe assembly No.1 to No.4.
Tighten the fuel injection pipe assembly No.1 to No.4 to the specified torque of 35 ± 5 N·m at injector side.
7.Install fuel return pipe assembly to the common rail with gasket, eye bolt to the specified torque to 20 ± 2 N·m.
8.Tighten the common rail assembly to the specified torque of 24 ± 4 N·m.
Tighten the fuel injection pipe assembly No.1 to No.4 to the specified to torque of 35 ± 5 N·m at common rail side.
When there is a fear that a bruise is put, wind sealing tape around the fuel pipe, to prevent
note damage.
10.Install fuel return pipe assembly to the common rail assembly with gasket, eye bolt to the specified torque to 20 ± 2 N·m.
11.Install fuel return hose to the fuel return pipe assembly with hose clip.
12.Tighten the fuel pipe bracket to the specified torque of 10 ± 2 N·m.
13.Tighten the fuel return pipe assembly to the specified torque of 10 ± 2 N·m.
>>B<< FUEL SUPPLY PUMP GEAR / IDLER GEAR B ASSEMBLY

INSTALLATION
1.Using the special tool Supply pump gear stopper (MB992096), hold the fuel supply pump gear and idler gear B.
2.Torque the fuel supply pump gear nut to the specified torque 64 ± 5 N·m.
3.Torque the idler gear B bolt to the specified torque 43 ± 2 N·m.
>>C<< FUEL SUPPLY PUMP ASSEMBLY AND HOLDER INSTALLATION
1.Turn the crankshaft clockwise to bring No. 1 cylinder to the top dead centre position.
2.Install the front plate after aligning the marks on the fuel supply pump gear and the fuel supply pump holder so that the fuel
supply gear cannot be rotated.
It’s installed in front plate so that fuel supply pump gear doesn’t revolve together with a match mark of fuel supply pump gear
and fuel supply pump holder.
3.A white paint is applied to the gears having the alignment mark of the fuel supply pump gear. Confirm the white paint on the
fuel supply pump gear is aligned with the alignment mark of the front plate.
When viewed from the front, the alignment mark on the fuel supply pump gear deviates from
note that on the front plate by about 1 - 2 gears.
note Confirm three marks of the supply pump gear are visible from the installation hole of the
power steering pump.
>>D<< OIL PRESSER SWITCH INSTALLATION
1.
caution Be careful not to block the oil passage with sealant.
Specified Sealant:
2.Tighten the oil pressure switch together with the oil filter bracket to the specified torque, using special tool MB992118.
TORQUE SPECIFICATIONS
Item N·m
Alternator
Cooling fan bolt 11 ± 1
Fan clutch bolt 11 ± 1
Crankshaft bolt 265 → 0 → 275
Idler pulley bolt <High power> 50 ± 5
Power steering pump bracket "A" bolt (Bolt, washer assembly) 20 ± 4
Power steering pump bracket "A" bolt (Flange bolt) 24 ± 4
Power steering pump bracket "B" bolt (M8 × 30) 23 ± 2
Power steering pump bracket "B" bolt (M8 × 90) 24 ± 4
Alternator pivot nut 44 ± 10
Oil level gauge bolt 48 ± 6
Inlet manifold
Vacuum pump pipe "B" bolt 24 ± 3
Air temperature sensor 14 ± 1
EGR pipe "B" bolt (EGR valve side) 49 ± 6
EGR pipe "B" bolt (EGR cooler side) 17 ± 2
EGR pipe "A" heat protector bolt 11 ± 1
EGR pipe "A" bolt and nut 17 ± 2
EGR valve bolt 48 ± 6
Throttle body bolt 13 ± 2
Fuel inlet pipe bolt 20 ± 4
Inlet manifold stay bolt 24 ± 3
Inlet manifold bolt 24 ± 3
Inlet manifold nut 20 ± 2
Exhaust manifold
<Except High power>
Engine hanger bolt 24 ± 3
Eye bolt (oil pipe) 17 ± 2
Oil pipe bolt 9.0 ± 1.0
Eye bolt (water pipe) 53 ± 7
Water pipe bolt 11 ± 1
Oil return pipe bolt 9.0 ± 1.0
Turbocharger nut 59 ± 10
Exhaust manifold heat protector bolt 14 ± 1
Exhaust manifold nut (M8) 18 ± 2
<High power>
Eye bolt 17 ± 2
Oil pipe bolt 24 ± 3
Heat protector bolt 9.0 ± 1.0
Heat protector bracket bolt (M6) 9.0 ± 1.0
Heat protector bracket bolt (M8) 24 ± 3
Turbocharger water pipe bolt (M6) 11 ± 1
Turbocharger water pipe bolt (M8) 24 ± 3
Vacuum pipe and hose bolt 23 ± 6
Connector bracket bolt 9.5 ± 1.5
E-VRV bolt 9.5 ± 2.5
Turbocharger heat protector bolt 14 ± 1
Turbocharger bolt and nut 59 ± 10
Exhaust manifold heat protector A bolt 14 ± 1
Exhaust manifold heat protector B bolt 14 ± 1
Timing belt
Vacuum pump bolt 24 ± 3
Vacuum pump pipe "A" bolt 24 ± 3
Cover bolt 11 ± 1
Crank angle sensor bolt 11 ± 1
Timing belt cover bolt 10 ± 2
Glow plug plate nut 1.8 ± 0.2
Glow plug 9.0 ± 1.0 → +30° to 34°
Tensioner arm bolt 48 ± 6
Auto tensioner bolt 23 ± 3
Pump sprocket nut 64 ± 5
Idler pulley bolt 44 ± 10
Hexagon socket head bolt 20 ± 4
Timing belt tensioner "B" bolt 23 ± 3
Balancer shaft sprocket bolt and nut 36 ± 3
Common rail and supplypump
EGR cooler bracket bolt 24 ± 3
EGR cooler bolt 24 ± 3
Supply pump bolt 24 ± 4
Suction control valve kit bolt 8.9 ± 1.9
Fuel supply pump pipe flare nut 35 ± 5
Fuel supply pump pipe bolt 10 ± 2
Fuel supply pump pipe bracket bolt 10 ± 2
Bracket bolt <High power> 20 ± 4
Fuel injection pipe flare nut 35 ± 5
Fuel injection pipe bolt 10 ± 2
Common rail bolt 24 ± 4
Fuel return pipe bolt 10 ± 2
Eyebolt (Cylinder head side) 17 ± 2
Eyebolt (Common rail side) 20 ± 2
Rocker cover and injector
Rocker cover bolt 3.0 ± 1.0 → 10 ± 2
Injector holder bolt 10 ± 1 → +120° to 125°
Eye bolt 15 ± 2
Camshaft sprocket bolt 88 ± 10
Timing belt rear cover bolt 10 ± 2
Water hose and pipe
Water pipe "A" bolt <Except High power> 24 ± 3
Water pipe bolt (M6) 11 ± 1
Water pipe bolt (M8) 24 ± 3
Water pipe "D" flare nut 54 ± 4
Water pipe "D" bolt 24 ± 3
Joint 39 ± 5
Front upper case stiffener bolt 50 ± 5
Engine coolant temperature gauge unit 11 ± 1
Engine coolant temperature sensor 29 ± 10
Water outlet fitting bolt and nut 24 ± 3
Water inlet fitting bolt 24 ± 3
Plate bolt 10 ± 2
Water pump bolt 24 ± 3
Rocker arm and camshaft
Cam position sensor bolt 11 ± 1
Camshaft bearing cap bolt (M6) 11 ± 1
Camshaft bearing cap bolt (M8) 20 ± 1
Pivot bolt 18 ± 2
Cylinder head and valves
Cylinder head bolt 78 ± 2 → 0 → 29 ± 2 → +90° → +90°
Oil pan and oil pump
Oil filter 22 ± 2
Oil pressure switch 10 ± 2
Oil cooler bolt 39 ± 5
Heat protector bolt <Except High power> 10 ± 2
Oil filter bracket bolt 24 ± 4
Harness bracket bolt 9.5 ± 2.5
Oil drain plug 39 ± 5
Oil pan bolt 9.0 ± 3.0
Oil screen bolt 19 ± 3
Stiffener bolt 19 ± 3
Front upper case bolt 24 ± 4
Plug cap 23 ± 3
Balancer shaft driven gear bolt 37 ± 3
Front lower case bolt 24 ± 4
Plug 37 ± 7
Oil pump cover screw 12 ± 2
Balancer shaft gear cover bolt 23 ± 4
Piston and connecting rod
Connecting rod cap nut 27 ± 2 → +90° to 94°
Crankshaft and cylinder block
Drive plate bolt (A/T) 135 ± 5
Flywheel bolt (M/T) 132 ± 5
Rear plate bolt 9.0 ± 1.0
Bell housing cover bolt 9.0 ± 1.0
Oil seal case bolt 11 ± 1
Bearing cap bolt 40 ± 2 → +35° to 39°
Check valve 32 ± 2
Engine support bracket bolt 54 ± 5
Item Torque N·m
Alternator
Fan pulley bolt 10 ± 2
Plate bolt and nut 13 ± 2
Crankshaft bolt 50→ +90° → 0 → 50 → +90°
Alternator pivot nut 47 ± 9
Alternator brace bolt 26 ± 5
Lock bolt 24 ± 4
Oil level gauge bolt 24 ± 4
EGR system
EGR pipe "B" bolt (EGR valve side) 49 ± 6
EGR pipe "B" nut (EGR cooler side) 17 ± 2
EGR pipe bracket bolt 24 ± 3
EGR water inlet pipe bolt 24 ± 3
EGR pipe insulator bolt 11 ± 2
EGR pipe assembly bolt 24 ± 4
EGR pipe assembly nut 17 ± 2
EGR cooler bolt 24 ± 3
Vacuum pipe and hose assembly bolt <LHD only> 21 ± 8
Vacuum pipe and hose assembly bolt 9.0 ± 3.0
Intake temperature sensor 14 ± 1
Air inlet pipe bolt 24 ± 3
Exhaust manifold
Cover bolt 9.0 ± 1.0
Catalytic converter front bolt and nut 59 ± 5
Turbocharger heat protector bolt 14 ± 1
Oil pipe assembly eye bolt 17 ± 2
Oil pipe assembly bolt 9.0 ± 1.0
Turbocharger assembly nut 59 ± 10
Exhaust manifold heat protector bolt 14 ± 1
Exhaust manifold nut 30 ± 3
EGR cooler bracket bolt 24 ± 3
Vacuum pipe assembly bolt 24 ± 3
Turbocharger water inlet pipe bolt 24 ± 3
EGR water outlet pipe bolt 24 ± 3
Turbocharger water outlet pipe eye bolt 31 ± 2
Turbocharger water inlet pipe eye bolt 31 ± 2
Water hose and pipe
Heater return pipe bolt 24 ± 3
Thermostat cover bolt 13 ± 2
Thermostat case bolt 13 ± 2
By-pass pipe bolt 24 ± 3
Injection pump assembly
Oil pipe assembly eye bolt 20 ± 2
Oil pipe assembly bolt 10 ± 2
Fuel supply pump holder bracket bolt 50 ± 5
Fuel supply pump pipe bolt 10 ± 2
Fuel supply pump pipe flare nut 35 ± 5
Fuel supply pump gear bolt 64 ± 5
Idler gear "B" assembly bolt 43 ± 2
Fuel supply pump holder bolt 24 ± 4
Fuel supply pump assembly bolt 24 ± 3
Fuel pipe bracket bolt 10 ± 2
Fuel injection pipe bolt 10 ± 2
Fuel injection pipe flare nut 35 ± 5
Common rail assembly bolt 24 ± 4
Fuel return pipe assembly eye bolt 20 ± 2
Fuel return pipe assembly bolt 24 ± 4
Suction control valve kit bolt 8.9 ± 1.9
Bracket bolt 9.0 ± 3.0
Inlet manifold
Inlet manifold bolt 17 ± 4
Glow plug 9.0 ± 1.0 → +30° to 40°
Glow plug nut 1.8 ± 0.2
Vacuum pump 24 ± 4
Vacuum inlet pipe eye bolt 20 ± 2
Engine coolant temperature sensor 30 ± 9
Water outlet fitting bolt 24 ± 3
Rocker cover and injector
Rocker cover bolt 3.0 ± 1.0
Fuel leakage pipe bolt 24 ± 4
Fuel leakage pipe eye bolt 15 ± 2
Injector holder support bolt 10 ± 1 → +120° to 125°
Pivot bar 10 ± 2
Oil pan and oil strainer
Stiffener RH bolt 24 ± 4
Stiffener LH bolt 24 ± 4
Oil pan cover assembly front bolt 13 ± 2
Oil pan cover assembly right bolt (M8) 13 ± 2
Oil pan cover assembly right bolt (M10) 26 ± 5
Oil drain plug 39 ± 5
Oil pan bolt 24 ± 4
Oil strainer bolt 24 ± 4
Oil filter 22 ± 2
Water drain plug 31 ± 2
Plug 44 ± 4
Oil cooler bolt (M8) 24 ± 3
Oil cooler bolt (M10) 44 ± 10
Oil cooler element nut 20 ± 2
Timing chain
Harness bracket bolt 9.0 ± 3.0
Timing gear case stiffener bolt 24 ± 4
Crank angle sensor bolt 11 ± 1
Camshaft position sensor bolt 11 ± 1
Timing gear case bolt (M8) 24 ± 4
Timing gear case bolt (M10) 50 ± 5
Timing chain tensioner bolt 24 ± 4
Guide plate upper bolt 24 ± 4
Guide plate lower bolt 10 ± 2
Chain bracket bolt 50 ± 13
Oil jet bolt 24 ± 4
Idler washer bolt 44 ± 4
Tensioner lever assembly bolt 38 ± 2
Tensioner lever loose side bolt 33 ± 3
Timing gear and balance shaft
Balance shaft RH gear bolt 35 ± 4
Plug 45 ± 3
Oil pump cover bolt 9.8 ± 2.0
Oil pump body and gear assembly bolt 24 ± 4
Balance shaft LH gear bolt 41 ± 5
Thrust LH plate assembly bolt 19
Camshaft bolt 88 ± 10
Rocker arms and camshaft
Camshaft cap bolt 19.6 ± 1.0
Locking nut 9.5 ± 0.5
Pivot bolt 38 ± 8
Cylinder head bolt (M12) 98 → 0 → 49 → +90° → +90°
Cylinder head bolt (M10) 58 ± 6
Connecting rod cap nut 50 → +90°
Drive plate bolt 135 ± 5
Flywheel bolt 132 ± 5
Rear plate bolt 50 ± 5
Bell housing cover bolt 10 ± 2
Engine support bracket right bolt 48 ± 6
Engine support bracket left bolt 48 ± 6
Front plate bolt (M6) 10 ± 2
Front plate bolt (M8) 24 ± 4
Crank case lower bolt (M8) 25
Crank case lower bolt (M12) 20 → +180°
Check valve 32
Item N·m
Alternator
Cooling fan 11 ± 1
Fan clutch 11 ± 1
Cooling fan bracket bolt 41 ± 8
Auto tensioner bolt (M8) 26 ± 6
Auto tensioner bolt (M10) 54 ± 13
Alternator bolt (M8) 25 ± 4
Alternator bolt (M10) 44 ± 10
Oil level gauge guide bolt 9.5 ± 2.5
Accessory mount stay bolt 20 ± 5
Thermostat case bracket bolt 23 ± 6
Accessory mount bolt (M8) 23 ± 6
Accessory mount bolt (M10) 54 ± 13
Crankshaft pulley centre bolt 200 → 0 → 110 → +60°
Air intake plenum and throttle body
Solenoid valve nut 5.5 ± 1.5
Vacuum tank bracket bolt 11 ± 1
Vacuum pipe and hose bolt 11 ± 1
Solenoid valve bolt 9.5 ± 2.5
Boost sensor bolt 5.5 ± 1.5
Throttle body bolt 9.5 ± 2.5
Air intake plenum bolt 22 ± 1
Water hose and pipe
Coolant temperature gauge unit 10.5 ± 0.5
Coolant temperature sensor 29 ± 10
Water outlet pipe bolt 23 ± 6
Thermostat case bolt 23 ± 6
Water passage bolt 23 ± 6
Water pipe bolt 23 ± 6
Oil feeder control valve bolt 11 ± 1
Taper plug 10 ± 2
Oil feeder control valve housing bolt 24 ± 3
Timing belt
Timing belt front cover bolt 6.5 ± 1.5
Crank angle sensor bolt 9.5 ± 2.5
Auto-tensioner bolt 23 ± 6
Inlet manifold
Ignition coil bolt 9.5 ± 2.5
Spark plugs 18 ± 2
Fuel pipe bolt 9.5 ± 2.5
Injector and delivery bolt 12 ± 1
Exhaust manifold
Exhaust manifold cover bolt 14 ± 1
Exhaust manifold bolt and nut 49 ± 5
Rocker cover and camshaft
PCV valve 2.5 ± 0.4
Rocker arms and shaft bolt intake side 31 ± 3
Rocker arms and shaft bolt exhaust side 13 ± 1
Rocker arm adjusting nut 9.0 ± 1.0
Cam position sensing cylinder bolt 22 ± 4
Camshaft position sensor bolt 9.5 ± 2.5
Camshaft position sensor support bolt 23 ± 6
Cylinder head bolt 45 ± 2 → +150 to 154°
Drain plug 39 ± 5
Oil filter <MD360935> 14 ± 2
Oil filter <MD332687, MD365876> 16 ± 4
Oil screen bolt 20 ± 5
Bearing cap bolt 24 ± 2 → +60° ± 2°
Plate bolt 23 ± 6
Relief plug 44 ± 5
Oil pump cover bolt 9.9 ± 2.1
Oil pump case bolt 23 ± 6
Connecting rod cap nut 20 → +90°
Drive plate bolt 20 ± 2 → 76 ± 4
Rear plate bolt 9.5 ± 2.5
Oil seal case bolt 9.5 ± 2.5
Bearing cap bolt 24 ± 2 → +90° ± 2°
Crankshaft sensing ring bolt 12 ± 2
Detonation sensor 20 ± 2
Bank stiffener bolt 23 ± 6
Bracket
Engine support bracket bolt 47 ± 11
Item N·m
Alternator and drive belt
Cooling fan bolt 11 ± 1
Fan clutch nut 11 ± 1
Cooling fan clutch bracket bolt 41 ± 8
Auto tensioner bolt M10 44 ± 10
Auto tensioner bolt M8 24 ± 4
Alternator bolt M10 49 ± 5
Alternator bolt M8 23 ± 3
Accessory mount stay bolt 24 ± 4
Timing indicator bolt 11 ± 1
Clip bolt 11 ± 1
Accessory mount bolt M10 pitch 1.25 44 ± 10
Accessory mount bolt M10 pitch 1.5 41 ± 8
Accessory mount bolt M12 74 ± 9
Power steering pump bracket bolt 44 ± 10
Crankshaft bolt 185
Emission control system
Vacuum pipe bolt 11 ± 1
Solenoid valve bolt 9.5 ± 2.5
Purge solenoid valve bolt 5.0 ± 1.0
EGR pipe bolt 18 ± 2
EGR pipe flare nut 59 ± 9
Upper inlet manifold and throttle body
Upper inlet manifold stay bolt M10 49 ± 6
Upper inlet manifold stay bolt M8 22 ± 1
Water outlet fitting bracket bolt 14 ± 1
Boost sensor bolt 5.0 ± 1.0
Air intake fitting bolt 22 ± 1
Air intake fitting nut 18 ± 1
Upper inlet manifold bolt 22 ± 1
Ignition system
Ignition coil bolt 10 ± 2
Spark plugs 25 ± 5
Camshaft position sensor bolt 11 ± 1
Camshaft position sensor support bolt 14 ± 1
Cam position sensing cylinder bolt 22 ± 4
Timing belt
Timing belt front cover M8 14 ± 1
Timing belt front cover M6 11 ± 1
Crank angle sensor bolt 9.0 ± 1.0
Auto-tensioner bolt 23 ± 3
Tensioner pulley bolt 48 ± 6
Water hose and pipe
Coolant temperature gauge unit 11 ± 1
Coolant temperature sensor 29 ± 10
Water outlet pipe bolt 14 ± 1
Thermostat case bolt 9.0 ± 1.0
Fitting bolt 12 ± 1
Water passage bolt 19 ± 1
Water pipe bolt <Cylinder head side> 14 ± 1
Water pipe bolt <Thrust case side> 13 ± 2
Inlet manifold and fuel system
Injector and delivery pipe bolt 12 ± 3
Exhaust manifold
Oil level guide bolt 14 ± 1
Heat protector cover bolt 14 ± 1
Exhaust manifold nut 44 ± 5
Rocker arm and camshaft
Rocker shaft bolt 31 ± 3
Thrust case bolt 13 ± 2
Cylinder head and valve
Cylinder head bolt 108 ± 5 → 0 → 108 ± 5
Drain plug 39 ± 5
Cover bolt M6 × 10 11 ± 1
Cover bolt M6 × 18 9.0 ± 3.0
Baffle plate bolt 11 ± 1
Oil screen bolt M8 22 ± 4
Oil screen bolt M6 9.0 ± 2.0
Relief plug 44 ± 5
Oil pump case bolt 14 ± 1
Oil pump cover bolt 10 ± 2
Connecting rod cap nut 27 ± 2 → +90° to 94°
Drive plate bolt 74 ± 2
Flywheel bolt 74 ± 2
Rear plate bolt 11 ± 1
Bearing cap bolt 74 ± 4
Detonation sensor bolt 20 ± 2
Detonation sensor bracket bolt 28 ± 2
Bracket
Engine support bracket bolt M12 75 ± 10
Engine support bracket bolt M10 41 ± 8
REWORK DIMENSIONS
Item Standard value
Cylinder head oversize valve seat bore diameter mm Intake 0.30 O.S. 36.300 - 36.325
Exhaust 0.30 O.S. 32.300 - 32.325
Cylinder head oversize valve guide bore diameter mm 0.05 O.S. 11.050 - 11.068
REWORK DIMENSIONS
Item Standard value
Cylinder head oversize valve guide hole diameter mm 0.05 O.S. 11.050 - 11.068
Cylinder head oversize valve seat hole diameter, intake mm 0.30 O.S. 33.300 - 33.325
Cylinder head oversize valve seat hole diameter, exhaust mm 0.30 O.S. 29.300 - 29.321
REWORK DIMENSIONS
Item Standard value
Cylinder head oversize valve guide hole diameter mm 0.05 O.S. 12.050 - 12.068
Cylinder head oversize valve seat hole diameter, intake mm 0.30 O.S. 35.300 - 35.325
Cylinder head oversize valve seat hole diameter, exhaust mm 0.30 O.S. 33.300 - 33.325
REWORK DIMENSIONS
Item Standard value
Diameter of oversize valve seat ring hole in cylinder head mm Intake 0.3 oversize 34.30 - 34.33
Exhaust 0.3 oversize 31.80 - 31.83
Diameter of oversize valve guide hole in cylinder head mm 0.05 oversize 11.05 - 11.07
Removal steps
1. Vacuum hose
2. Vacuum pump pipe "B"
3. Air temperature sensor
4. Gasket
5. EGR pipe "B"
6. EGR pipe gasket
7. EGR pipe gasket
8. EGR pipe heat protector
9. EGR pipe "A"
10. EGR pipe gasket
>>D<< 11. EGR pipe gasket
12. EGR valve
>>C<< 13. EGR valve gasket
14. Throttle body
>>B<< 15. Throttle body gasket
16. Fuel inlet pipe
17. Inlet manifold stay
>>A<< 18. Inlet manifold
19. Herical gasket
20. Tangential gasket
>>A<< INLET MANIFOLD INSTALLATION
1.As shown in the illustration, temporarily tighten to 6.0 ± 1.0 N·m the bolts located at side "A."
2.As shown in the illustration, tighten to the specified torque of 24 ± 3 N·m the bolts located at side "B" Tighten nuts to the
specified torque of 20 ± 2 N·m.
3.As shown in the illustration, tighten to the specified torque of 24 ± 3 N·m the bolts located at side "A."
>>B<< THROTTLE BODY GASKET INSTALLATION
>>C<< EGR VALVE GASKET INSTALLATION
>>D<< EGR PIPE GASKET INSTALLATION

Removal steps (Cont.)

1. Inlet manifold assembly
2. Gasket
3. Vacuum inlet pipe assembly
4. Vacuum pump
6. Water hose
9. Engine hunger
10. Glow plug plate
<<A>> >>A<< 11. Glow plug
<<A>> GLOW PLUG REMOVAL
When removing the glow plug, you may loosen using a tool up to the point where one or more threads are left in engagement.
Beyond this point, loosen with fingers.
caution Do not reuse a glow plug, that has been dropped from a height of 10 cm or more.
>>B<< COOLANT TEMPERATURE SENSOR INSTALLATION
Specified sealant:
>>A<< GLOW PLUG INSTALLATION
1.Check that the glow plug, glow plug mounting threads and plug seating of cylinder head are dry.
2.When installing the glow plug, screw in one thread or more with fingers and then tighten with a tool.
3.Tighten the glow plugs to 9.0 ± 1.0 N·m.
4.Using the special tool Angle gauge (MB991614), tighten the glow plug to a further 30° to 40°.
Removal steps
1. Ignition coil
<<A>> >>F<< 2. Spark plugs
<> >>E<< 3. Fuel high pressure tube
<> >>E<< 4. Fuel high pressure tube
5. Fuel pipe
6. Delivery pipe and injector
7. Insulator
>>D<< 8. Injector support
>>C<< 9. O-ring
>>B<< 10. Injector
11. O-ring
12. Delivery pipe
14. Inlet manifold gasket
<<A>> SPARK PLUG REMOVAL
Using special tool Spark plug wrench (MB991398), removal the spark plug.
<> FUEL HIGH PRESSURE TUBE REMOVAL
1.Insert a flathead screwdriver into the clearance between the quick connector and the retainer.
2.Rotate the flathead screwdriver 90°, hold up the retainer.
3.Remove the fuel high-pressure tube.
1.cost the inlet manifold mounting studs with engine oil.

2.Tighten the nuts on the left bank to 6.5 ± 1.5 N·m.
3.Tighten the nuts on the right bank to the specified torque.
4.Tighten the nuts on the left bank to the specified torque.
5.Tighten the nuts on the right bank to the specified torque.
6.Tighten the nuts on the left bank to the specified torque.
>>B<< INJECTOR INSTALLATION
caution Use care not to let gasoline enter the delivery pipe.
1.Apply gasoline to the O-ring.
2.Insert the injector into the delivery pipe.
3.Make sure the injector rotates smoothly. If not, remove the injector to check the O-ring for damage, and replace the O-ring
if necessary. Then reinsert the injector and check that it rotates smoothly.
>>C<< O-RING INSTALLATION

When inserting an O-ring into the injector on the injection nozzle side, use special tool O-ring installer (MB992106) to
gradually expand the O-ring, and fit it in place.
>>D<< INJECTOR SUPPORT INSTALLATION
1.Make sure that the protrusion of the injector is at the centre as shown in the illustration.
2.Securely assemble the injector to the injector groove and delivery pipe collar.
>>E<< FUEL HIGH PRESSURE TUBE INSTALLATION
caution Pay attention that the o-ring of the quick connector has neither scratches nor a fall.
1.Insert the quick connector of the fuel high pressure tube into the delivery pipe.
2.Fit the retainer of the fuel high-pressure tube in the direction shown in the illustration.
note Make sure the fuel high pressure tube is not pulled out when pulled lightly.
note Must confirm there is play of about 1 mm between quick connector and delivery pipe.
>>F<< SPARK PLUG INSTALLATION
Using special tool Spark plug wrench (MB991398), tighten the spark plug to the specified torque.
Removal steps
1. Harness bracket
2. Timing gear case stiffener
3. Crank angle sensor
4. Camshaft position sensor
>>E<< 5. Front oil seal
>>D< 6. Timing gear case
7. Crankshaft sensing blade
>>C<< 8. Timing chain tensioner
>>C<< 9. Timing chain tensioner gasket
10. Guide plate upper
11. Guide plate lower
>>B<< 12. Chain bracket
>>B<< 13. Idler A washer
14. Oil jet
>>A<< 15. Idler washer
>>A<< 16. Timing chain
17. Tensioner lever tension side
18. Tensioner lever shaft
19. Tensioner lever loose side
>>A<< TIMING CHAIN / IDLER WASHER INSTALLATION
1.Check that the match mark "1" on the idler gear and sprocket assembly is in alignment with that on the crankshaft gear.
2.Align the match mark on the idler gear and sprocket assembly with the mark link plate of the timing chain.
caution The
timing chain has the match mark provided at two places: one bright white link at on place
and pair of bright white link plates at the other.
3.Place the timing chain around the camshaft sprockets while aligning the timing mark on the camshaft sprockets with the
mark link plate on the timing chain.
4.After installing the timing chain attach the idler washer with the front mark "F" facing outward.
>>B<< IDLER A WASHER / CHAIN BRACKET INSTALLATION
Then, install the idler A washer to the idler gear LH assembly with its front mark "F" facing outward.
>>C<< TIMING CHAIN TENSIONER GASKET / TIMING CHAIN TENSIONER

INSTALLATION
1.Fit the gasket to the cylinder head assembly in the direction shown in the illustration.
2.Turn the cam of the tensioner to thrust the plunger in and lock the plunger with the hook. Then, install the tensioner in that
state.
3.Crank the engine in the clockwise direction.
If the tensioner is installed without thrusting the plunger in, the timing chain may be
damaged by excessive tension.
caution
The tensioner stretches the timing chain to optimum tension by means of the internal
ratchet mechanism. If the engine is cranked counter clockwise (as viewed from the
front) after the tensioner is installed, an excessive thrust is exerted to the plunger and
the cam may be damaged as a result. Should the engine be cranked counter clockwise,
remove the tensioner and re-install it in the sequence described above.
If the engine is cranked in the normal direction (clockwise) after the tensioner has been
note installed, the hook will be released automatically, the timing chain being adjusted to optimum
tension by means of the internal ratchet mechanism.
>>D<< TIMING GEAR CASE INSTALLATION
1.Apply a 3.5 ± 1.0 mm wide bead of sealant to the entire circumference of the timing chain case.
caution The timing chain case should be installed within 3 minutes of applying liquid gasket.
Specified sealant:
2.Install the timing chain case.

note The retaining bolts have different lengths. Be sure to use the correct bolt for each location.
>>E<< FRONT OIL SEAL INSTALLATION
Using special tool Crankshaft rear oil seal installer plate (MD998011), press-fit the oil seal into timing chain case.
INSPECTION
VALVE CLEARANCE CHECK AND ADJUSTMENT
caution Leaked fuel on parts causes a decrease in function and burning. Therefore, place waste to absorb leaked fuel.
1.Remove the rocker cover.
2.Align the camshaft sprocket timing marks and set the No. 1 cylinder at top dead centre.
caution The crankshaft should always be turned in a clockwise direction.
3.Measure the valve clearance.

If the valve clearance is not as specified, loosen the rocker arm lock nut and adjust the clearance using a free gauge between
the cam shaft and the roller while turning the adjusting screw.
Standard value (cold engine):
Intake valve: 0.10 mm
Exhaust valve: 0.15 mm
4.While holding the adjusting screw with a screwdriver to prevent it from turning, tighten the lock nut to the specified torque
using a special tool Valve adjusting socket (MB992046).
Tightening torque: 9.5 ± 0.5 N·m
5.Turn the crankshaft 360° clockwise to bring No. 4 cylinder to the top dead centre position.
6.Measure the valve clearances at the places indicated by arrows in the illustration. If the clearance is not within the standard
value, repeat steps 3 and 4 above.
<RHD>
Removal steps
<<A>> 1. EGR pipe B
>>C<< 2. EGR pipe gasket
<<A>> 4. EGR pipe bracket
5. EGR valve
7. EGR water inlet hose
8. EGR water inlet pipe
9. O-ring
10. EGR water outlet hose
11. EGR pipe insulator
12. EGR pipe assembly
>>B<< 13. EGR pipe assembly gasket
15. EGR cooler
16. Vacuum pipe and hose assembly
>>A<< 17. Throttle body
18. Throttle body gasket
19. Intake temperature sensor
20. Air inlet pipe
21. Air inlet pipe gasket
<LHD>
Removal steps
<<A>> 1. EGR pipe B
<<A>> 4. EGR pipe bracket
5. EGR valve
7. EGR water inlet hose
8. EGR water inlet pipe
9. O-ring
10. EGR water outlet hose
11. EGR pipe insulator
12. EGR pipe assembly
15. EGR cooler
>>A<< 18. Throttle body
19. Throttle body gasket
20. Intake temperature sensor
21. Air inlet pipe
22. Air inlet pipe gasket
<<A>> EGR PIPE BRACKET / EGR PIPE B REMOVAL
caution Don’t remove the illustration bolt of the EGR pipe B. When a bolt is removed, a plate comes off.

>>A<< THROTTLE BODY GASKET INSTALLATION
Install the throttle body gasket in such a way that its projection is located at the illustrated position.
>>B<< EGR PIPE ASSEMBLY GASKET INSTALLATION
Install the EGR pipe assembly gasket in such a way that its projection is located at the illustrated position.
>>C<< EGR PIPE B ASSEMBLY GASKET / EGR VALVE GASKET

INSTALLATION

Removal steps
1. Drive belt
2. Fan pulley
3. Fan clutch
4. Plate
5. Water pump pulley
<<A>> >>A<< 6. Crankshaft bolt
>>A<< 7. Crankshaft bolt washer
>>A<< 8. Crankshaft pulley
9. Alternator
10. Alternator brace
11. Oil level gauge
12. Oil level gauge guide
13. O-ring
14. Oil level gauge guide bracket
<<A>> CRANKSHAFT BOLT REMOVAL
1.Use the special tool Flywheel stopper (MD998781), hold the drive plate or flywheel.
2.Remove the crankshaft pulley bolt.
>>A<< CRANKSHAFT PULLEY BOLT / CRANKSHAFT PULLEY BOLT

WASHER / CRANKSHAFT PULLEY INSTALLATION
1.Use the special tool Flywheel stopper (MD998781), hold the flywheel or drive plate.
2.Using a rag, wipe dirt on the crankshaft thread hole and the crankshaft pulley washer.
3.Using a rag, wipe dirt on the crankshaft pulley and then degrease the place specified in the illustration
Perform degreasing to prevent the friction resistance from decreasing in the compressed
note
area due to the residual oil.
4.Install the crankshaft pulley.
5.Apply the minimum amount of engine oil to the crankshaft bolt threads and the seating surface.
6.Turning the inside chamfer side of the crankshaft pulley washer toward the bolt head, install the crankshaft pulley washer to
the crankshaft bolt.
7.Tighten the crankshaft pulley bolt to the specified torque of 50 N·m.
8.Tighten the crankshaft pulley bolt 90° in the specified order.
9.Loosen the crankshaft pulley bolt fully.
10.Tighten the crankshaft pulley bolt to the specified torque of 50 N·m.
11.Tighten the crankshaft pulley bolt 90° in the specified order.
<Except High power>

Removal steps
1. Cooling fan
2. Fan clutch
<<A>> >>A<< 5. Crankshaft pulley washer
<> >>A<< 6. Crankshaft pulley
7. Power steering pump bracket "A"
8. Power steering pump bracket "B"
9. Alternator
10. Oil level gauge
11. O-ring
13. O-ring
<High power>
Removal steps
1. Cooling fan
2. Fan clutch
<<A>> >>A<< 5. Crankshaft pulley washer
<> >>A<< 6. Crankshaft pulley
7. Idler pulley
8. Power steering pump bracket "A"
9. Power steering pump bracket "B"
10. Alternator
11. Oil level gauge
12. O-ring
14. O-ring
<<A>> CRANKSHAFT BOLT / CRANKSHAFT PULLEY WASHER REMOVAL
1.Use the special tool Flywheel stopper (MD998781), hold the flywheel.
2.Remove the crankshaft bolt and washer.
<> CRANKSHAFT PULLEY REMOVAL
1.Screw securely the crankshaft bolt into the crankshaft.

2.Use the special tool, remove the crankshaft pulley.
Crank pulley puller (MB992099)

Crank pulley holder (MB992100)
3.Remove the crankshaft bolt.
>>A<< CRANKSHAFT BOLT / CRANKSHAFT PULLEY WASHER /

CRANKSHAFT PULLEY INSTALLATION
1.Use the special tool Flywheel stopper (MD998781), hold the flywheel.
2.Wipe the dirt on the crankshaft pulley washer using a rag.
3.Using a rag, wipe the dirt on the crankshaft pulley, the crankshaft sprocket, the thread hole of the crankshaft and then
remove the grease.
note Degreasing is necessary to prevent decrease in the friction between contacting surfaces.
4.Install the front flange and crankshaft pulley.
5.Apply an appropriate and minimum amount of engine oil to the threads of crankshaft bolt and lower part of the flange.
6.Install the crankshaft pulley washer to the crankshaft bolt.
7.Tighten the crankshaft bolt to the specified torque of 265 N·m.
8.Loosen the bolt completely.
9.Tighten the crankshaft bolt again to the specified torque of 275 N·m.
Removal steps
1. Cooling fan
2. Fan clutch
3. Fan drive pulley
4. Cooling fan bracket
5. Idler pulley
6. Idler pulley
7. Auto tensioner
8. Harness bracket
9. Alternator
10. Oil level gauge
12. O-ring
13. Accessory mount stay
14. Thermostat case bracket
15. Accessory mount
17. Washer
18. Damper pulley
19. Front bracket
<<A>> CRANKSHAFT PULLEY CENTRE BOLT REMOVAL
2.Remove the crankshaft pulley centre bolt.
INSTALLATION SERVICE POINT
>>A<< CRANKSHAFT PULLEY CENTRE BOLT INSTALLATION
2.Wipe the dirt on the crankshaft pulley washer using a rag.
3.Using a rag, wipe the dirt on the crankshaft pulley, the front flange, the crankshaft sprocket, the thread hole of the crankshaft
and then remove the grease.
4.Install the front flange and crankshaft pulley.
5.Apply an appropriate and minimum amount of engine oil to the threads of crankshaft pulley centre bolt and lower part of the
flange.
6.Install the crankshaft pulley washer to the crankshaft pulley centre bolt.
7.Tighten the crankshaft pulley centre bolt to 200 N·m.
8.Loosen the crankshaft pulley centre bolt fully.
9.Tighten the crankshaft pulley centre bolt to 110 N·m.
10.Make a paint mark on the crankshaft pulley centre bolt.
11.Make a paint mark on the bolt end at a position 60° from the paint mark made on the crankshaft pulley in the direction of
tightening the crankshaft pulley centre bolt.
12.Turn the crankshaft pulley centre bolt another 60° and make sure that the paint marks on the crankshaft pulley and
crankshaft pulley centre bolt are aligned.
Removal steps
1. Stiffener RH
2. Stiffener LH
3. Oil pan cover assembly front
4. Oil pan cover assembly right
>>D<< 5. Oil drain plug
>>D<< 6. Oil drain plug gasket
<<A>> >>C<< 7. Oil pan
>>C<< 8. Oil pan gasket*
9. Oil strainer
10. O-ring
<> >>B<< 11. Oil filter
13. O-ring
14. O-ring
15. Water drain plug
16. Plug
17. Gasket
18. Relief spring
19. Relief plunger
>>A<< 20. Oil cooler
21. O-ring drain plug
22. Oil cooler gasket
23. Water separator lip
24. Oil cooler element
25. Gasket
note *:Use either an oil pan gasket or a sealant for installing the oil pan.
<<A>> OIL PAN REMOVAL
1.Knock the special tool Oil pan FIPG cutter (MD998727) deeply between the oil pan and the cylinder block.
2.Hitting the side of the special tool, slide the special tool along the oil pan to remove it.
<> OIL FILTER REMOVAL
Remove the oil filter using an oil filter wrench (commercially available).
>>A<< OIL COOLER INSTALLATION
Install the oil cooler.

note The retaining bolts have different lengths. Be sure to use the correct bolt for each location.
>>B<< OIL FILTER INSTALLATION
1.Clean the filter mounting surface on the cylinder block.

2.Apply engine oil to the oil filter gasket as shown in the drawing.
3.
caution Tighten the oil filter using a filter wrench (commercially available). Manual tightening cannot
generate the required torque, leading to oil leakage.
Screw in the oil filter until the O-ring contacts the mounting surface. Further tighten by 3/4 of a turn or to 22 ± 2 N·m using a
filter wrench.
>>C<< OIL PAN / OIL PAN GASKET INSTALLATION
Use either an oil pan gasket or a sealant for installing the oil pan. Install the oil pan in accordance with the following
procedure respectively.
<SEALANT>
2.Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan flange.
Specified sealant:
3.The oil pan should be installed in 15 minutes after the application of sealant.
<GASKET>
Clean both mating surfaces of oil pan and cylinder block.
>>D<< OIL DRAIN PLUG GASKET / OIL DRAIN PLUG INSTALLATION
Replace the gasket with a new one and install it in the direction shown in the illustration.
Removal steps
1. Breather hose
2. Oil filler cap
>>F<< 3. Rocker cover
4. Gasket "A"
5. Gasket "B"
6. Gasket "C"
>>E<< 7. Oil seal
>>D<< 8. Oil seal
>>C<< 9. Semi-circular packing
>>B<< 10. Injector holder bolt
>>B<< 11. Injector holder
>>B<< 12. Fuel leakage pipe
>>B<< 13. Eye bolt
>>B<< 14. Fuel leak-off gasket
>>B<< 15. Pivot boss
>>B<< 16. Injector
17. Nozzle gasket
>>A<< 18. Camshaft sprocket bolt
<<A>> >>A<< 19. Camshaft sprocket
20. Timing belt rear cover
<<A>> CAMSHAFT SPROCKET REMOVAL
Remove the camshaft sprocket holding the hexagonal area of the camshaft with a wrench.
>>A<< CAMSHAFT SPROCKET INSTALLATION
Tighten the camshaft sprocket to the specified torque of 88 ± 10 N·m holding the hexagonal area of the camshaft with a
wrench.
>>B<< INJECTOR / PIVOT BOSS / FUEL LEAK-OFF GASKET / EYE BOLT /

FUEL LEAKAGE PIPE / INJECTOR HOLDER / INJECTOR HOLDER BOLT
INSTALLATION
1.Clean the fuel injector assembly (nozzle) and the cylinder head (fuel injector insertion hole) by following the procedure
below.
(1)
Do not clean the injection part of the nozzle with a resin
caution spatula.
Using a resin spatula, scrape off the carbon deposit on the fuel injector nozzle side face ("A" shown in the figure).
(2) Spray the carburetor cleaner (MZ100139) or equivalent to the nozzle side face ("A" shown in the figure).
(3)
Do not touch the injection part of the nozzle with hand or
caution wipe it with a rag.
Leave the injection part for a while until the carbon deposit melts down, and then blow air to the injection part.
(4) Insert the special tool ornament remover (MB990784) to the cylinder head (fuel injector insertion hole) with turning the
special tool as shown, and scrape off the carbon deposit.
(5)
In order to prevent carbon from adhering to the inner
caution surface of the cylinder, blow air with the piston in the TDC
position.
Remove the special tool MB990784, and blow off the carbon deposit on the cylinder head (fuel injector insertion hole) by air.
(6) Check that there is no carbon deposit remaining on the contact surface of the fuel injector nozzle gasket.
note Repeat step 4 to step 6 several times until the carbon

deposit is completely removed.
2.Install the nozzle gasket, fuel injector, pivot boss, and injector supporter to the cylinder head as shown in the figure.
3.Apply a small amount of engine oil to the seat surface and thread of injector holder bolt, and then temporarily tighten the bolt
to the cylinder head.
4.Set the fuel leak-off gasket to the fuel leakage pipe, and temporarily tighten to the fuel injector and to the cylinder head using
the eye bolt.
5.Tighten the eye bolt of the fuel injector side to the specified torque.
6.Tighten the eye bolt of the cylinder head side to the specified torque.
7.Tighten the injector holder bolt to the specified torque.
8.Using the special tool Angle gauge (MB991614), tighten the injector holder bolt in the illustrated sequence by a further
120 to 125°.
>>C<< SEMI-CIRCULAR PACKING INSTALLATION
Apply specified sealant to portions indicated in illustration.

Specified sealant:
Using a proper socket wrench, the oil seal is pressed and fit into the rocker cover.
>>E<< OIL SEAL INSTALLATION
>>F<< ROCKER COVER INSTALLATION
1.Apply specified sealant to portions indicated in illustration.

Specified sealant:
2.
caution Pay attention that the connector does not damage the seal lip when inserting the rocker cover.
Slightly press the oil seal lip to the place in the opposite direction of the connector, shown in the illustration.
3.Leave enough clearance for the connector to avoid touching the seal lip.
4.Slowly get the seal lip through not making contact with the connector.
5.Put the rocker cover down to the installation location.
6.Check that the injector-sealing surface has the seal lip.
7.In accordance with the tightening order shown in the illustration, tighten bolts to 3.0 ± 1.0 N·m.
8.Again, in accordance with the tightening order shown in the illustration, tighten bolts to the specified torque of 10 ± 2 N·m.
Removal steps
1. Breather hose
2. Oil filler cap
>>D<< 3. Rocker cover
4. Rocker cover gasket
>>C<< 5. Oil seal
>>B<< 6. Oil seal
>>A<< 7. Fuel leakage pipe
>>A<< 8. Fuel leak-off gasket
>>A<< 9. Injector holder support bolt
>>A<< 10. Injector holder support
>>A<< 11. Injector
>>A<< 12. Nozzle gasket
13. Pivot boss
14. Pivot bar
>>A<< NOZZLE GASKET / INJECTOR / INJECTOR HOLDER SUPPORT /

INJECTOR HOLDER SUPPORT BOLT / FUEL LEAK-OFF GASKET / FUEL
LEAKAGE PIPE INSTALLATION
1.Clean the fuel injector assembly (nozzle) and the cylinder head (fuel injector insertion hole) by following the procedure
below.
(1)
caution Do
not clean the injection part of the nozzle with a resin
spatula.
Using a resin spatula, scrape off the carbon deposit on the fuel injector nozzle side face ("A" shown in the figure).
(2) Spray the carburetor cleaner (MZ100139) or equivalent to the nozzle side face ("A" shown in the figure).
(3)
caution Do not touch the injection part of the nozzle with hand or
wipe it with a rag.
Leave the injection part for a while until the carbon deposit melts down, and then blow air to the injection part.
(4) Insert the special tool ornament remover (MB990784) to the cylinder head (fuel injector insertion hole) with turning the
special tool as shown, and scrape off the carbon deposit.
(5)
In order to prevent carbon from adhering to the inner
caution surface of the cylinder, blow air with the piston in the TDC
position.
Remove the special tool MB990784, and blow off the carbon deposit on the cylinder head (fuel injector insertion hole) by air.
(6) Check that there is no carbon deposit remaining on the contact surface of the fuel injector nozzle gasket.
Repeat step 4 to step 6 several times until the carbon
note deposit is completely removed.
2.Replace the nozzle gasket with a new one.
3.Install the injector.
4.Apply the engine oil to the bearing surface and thread of injector support mounting bolts.
5.Temporarily tighten the injector holder support bolt.
6.Install the fuel leak-off gasket to the fuel leakage pipe.
7.Temporarily tighten the fuel leakage pipe at injector. Temporarily tighten the fuel leakage pipe at cylinder head and
camshaft cap.
8.Tighten the fuel leakage pipe bolt to specified torque 15 ± 2 N·m at injector side.
9.Tighten the fuel leakage pipe bolt to specified torque 15 ± 2 N·m at cylinder head side.
10.Tighten the fuel leakage pipe bolt to specified torque 24 ± 4 N·m at camshaft cap side.
11.Tighten the injector holder support bolt to specified torque 10 ± 1 N·m.
12.
Using the special tool Angle gauge (MB991614), tighten the bearing cap bolts in the illustrated sequence by a further 120°
to 125°.
>>B<< OIL SEAL INSTALLATION
>>C<< OIL SEAL INSTALLATION
Using the special tool Oil seal installer (MB992104) and Handle (MB992075), the oil seal is pressed and fit into the rocker
cover.
>>D<< ROCKER COVER INSTALLATION
caution Pay attention that the connector does not damage the seal lip when inserting the rocker cover.
1.Slightly press the oil seal lip to the place in the opposite direction of the connector, shown in the illustration.
2.Leave enough clearance for the connector to avoid touching the seal lip.
3.Slowly get the seal lip through not making contact with the connector.
4.Put the rocker cover down to the installation location.
5.Check that the injector-sealing surface has the seal lip.
6.Tighten the rocker cover bolt to the specified torque of 3.0 ± 1.0 N·m.
Removal steps
1. Fuel return hose
2. Fuel inlet hose
>>B<< 3. EGR cooler bracket
>>B<< 4. EGR cooler
>>B<< 5. Supply pump
6. Suction control valve kit *1
>>B<< 7. Fuel supply pump pipe bracket
>>B<< 8. Fuel supply pump pipe
>>A<< 9. Bracket <High power>
>>A<< 10. Fuel injection No.1 pipe
>>A<< 14. Common rail
>>A<< 15. Eye bolt (Cylinder head side)
>>A<< 16. Fuel return gasket
>>A<< 17. Eye bolt (Common rail side)
>>A<< 18. Fuel return gasket
>>A<< 19. Fuel return pipe
caution *1: Unless replaced, do not remove the sensor.
>>A<< BRACKET / FUEL INJECTION PIPE / COMMON RAIL / EYE BOLT /

FUEL RETURN GASKET / FUEL RETURN PIPE INSTALLATION
The reinstallation histories of the removed injection pipe are up to five times. To count how many times the
injection pipe is reinstalled, record the number of the reinstallation histories on the service booklet by
adding this latest number of the histories, which is usually "1", to the previous one. Use a new injection
pipe when the total reinstallation history numbers reach five times, or when the injector or common rail is
replaced. In this case, record "a new injection pipe, the number of the reinstallation histories is zero" on
the service booklet.
caution If a fuel leak is present in the fuel injection pipe and fuel injection pipe set once, do not reuse it and replace
with a new one.
If the fuel injector assembly, common rail assembly or supply pump assembly is replaced, the contact
surface (seal surface) between the fuel injection pipe and fuel injection pipe set, and the other side
component is changed, do not reuse the fuel injection pipe and fuel supply pump pipe and replace with a
new one.
When the injection pipe is reinstalled, confirm there is no foreign material on the seal surface or in the
pipe and then install it not to deviate from the axis, fitting the seal surface.
1.Temporarily tighten the fuel return pipe with bolts.

2.Slightly put the hatched area of the bracket to the cylinder port and tighten it to the specified torque of 20 ± 2 N·m. <High
power>
3.Tighten to the specified torque of 20 ± 2 N·m the eye bolt and the fuel return gasket located at the cylinder head side.
4.Temporarily tighten the common rail with bolts, holding the common rail body.
note At this time, do not hold the pressure limiter or pressure sensor of the common rail.
note Before the installation, confirm there is neither foreign material nor a rust on the threads and
the sealing surface of a high-pressure pipe.
5.Align the fuel injection pipe centre axis with the other side components (fuel injector assembly and common rail assembly)
centre axis to install the fuel injection pipe. Then, tighten the flare nut temporarily until the tip of pipe (seal surface) contacts
with the other side components.
note When the fuel injection pipe is installed, tighten the flare nut while shaking the pipe lightly to
align the centre axis of both components.
Tighten to the specified torque of 35 ± 5 N·m the flare nuts of the fuel injection pipe No.1 to No.4 at injector side.
Tighten to the specified torque of 35 ± 5 N·m the flare nuts of the fuel injection pipe No.1 to No.4 at common rail side.
8.Tighten the common rail to the specified torque of 24 ± 4 N·m.
9.Tighten to the specified torque of 20 ± 2 N·m the eye bolt and the fuel return gasket located at the common rail side.
10.Tighten the fuel return pipe to the specified torque of 10 ± 2 N·m.
11.Tighten to the specified torque of 10 ± 2 N·m the bolts of the fuel injection pipe No.1 to No.4.
>>B<< EGR COOLER / EGR COOLER BRACKET / SUPPLY PUMP / FUEL

SUPPLY PUMP PIPE / FUEL SUPPLY PUMP PIPE BRACKET INSTALLATION
The reinstallation histories of the removed fuel supply pump pipe are up to five times. To count how many
times the fuel supply pump pipe is reinstalled, record the number of the reinstallation histories on the
service booklet by adding this latest number of the histories, which is usually "1", to the previous one. Use
a new fuel supply pump pipe when the total reinstallation history numbers reach five times, or when the
supply pump or common rail is replaced. In this case, record "a new fuel supply pump pipe, the number of
the reinstallation histories is zero" on the service booklet.
caution If a fuel leak is present in the fuel injection pipe and fuel injection pipe set once, do not reuse it and replace
with a new one.
If the fuel injector assembly, common rail assembly or supply pump assembly is replaced, the contact
surface (seal surface) between the fuel injection pipe and fuel injection pipe set, and the other side
component is changed, do not reuse the fuel injection pipe and fuel supply pump pipe and replace with a
new one.
When the fuel supply pump pipe is reinstalled, confirm there is no foreign material on the seal surface or
in the pipe and then install it not to deviate from the axis, fitting the seal surface.
1.Align the fuel supply pump pipe centre axis with the other side components (common rail assembly and supply pump
assembly) centre axis to install the fuel supply pump pipe. Then, tighten the flare nut temporarily until the tip of pipe (seal
surface) contacts with the other side components.
note When the fuel supply pump pipe is installed, tighten the flare nut while shaking the pipe lightly
to align the centre axis of both components.
2.Temporarily tighten the supply pump with bolts.
3.Temporarily tighten the fuel supply pump pipe flare nuts.
4.Tighten to the specified torque of 35 ± 5 N·m the flare nuts of the fuel supply pump pipe together with the supply pump and
common rail.
5.Tighten the supply pump to the specified torque of 24 ± 4 N·m.
6.Tighten the EGR cooler to the specified torque of 24 ± 3 N·m.
note The arrow position shown in the illustration is tightened together with the fuel supply pump
pipe bracket.
7.Tighten the EGR cooler bracket to the specified torque of 24 ± 3 N·m.
8.Tighten to the specified torque of 10 ± 2 N·m the installation fuel supply pump pipe bolts together with the fuel supply pump
pipe bracket.
Removal steps
1. Injector harness
2. Injector and delivery pipe
3. Insulator
4. Insulator
>>B<< 5. Injector
6. O-ring
7. Grommet
8. Delivery pipe
10. Inlet manifold gasket
1.Tighten the nuts on the right bank to 6.5 ± 1.5 N·m.

2.Tighten the nuts on the left bank to the specified torque of 22 ± 1 N·m.
Tighten the nuts on the right bank to the specified torque of 22 ± 1 N·m.
3.Tighten the nuts on the left bank and those on the right bank again in that order.
>>B<< INJECTOR INSTALLATION
1.
caution Use care not to let gasoline enter the delivery pipe.
Before installing the fuel pressure regulator, lubricate the O-ring with a drop of gasoline for easy installation.
2.Insert the injector top end into the delivery pipe. Be careful not to damage the O-ring during installation.
Removal steps
1. PCV hose
2. Breather hose <except RUSSIA>
3. Breather & water hose <RUSSIA>
4. Blow-by hose
5. Vacuum hose
6. Vacuum hose
7. Purge hose
8. Vacuum pipe
9. Solenoid valve
10. Purge solenoid valve
11. O-ring
12. EGR valve
>>B<< 13. EGR valve gasket
14. EGR pipe
>>A<< 15. EGR pipe gasket
>>A<< EGR PIPE GASKET INSTALLATION
Install a new gasket is positioned as shown in the illustration.
>>B<< EGR VALVE GASKET INSTALLATION

Removal steps
1. Upper inlet manifold stay
2. Water outlet fitting bracket
3. Throttle body
>>A<< 4. Throttle body gasket
5. Boost sensor
6. Air intake fitting
7. Air intake fitting gasket
8. Upper inlet manifold
9. Upper inlet manifold gasket
>>A<< THROTTLE BODY GASKET INSTALLATION

GENERAL INFORMATION
4M41 engine is a DOHC. Employing a common rail system allows this engine to be lower fuel consumption and higher outputs, reducing exhaust gasses and noises.
MAJOR SPECIFICATIONS
Item Specification
Engine model 4M41
Type Inline OHV, DOHC
Number of cylinder 4
Cylinder bore mm 98.5
Piston stroke mm 105
Compression ratio 17
Compression chamber Direct injection type
Maximum output kW / r/min 120 / 3,800 <for Thailand, Brazil, South Africa>
120 / 3,500 <for General Export, Argentina, Russia>
Maximum torque N·m / r/min 343 / 2,000
Fuel injection system Common rail fuel injection
GENERAL INFORMATION
The 3.5L 6G74 engine features 6-cylinder, 24-valve, and single overhead camshafts (SOHC).
Item Specification
Engine model 6G74
Type 60° V, SOHC
Number of cylinders 6
Compression chamber Pentroof type
Cylinder bore mm 93.0
Piston stroke mm 85.8
Compression ratio 9.0
Max. output kW/r/min 137/4,750
Max. torque N·m/r/min 303/3,750
Fuel system Electronically controlled multipoint fuel injection
Ignition system Electronic-controlled 4-coil
GENERAL INFORMATION
4D56 Engine is a DOHC. Employing a common rail system allows this engine to be lower fuel consumption and higher outputs, reducing exhaust gasses and noises.
The tensioner is used to maintain the belt tension constant by using the timing belt.
The balancer shaft is used to reduce the engine vibration.
Item Specification
Engine model 4D56
Type In-line, DOHC
Number of cylinder 4
Bore × Stroke mm 91.1 × 95.0
Compression ratio Except Vehicles for Australia and New Zealand 17
Vehicles for Australia and New Zealand 16.5
Compression chamber Direct injection type
Maximum output kW/rpm Except Vehicles for Australia and New Zealand 100/4,000
Vehicles for Australia and New Zealand 131/4,000
Maximum torque N·m/rpm Except Vehicles for Australia and New Zealand 314/2,000
Vehicles for Australia and New Zealand 400/2,000 <M/T>, 350/2,000 <A/T>
Fuel system Common rail fuel injection
BASE ENGINE
TIMING TRAIN
The timing gears have mating marks as "1", "3", "5", "6" and "O" on them so that the various gears can be engaged in the correct positions when they are installed.
The timing chain is an endless chain consisting of 110 links which is installed to the camshaft sprockets to the idler sprocket.
The timing chain has three mark link plates (glossy yellow) which are used to ensure that the crankshaft and camshaft are installed in the correct timing positions. There are two plates installed in position A and one
plate in position B. For correct installation, the two plate at position A should be aligned with the "O" marks on the camshaft sprockets and the single plate at position B should be aligned with the "O" marks on the idler
sprocket.
The tension of the timing chain is regulated by the tensioner. The tensioner includes a plunger, has a built-in plunger spring inside it.
When the tensioner is installed, the plunger directly presses against the tension lever and the tension of the timing chain is determined automatically by the force of the plunger spring and hydraulic pressure.
A cam is used to lock the plunger in position after installation, in order to prevent any runout in the timing chain when it is being driven. Care should be taken if cranking the engine anti-clockwise (reverse direction)
after the tensioner has been installed, as this can cause excessive force to be applied to the plunger, which can in turn cause problems such as slippage of the cam.
CYLINDER HEAD
The cylinder head is a DOHC and corresponds to a cross flow.
ROCKER COVER
Corresponding to the common rail system, a rocker cover gasket has a favorable construction to durability.
CYLINDER HEAD GASKET
The cylinder head gasket is a metal gasket which has been selected to have the appropriate thickness to match the projection amounts of the pistons. The thicknesses of the gaskets can be identified by the differences
in the shape of notch.
PISTON
By a deep bowl type combustion chamber corresponding to a direct injection, a exhaust gas performance is improved.
To optimum piston’s slap sound, the pinhole is offset.
ROLLER ROCKER ARM
By the roller sliding friction reduced, a lower friction is realized.

A double roller proved in a diesel engine is used in the rocker arm construction.
EGR COOLER
The nine layer type of the EGR cooler is used to improve the EGR cooler efficiency.
BASE ENGINE
CYLINDER HEAD
A cylinder head made of an aluminum alloy. which is lightweight and offers high level of cooling.
VALVE SEAT
A sintered alloy valve sheet is used. The oversized (0.3 mm, 0.6 mm) service parts are available.
Item Intake Exhaust
D (Outer diameter) mm 34 31.5
d (Inner diameter) mm 28 25
h (height) mm 7.8 8.0
VALVE GUIDE
A sintered alloy valve guide is used. The oversized (0.05 mm, 0.25 mm, 0.50 mm) service parts are available.
Item Intake Exhaust
D (Outer diameter) mm 11.0 11.0
d (Inner diameter) mm 5.4 5.4
h (height) mm 45.5 50.5
A double-layered metal gasket having higher heat resistance and better sealing-properties is used for the cylinder gasket.
ROCKER COVER
A general steel rocker cover is used.
CYLINDER BLOCK
An alloy cast-iron cylinder block is used. The V-bank angle is 60°, and the bore pitch is 108 mm. The bore offset between the front and the rear banks is 40 mm. A short 10 mm block skirt is used to be lightweight. The
water jacket is a full-jacket type. The crankshaft journal has 4 bearings arranged every two-cylinder. No. 3 bearing bears the thrust load on the crankshaft.
Item Dimension
Overall length mm 384
Top face to crankshaft center mm 228
Crankshaft center to bottom face mm 10
Bore mm 93
Bore pitch mm 108
Stroke mm 85.8
PISTON
The piston is made of special aluminum alloy cast.

The center of the piston pin hole is offset by 1.5 mm from the center of the piston towards the thrust side.
Item Dimension
Base diameter mm 93
Pin diameter mm 22
Overall height mm 64
PISTON PIN
The piston pin is of a full-floating type.

Item Dimension
D (Outer diameter) mm 22
d (Inner diameter) mm 12
h (Overall length) mm 64
PISTON RING
The piston rings consist of No. 1 and No. 2 rings and an oil ring.
The longer life given by the surface finish and the low-tension piston ring are designed to reduce the friction.
Item No. 1 piston ring No. 2 piston ring Oil ring
Shape Inside bevel Taper undercut 3-piece
Surface treatment (Contact face with cylinder) Chrome plating Parkerized Chrome plating
Maker mark 1T 2T No marking
CONNECTING ROD
The connecting rod is made of highly rigid, forged carbon steel. The rod portion has an H-shaped cross section.
The connecting rod big end bearing is lubricated through an oil passage running from the main journal to the crankshaft pin.
Item Dimension
d (Small end inner diameter) mm 22
D (Large end inner diameter) mm 58
L (Center distance) mm 153.5
CONNECTING ROD BEARING
The upper and lower connecting rod bearing halves are identical.
The connecting rod bearing is equipped with back metal. While the bearing itself is made of metal alloy, the back metal is normally made of steel sheet.
The connecting rod bearing is narrower than the bearing cap, this is to minimize wear.
Item Dimension
H (Width) mm 15.4
A (Thickness) mm 1.5
CRANKSHAFT
A forged crankshaft, which is a 6-pin, 5-weight and 4-journal type, is used. The oil hole leads lubricating oil to the pin from the journal.
CRANKSHAFT BEARING, THRUST BEARING
The upper crankshaft oil bearings have oil grooves and the lower crankshaft oil bearings do not have oil grooves. Each crankshaft bearing is provided with a backing plate. Its bearing portion is made of an metal alloy
and its backing plate is made of ordinary sheet steel. A thrust bearing, which sustains the load in the thrust direction, is provided at each end of the No. 3 bearing.
Item Dimension
Crankshaft bearing Width mm 17
Thickness mm 2
Crankshaft thrust bearing Thickness mm 2
CRANKSHAFT PULLEY
The crankshaft pulley is made of aluminum alloy cast. The pulley has grooves to engage with a V-ribbed belt (7 ribs).
An ignition timing mark (notch) is stamped on the flange of the pulley.
DRIVE PLATE / FLYWHEEL
The drive plate/flywheel is mounted with 8 bolts.
VALVE
The valves have heat-resistance. The entire valve surface is treated with Tufftride.
Item Intake valve Exhaust valve
D (Head diameter) mm 32.0 28.0
d (Stem diameter) mm 6.0 6.0
L (Overall length) mm 112.30 114.11
VALVE STEM SEAL
The valve stem seal employs springs to enhance sealing performance, minimizing oil passing down to the port.
VALVE SPRING
The valve spring has a dual pitch spring to prevent surging in the high speed range.
Item Specification
h (Free length) mm 51.03
No. of spring turns 9.63
CAMSHAFT
A cast-iron camshaft is used. The surface hardening is applied to the camshaft by the process of induction hardening.
Item Dimension
Overall length mm Right 390
Left 430
Journal mm 45
Valve lift mm 8.5
BASE ENGINE
COOLING FAN
To increase a total airflow volume, a fan having six blades is used.
CYLINDER BLOCK
To reduce the residual sand of a cast within the water jacket, the water hole shapes on the upper surface of the cylinder block are increased maintaining the current change amount of the cylinder.
To reduce the amount of the components, the sleeve of the cylinder liner is deleted maintaining durability.
To bring the smooth flow of the cooling fluid along the cylinder liner, a corrugated type is used for the cross sectional area of the water jacket.
CYLINDER HEAD
The cylinder head is a DOHC and corresponds to a cross flow.

Two kinds of longitudinal intake ports are used.
ROCKER COVER
Corresponding to the common rail system, a rocker cover gasket has a favorable construction to durability.
A carbon-coated gasket is inherited corresponding to high pressure in the cylinder, and this has the shapes of the water holes in which the cooling capability of the newer cylinder head is considered.
PISTON
<Except Vehicles for Australia and NewZealand>

By a deep bowl type combustion chamber corresponding to a direct injection, a low speed torque is improved.
To improve durability, the piston pin diameter is increased and the dimension is reduced between the piston pin and the boss.
To optimum piston’s slap sound, the pinhole is offset.
<Vehicles for Australia and NewZealand>
The top shape of the high power engine is improved to increase the combustion efficiency.
VALVE MECHANISM
To improve an engine performance and correspond to exhaust gas regulation, a DOHC 4 valve construction is used.
4 valves and an injection nozzle located at the center optimize fuel combustion efficiency.
By using the roller rocker arm, a higher output and lower friction are realized.
A gear drive is applied between intake and exhaust cams, and the cylinder head is designed to be compact.
By using the scissors gear between cam gears, a gear backlash noise is reduced.
ROLLER ROCKER ARM
By the lightweight rocker arm made of steel plate and the roller sliding friction reduced, a lower friction is realized.
A double roller proved in a diesel engine is used in the rocker arm construction.
By using the rocker arm made of steel plate, the lightweight roller rocker arm is realized, assuring stiffness.
CAMSHAFT
By using the scissors gear in drive gears between cams, the noise is reduced.
By placing a main gear and a sub gear to a drive side, a load can be applied to the direction in which the sub gear has no backlash, resulting a gear backlash sound greatly reduce
EGR COOLER
The seven layer type of the EGR cooler is used to improve the EGR cooler efficiency.
DRIVE BELT
<Except Vehicles for Australia and NewZealand>
<Vehicles for Australia and NewZealand>
A Serpentine belt drive is used, which is a maintenance-free and drives all accessories using one V-ribbed belt.

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GENERAL INFORMATION

REMOVAL SERVICE POINTS

<<A>> CYLINDER HEAD BOLTS REMOVAL

<<B>> VALVE SPRING RETAINER LOCK REMOVAL

INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEAL INSTALLATION

1.Install the valve spring seat.

>>C<< VALVE SPRING RETAINER LOCK INSTALLATION

>>D<< CYLINDER HEAD GASKET INSTALLATION

>>E<< CYLINDER HEAD BOLT / CYLINDER HEAD BOLT WASHER / CYLINDER

REMOVAL SERVICE POINTS

<<A>> CYLINDER HEAD BOLTS REMOVAL

<<B>> VALVE SPRING RETAINER LOCK REMOVAL

INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEAL INSTALLATION

caution Do not reuse removed valve stem seals.

>>C<< CYLINDER HEAD GASKET INSTALLATION

<Except High power>

>>D<< CYLINDER HEAD BOLT INSTALLATION

3.Tighten the bolts to 78 ± 2 N·m in the indicated sequence.

REMOVAL SERVICE POINTS

<<A>> RETAINER LOCK REMOVAL

<<B>> VALVE STEM SEAL REMOVAL

INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEAL INSTALLATION

1.Install the valve spring seat to the valve guide.

Exhaust: Grey green

>>C<< RETAINER LOCK INSTALLATION

>>D<< CYLINDER HEAD BOLT INSTALLATION

* Includes combined with cylinder block grinding.

VALVE GUIDE REPLACEMENT PROCEDURE

3.Press-fit the valve guide until it projects by the specified amount.

VALVE SEAT REPLACEMENT PROCEDURE

VALVE SEAT RECONDITIONING PROCEDURE

VALVE SEAT RECONDITIONING PROCEDURE

VALVE GUIDE REPLACEMENT PROCEDURE

note Do not install a valve guide of the same size again.

VALVE SEAT RECONDITIONING PROCEDURE

VALVE SEAT REPLACEMENT PROCEDURE

VALVE GUIDE REPLACEMENT PROCEDURE

note Do not install a valve guide of the same size again.

* Includes combined with cylinder block grinding.

VALVE SEAT RECONDITIONING PROCEDURE

VALVE GUIDE REPLACEMENT PROCEDURE

1.Remove the snap ring from the exhaust valve guide.

REMOVAL SERVICE POINTS

<<A>> OIL PRESSURE SWITCH REMOVAL

<<B>> OIL PAN REMOVAL

1.Remove the plug on the right side of cylinder block.

<<D>> OUTER ROTOR / INNER ROTOR REMOVAL

<<E>> BALANCER SHAFT BEARING REMOVAL

INSTALLATION SERVICE POINTS

>>A<< BALANCER SHAFT BEARING INSTALLATION

Balance shaft bearing installer (MD998250)

>>B<< BALANCER SHAFT DRIVE GEAR / BALANCER SHAFT DRIVEN GEAR

>>C<< INNER ROTOR / OUTER ROTOR INSTALLATION

>>D<< OIL SEAL INSTALLATION

1.Apply engine oil to the oil seal outer surface.

>>E<< CRANKSHAFT FRONT OIL SEAL INSTALLATION

>>F<< FLANGE BOLT INSTALLATION

>>G<< FRONT UPPER CASE OIL SEAL INSTALLATION

>>H<< OIL PAN / OIL PAN GASKET INSTALLATION

>>I<< OIL DRAIN PLUG GASKET INSTALLATION

>>J<< OIL COOLER SWITCH INSTALLATION