2002 toyota corolla service repair manual

2000-01 ENGINES
1.8L 4-Cylinder - Prizm
ENGINE IDENTIFICATION
Vehicle Identification Number (VIN) is located on top of dash panel, near lower left corner of
windshield. Engine may be identified by the eighth character of VIN.
ENGINE IDENTIFICATION CODES
ADJUSTMENT
VALVE CLEARANCE ADJUSTMENT
1. Disconnect negative battery cable. Disconnect all necessary control cables, hoses and
electrical connections. Remove valve cover and gasket.
2. Rotate crankshaft so cylinder No. 1 is at TDC of compression stroke. Valve lifters on
cylinder No. 1 should be loose and valve lifters on cylinder No. 4 should be tight. If they are
not, rotate crankshaft one revolution. Ensure timing mark on crankshaft pulley aligns with
"0" mark on timing belt cover.
3. Using feeler gauge, check clearance between camshaft lobe and adjusting shim for the
following: all valves on cylinder No. 1, intake valves on cylinder No. 2 and exhaust valves
on cylinder No. 3. Record all readings.
4. Rotate crankshaft 360 degrees. Check clearance between camshaft lobe and adjusting shim
for the following: all valves on cylinder No. 4, intake valves on cylinder No. 3 and exhaust
valves on cylinder No. 2. If clearance is not within specification, adjust by replacing
adjusting shim. See VALVE CLEARANCE SPECIFICATIONS table.
VALVE CLEARANCE SPECIFICATIONS
NOTE: For repair procedures not covered in this article. See ENGINE
OVERHAUL PROCEDURES article in GENERAL INFORMATION.
Application Code
Prizm LSi 1.8L 8
NOTE: Adjust valve clearance with engine cold.
Application Clearance: In. (mm)
Intake (1)
.006-.010 (.15-.25)
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
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Tuesday, March 31, 2009 10:43:14 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
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5. Rotate engine until camshaft lobe faces away from valve to be adjusted. Insert Valve Spring
Depressor (J-39871-1) between camshaft and adjusting shim. See Fig. 1 .
6. Install Valve Lash Spring Spacer (J-39871-2) between camshaft and valve lifter. Ensure
bottom edge of valve lash spring spacer contacts valve lifter, NOT adjusting shim. Remove
valve spring depressor. Using small screwdriver and magnet, remove adjusting shim from
valve lifter.
Fig. 1: Adjusting Valve Clearance (Typical)
Courtesy of GENERAL MOTORS CORP.
7. To determine correct adjusting shim thickness for shim replacement, measure and record
thickness of removed shim. Locate measured values of removed shim and valve clearance on
appropriate adjusting shim selection chart to determine correct shim thickness. See Fig. 2
Exhaust (1)
.010-.014 (.25-.35)
(1) Adjust valve clearance with engine cold.
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and Fig. 3 .
8. Install correct shim thickness to obtain proper clearance. See VALVE CLEARANCE
SPECIFICATIONS table. Repeat procedure if necessary. Before installing valve cover,
install NEW gasket to cylinder head and NEW seal washers to valve cover. Install valve
cover in reverse order of removal.
Fig. 2: Exhaust Valve Adjusting Shim Selection Chart
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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Fig. 3: Intake Valve Adjusting Shim Selection Chart
TROUBLE SHOOTING
REMOVAL & INSTALLATION
FUEL PRESSURE RELEASE
NOTE: To trouble shoot engine mechanical components, see appropriate
table in TROUBLE SHOOTING article in GENERAL INFORMATION.
NOTE: For installation reference, label all electrical connectors, vacuum
hoses and fuel lines before removing. Also place mating marks on
engine hood and other major assemblies before removing.
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1. Loosen fuel tank cap to release fuel tank pressure. Disconnect circuit opening relay located
behind radio. Start engine and allow engine to stall. Crank engine again for an additional 3
seconds, to ensure relief of any remaining pressure.
2. Disconnect negative battery cable. Connect circuit opening relay and tighten fuel filler cap.
Wrap fuel component or fitting with shop towel during removal.
ENGINE
Removal
1. Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect battery cables, and
remove battery. Remove hood. Raise and support vehicle. Drain engine oil and cooling
system. Remove lower engine splash covers.
2. Disconnect necessary coolant hoses and fuel lines. Remove air intake duct and control
cables from throttle body. Remove air cleaner. Disconnect necessary vacuum hoses,
electrical connections and engine ground wires. Remove cruise control actuator (if
equipped). Remove 4 ignition coil bolts. Remove ignition coils with spark plug wires
attached.
3. Remove serpentine belt. Unplug and remove washer reservoir. On M/T models, remove
crankshaft pulley, generator, and drive belt tensioner. Disconnect and remove oxygen sensor
and gasket. Unbolt ground wire at engine lift hook. Disconnect starter wiring, then remove
starter. Unbolt all wiring harness brackets. Ensure all electrical connectors are disconnected,
then reroute harness off to side.
4. On A/T models, remove torque converter access cover, then remove 6 torque converter
bolts. Remove power steering through-bolts and nuts. Secure power steering pump aside.
Remove exhaust pipe retainer bolts and springs from exhaust manifold. Also remove heat
shield around axle shaft boot. Remove the 4 bottom transmission-to-engine mounting bolts.
5. Lower vehicle and connect engine hoist. Unbolt upper transmission-to-engine mounting
bolts. Remove right side engine mount and bracket. Verify all hoses and wires are
disconnected from engine, then lift engine out of vehicle.
Installation
To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS . Adjust all control cables. Adjust fluid levels.
INTAKE MANIFOLD
NOTE: Engine and transaxle are removed separately.
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Removal
1. Disconnect negative battery cable. Drain cooling system. Disconnect throttle cable and TV
cable (A/T models) from throttle body.
2. Unhook IAT sensor from air cleaner, and remove air cleaner hose from throttle body.
Remove air cleaner top assembly. Disconnect all electrical components and coolant by-pass
hoses from throttle body.
3. Disconnect fuel injector connectors. Remove harness bolts, then disconnect wiring harness
from intake manifold. Remove intake manifold support bracket bolts and bracket.
Disconnect upper radiator hose at radiator, then remove radiator hose support bracket.
Remove injector harness support brackets. Remove intake manifold with throttle body.
Inspection
Check intake manifold for cracks and warpage. Replace intake manifold if warpage
exceeds .004" (.10 mm).
Installation
To complete installation, reverse removal procedure. Tighten all fasteners to specification. See
TORQUE SPECIFICATIONS .
EXHAUST MANIFOLD
Removal
Disconnect negative battery cable. Disconnect oxygen sensor wiring connector. Remove exhaust
manifold brace. Disconnect exhaust pipe from exhaust manifold. Remove heat shield from exhaust
manifold. Remove exhaust manifold bolts/nuts, exhaust manifold and gasket.
Inspection
Check exhaust manifold for cracks and warpage. Replace exhaust manifold if warpage
exceeds .004" (.10 mm).
Installation
To install, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE
SPECIFICATIONS .
NOTE: Always install NEW gasket whenever intake manifold is removed.
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CYLINDER HEAD
Removal
1. Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect battery. Drain
cooling system and engine oil. Disconnect throttle cable, all electrical components and 2
coolant bypass hoses from throttle body. Remove air cleaner hose and upper air cleaner
assembly.
2. Disconnect temperature sensor. Disconnect fuel injector connectors and move injector
harness aside. Remove upper radiator hose, injector harness brackets, intake manifold
support brackets, oxygen sensor and gasket, and all necessary vacuum hoses.
3. Disconnect and remove ignition coils, with spark plug wires attached. Disconnect fuel line
at fuel rail, then unbolt and remove fuel rail. Disconnect all electrical connectors, hoses and
vacuum lines. Remove coolant bypass pipe. Position wiring harness aside. Remove camshaft
position and coolant temperature sensors.
4. Remove exhaust pipe bolts and springs, pipe-to-manifold seal, and support bracket bolt.
Remove PCV valve and hoses, then unbolt and remove valve cover. Remove timing chain.
See TIMING CHAIN .
5. Remove intake and exhaust camshaft sprockets. Note original location of camshaft bearing
caps for installation reference. Remove camshaft bearing cap bolts in sequence. See Fig. 4 .
Remove camshafts.
6. Using a wooden block, lift engine with a floor jack and reposition holding fixture. Loosen
cylinder head bolts in sequence. See Fig. 5 . Remove head bolts and washers. Remove
cylinder head.
NOTE: Manufacturer recommends removing timing chain and camshaft
sprockets when removing cylinder head.
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Fig. 4: Camshaft Bearing Cap Bolt Removal & Installation Sequence
Fig. 5: Cylinder Head Bolt Removal & Installation Sequence
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Fig. 6: Exploded View Of Cylinder Head & Timing Chain Components
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Inspection
Inspect cylinder head surface and manifold sealing areas for cracks and warpage. Replace
cylinder head if warpage exceeds specification. Inspect cylinder block deck warpage along all 4
edges and diagonally across cylinder head. Replace cylinder block if warpage exceeds
specification. See CYLINDER HEAD and CYLINDER BLOCK tables under ENGINE
SPECIFICATIONS.
Installation
1. Before installing cylinder head bolts, apply light coat of engine oil onto threads and below
bolt heads. Using multiple steps, tighten cylinder head bolts in sequence to specification.
See Fig. 5 . See TORQUE SPECIFICATIONS . Install manifolds, if removed. See
INTAKE MANIFOLD and EXHAUST MANIFOLD .
2. Reposition engine holding fixture, and support engine by support hook. Remove floorjack.
Install camshafts and timing chain. See CAMSHAFT and TIMING CHAIN . If cylinder
head components were serviced, check valve clearance. See VALVE CLEARANCE
ADJUSTMENT under ADJUSTMENTS. Install valve cover.
3. Install coolant temperature and camshaft position sensors. Tighten camshaft position sensor
bolt to specification. See TORQUE SPECIFICATIONS . Install coolant bypass pipe to
cylinder head, and tighten bolt to specification. See TORQUE SPECIFICATIONS .
4. Reinstall engine ground wires. Use new "O" rings on fuel injectors and install fuel rail to
cylinder head. Secure fuel rail with 3 bolts, and reconnect fuel line to fuel rail. Install 2
ignition coils and spark plug wires. Tighten 4 bracket bolts to specification. See TORQUE
SPECIFICATIONS . Reconnect coil connectors.
5. Raise vehicle and install exhaust manifold bracket bolt. Replace exhaust pipe seal, and
secure pipe onto manifold using 2 springs and bolts. Tighten exhaust pipe-to-manifold bolts
to specification. See TORQUE SPECIFICATIONS . Lower vehicle. Install oxygen
sensor, harness and manifold support brackets, all vacuum hoses, and all electrical
connectors.
6. Install upper radiator hose and reconnect coolant bypass hoses to throttle body. Install air
cleaner, and reconnect IAT sensor. Use 2 bolts to attach generator to engine. Tighten bolts
to specification. See TORQUE SPECIFICATIONS . Connect positive cable and
electrical connector to generator. Install serpentine belt.
7. Reconnect fluid line and washer pump connector to window washer reservoir, then reinstall
reservoir. Refill engine oil and coolant.
CRANKSHAFT FRONT SEAL
Removal & Installation
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1. Crankshaft front seal is mounted in timing chain cover. See Fig. 6 . Remove serpentine belt
and crankshaft pulley bolt. Using puller, remove crankshaft pulley. Pry seal from timing
chain cover. DO NOT damage sealing surfaces.
2. Coat lip of NEW seal with grease. Using hammer and Seal Installer (SST 09309-37010),
install seal until seal surface is flush with timing chain cover. Install crankshaft pulley and
torque to specifications. See TORQUE SPECIFICATIONS . To install remaining
components, reverse removal procedure.
TIMING CHAIN
Removal
IMPORTANT: When performing any service procedure that pertains to the
camshaft or the camshaft actuator, unlock the camshaft
actuator locking pin.
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Fig. 7: Removing Or Installing Serpentine Belt
1. Remove the accessory drive belt.
2. Remove the generator from the engine.
CAUTION: Before servicing any electrical component, the ignition
and start switch must be in the OFF or LOCK position and
all electrical loads must be OFF, unless instructed
otherwise in these procedures. If a tool or equipment
could easily come in contact with a live exposed
electrical terminal, also disconnect the negative battery
cable. Failure to follow these precautions may cause
personal injury and/or damage to the vehicle or its
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3. Disconnect the negative battery cable.
4. Drain the cooling system.
5. Remove the windshield washer fluid reservoir mounting bolt.
6. Disconnect the windshield washer pump connector.
7. Disconnect the windshield washer pump fluid line.
8. Plug the pump outlet.
9. Remove the windshield washer fluid reservoir.
10. Install the engine support fixture.
Fig. 8: Engine Mounting Hardware
components.
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11. Remove the following fasteners from the right side engine mount: The 2 nuts (3), The 4
bolts (1).
12. Loosen the A/C receiver pinch clamp.
13. Lift the A/C receiver in order to access the right side engine mount.
14. Remove the right side engine mount.
15. Remove the cylinder head cover.
Fig. 9: Aligning Engine To TDC
16. Set the number one piston to the top dead center position.
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17. Align the camshaft timing sprockets.
18. Disconnect the power steering oil pressure switch connector.
19. Raise and properly support the vehicle.
20. Remove the right side lower engine splash shield.
Fig. 10: Power Steering Mounting View
21. Remove the two power steering pump through bolts and the nuts (1).
22. Remove the power steering pump from the mounting surface. Move the pump to the side.
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Fig. 11: Loosening/Tightening Crankshaft Bolt
23. Remove the crankshaft pulley retaining bolt using J 8614-01 to prevent crankshaft rotation
when loosening the bolt.
24. Remove the crankshaft pulley.
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Fig. 12: Identifying Engine Components
25. Remove the following components: The crankshaft position sensor bolt (5), The sensor.
26. Lower the vehicle.
27. Remove the following components from the mounting surface: The drive belt tensioner bolt,
The drive belt tensioner nut, The drive belt tensioner.
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Fig. 13: Chain Tensioner Bolts
28. Remove the timing chain tensioner bolts (1,2).
29. Remove the timing chain tensioner.
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Fig. 14: Timing Chain Cover Fasteners
30. Remove the following fasteners: The timing chain cover bolts (1-14), The timing chain
cover nut (15).
31. Remove the timing chain cover.
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Fig. 15: Crankshaft Sensor Reluctor
32. Remove the crankshaft sensor reluctor (1).
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Fig. 16: Timing Chain Components
33. Remove the following components: The timing chain dampener bolt (1), The timing chain
dampener, The timing chain shoe bolts (2), The timing chain shoe.
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Fig. 17: Removing Crankshaft Sprocket & Chain
34. Remove the following components: The crankshaft sprocket, The timing chain.
35. Remove the three bolts from the front camshaft bearing cap.
36. Remove the front camshaft bearing cap in order to access the oil passage to the CMP
actuator.
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Fig. 18: Applying Air Pressure To Advance Passage
37. Ensure that the CMP actuator will not turn.
38. Apply air pressure of approximately 100 kPa (14 psi) to the advance passage of the
camshaft.
39. Turn the CMP actuator to the advanced angle side by hand.
40. Rotate the actuator back and forth through the advanced positions to ensure 21 degrees of
movement.
41. Remove the air pressure and turn the CMP actuator back to the minimum advanced angle
position to lock it.
42. Replace the CMP actuator if the following conditions exist:
CMP actuator does not lock with air pressure removed.
CMP actuator does not unlock with air pressure applied.
CMP actuator does not rotate smoothly through the advanced positions.
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CMP actuator does not rotate completely through the advance positions.
43. Install the front camshaft bearing cap.
44. Install the front camshaft bearing cap bolts. Tighten the camshaft bearing cap bolts to 23
N.m (17 lb ft).
Installation
Fig. 19: Align The Camshaft Timing Marks
1. Use a wrench in order to align the camshaft timing marks. Be sure to place the wrench on
the hexagonal portion of the camshafts.
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Fig. 20: Timing Mark Alignment
2. Turn the camshafts in order to align the timing marks.
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Fig. 21: Crankshaft Keyway Facing Up
3. Temporarily install the crankshaft bolt.
4. Turn the crankshaft until the crankshaft keyway (1) faces upward.
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Fig. 22: Installing Timing Chain
5. Install the following components: The timing chain (2), The crankshaft timing sprocket
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Fig. 23: Timing Chain Shoe Bolts
6. Install the timing chain shoe. Secure the timing chain shoe using two bolts (1,2). Tighten the
bolts to 10 N.m (89 lb in).
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Fig. 24: Aligning All Timing Marks
7. Install the timing chain (1) onto the exhaust camshaft sprocket (4) and the intake camshaft
sprockets (5). Ensure that the timing chain links (2) are aligned with the timing marks (3).
The intake cam phaser mark (7) should be at the 9 o'clock position and the "Ex" timing
mark (8) on the exhaust camshaft sprocket (4) should be at the 3 o'clock position. The
colored links (2) will line up around the 12 o'clock position with the double dots (3) on the
exhaust sprocket and the line (6) on the cam phaser body.
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Fig. 25: Timing Chain Components
8. Install the timing chain dampener. Secure the timing chain dampener using one bolt (1).
Tighten the bolt to 18 N.m (14 lb ft).
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Fig. 26: Crankshaft Sensor Reluctor
9. Install the crankshaft sensor reluctor (1) onto the crankshaft. Insure that the letter "F" on the
reluctor is facing outward.
10. Apply a continuous bead of GM P/N 12346240 or an equivalent to the timing chain cover
mating surface.
11. Unlock the intake camshaft actuator locking pin.
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Fig. 27: Tightening Timing Chain Cover Bolts
12. Install the timing chain cover. Use the following fasteners in order to secure the cover:
Fifteen bolts (1-14), One nut (15)
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Tighten the timing chain cover nut and bolts (10 mm (0.394 in) head) to 10 N.m (89 lb in).
Tighten the timing chain cover nut and bolts (12 mm (0.394 in) head) to 18 N.m (14 lb ft).
Fig. 28: Timing Chain Tensioner
13. Use the following steps in order to install the timing chain tensioner:
A. Fully depress the plunger (4).
B. Apply the hook (2) to the pin (3).
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C. Install the timing chain tensioner.
Fig. 29: Installing Timing Chain Tensioner
14. Install the timing chain tensioner. Secure the timing chain tensioner using 2 bolts (1).
Tighten the bolts to 10 N.m (89 lb in).
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Fig. 30: Identifying Engine Components
15. Install the right side engine mounting bracket. Secure the bracket using 3 bolts. Tighten the
bolts to 54 N.m (40 lb ft).
16. Install the drive belt tensioner. Secure the tensioner using one bolt and one nut.
Tighten the bolt to 69 N.m (51 lb ft).
Tighten the nut to 29 N.m (21 lb ft).
17. Raise the vehicle. Support the vehicle.
18. Install the crankshaft position sensor. Secure the sensor using one bolt (5).
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Tighten the bolt to 12 N.m (106 lb in).
Fig. 31: Torquing Crank Shaft Bolt
19. Install the crankshaft pulley. Secure the crankshaft pulley using one bolt. Tighten the
crankshaft pulley to 142 N.m (105 lb ft).
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Fig. 32: Power Steering Mounting View
20. Install the power steering pump.
21. Use the following fasteners in order to secure the power steering pump: 2 bolts (1), 2 nuts.
Tighten the bolts to 37 N.m (27 lb ft).
22. Install the right side lower engine splash shield.
23. Lower the vehicle.
24. Connect the power steering oil pressure switch connector.
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Fig. 33: Rotating Engine To Release Plunger
25. Rotate the crankshaft clockwise one revolution. Ensure that the plunger on the timing chain
tensioner has released. Complete the following steps if the plunger does not release:
Use a screwdriver or your finger in order to press the timing chain dampener into the
timing chain tensioner.
Release the hook from the pin.
Verify proper timing chain alignment after the plunger has released.
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26. Install the cylinder head cover.
Fig. 34: Engine Mounting Hardware
27. Install the right side engine mount.
28. Use the following fasteners in order to secure the mount: 3 bolts (1), 2 nuts (3).
Tighten the right side engine mount bolts (1,2,4) to 54 N.m (40 lb ft).
Tighten the right side engine insulator nuts (3) to 54 N.m (40 lb ft).
29. Lower the A/C receiver. Tighten the pinch clamp.
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Fig. 35: Using J 28467-A To Support The Engine
30. Remove the engine support fixture (J 28467-A).
31. Install the generator.
32. Remove the plug from the windshield washer reservoir.
33. Connect the windshield washer fluid line.
34. Connect the windshield washer pump connector.
35. Install the windshield washer reservoir. Secure the reservoir using one bolt.
36. Fill the cooling system.
37. Connect the negative battery cable. Tighten the cable bolt to 15 N.m (11 lb ft).
CAMSHAFT
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Removal
Remove timing chain, valve cover and camshaft sprockets. See TIMING CHAIN . Note original
location of camshaft bearing caps for installation reference. Remove cam bearing cap bolts in
sequence. See Fig. 4 . Remove camshafts.
Inspection
Inspect camshaft lobe height, journal diameter and runout. Replace camshaft if not within
specifications. See CAMSHAFT table under ENGINE SPECIFICATIONS. Use Plastigage to
check camshaft oil clearance. Install camshaft into cylinder head and tighten bearing cap bolts in
sequence to specification. See Fig. 4 . See TORQUE SPECIFICATIONS . Replace camshaft
and/or cylinder head if oil clearance is not within specifications. See CAMSHAFT table under
ENGINE SPECIFICATIONS.
Installation
Install camshafts into cylinder head. Install camshaft bearing caps, and tighten cap bolts in
sequence to specification. See Fig. 4 . See TORQUE SPECIFICATIONS . Install camshaft
sprockets and bolts. Tighten camshaft sprocket bolts to specification. Install timing chain. See
TIMING CHAIN .
VALVE LIFTER
Removal
Remove camshaft. See CAMSHAFT . Note location of adjusting shims and valve lifters for
installation reference. Remove adjusting shims and valve lifters from cylinder head.
Inspection
Inspect valve lifter and bore for damage. Replace lifter or shim if excessively worn.
Installation
To install, reverse removal procedure. Ensure components are installed in original location. If
camshaft, adjusting shims or valve lifters are replaced, check valve clearance. See VALVE
CAUTION: Ensure camshaft bearing caps are install in their original
location.
NOTE: No further information is available from manufacturer.
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CLEARANCE ADJUSTMENT under ADJUSTMENTS.
CRANKSHAFT REAR OIL SEAL
Removal
1. Remove transaxle. For A/T, see appropriate TRANSMISSION REMOVAL &
INSTALLATION article in TRANSMISSION SERVICING. For M/T, see appropriate
article in CLUTCHES. Place reference mark on crankshaft and flywheel/drive plate.
Remove flywheel/drive plate.
2. Pry crankshaft rear oil seal from seal retainer. DO NOT damage seal retainer or crankshaft.
Installation
1. Ensure all sealing surfaces are clean. Lubricate seal lip with grease. Using Handle (SST
09951-07100) and Seal Installer (SST 09223-15030), install oil seal until edge is flush with
cylinder block.
2. To install remaining components, reverse removal procedure. Ensure reference mark on
flywheel/drive plate aligns with mark on crankshaft.
WATER PUMP
1. Raise vehicle and remove lower right engine cover. Drain cooling system. Remove
serpentine belt.
2. Note water pump bolt location for installation reference. Remove bolts, water pump and
"O" ring. See Fig. 6 .
3. To install, reverse removal procedure using NEW "O" ring. Tighten bolts to specification.
See TORQUE SPECIFICATIONS . Fill cooling system.
OIL PAN
1. Raise and support vehicle. Drain engine oil. Remove lower engine covers. Remove oil pan
bolts, nuts and oil pan.
2. To install, reverse removal procedure. Apply a continuous bead of RTV silicone
sealer/adhesive to oil pan mating surface. Install oil pan. Tighten bolts to specification. See
TORQUE SPECIFICATIONS .
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OVERHAUL
CYLINDER HEAD
Cylinder Head
Inspect cylinder head for cracks and warpage. Using a straightedge and feeler gauge, check
cylinder head at manifold and cylinder block surfaces for warpage (along all 4 edges and
diagonally across cylinder head). Replace cylinder head if warpage exceeds specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Valve Springs
Using a valve spring tester, measure tension of valve springs at specified length. Ensure valve
spring free length and out-of-square are within specification. See VALVES & VALVE
SPRINGS table under ENGINE SPECIFICATIONS.
Valve Stem Oil Seals
Install oil seal using Valve Guide Seal Installer (SST 09201-41020).
Valve Guides
1. To determine valve stem-to-guide clearance, measure and record valve stem diameter.
Measure and record valve guide inside diameter. Subtract valve stem diameter from valve
guide inside diameter. Ensure valve stem and guide oil clearance are within specification.
Replace as necessary. See VALVES & VALVE SPRINGS and CYLINDER HEAD
tables under ENGINE SPECIFICATIONS.
2. To remove valve guide, gradually heat cylinder head to 176-212°F (80-100°C). Heat
cylinder head uniformly to prevent head warpage. Using hammer and Valve Guide
Remover/Installer (SST 09201-01055), drive valve guide from cylinder head.
NOTE: For repair procedures not covered in this article, see ENGINE
OVERHAUL PROCEDURES article in GENERAL INFORMATION.
NOTE: Intake valve stem oil seal is Light Brown and exhaust valve oil seal
is Gray.
NOTE: Valve guide bore specifications are not available from
manufacturer.
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3. To install valve guide, gradually heat cylinder head to 176-212°F (80-100°C). Heat cylinder
head uniformly to prevent head warpage. Using hammer and valve guide remover/installer,
drive valve guide into cylinder head. Install valve guide so installed height above cylinder
head surface is .342-.358" (8.70-9.10 mm).
4. Using .217" (5.5 mm) reamer, ream valve guide to obtain correct valve stem oil clearance.
See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Valve Seat
Replacement information is not available from manufacturer.
Valves
Ensure valve stem diameter and valve margin are within specification. Check valve contact
pattern and overall length. See VALVES & VALVE SPRINGS table under ENGINE
SPECIFICATIONS.
Seat Correction Angles
To lower valve seat surface on valve, cut seat at 30 degrees and 45 degrees. To raise valve seat
surface on valve, cut seat at 75 degrees and 45 degrees.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number
for installation reference. Piston, connecting rod and connecting rod cap must be installed
with front mark toward timing chain end of engine. See Fig. 36 .
2. Before disassembling piston and connecting rod, attempt to move piston back and forth on
piston pin. Replace piston and piston pin as a set if any movement is felt.
3. When removing piston from connecting rod, remove snap rings from piston. Note direction
of piston installation on connecting rod in relation to front mark (cavity) on piston and front
mark (protrusion) on connecting rod. See Fig. 36 .
4. Using hammer and brass drift, tap piston pin from piston and connecting rod. Separate
piston from connecting rod.
5. Measure piston skirt diameter at 1.008" (25.60 mm) from top of piston at 90-degree angle
to piston pin. Ensure piston and piston pin diameter are within specification. See PISTON,
PINS & RINGS table under ENGINE SPECIFICATIONS.
6. Ensure connecting rod bend and twist are within specification. See CONNECTING RODS
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table under ENGINE SPECIFICATIONS.
7. Bushing in connecting rod may be replaced if bore diameter is not within specification.
Ensure bushing oil hole aligns with connecting rod oil hole. Bushing must be honed to
obtain correct piston pin-to-rod clearance. See PISTON, PINS & RINGS table under
8. To reassemble, install NEW snap ring in one side of piston. Ensure ends of snap ring are not
aligned with cutout area on piston. Install piston on connecting rod with front mark on top
of piston aligned with front mark on connecting rod. See Fig. 36 .
9. Coat piston pin with engine oil and install. Install NEW snap ring on other end of piston.
Ensure ends of snap ring are not aligned with cutout area on piston.
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Fig. 36: Aligning Piston, Connecting Rod & Bearing Caps
Fitting Pistons
1. To determine if piston-to-cylinder clearance is within specification, measure piston skirt
diameter at 90-degree angle to piston pin, 1.008" (25.6 mm) from top of piston. Ensure
piston diameter is within specification. See PISTON, PINS & RINGS table under
2. Measure cylinder bore diameter at 2 different places, 90 degrees apart at .39" (10.0 mm)
from top and bottom of cylinder bore and at middle of cylinder bore. Ensure cylinder bore
diameter is within specification. See CYLINDER BLOCK table under ENGINE
SPECIFICATIONS.
3. Determine piston-to-cylinder clearance. Replace cylinder block and/or all 4 pistons if
clearance exceeds specification. See PISTON, PINS & RINGS table under ENGINE
SPECIFICATIONS.
Piston Rings
Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS
table under ENGINE SPECIFICATIONS. Position piston ring gaps 90 degrees apart. Ensure
ring end gaps are not aligned, and ensure ring gaps do not align with piston pin.
Rod Bearings
1. Note direction of connecting rod and cap before removal for reassembly reference. If
bearings are to be reused, measure bearing oil clearance using Plastigage before removing
pistons. Check rod side play. See CONNECTING RODS and CRANKSHAFT, MAIN
& CONNECTING ROD BEARINGS tables under ENGINE SPECIFICATIONS.
2. Install piston and rod assembly. Check rod bearing clearance using Plastigage method.
Tighten rod bolts in 2 steps to specification. If rod bearing clearance is excessive, measure
crankpin journal diameter. If crankpin journal diameter is within specification, replace
bearing with a standard bearing. If crankpin journal is less than minimum specification, an
undersize bearing is available. Regrind crankshaft to fit undersize bearing if necessary.
Crankshaft & Main Bearings
1. Ensure main bearing caps are numbered for location, and arrow on cap points toward timing
chain end of crankshaft. Remove main bearing caps and bolts, along with lower bearing
NOTE: No other information is available from manufacturer.
MY

half.
2. Measure main bearing clearance using Plastigage method. Main bearing clearance should
be .0006-.0013" (.015-.032 mm). Maximum wear tolerance is .002" (.050 mm). If bearing
clearance is excessive, measure crankshaft main bearing journals. Measure journals at each
end of journal and 90 degrees from first readings. Grind crankshaft, or replace crankshaft if
journal minimum diameter, taper or out-of-round are not within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS.
3. When installing main bearing caps, ensure arrow on cap points toward timing chain end of
crankshaft. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
4. Ensure crankshaft end play is within specification. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
Thrust Bearing
Install thrust bearing on main bearing, with grooves toward crankshaft, away from cylinder block.
Replace thrust bearing if crankshaft end play is not within specification. See CRANKSHAFT,
MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
Cylinder Block
1. Using feeler gauge and straightedge, check cylinder block deck surface in 6 places for
warpage. If warpage exceeds specification, replace cylinder block. See CYLINDER
BLOCK table under ENGINE SPECIFICATIONS.
2. Check cylinder bore wear and taper in 3 places. Cylinder block bore diameter is
measured .39" (10 mm) from top and bottom of bore, and at middle of bore. See
CYLINDER BLOCK table under ENGINE SPECIFICATIONS.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
The crankshaft-driven oil pump provides lubrication to the main gallery. See Fig. 37 .
Crankcase Capacity
Crankcase capacity with oil filter change is 3.9 qts. (3.7L).
NOTE: No further main bearing size information is available from
manufacturer.
MY

Oil Pressure
With engine at normal operating temperature, oil pressure should be greater than 4.3 psi (.3
kg/cm2
) at idle and 43-78 psi (3.0-5.5 kg/cm2
) at 3000 RPM.
Fig. 37: Cross-Sectional View Of Engine Oil System
MY

MY

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