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Brochure 23 Pages. Best Windshield Repair Kit. NOTE Do not apply oil between connecting rod and bearing or between bearing cap and bearing. If any one of four cylinders has to be rebored, rebore all four to the same next oversize. This is necessary for the sake of uniformity and balance.

Piston clearance should be within specification as follows. If it is out of specification, rebore cylinder and use oversize piston. On crank web No. To distinguish them, they are painted in and alphabets stamped on crank web No. CKP sensor if equipped Rear oil seal housing Knock sensor Rear oil seal Sensor plate bolt 3. Cylinder block Face oil groove 2 sides to NOTE crank webs. Crankshaft Runout Using a dial gauge, measure runout at center journal.

NOTE Rotate crankshaft slowly. On mating surface of cylinder block, five alphabets are stamped as shown in the figure.

To distinguish them, each bearing is painted in the following colors at such position as indicated in the figure. Each color represents the following thickness at the center of bearing. A 1 Red and Purple Red and Brown The double overhead camshaft is mounted over the cylinder head; IMT valve 3.

Engine torque [B]: IMT valve closed 2. Intake manifold 4. Engine speed IMT Intake manifold tuning system varies effective length of intake pipe by opening and closing IMT valve in order to improve air volumetric efficiency.

Under this condition, the negative pressure is not applied to IMT valve actuator. Page Engine Vacuum Check 12 After checking, install spark plugs 2 and ignition Special tool coils 1. I5JB0A 5 Start engine and run engine at specified idle speed, and read vacuum gauge.

Electric throttle body assembly : Never disassemble intake manifold. Disassembly will spoil its original performance. If faulty condition is found, replace it with new one. Engine front mounting 6. Engine splash cover 2. Engine front mounting right bracket 7. Engine front mounting nut 3. Engine front mounting left bracket 8. Engine rear mounting member bolt 4. Crankshaft pulley bolt 6. Crankshaft pulley 7. Installation To remove crankshaft pulley, use special tools 1 Clean sealing surfaces on timing chain cover, Steering wheel remover, Bearing puller attachment cylinder block and cylinder head.

Remove oil, oil sealant and dust from sealing surface. Page 4 Apply engine oil to oil seal lip, then install timing in figure. Tighten bolts and nut to specified torque. To remove them, fit a spanner 4 2nd timing chain and match marks on idler sprocket.

To tighten it, fit a sprockets are in match with timing marks 4, 6 and 8 spanner 2 to hexagonal part 3 at the center of of cylinder head, cylinder block and lower crank camshaft to hold it stationary. Timing chain guide No. Camshaft Sprocket Check teeth of sprocket for wear or damage. Spacer 12 Check that dark blue and yellow plates of 1st timing chain are in match with match marks on sprockets 8 With latch of tensioner adjuster No.

Exhaust camshaft housing 9. Exhaust camshaft 6. Shim Camshaft housing bolt : Direct shim No. If any malcondition is found, replace camshaft or cylinder 10 Install cylinder head cover. Journal clearance Standard Limit 0. I2RH0B Measure cylinder head bore and tappet outside diameter Cylinder block 7. Valve stem seal Cylinder head bolt M6 : Be sure to tighten cylinder head bolt M8 after securing cylinder head bolt M After reaming, clean bore.

Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore, and valve stem. Special tool A : — B : — If runout exceeds its limit, replace valve.

Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure. Top ring 8. Guide connecting installation. When installing a standard size piston, make sure to match piston with cylinder as follows.

S5JB0A Damaged or faulty piston should be replaced. If measured gap is out of specification, replace ring. NOTE Clean carbon and any other dirt from top of cylinder bore before inserting piston ring. Check big-end of connecting rod for side clearance, Measure crank pin for out-of-round or taper with a with rod fitted and connected to its crank pin in the micrometer.

Remove connecting rod bearing cap, and using a scale 2 on gauging plastic envelope, measure a. Before checking bearing clearance, clean bearing gauging plastic 1 width at the widest point and crank pin. Next, check crank pin diameter. On crank web of No. Cylinder block 9. Check valve Lower crankcase Page Make sure that two halves are painted in the same surface area as shown in figure.

Bond No. Special tool A : — B : — 10 Install dowel pin 2. I2RH 2. If engine is under the following conditions, select a new standard bearing as followings and install it. On lower 3 There are 5 kinds of standard bearings differing in crankcase five alphabets are stamped as shown in thickness. To distinguish them, they are painted 1 figure. For example, if number stamped on crank web No. Regrind journal to the following finished diameter.

Finished journal diameter Check oil pump chain for wear or damage. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. If oil leakage is found, repair it.

Rotor plate 6. Rotor plate bolt Circlip 2. O-ring 7. Outer rotor 8. Spring : Do not reuse. The filtered oil flows into two paths in cylinder block. When servicing, be sure to perform it after exhaust system has cooled down. Oil pan 8. Gasket : Apply sealant to mating surface.

Oil pump strainer 9. Baffle plate 3. If the measured values of length or tension is less than the specification, replace oil pump relief valve set.

If side clearance exceeds its limit, replace oil pump assembly. Limit on side clearance 0. I2RH 1. Oil pump case No. I5JB0A 1. Radiator inlet hose 5. Thermostat 9. Heater core inlet hose 2. Radiator outlet hose 6. Radiator fan operates Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace. Page Engine Cooling System: 1F-5 www. Thermostat To cylinder head [B]: J20 engine model Thermostat cap To water pump 1.

Radiator Radiator inlet No. To heater core 2. Reservoir Installation 1 Apply sealant to mating surface of water pump 1 as shown in the figure. Incorporated in the pump assembly are; a fuel filter 2 included and a fuel level gauge 3 attached. S5JB0A 5 Measure fuel pressure at each condition. Page 1G-6 Fuel System: www. Page Fuel System: 1G-7 www. Fuel pump gasket To fuel tank [B]: For J20 engine model Fuel tank bolt Fuel pump bolt Sub fuel level sensor 1.

Be sure to connect and clamp each hose correctly as shown in figure. Page Fuel System: 1G-9 www. Due to the fact that fuel feed line 1 is under high pressure, use special care when 2 Install pipes with pipe clamps to vehicle. Replace O-ring with new one. Check fuel tank inlet valve for the following. If any damage or malfunction is found, replace. Page 1G Fuel System: www. Main relay The taillights have changed, and above all the engines.

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