GA15 Engine disassembly

• Engine room cover

•
1. Engine room cover
2. Mounting rubber (Black)
3. Mounting rubber (Gray)
Removal and Installation
REMOVAL
CAUTION:
Do not damage or scratch engine room cover when installing or removing.
Remove engine room cover by pulling straight up to release mounting rubber.
INSTALLATION
Installation is in the reverse order of removal.
• Air cleaner and air duct
•
1. Mass air flow sensor
2. Mass air flow gasket
3. Clamp
4. Air duct (suction side)
5. Resonator
6. Clamp
7. PCV hose
8. Clamp
9. Clamp
10. Air cleaner cover
11. Mounting rubber
12. Air cleaner filter
13. Air cleaner body
14. Air duct inlet (lower)
15. Air duct inlet (upper)
16. Mounting rubber
17. Bracket
18. Grommet
Removal and Installation
REMOVAL
 NOTE:
Mass air flow sensor is removable under the car-mounted condition.
1. Remove engine room cover. Refer to EM-24, "Exploded View".
2. Remove air duct inlet (upper).
3. Remove air cleaner filter from the air cleaner cover.
4. Disconnect mass air flow sensor harness connector, and remove harness clamp from air cleaner body
assembly.
5. Disconnect PCV hose and transaxle breather hose.
6. Remove air cleaner body.
7. Remove air duct (suction side).
• Add matching marks if necessary for easier installation.
8. Remove air cleaner cover.
9. Remove mass air flow sensor from air cleaner cover, if necessary.
CAUTION:
Handle the mass air flow sensor with following cares.
• Do not shock the mass air flow sensor.
• Do not disassemble the mass air flow sensor.
• Do not touch the sensor of the mass air flow sensor.
10. Remove air duct inlet (lower) with the following procedure.
a. Remove front combination lamp (LH). Refer to EXL-119, "Exploded View".
b. Remove air duct inlet (lower).
INSTALLATION
CAUTION:
Do not reuse O-rings.
Installation is in the reverse order of removal.
• Align marks. Attach each joint. Screw clamps firmly.
• Tabs shall be fixed after inserting air cleaner body assembly protrusion to air cleaner case notch hole.
• Make sure whether air cleaner body has been firmly installed by shaking it.
• Intake manifold
 •
1. Clamp
2. PCV hose
3. Bracket
4. Intake manifold gasket
5. Intake manifold
6. Mount rubber
7. Clamp
8. EVAP hose
9. EVAP canister purge volume control solenoid valve
10. Electric throttle control actuator gasket
11. Electric throttle control actuator
12. Clamp
13. Water hose
14. Water hose
A. To brake booster
B. To water outlet
C. Electric throttle control actuator exploded view
Removal and Installation
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from
spilling.
REMOVAL
1. Remove engine room cover. Refer to EM-46, "Exploded View".
2. Remove air cleaner body. Refer to EM-25, "Exploded View".
3. Disconnect the radiator hose (upper) from the water outlet. Refer to CO-15, "Exploded View".
4. Disconnect water hoses from electric throttle control actuator
5. Disconnect electric throttle control actuator harness connector.
6. Remove electric throttle control actuator.
CAUTION:
• Handle carefully to avoid any shock to electric throttle control actuator.
• Do not disassemble electric throttle control actuator.
7. Pull out oil level gauge.
CAUTION:
Cover the oil level gauge guide openings to avoid entry of foreign materials.
8. Disconnect vacuum hose and EVAP hose from intake manifold.
9. Disconnect PCV hose from intake manifold.
10. Disconnect harness connectors from the runner control valve, runner control valve position sensor,
and the tuning valve.
11. Loosen intake manifold nuts and bolts in the reverse order as shown.

: Engine front

NOTE:
Disregard the numerical order No.6 in removal.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
12. Remove intake manifold and intake manifold gasket.
INSTALLATION
Installation is in the reverse order of removal.
Intake Manifold
1. Securely install intake manifold gasket to the mounting groove of the intake manifold.
CAUTION:
Do not reuse intake manifold gasket.
2. Install intake manifold with the following procedure:
a. Tighten intake manifold nuts and bolts in the numerical order as shown.
b. Tighten No. 1 bolt again.
3. Tighten bolts of electric throttle control actuator equally and diagonally in several steps.
NOTE:
After installation, it is necessary to re-calibrate the electric throttle control actuator as follows:
• Perform “Throttle Valve Closed Position Learning” after repair when removing harness
connector of the electric throttle control actuator. Refer to EC-139, "Description".
• Perform “Idle Air Volume Learning” after repair when replacing electric throttle control actuator.
Refer to EC- 140, "Description".
1. Air fuel ratio sensor
2. Exhaust manifold heat shield (upper)
3. Exhaust manifold and three way catalyst
4. Exhaust manifold heat shield (rear)
5. Exhaust manifold heat shield (front)
6. Exhaust manifold gasket
7. Cylinder head
EXCEPT CALIFORNIA
1. Air fuel ratio sensor
2. Bracket
3. Exhaust manifold
4. Exhaust manifold gasket
5. Cylinder head
6. Exhaust manifold heat shield
Removal and Installation
REMOVAL
1. Remove the cowl top. Refer to EXT-25, "Exploded View".
2. Remove front exhaust tube. Refer to EX-5, "Exploded View".
3. Disconnect air fuel ratio sensor harness connector and remove air fuel ratio sensor if necessary.
4. Remove exhaust manifold cover.
5. Remove exhaust manifold.
• Loosen nuts in reverse order as shown.
NOTE:
Disregard the numerical order No. 6-8 in removal.
6. Remove exhaust manifold gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSTALLATION
1. Install exhaust manifold gasket (1) to cylinder head as shown.
CAUTION:
Do not reuse exhaust manifold gasket (1).

2. Install exhaust manifold with the following procedure:

a. Tighten nuts in numerical order as shown.
NOTE:
• Tighten nuts the No.1-3 in two steps.
• The numerical order No.6-8 shows the second step.
3. Installation of remaining components is in the reverse order of removal.
4. Exhaust manifold

1. Air fuel ratio sensor

2. Exhaust manifold heat shield (upper)
3. Exhaust manifold and three way catalyst
4. Exhaust manifold heat shield (rear)
5. Exhaust manifold heat shield (front)
6. Exhaust manifold gasket
7. Cylinder head
EXCEPT CALIFORNIA

1. Air fuel ratio sensor

2. Bracket
3. Exhaust manifold
4. Exhaust manifold gasket
5. Cylinder head
6. Exhaust manifold heat shield
Removal and Installation
REMOVAL
1. Remove the cowl top. Refer to EXT-25, "Exploded View".
2. Remove front exhaust tube. Refer to EX-5, "Exploded View".
3. Disconnect air fuel ratio sensor harness connector and remove air fuel ratio sensor if necessary.
4. Remove exhaust manifold cover.
5. Remove exhaust manifold.
• Loosen nuts in reverse order as shown.
NOTE:
Disregard the numerical order No. 6-8 in removal.
6. Remove exhaust manifold gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSTALLATION
1. Install exhaust manifold gasket (1) to cylinder head as shown.
CAUTION:
Do not reuse exhaust manifold gasket (1).

2. Install exhaust manifold with the following procedure:

a. Tighten nuts in numerical order as shown.
NOTE:
• Tighten nuts the No.1-3 in two steps.
• The numerical order No.6-8 shows the second step.
3. Installation of remaining components is in the reverse order of removal.
Inspection
INSPECTION AFTER REMOVAL
Surface Distortion
• Using feeler gauge (A) and straightedge (B), check the surface distortion of exhaust manifold mating
surface in each exhaust port and entire part.
Limit : Refer to EM-119, "Exhaust Manifold".
• If it exceeds the limit, replace exhaust manifold.
• Oil pan

1. O-ring
2. Oil pan (upper)
3. Oil level gauge guide
4. O-ring
5. Oil level gauge
6. Oil pump drive chain
7. Crankshaft sprocket
8. Oil pump sprocket
9. Oil pump chain tensioner
10. Oil pump
11. Drain plug
12. Drain plug washer
13. Oil pan (lower)
14. Oil filter
15. Clamp
16. Water hose
17. Oil cooler
18. Crankshaft position sensor
19. Rear oil seal
A. Refer to LU-10
B. To thermostat housing
C. To thermostat housing (M/T models) To CVT oil warmer (CVT models)
D. Oil pan side
Removal and Installation (Lower Oil Pan)
REMOVAL
1. Drain engine oil. Refer to LU-8, "Draining".
2. Remove oil pan (lower) bolts in reverse order as shown.
NOTE:
Disregard the numerical order No.7 and 11 in removal.

3. Insert Tool between oil pan (upper) and oil pan (lower).
CAUTION:
• Do not damage the mating surface.
• Do not insert a screwdriver. This damages the mating surfaces.
• Slide Tool by tapping on the side of Tool (A) using a plastic hammer.
Tool number : KV10111100 (J-37228)
4. Remove oil pan (lower).
 INSTALLATION
CAUTION:
Do not reuse O-rings or washers.
1. Install oil pan (lower) as follows:
a. Use a suitable tool (A) to remove old liquid gasket from mating surfaces.
• Also remove old liquid gasket from mating surface of oil pan (upper).
• Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surface when cleaning off old liquid gasket.

b. Apply a continuous bead of liquid gasket (A) using suitable tool as shown as shown.
(1) : Oil pan (lower)
(b) : 7.5-9.5mm (0.295 - 0.374 in)
(c) : 4.0 - 5.0 mm (0.157 - 0.197 in)
 Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-21, "Recommended Chemical
Products and Sealants".
CAUTION:
• Installation should be done within 5 minutes after applying liquid gasket.
• Do not fill the engine with oil for at least 30 minutes after the components are installed to allow
the sealant to cure.
c. Tighten bolts in numerical order as shown.
NOTE:
• Tighten bolts the No.1 and 2 in two steps.
• The numerical order No.7 and 11 shows the second steps.
2. Install oil pan drain plug.
CAUTION:
• Do not reuse drain plug washer.
• Refer to exploded view installation direction of drain plug washer. Refer to EM-33, "Exploded
View".
3. Refill the engine with engine oil. Refer to LU-9, "Refilling".
Inspection
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSPECTION AFTER INSTALLATION
1. Check the engine oil level and adjust engine oil. Refer to LU-7, "Inspection".
2. Start engine, and check for leaks of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check the engine oil level again. Refer to LU-7, "Inspection".
Removal and Installation (Upper Oil Pan)
REMOVAL
1. Remove the engine and transaxle assembly. Refer to EM-82, "M/T : Exploded View" (M/T) or EM-86,
"CVT : Exploded View" (CVT).
2. Remove the clutch cover and clutch disc. Refer to CL-17, "Exploded View".
3. Remove the flywheel (M/T) or drive plate (CVT). Refer to EM-90, "Exploded View" (M/T) or EM-92,
"Exploded View" (CVT).
4. Mount the engine on an engine stand. Refer to EM-72, "Removal and Installation".
5. Remove the generator and generator bracket. Refer to CHG-29, "Exploded View".
6. Remove oil pan (lower). Refer to EM-33, "Removal and Installation (Lower Oil Pan)".
7. Remove oil filter. Refer to LU-10, "Removal and Installation".
8. Remove timing chain. Refer to EM-48, "Exploded View".
9. Remove oil level gauge and oil level gauge guide.
10. Remove oil pump if necessary. Refer to LU-12, "Exploded View".
NOTE:
The oil pan (upper) can be removed and installed without removing the oil pump.
11. Remove oil pan (upper) with the following procedure:
a. Loosen bolts in reverse order as shown.
b. Using suitable tool as shown by the arrow ( ) open up a crack between oil pan (upper) and cylinder
block.
CAUTION:
Do not use suitable tool anywhere other than shown, sealant used is more adhesive than previous
types when shipped.

c. Insert Tool (A) between oil pan (upper) and cylinder block.
Tool Number : KV10111100 (J-37228)

CAUTION:
Do not damage the mating surface.
• In areas where the cutter is difficult to use, use a plastic hammer to lightly tap (1) the cutter where the
liquid gasket is applied. Use a plastic hammer to slide (2) the cutter by tapping on the side.
12. Remove O-ring between cylinder block and oil pan (upper).
INSTALLATION
CAUTION:
Do not reuse O-rings or washers.
1. Install oil pan (upper) with the following procedure:
a. Use a suitable tool (A) to remove old liquid gasket from mating surfaces.
• Remove the old liquid gasket from mating surface of cylinder block.
• Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.

b. Apply a continuous bead of liquid gasket (D) using suitable tool as shown.
(1) : Oil pan (upper)
(A) : 2 mm (0.08 in) protruded to outside
(B) : 2 mm (0.08 in) protruded to rear oil seal mounting side
(c) : 5.5 - 7.5 mm (0.217 - 0.295 in)
(e) : 4.0 - 5.0 mm (0.157 - 0.197 in)
 Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-21, "Recommended Chemical
Products and Sealants".
CAUTION:
• Installation should be done with 5 minutes after applying liquid gasket.
• Do not fill the engine with oil for at least 30 minutes after the components are installed to allow
the sealant to cure.
NOTE:
Apply liquid gasket to the outside of bolt holes show by mark

c. Install new O-ring at cylinder block side.

CAUTION:
• Install avoiding misalignment of O-ring.
• Do not reuse O-ring.
d. Tighten bolts in numerical order as shown.

2. Install rear oil seal with the following procedure

CAUTION:
• The installation of rear oil seal should be completed within 5 minutes after installing oil pan
(upper).
• Always replace rear oil seal with new one.
• Do not touch oil seal lip.
• Do not reuse rear oil seal.
a. Wipe off liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block
using suitable tool.
b. Apply engine oil to entire outside area of rear oil seal.
c. Press-fit the rear oil seal using a suitable drift (A) with outer diameter 115 mm (4.53 in) and inner
diameter 90 mm (3.54 in).
• Press-fit to the specified dimensions as shown.
(1) : Rear oil seal
(A) : Cylinder block rear end surface

CAUTION:
• Do not touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting part of oil pan (upper) and cylinder block
or the crankshaft.
• Press-fit straight, checking that rear oil seal does not curl or tilt.
NOTE:
The standard surface of the dimension is the rear end surface of cylinder block.
3. Installation of remaining components is in the reverse order of removal.
• Fuel injector and fuel tube

1. Bracket
2. Fuel tube bracket
3. Fuel feed tube
4. Quick connector cap
5. Fuel tube
6. O-ring (black)
7. Fuel injector
8. O-ring (green)
9. Injector clip
CAUTION:
Do not remove or disassemble parts unless instructed.
Removal and Installation
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Do not smoke while servicing fuel system. Keep open flames and sparks away from the work
area.
REMOVAL
1. Remove engine room cover. Refer to EM-24, "Exploded View".
2. Release the fuel pressure. Refer to EC-143, "Work Procedure".
3. Remove intake manifold. Refer to EM-27, "Exploded View".
4. Disconnect quick connector with the following procedure. Disconnect fuel feed tube (1) from fuel tube
(3).
NOTE:
There is no fuel return path.
a. Remove quick connector cap (engine side) (2) from quick connector connection.

b. With the sleeve (B) side of Tool (A) facing quick connector, install Tool (A) onto fuel tube.
c. Insert Tool (A) into quick connector (2) until sleeve (B) contacts and goes no further. Hold quick
connector release on that position (C).
(D) : Insert and retain

CAUTION:
Inserting quick connector release hard will not disconnect quick connector. Hold quick connector
release where it contacts and goes no further.
Draw and pull out quick connector straight from fuel tube (1).
CAUTION:
• Pull quick connector (E) holding position (C).
• Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth beforehand as fuel will leak out.
• Avoid fire and sparks.
• Keep parts away from heat source. Especially, be careful when welding is performed around
them.
• Do not expose parts to battery electrolyte or other acids.
• Do not bend or twist connection between quick connector and fuel feed tube during
installation/ removal.
• To keep the connecting portion clean and to avoid damage and foreign materials, cover them
completely with plastic bags, etc. (A) or something similar.

5. Disconnect harness connector from fuel injector.

6. Loosen fuel tube bracket nuts and end bolts and remove fuel tube brackets.
7. Remove fuel tube and fuel injector assembly.
• Loosen bolts in the reverse order as shown.
CAUTION:
• When removing, be careful to avoid any interference with fuel injector.
• Use a shop cloth to absorb any fuel leaks from fuel tube.

8. Remove fuel injector from fuel tube with the following procedure:
a. Open and remove clip (2)
b. Remove fuel injector (3) from fuel tube (1) by pulling straight.
 CAUTION:
• Be careful with remaining fuel that may leak from fuel tube.
• Be careful not to damage fuel injector nozzle during removal.
• Do not bump or drop fuel injector.
• Do not disassemble fuel injector.
INSTALLATION
1. Install O-rings to fuel injector.
CAUTION:
• Do not reuse O-ring.
• Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side : Black
Nozzle side : Green
• Handle O-ring with bare hands. Do not wear gloves.
• Lubricate O-ring with new engine oil.
• Do not clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not
to twist or stretch O-ring. If O-ring is stretched while installing, do not insert it quickly into fuel
tube.
• Insert O-ring straight onto fuel injector. Do not decenter or twist it.
2. Install fuel injector to fuel tube with the following procedure:
a. Insert clip (2) into clip mounting groove (F) on fuel injector (4).
(3) : O-ring (black)
(5) : O-ring (green)
• Insert clip so that protrusion (G) of fuel injector matches cutout (D) of clip.
CAUTION:
• Do not reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube (1) with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (B) of fuel tube matches cut-out (C) of clip.
• Check that fuel tube flange (A) is securely locked in flange groove (E) on clip.
c. Check that installation is complete by checking that fuel injector does not rotate or come off.
3. Set fuel tube and fuel injector assembly at its position for installation on cylinder head.
CAUTION:
For installation, be careful not to interfere with fuel injector nozzle.
4. Install fuel tube and injector assembly onto cylinder head.
• Tighten bolts in the order as shown.

5. Connect harness connector to fuel injector.

6. Install fuel tube bracket.
7. Connect fuel feed tube with the following procedure.
a. Check for damage or foreign material on the fuel tube and quick connector.
b. Apply new engine oil lightly to area around the top of fuel tube.
c. Align center to insert quick connector straightly into fuel tube.
• Insert quick connector (1) to fuel tube until the top spool (3) on fuel tube is inserted completely and the
2nd level spool (D) is positioned slightly below quick connector bottom end.
(B) : Insertion direction
(E) : Fitted condition

CAUTION:
• Hold (A) position when inserting fuel tube into quick connector.
• Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick
connector.
• Insert until you hear a “click” sound and actually feel the engagement.
• To avoid misidentification of engagement with a similar sound, be sure to perform the next
step.
d. Pull quick connector hard by hand holding position. Check it is completely engaged (connected) so
that it does not come out from fuel tube.
e. Install quick connector cap (engine side) (2) to quick connector connection.
(1) : Fuel feed hose
(3) : Fuel tube
• Install quick connector cap (engine side) with the side arrow facing quick connector side (fuel feed
tube side).
CAUTION:
• Check that the quick connector and fuel tube are securely engaged with the quick connector
cap (engine side) mounting groove.
• Quick connector may not be connected correctly if quick connector cap (engine side) cannot
be installed easily. Remove the quick connector cap (engine side), and then check the
connection of quick connector again.
f. Install fuel feed hose to hose clamp.
8. Installation of remaining components is in the reverse order of removal.
Inspection

• Ignition coil
1. Ignition coil
2. Spark plug
3. Rocker cover
Removal and Installation
REMOVAL
1. Remove the engine room cover. Refer to EM-24, "Exploded View".
2. Disconnect the harness connector from the ignition coil.
3. Remove the ignition coil.
CAUTION:
Do not drop or shock it.
INSTALLATION
Installation of remaining components is in the reverse order of removal
• Rocker cover
1. Oil filler cap
2. Rocker cover protector
3. Oil filler tube
4. O-ring
5. Rocker cover
6. Rocker cover gasket
A. Refer to INSTALLATION
Removal and Installation
REMOVAL
1. Remove intake manifold. Refer to EM-27, "Exploded View".
2. Remove rocker cover protector.
3. Remove ignition coils. Refer to EM-45, "Exploded View".
CAUTION:
• Do not drop or shock ignition coil.
• Do not disassemble ignition coil.
4. Move ignition harness aside.
5. Remove rocker cover.
• Loosen bolts in reverse order shown.
6. Remove PCV valve and PCV hose, if necessary.
7. Remove rocker cover gasket from rocker cover.
INSTALLATION
CAUTION:
Do not reuse O-rings.
1. Install the rocker cover gasket to rocker cover.
CAUTION:
Check the gasket is not dropped.
2. Install rocker cover.
• Tighten bolts in two steps separately in numerical order as shown.
Step 1 : 1.96 NВ·m (0.20 kg-m, 17 in-lb)
Step 2 : 8.33 NВ·m (0.85 kg-m, 74 in-lb)

3. Installation of remaining components is in the reverse order of removal.

• Timing chain
1. Timing chain slack guide
2. Timing chain tensioner
3. Timing chain
4. Oil pump drive chain
5. Crankshaft sprocket
6. Crankshaft key
7. Oil pump sprocket
8. Front cover
9. O-ring
10. O-ring
11. Valve timing control solenoid valve cover
12. O-ring
13. Valve timing control solenoid valve (EXH)
14. Valve timing control solenoid valve (INT)
15. Crankshaft pulley bolt
16. Crankshaft pulley
17. Front oil seal
18. Oil pump drive chain tensioner
19. O-ring
20. Timing chain tension guide
21. Camshaft sprocket (INT)
22. Camshaft sprocket (EXH)
23. O-ring
A. Refer to EM-60
B. Refer to INSTALLATION
Removal and Installation
REMOVAL
CAUTION:
The rotating direction is shown from the engine front.
1. Disconnect battery negative terminal. Refer to PG-50, "Exploded View".
2. Drain engine oil. Refer to LU-8, "Draining".
CAUTION:
Perform this step when engine is cold.
3. Remove intake manifold. Refer to EM-27, "Exploded View".
4. Remove the rocker cover. Refer to EM-12, "Exploded View".
5. Remove fender protector side cover (RH). Refer to EXT-27, "FENDER PROTECTOR : Exploded
View".
6. Support engine (1) and transaxle (2) using suitable jack (A).
CAUTION:
• Position a suitable jack under the engine and transaxle assembly as shown.
• Do not damage the front exhaust tube or transaxle oil pan with the jack.
7. Remove upper torque rod and engine mounting insulator (RH). Refer to EM-82, "M/T : Exploded View"
(M/T) or EM-86, "CVT : Exploded View" (CVT).
8. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on
front cover.
(C) : White paint mark (Not used for service)

b. At the same time, check that the cam lobes of the No. 1 cylinder are located ( ) as shown.

(1) : Camshaft (INT)

(2) : Camshaft (EXH)
• If not, rotate crankshaft pulley one revolution (360 degrees) and align as shown.
9. Remove crankshaft pulley with the following procedure:
a. Remove drive belt. Refer to EM-15, "Exploded View".
b. Lock crankshaft pulley (1) using suitable tool (A), loosen crankshaft pulley bolt, and locate bolt seating
surface at 10 mm (0.39 in) from its original position.
CAUTION:
Do not remove the crankshaft pulley bolt as it will be used as a supporting point for the Tool.
Tool number : KV11103000 ( — )

c. Attach Tool (A) in the M6 thread hole on crankshaft pulley (1), and remove crankshaft pulley.
Tool number : KV11103000 ( — )

10. Remove oil pan (lower). Refer to EM-33, "Exploded View".

NOTE:
If crankshaft sprocket and oil pump drive component are not removed, this step is unnecessary.
11. Remove intake valve timing control solenoid valve.
12. Remove drive belt auto-tensioner. Refer to EM-16, "Exploded View".
13. Remove front cover with the following procedure:
a. Loosen bolts in reverse order as shown.
b. Cut liquid gasket by prying the position ( ) shown using suitable
tool, and then remove the front cover.

CAUTION:
• Be careful not to damage the mating surface.
• Do not use suitable tool anywhere other than shown, sealant used is more adhesive than
previous types when shipped.
14. Remove front oil seal from front cover.
 CAUTION:
Be careful not to damage front cover.
• Pull out front oil seal using suitable tool.
15. Remove valve timing control cover, if necessary.
• Loosen bolts in reverse order as shown.
NOTE:
Disregard the numerical order No.1 in removal

16. Remove timing chain tensioner with the following procedure:

a. Insert a stopper pin (A) into the top groove with the timing chain tensioner plunger pressed.
NOTE:
Timing chain tensioner plunger is securely locked by inserting a stopper pin.
b. Remove timing chain tensioner (1).
17. Remove slack guide (2), tension guide (3) and timing chain (1).
CAUTION:
Do not rotate each crankshaft and camshaft individually while timing chain is removed. It causes
interference between valve and piston.
NOTE:
If timing chain is difficult to remove, remove camshaft sprocket (EXH) first to remove timing chain.
18.Remove crankshaft sprocket and oil pump drive component with the following procedure:
a. Push oil pump drive chain tensioner (1) in the direction as shown.
b. Insert a stopper pin (A) into the body hole (B).
c. Remove oil pump chain tensioner.
• When the holes on lever and tensioner body cannot be aligned, align these holes by slightly moving
the oil pump chain tensioner slack guide.
d. Hold the WAF part of oil pump shaft [WAF: 10 mm (0.39 in)] (A), and then loosen the oil pump
sprocket bolt and remove it.
(1) : Oil pan (upper)
 CAUTION:
• Secure the oil pump shaft with the WAF part.
• Do not loosen the oil pump sprocket bolt by tightening the oil pump drive chain.
INSTALLATION
CAUTION:
Do not reuse O-rings.
NOTE:
The figure shows the relationship between the matching mark on each timing chain and that on the
corresponding sprocket, with the components installed.
(1) : Timing chain
(2) : Camshaft sprocket (EXH)
(3) : Slack guide
(4) : Timing chain tensioner
(5) : Crankshaft sprocket
(6) : Oil pump drive chain
(7) : Oil pump sprocket
(8) : Oil pump drive chain tensioner
(9) : Tension guide
(10) : Camshaft sprocket (INT)
(A) : Matching mark (dark blue link)
(B) : Matching mark (outer groove)
(C) : Crankshaft key position (straight up)
(D) : Matching mark (stamping)
(E) : Matching mark (white link)
(F) : Matching mark (yellow link)
(G) : Matching mark (outer groove)

1. Check that crankshaft key points straight up.

2. Install crankshaft sprocket (2), oil pump sprocket (3) and oil pump drive chain (1).
(A) : Matching mark (stamping)
(B) : Matching mark (yellow link)
(C) : Matching mark (dark blue link)
• Install it by aligning matching marks on each sprockets and oil pump drive chain.
• If these matching marks are not aligned, rotate the oil pump shaft slightly to correct the position.
CAUTION:
Check matching mark position of each sprocket after installing the oil pump drive chain.
3. Hold the WAF part of oil pump shaft [WAF: 10 mm (0.39 in)] (A), and then tighten the oil pump shaft
sprocket bolt.
(1) : Oil pan (upper)
 CAUTION:
• Secure the oil pump shaft with the WAF part.
• Do not loosen the oil pump shaft sprocket bolt by tightening the oil pump drive chain.
4. Install oil pump chain tensioner (1).
• Fix the face of the oil pump tensioner at the most compressed position using a stopper pin (A), and
then install it.
• Securely pull out ( ) the
stopper pin after installing the oil pump chain tensioner.
• Check matching mark position of oil pump drive chain and each sprocket again.

5. Align the matching marks of each sprocket with the matching marks of timing chain.
(1) : Camshaft sprocket (EXH)
(2) : Camshaft sprocket (INT)
(3) : Timing chain
(A) : Matching mark (dark blue link)
(B) : Matching mark (outer groove)
(C) : Matching mark (outer groove)
(D) : Matching mark (copper link)
(E) : Matching mark (stamping)
• If these matching marks are not aligned, rotate the camshaft slightly by holding the hexagonal portion
to correct the position.
 CAUTION:
Check matching mark position of each sprocket and timing chain again after installing the timing
chain.
6. Install the slack guide (2) and the tension guide (3).
(1) : Timing chain
7. Install timing chain tensioner.
• Lock the plunger at the most compressed position using a stopper pin, and then install it.
• Securely pull out the stopper pin after installing the timing chain tensioner.
CAUTION:
• After installing tensioner on the cam side, pull out lock pin.
• If plunger pops out after pulling out lock pin without installing the tensioner to the engine, do
not use the tensioner. (If used, the plunger does not side smoothly.)
• To reuse tensioner on the cam side: After installation, pick up and move ratchet clip toward the
tip of the plunger and position the tensioner parallel to the groove of the plunger.
8. Check matching mark position of timing chain and each sprocket again
9. Install front oil seal. Refer to EM-70, "FRONT OIL SEAL : Removal and Installation".
10. Install front cover with the following procedure:
a. Install valve timing control cover, if removed.
• Apply a continuous bead of liquid gasket (E) using suitable tool to valve timing control cover as shown.
(1) : Front cover
(2) : Valve timing control cover
(A) : Start and end of gasket application
(B) : Liquid gasket application area
(E) : Gasket
(c) : 4.0 - 5.6 mm (0.157 - 0.220 in)
(d) : 3.4 - 4.4 mm (0.134 - 0.173 in)

NOTE:
The start and end of gasket application must overlap 5 mm or more with one another.
Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-21, "Recommended Chemical Products
and Sealants".
CAUTION:
• Installation should be done within 5 minutes after applying liquid gasket.
• Do not fill the engine with oil for at least 30 minutes after the components are installed to allow
the sealant to cure.
• Tighten bolts in numerical order as shown.
NOTE:
Tighten bolt the No.1 in two step. The numerical order No.6 shows the second step.
b. Install new O-ring to cylinder block
CAUTION:
• Do not misalign O-ring.
• Do not reuse O-ring.
c. Apply a continuous bead of liquid gasket (D) using suitable tool to front cover as shown.
(1) : Cylinder head
(2) : Front cover
(A) : Liquid gasket application area
(b) : 4.0 - 5.6 mm (0.157 - 0.220 in)
(c) : 3.4 - 4.4 mm (0.134 - 0.173 in)
Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-21, "Recommended Chemical
Products and Sealants".
 CAUTION:
• Installation should be done within 5 minutes after applying liquid gasket.
• Do not fill the engine with oil for at least 30 minutes after the components are installed to allow
the sealant to cure.
d. Check that matching marks of timing chain and each sprocket are still aligned. Then install front cover.
CAUTION:
• Check O-ring on cylinder block is correctly installed.
• Be careful not to damage front oil seal by interference with front end of crankshaft.
e. Install front cover, and tighten bolts in numerical order as shown.
• Refer to the following for the installation position of bolts.
 M6 bolt : No. 1
M10 bolts : No. 6, 7, 10, 13, 21
M12 bolts : No. 2, 4, 8, 11
M8 bolts : Except the above
f. After all bolts are tightened, retighten them to specified torque in numerical order as shown.
CAUTION:
Be sure to wipe off any excessive liquid gasket.
11. Install crankshaft pulley with the following procedure:
a. When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Do not damage front oil seal lip.
b. Secure crankshaft pulley (1) using suitable tool (A).
c. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
d. Tighten crankshaft pulley bolt.
Crankshaft pulley bolt : 29.4 NВ·m (3.0 kg-m, 22 ft-lb)
e. Put a paint mark (B) on crankshaft pulley (2), matching with any one of six easy to recognize angle
marks (A) on crankshaft pulley bolt (1) flange.
f. Turn another 60 degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark.
g. Check that crankshaft rotates clockwise smoothly.

12. Installation of remaining components is in the reverse order of removal.

Inspection
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks (A) and any excessive wear (B) at link plates and roller links of timing chain. Replace
timing chain if necessary.

• Camshaft
1. Camshaft position sensor (EXH)
2. O-ring
3. Camshaft bracket
4. Camshaft (EXH)
5. Camshaft sprocket (EXH)
6. Camshaft sprocket (INT)
7. Camshaft (INT)
8. Valve lifter (EXH)
9. Valve lifter (INT)
10. Signal plate (INT)
11. Signal plate (EXH)
12. O-ring
13. Camshaft position sensor (INT)
A. Refer to INSTALLATION
 Removal and Installation
CAUTION:
The rotating direction is shown from the engine front.
REMOVAL
1. Remove intake manifold. Refer to EM-27, "Exploded View".
2. Remove rocker cover. Refer to EM-12, "Exploded View".
3. Remove timing chain. Refer to EM-48, "Exploded View".
NOTE:
Removal of oil pump drive related part is not necessary.
4. Remove camshaft position sensor (INT) and camshaft position sensor (EXH) from camshaft bracket.
CAUTION:
• Handle camshaft position sensor (INT) and camshaft position sensor (EXH) carefully and avoid
impacts.
• Do not disassemble camshaft position sensor (INT) and camshaft position sensor (EXH).
• Do not place sensor where it is exposed to magnetism.
5. Put painted matching mark (A) on the camshaft sprocket (INT) (2), camshaft sprocket (EXH) (3) and
the camshaft bracket (1) as shown.
NOTE:
When camshaft alignment is as show in installation, it prevents the knock pin of the camshaft (INT) from
engaging with the incorrect pin hole when installing the camshaft sprocket (INT).

6. Remove camshaft sprockets (INT and EXH).

• Secure hexagonal part (A) of camshaft using suitable tool.
Loosen camshaft sprocket bolts and remove camshaft sprocket.
(1) : Camshaft sprocket (INT)
(2) : Camshaft sprocket (EXH)
 CAUTION:
• Do not rotate crankshaft or camshaft while timing chain is removed. It causes interference
between valve and piston.
• Do not loosen the bolts with securing anything other than the camshaft hexagonal part.
7. Remove camshaft bracket with the following procedure:
a. Loosen bolts in reverse order as shown.

b. Cut liquid gasket by prying the position ( ) shown using suitable

tool, and then remove the camshaft bracket.
 CAUTION:
• Do not damage the mating surface.
• Do not use suitable tool anywhere other than shown, sealant used is more adhesive than
previous types when shipped.
8. Remove camshafts.
9. Remove valve lifters, if necessary
• Identify installation positions, and store them without mixing them up.
10. Remove signal plate from camshaft, if necessary.
INSTALLATION
CAUTION:
Do not reuse O-rings.
1. Install valve lifters.
• Install them in the original positions.
2. Install camshafts.
• Clean camshaft journal to remove any foreign material.
• Distinguish between the intake and the exhaust by looking at the different shapes of the front and rear
ends of the camshaft or using the identification colors (A) and (B).
(1) : Camshaft (EXH)
(2) : Camshaft (INT)
• Install camshafts so that camshaft dowel pins (A) on the front side are positioned as shown.
NOTE:
Though camshaft does not stop at the positions as shown, for the placement of cam nose, it is generally
accepted camshaft is placed for the same direction as shown.

3. Install camshaft bracket with the following procedure:

a. Remove foreign material completely from camshaft bracket backside and from cylinder head
installation face.
b. Apply liquid gasket (A) to camshaft bracket as shown.
(b) : Plug hole inner wall
(c) : 3.4 - 4.4 mm (0.134 - 0.173 in)
Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-21, "Recommended Chemical
Products and Sealants".
CAUTION:
• Installation should be done within 5 minutes after applying liquid gasket
• Do not fill the engine with oil for at least 30 minutes after the components are installed to allow
the sealant to cure.
c. Tighten bolts of camshaft brackets in the following steps, in numerical order as shown.
• There are two types of bolts. Refer to the following for locating bolts.

M6 bolts [thread length: 57.5 mm (2.264 in)] : 13, 14, and 15

M6 bolts [thread length: 35.0 mm (1.378 in)] : Except the above
i. Tighten bolts to the specified torque in three steps in the order as shown.
Step 1 : 1.96 NВ·m (0.20 kg-m, 17 in-lb)
Step 2 : 5.88 NВ·m (0.60 kg-m, 52 in-lb)
Step 3 : 9.5 NВ·m (0.97 kg-m, 84 in-lb)
 CAUTION:
After tightening bolts of camshaft bracket, be sure to wipe off excessive liquid gasket from the
mating surface of cylinder head.
4. Install the camshaft sprocket to the camshaft with the following procedure.
a. When the camshaft sprocket (INT) (2) and camshaft sprocket (EXH) (3) is installed, refer to the paint
matching marks (A) made during removal. Securely align the knock pin and the pin hole, and then
install them.

b. Tighten bolts in the following steps.

• Secure the hexagonal part of camshaft using suitable tool to tighten bolt.
CAUTION:
Check the tightening angle using Tool (B). Do not judge by visual inspection.
Step 1 : 35.0 NВ·m (3.6 kg-m, 26 ft-lb)
Step 2 : 30.5 degrees rotation
Tool number : KV10112100 (BT-8653-A)

(1) : Camshaft sprocket

(A) : Camshaft hexagonal part
5. Install timing chain. Refer to EM-48, "Exploded View".
6. Inspect and adjust valve clearance. Refer to EM-20, "Inspection and Adjustment".
7. Installation of remaining components is in the reverse order of removal.
Inspection
INSPECTION AFTER REMOVAL
Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 journal of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
2. Set suitable tool (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the camshaft runout on dial indicator. (Total
indicator reading)
Standard and Limit : Refer to EM-119, "Camshaft".

4. If it exceeds the limit, replace camshaft.

Camshaft Cam Height
1. Measure the camshaft cam height using suitable tool (A).
Standard and Limit : Refer to EM-119, "Camshaft".

2. If it exceeds the limit, replace camshaft.

Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER
Measure the outer diameter of camshaft journal using suitable tool (A).
Standard : Refer to EM-119, "Camshaft".
If it exceeds the limit, replace camshaft.

CAMSHAFT BRACKET INNER DIAMETER

• Tighten camshaft bracket bolts with specified torque. Refer to EM-60, "Removal and Installation".
• Measure the inner diameter of camshaft bracket using suitable tool (A).
(B) : Measuring direction of inner diameter
Standard : Refer to EM-119, "Camshaft".
• If it exceeds limit, replace camshaft bracket.

CAMSHAFT JOURNAL OIL CLEARANCE

• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)
Standard and Limit : Refer to EM-119, "Camshaft".
• If it exceeds the limit, replace camshaft or cylinder head, or both.
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder
head.
 Replace cylinder head assembly.
Camshaft End Play
1. Install camshaft in cylinder head. Refer to EM-60, "Removal and Installation".
2. Install suitable tool in thrust direction on front end of camshaft.
Read the end play on suitable tool (A) when camshaft is moved forward/backward (in direction to
axis).
Standard and Limit : Refer to EM-119, "Camshaft".

• Measure the following parts if out of the standard.

• Dimension (A) for groove of cylinder head No. 1 journal
Standard : 4.000 - 4.030 mm (0.1575 - 0.1587 in)
• Dimension (B) for camshaft flange
Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in)
• Refer to the standards above, and then replace camshaft and/ or cylinder head.

Camshaft Sprocket Runout

1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
2. Measure the camshaft sprocket runout using suitable tool (A).
(Total indicator reading)
Limit : Refer to EM-119, "Camshaft".
• If it exceeds the limit, replace camshaft sprocket.

Valve Lifter
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-119, "Camshaft".

Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER
• Measure the outer diameter of valve lifter using suitable tool (A).
Standard : Refer to EM-119, "Camshaft".
VALVE LIFTER HOLE DIAMETER
Measure the inner diameter of valve lifter hole of cylinder head using suitable tool (A).
Standard : Refer to EM-119, "Camshaft".
VALVE LIFTER CLEARANCE
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
Standard : Refer to EM-119, "Camshaft".
• If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole
diameter, replace either or both valve lifter and cylinder head.

• Oil seal
REMOVAL
1. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
2. Remove camshafts. Refer to EM-60, "Exploded View".
3. Remove valve lifters. Refer to EM-60, "Exploded View".
4. Remove valve collet, valve spring retainer, and valve spring using Tools
Tool number (A) : KV1016200 (J-26336-A)
Tool number (B) : KV10109220 ( — )
Tool number (C) : KV10115900 (J-26336-20)
 CAUTION:
• Do not damage valve lifter holes.
• Install Tool (A) in the center of valve spring retainer to press it.
(1) : Valve spring retainer
(A) : Attachment
Tool number : KV10115900 (J-26336-20)

5. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
Do not remove valve spring seat from valve spring.
6. Remove valve oil seal using Tool (A).
Tool number : KV10107902 (J-38959)
 INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the height (H) shown using Tool (A).
Height (H) : 15.1 - 15.7 mm (0.594 - 0.618 in)
Tool number : KV10115600 (J-38958)

3. Installation of remaining components is in the reverse order of removal.

Front oil seal : Removal and Installation
REMOVAL
1. Remove front fender protector (RH). Refer to EXT-27, "FENDER PROTECTOR : Exploded View".
2. Remove drive belt. Refer to EM-15, "Exploded View".
3. Remove crankshaft pulley. Refer to EM-48, "Exploded View".
4. Remove front oil seal using suitable tool.
CAUTION:
Do not damage front cover and crankshaft.
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown.
(A) : Dust seal lip
(B) : Oil seal lip

• Press-fit front oil seal using a suitable tool with outer diameter 57 mm (2.24 in) and inner diameter 45
mm (1.77 in).
Within 0.3 mm (0.012 in) toward engine front (crankshaft pulley side)
Within 0.5 mm (0.020 in) toward engine rear (crankshaft sprocket side)
CAUTION:
• Be careful not to damage front cover and crankshaft.
• Press-fit oil seal straight to avoid causing burrs or tilting.
3. Installation of remaining components is in the reverse order of removal.
Rear oil seal : Removal and Installation
REMOVAL
1. Remove engine and transaxle assembly. Refer to EM-86, "CVT : Exploded View" (CVT models) or
TM-28, "Exploded View" (M/T models).
2. Remove clutch cover and clutch disc (M/T models). Refer to CL-17, "Exploded View".
3. Remove drive plate (CVT models) or flywheel (M/T models). Refer to EM-94, "Exploded View".
4. Remove rear oil seal using suitable tool.
CAUTION:
Do not damage crankshaft and cylinder block.
INSTALLATION
1. Apply the liquid gasket lightly to entire outside area of new rear oil seal.
Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-21, "Recommended Chemical Products
and Sealants".
2. Install rear oil seal so that each seal lip is oriented as shown.
(A) : Dust seal lip
(B) : Oil seal lip
• Press-fit rear oil seal using suitable tool (A) with outer diameter 115 mm (4.53 in) and inner diameter
90 mm (3.54 in).
CAUTION:
• Do not damage crankshaft and cylinder block.
• Press-fit oil seal straight to avoid causing burrs or tilting.
• Do not touch grease applied onto oil seal lip.

• Press in rear oil seal (1) to the position as shown.

(A) : Rear end surface of cylinder block
3. Installation of the remaining components is in the reverse order of removal

1. Cylinder head assembly

2. Cylinder head bolt
3. Cylinder head gasket
A. Refer to INSTALLATION
Removal and Installation
REMOVAL
1. Release fuel pressure. Refer to EC-143, "Work Procedure".
2. Drain engine coolant and engine oil. Refer to CO-12, "Changing Engine Coolant" (for Coolant) and
LU-8, "Draining" (for Oil).
3. Remove fan motor and shroud assembly. Refer to CO-17, "Component".
4. Remove the exhaust manifold. Refer to EM-30, "Exploded View"
5. Remove the intake manifold. Refer to EM-27, "Exploded View".
6. Remove the fuel injector and fuel tube assembly. Refer to EM-40, "Exploded View".
7. Remove the water outlet. Refer to CO-24, "Exploded View".
8. Remove the rocker cover. Refer to EM-46, "Exploded View".
9. Remove the front cover and timing chain. Refer to EM-48, "Exploded View".
10. Remove the camshaft. Refer to EM-60, "Exploded View".
11. Remove cylinder head.
• Loosen cylinder head bolts in the reverse order as shown.

12. Remove cylinder head gasket.

INSTALLATION
1. Install cylinder head gasket.
CAUTION:
Do not reuse cylinder head gasket.
2. Install cylinder head, and tighten cylinder head bolts in order as shown using Tool (A).
• Clean threads and seating surfaces of bolts.
• Apply new engine oil to threads and seating surface of bolts.
CAUTION:
• If cylinder head bolts are reused, check their outer diameters before installation. Refer to EM-
79, "Inspection".
• Check and confirm the tightening angle by using Tool. Do not judge by visual inspection
without the tool.
Tool number : KV10112100 (BT-8653-A)
 Step 1 : 40.0 NВ·m (4.1 kg-m, 30 ft-lb)
Step 2 : 100В° clockwise in order
Step 3 : 0 NВ·m (0 kg-m, 0 ft-lb)
Step 4 : 40.0 NВ·m (4.1 kg-m, 30 ft-lb)
Step 5 : 100В° clockwise in order
Step 6 : 100В° clockwise in order

3. Installation of remaining components is in the reverse order of removal.

Exploded View

• Cylinder head
1. Valve collet
2. Valve spring retainer
3. Valve spring (EXH) (with valve spring seat)
4. Valve oil seal
5. Valve guide (EXH)
6. Valve lifter (EXH)
7. Valve seat (EXH)
8. Valve (EXH)
9. Valve (INT)
10. Valve seat (INT)
11. Cylinder head
12. Valve lifter (INT)
13. Valve guide (INT)
14. Spark plug tube
15. Valve spring (INT) (with valve spring seat)
A. Refer to INSTALLATION
Disassembly and Assembly
DISASSEMBLY
1. Remove spark plug using suitable tool.
2. Remove valve lifter.
• Identify installation positions, and store them without mixing them up.
3. Remove valve collet, valve spring retainer, and valve spring using Tools.
Tool number (A) : KV1016200 (J-26336-A)
Tool number (B) : KV10109220 ( — )
Tool number (C) : KV10115900 (J-26336-20)

CAUTION:
• Do not damage valve lifter holes.
• Install Tool (A) in the center of valve spring retainer (1) to install it.
Tool number : KV10115900 (J-26336-20)

4. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
Do not remove valve spring seat from valve spring.
5. Push valve stem to combustion chamber side, and remove valve.
• Identify installation positions, and store them without mixing them up.
6. Remove valve oil seal using Tool (A).
Tool number : KV10107902 (J-38959)
7. Remove valve seat, if necessary
• Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat
recess in cylinder head. Set the machine depth stop to ensure this. Refer to EM-121, "Cylinder Head".
CAUTION:
Do not bore excessively to prevent damage to cylinder head.
8. Remove valve guide, if necessary.
a. To remove valve guide, heat cylinder head to 110 to 130В°C (230 to 266В°F) by soaking in heated oil
(A).
WARNING:
Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.

b. Drive out valve guide using suitable tool.

 ASSEMBLY
1. Install valve guide, if removed.
CAUTION:
Replace with oversize [0.2 mm (0.008 in)] valve guide. Refer to EM-121, "Cylinder Head".
a. Ream cylinder head valve guide hole using suitable tool (A).

b. Heat cylinder head to 110 to 130В°C (230 to 266В°F) by soaking in heated oil (A).
WARNING:
Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
c. Press valve guide (1) from camshaft side to dimension as shown.
(2) : Cylinder head
Projection (H) : Refer to EM-121, "Cylinder Head".

d. Apply reamer finish to valve guide using suitable tool (A).

Standard : Refer to EM-121, "Cylinder Head".
2. Install valve seat, if removed.
CAUTION:
Replace with oversize [0.5 mm (0.020 in)] valve seat. Refer to EM-121, "Cylinder Head".
a. Ream cylinder head (1) recess diameter for service valve seat (2).
• Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.

b. Heat cylinder head to 110 to 130В°C (230 to 266В°F) by soaking in heated oil (A).
WARNING:
Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.

c. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head.
CAUTION:
Do not touch cold valve seats directly.
d. Finish valve seat to the specified dimension using suitable tool.
Refer to EM-121, "Cylinder Head".
CAUTION:
When using valve seat cutter, firmly grip the cutter handle with both hands. Then, press on the
contacting surface all around the circumference to cut in a single drive. Improper pressure on the
cutter or cutting many different times may result in stage valve seat.

e. Using compound, grind to adjust valve.

f. Check again for normal contact. Refer to EM-121, "Cylinder Head".

3. Install valve oil seal using Tool (A).

NOTE:
Dimension is height measured before installing valve spring (with valve spring seat).
Height (H) : 15.1 - 15.7 mm (0.594 - 0.618 in)
Tool number : KV10115600 (J-38958)
4. Install valve.
• Install larger diameter to intake side.
5. Install valve spring with valve spring seat (1) (do not remove from valve spring).
• Install smaller pitch (valve spring seat side) to cylinder head side (B).
• Confirm identification color (A) of valve spring.
Intake : White
Exhaust : Orange

6. Install valve spring retainer.

7. Install valve collet.
• Compress valve spring using Tool. Install valve collet with a magnet hand.
Tool number (A) : KV1016200 (J-26336-A)
Tool number (B) : KV10109220 ( — )
Tool number (C) : KV10115900 (J-26336-20)
 CAUTION:
When working do not damage valve lifter holes.
• Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition.
8. Install valve lifter.
• Install it in the original position.
9. Install spark plug. Refer to EM-12, "Exploded View"