ENGINE ASSEMBLY

1113-01/1532-00/1452-01/1130-07/1332-18/1221-01/1221-02/
1332-01/1124-17/1130-07/1131-02/1124-16/1130-01/1130-11/
1130-09/1311-31/1221-21/1211-32/1211-30/1532-19/1311-01/
1311-04/1311-09/1311-05/1130-04/1130-20/1130-13/1130-21/
1532-24/1532-00/1124-01/1211-02
ENGINE ASSEMBLY

GENERAL REMOVAL AND INSTALLATION

1. DESCRIPTION AND OPERATION.......... 3 1113-01 ENGINE ASSEMBLY.................... 30
2. G23D ENGINE ASSEMBLY.................... 5 1452-01 ALTERNATOR............................. 39
3. G23D ENGINE STRUCTURE.................. 7 1113-01 EINGINE MOUNT......................... 40
4. DIAGNOSTIC INFORMATION AND 1130-07 POLY V-BELT.............................. 41
PROCEDURE......................................... 9 1130-07 POLY V-BELT INSPECTION....... 42
5. GENERAL DIAGNOSIS.......................... 14 1332-18 TENSIONING DEVICE................. 44
6. SPECIFICATIONS.................................. 19 1332-18 TENSIONING DEVICE SHOCK
ABSORBER.................................. 45
1221-01 CYLINDER HEAD COVER............ 46
1221-02 CYLINDER HEAD FRONT
CONFIGURATION AND FUNCTIONS COVER......................................... 48
1221-02 CYLINDER HEAD......................... 50
1332-01 TIMING GEAR CASE COVER...... 54
1113-01 CRANKCASE VENTILATION
1124-17 CRANKSHAFT SEALING REAR
SYSTEM...................................... 24
COVER......................................... 57
1532-00 OIL CIRCULATION....................... 28
1130-07 BELT PULLEY AND VIBRATION
DAMPER...................................... 59
1131-02 CRANKSHAFT FRONT RADIAL
SEAL............................................ 62
1124-16 CRANKSHAFT REAR RADIAL
SEAL............................................ 63
1130-01 CRANKSHAFT.............................. 64
1130-11 ARRANGEMENT OF THE
THRUST BEARING AND THE
MAIN BEARING............................ 65
1130-09 FLYWHEEL/ DRIVE PLATE.......... 70
1311-31 CAMSHAFT ADJUSTER............... 71
1221-21 CAMSHAFT.................................. 75
1221-21 INSPECTION AND ADJUSTMENT
OF CAMSHAFT TIMING
POSITION.................................... 78
01-2 1113-01

REMOVAL AND INSTALLATION

1211-32 VALVE SPRING........................... 81

1211-30 VALVE STEM SEAL.................... 85
1532-19 CHAIN TENSIONER..................... 86
1311-01 TIMING CHAIN............................. 89
1311-04 TENSIONING RAIL....................... 94
1311-09 CYLINDER HEAD GUIDE RAIL..... 95
1311-05 CRANKCASE GUIDE RAIL........... 97
1130-04 CRANKSHAFT SPROCKET.......... 98
1130-20 PISTON........................................ 100
1130-13 CONNECTING ROD...................... 102
1130-21 PISTON RING............................... 105
1532-24 OIL PAN....................................... 106
1532-00 ENGINE OIL AND OIL FILTER
ELEMENT................................... 108
1532-00 OIL PUMP.................................... 110
1532-00 OIL PRESSURE RELIEF VALVE.. 111
1532-00 OIL NON-RETURN VALVE........... 112
1532-00 OIL DIPSTICK GUIDE TUBE....... 113
1311-31 REPAIR OF CORE PLUGS IN
CRANKCASE............................... 114
1124-01 CYLINDER BORE......................... 116
1311-31 CRANKCASE MATING
SURFACE..................................... 118
1211-02 CYLINDER HEAD MATING
SURFACE..................................... 120

ENGINE ASSEMBLY
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 1113-01 01-3

ENGINE ASSEMBLY 1113-01

1. DESCRIPTION AND OPERATION

1) Cleanliness and Care
An automobile engine is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in the ten-thousanths of an inch.
When any internal engine parts are serviced, care and cleanliness are important.
A liberal coating of enigne oil should be applied to friction areas during assembly, to protect and
lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces
and friction areas is part of the repair procedure.
This is considered standard shop practice even if not specifically stated.
Whenever valve train components are removed for service, they should be kept in order. They
should be installed in the same locations, and with the same mating surfaces, as when they
were removed.
Battery cables should be disconnected before any major work is performed on the engine.
Failure to disconnect cables may result in damage to wire harness or other electrical parts.

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ACTYON 2008.07
01-4 1113-01

2) On-engine Service

- Disconnect the negative battery cable before removing or installing any electrical unit, or
when a tool or equipment could easily come in contact with exposed electrical terminals.
Disconnecting this cable will help prevent personal injury and damage to the vehicle. The
ignition must also be in LOCK unless otherwise noted.

- Any time the air cleaner is removed, the intake opening should be covered. This will
protect against accidental entrance of foreign material, which could follow the intake
passage into the cylinder and cause extensive damage when the engine is started.

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 1113-01 01-5

2. G23D ENGINE ASSEMBLY

Front View

Rear View

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01-6 1113-01

LH Side View

RH Side View

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 1113-01 01-7

3. G23D ENGINE STRUCTURE

Front View

Side View

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01-8 1113-01

▶ Front View

NO. FUNCTION NO. FUNCTION

1 HFM Sensor 12 Intake Manifold
2 Intake Air Duct 13 Cylinder Head
3 Cylinder Head Cover 14 Exhaust Manifold
4 Ignition Coi 15 Dipstick Guide Tube and Gauge
5 Spark Plug Connector 16 Connecting Rod
6 Fuel Distributor 17 Crankshaft
7 Injector 18 Engine Mounting Bracket
8 Exhaust Camshaft 19 Starter
9 Intake Camshaft 20 Crankcase
10 Valve Tappet 21 Oil Pump Sprocket
11 Intake Valve 22 Oil Pan

▶ Side View

NO. FUNCTION NO. FUNCTION

23 Camshaft Adjuster 29 Oil Pump Drive Chain
24 Oil Filler Cap 30 Oil Strainer
25 Engine Hanger Bracket 31 Oil Pump
26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywheel of Drive Plate
27 Oil Filter 33 Piston
28 Timing Chain

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 1113-01 01-9

4. DIAGNOSTIC INFORMATION AND PROCEDURE

1) Oil Leak Diagnosis
Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or
repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or
repair. The following procedures may help you in locating and repairing most leaks.

▶ Finding the Leak

- Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power
steering fluid, etc.
- Identify where the fluid is leaking from.
· After running the vehicle at normal operating temperature, park the vehicle over a
large sheet of paper.
· Wait a few minutes.
· You should be able to find the approximate location of the leak by the drippings on
the paper.
- Visually check around the suspected component.
Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks
in areas that are hard to reach.
- If the leak still cannot be found, it may be necessary to clean the suspected area with a
degreaser, steam or spray solvent.
· Clean the area well.
· Dry the area.
· Operate the vehicle for several miles at normal operating temperature and varying
speeds.
· After operating the vehicle, visually check the suspected component.
· If you still cannot locate the leak, try using the powder or black light and dye method.

▶ Powder Method
- Clean the suspected area.
- Apply an aerosol-type powder (such as foot powder) to the suspected area.
- Operate the vehicle under normal operating conditoins.
- Visually inspect the suspected component. You should be able to trace the leak path
over the white powder surface to the source.

ENGINE ASSEMBLY
ACTYON 2008.07
01-10 1113-01

▶ Black Light and Dye Method

A dye and light kit is available for finding leaks, Refer to the manufacturer's directions when
using the kit.
- Pour the specified amount of dye into the engine oil fill tube.
- Operate the vehicle normal operating conditions as directed in the kit.
- Direct the light toward the suspected area. The dyed fluid will appear as a yellow path
leading to the source.

▶ Repairing the Leak

Once the origin of the leak has been pinpointed and traced back to its source, the cause of the
leak must be determined in order for it to be repaired properly.
If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak.
The bent flange must be repaired also. Before attempting to repair a leak, check for the
following conditions and correct them as they may cause a leak.

▶ Gaskets
- The fluid level/pressure is too high.
- The crankcase ventilation system is malfunctioning.
- The seal bore is damaged (scratched, burred or nicked).
- The seal is damaged or worn.
- Improper installation is evident.
- There are cracks in the components.
- The shaft surface is scratched, nicked or damaged.
- A loose or worn bearing is causing excess seal wear.

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-11

2) Compression Pressure Test

▶ Standard Service Data

- A9912 0012B (001 589 76 21 00) Compression Pressure Tester

▶ Measuring Procedure
- Warm the engine up to normal operating temperature.
- Remove the spark plugs using the spark plug wrench.
- Place the diagram sheet to compression pressure tester A9912 0012B (001 589 76 21
00).
- Connect the adaptor to compression pressure tester A9912 0012B (001 589 76 21 00)
and install it into the spark plug hole.
- Crank the engine approx. eight revolutions by using the start motor.
- Compare the measurements of compression pressure tester A9912 0012B (001 589 76
21 00) with the specifications.
- Measure the compression pressure of the other cylinders in the same way.
- If measured value is not within the specifications, perform the cylinder pressure leakage
test.

- Discharge the combustion residues in the cylinders before testing the compression
pressure.
- Apply the parking brake before cranking the engine.

ENGINE ASSEMBLY
ACTYON 2008.07
01-12 1113-01

3) Cylinder Pressure LeakageTest

▶ Permissible Pressure Leakage

At Whole Engine Max. 25 %

At Valve and Cylinder Head Gasket Max. 10 %
At Piston and Piston Ring Max. 20 %

▶ Cylinder Number

OT (TDC) 1, 4
UT (BDC 180 °) 2, 3

▶ Cylinder Number

Cylinder Pressure Bosch, EFAW210A

Leakage Tester Sun, CLT 228

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-13

▶ Leakage Test
- Warm the engine up to normal operating temperature.
- Disconnect the negative battery cable.
- Remove the spark plugs.
- Check the coolant level by opening the coolant reservoir cap and replenish if insufficient.
- Open the engine oil filler cap.
- Connect the tester to air pressure line and adjust the scale of tester.
- Install the connecting hose to spark plug hole.
- Position the piston of No.1 cylinder at TDC by rotating the crankshaft.
- Connect the connecting hose to tester and measure the leakage volume after blowing up
5 bar of compressed air.

- Measure the leakage volume in the completely opening condition of throttle valve by
pulling the acceleration cable.

- Perform the pressure test according to the firing order.

- Firing Order: 1 - 3 - 4 - 2

- Compare the leakage pressure with the specifications.

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01-14 1113-01

5. GENERAL DIAGNOSIS

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-15

▶ General Diagnosis (Cont'd)

ENGINE ASSEMBLY
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01-16 1113-01

▶ General Diagnosis (Cont'd)

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-17

▶ General Diagnosis (Cont'd)

ENGINE ASSEMBLY
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01-18 1113-01

▶ General Diagnosis (Cont'd)

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-19

6. SPECIFICATIONS
1) Engine Specifications

MSE : Engine Control Module

3.53D : 4 Cylinder Version

ENGINE ASSEMBLY
ACTYON 2008.07
01-20 1113-01

2) Fastener Tightening Specifications

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-21

▶ Fastener Tightening Specifications (Cont'd)

ENGINE ASSEMBLY
ACTYON 2008.07
01-22 1113-01

2) Performance Curve

ENGINE ASSEMBLY
ACTYON 2008.07
01-24 1113-01

1) Components Of Crankcase Ventilation System(I)

NO. FUNCTION NO. FUNCTION

Oil Separation Chamber
1 HFM Sensor 11 (Mid-Load at Idling)
2 Cylinder Head Cover 12 Crank Chamber
Oil Spearation Chamber
3 13 Oil Return Pipe
(Full-Load or Over Mid-Load)
4 Intake Air Duct (Cross Pipe) 14 Oil Pan
Vent Line
5 15 Timing Gear Case Cover
(Full-Load or Over Mid-Load)
6 Throttle Valve 16 Crankcase
Restrictor, Diameter 1.1mm
7 17 Chain Housing
(Mid-Load at Idling)
8 Intake Manifold A Fresh Air
9 Vent Line (Mid-Load at Idling) B Blow-By Gas
10 Air Conditioner Bracket D Vent Connection

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-25

2) Operation At Idling And Mid- Load

- The throttle valve (6) is closed or very partially opened, and the vacuum pressure in intake
manifold is high.
The blow-by gas and the fresh air that is additionally supplied through the vent connection
(D) in the crank-case in partial load gets supplied to the combustion chamber from the
crank chamber (12) through the oil separation chamber (11), airconditioner bracket (10),
vent line (9), and restrictor (7) mounted to the cylinder head.
- The circulated engine oil returns to the oil pan through the oil return pipe (13) at the bottom
of oil separation chamber (11).
The fresh air gets supplied to the crank chamber (12) through the HFM sensor (1), intake
air duct (4), vent line (5), oil separation chamber (3), chain housing (17), and the timing
gear case cover (15).
The additional supply of the fresh air is needed to prevent from forming the residues of the
engine oil.

ENGINE ASSEMBLY
ACTYON 2008.07
01-26 1113-01

3) Components Of Crankcase Ventilation System(II)

NO. FUNCTION NO. FUNCTION

Oil Separation Chamber
1 HFM Sensor 11 (Mid-Load at Idling)
2 Cylinder Head Cover 12 Crank Chamber
Oil Spearation Chamber
3 13 Oil Return Pipe
(Full-Load or Over Mid-Load)
4 Intake Air Duct (Cross Pipe) 14 Oil Pan
Vent Line
5 15 Timing Gear Case Cover
(Full-Load or Over Mid-Load)
6 Throttle Valve 16 Crankcase
Restrictor, Diameter 1.1mm
7 17 Chain Housing
(Mid-Load at Idling)
8 Intake Manifold A Fresh Air
9 Vent Line (Mid-Load at Idling) B Blow-By Gas
10 Air Conditioner Bracket D Vent Connection

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-27

4) Operation When Full- Load at Partial Load

- The throttle valve (6) is partially opened or fully opened.
The air flows very rapidly through the vent line (5) s connection (D) and the intake air duct
when full load at partial load.
- Consequently, most of the low-by gases are supplied to the combustion chamber through
the timing gear case cover (15), chain housing (17), oil separation chamber (3), vent line
(5), throttle valve (6), and intake manifold (8).

ENGINE ASSEMBLY
ACTYON 2008.07
01-28 1532-00

ENGINE ASSEMBLY
ACTYON 2008.07
 1532-00 01-29

NO. FUNCTION NO. FUNCTION

1 Oil Strainer 16 Oil Supply (To Chain Tensioner)

2 Oil Pump 17 Camshaft
3 Oil Pan 18 Cam Bearing
4 Oil Non-Return Valve 19 Valve
Oil Gallery
5 Oil Filter 20 (Supply Oil to Intake Tappet)
Oil Gallery
6 Oil Filter Bypass Valve 21 (Supply Oil to Exhaust Tappet)
7 Main Oil Gallery 22 Ball (φ 8 mm)
8 Closing Ball (φ 15 mm) 23 Camshaft Plug
9 Crankshaft 24 Seal
10 Connecting Rod Bearing 25 Screw Plug
Oil Return Gallery
11 Crankshaft Bearing 26
(Cylinder Head and Crankcase)
12 Connecting Rod 27 l Return Gallery (Crankcase)
13 Piston 28 End Cover (φ 20 mm)
14 Oil Spray (Piston Crown Area) 29 Oil Return Pipe
15 Non-Return Valve (Crankcase)

ENGINE ASSEMBLY
ACTYON 2008.07
01-30 1113-01

1. Disconnect the negative terminal of battery.

2. Remove the hood.

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-31

3. Remove the under cover.

(21 - 35 lb-ft)

4. Loosen the radiator drain cock and drain

the coolant.

- Open the coolant reservoir cap.

5. Loosen the cylinder block drain plug and

then drain the coolant completely.

- Open the coolant reservoir cap.

6. Disconnect the coupling of HFM sensor

and remove the air cleaner cross pipe.

ENGINE ASSEMBLY
ACTYON 2008.07
01-32 1113-01

7. Remove the air cleaner cover.

Remove the mounting bolts and air
cleaner housing and element assembly.

8. Remove the radiator and PWM electric

fans. For more information, refer to
"Engine Cooling" section.

- Drain the A/C refrigerant using the

refrigerant collector before removing the
radiator and PWM electric fan assembly.
- Disconnect the upper and the lower
hoses of the radiator.

- Be careful not to spill the coolant when

disconnecting the radiator hose.

- Disconnect the oil cooler pipe of the

automatic transmission.

- Be careful for the oil leakage and

collect it using designated collector.
- Be careful not to spill the oil on other
parts.

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-33

9. Disconnect the parts connected to the

engine from the engine compartment.

- Disconnect the terminals and the ground

terminal from the generator.

- Disconnect the ground terminal to the

intake manifold.

- Disconnect the vacuum hose and the

purge control hose to the intake manifold.

- Disconnect the inlet and outlet heater

hoses and main connector.

ENGINE ASSEMBLY
ACTYON 2008.07
01-34 1113-01

- Remove the fuel feed and return line. 21 - 25 Nm (15 - 18 lb-ft)

- Before removing the fuel lines, release the pressure in the fuel system.

- Remove the V-belt and the power steering pump assembly from the engine.

- Discharge the refrigerant from A/C

system, and disconnect the discharge
pipe and suction pipe from the
compressor.

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-35

10.By rotating the crankshaft from the front of engine, remove the 6 torque converter mounting
bolts from the engine ring gear plate.

11.Remove the automatic transmission oil

cooler line retaining bolts from the
automatic transmission side and oil pan
side.
Remove the automatic transmission oil
cooler line retaining bolts from engine
side and oil pan side.

ENGINE ASSEMBLY
ACTYON 2008.07
01-36 1113-01

12.Remove the automatic transmission.

Disconnect the terminals from starter Remove the exhaust manifold and
motor and remove the starter motor. exhaust pipe.

ENGINE ASSEMBLY
ACTYON 2008.07
 1113-01 01-37

13.Connect the chain to the engine bracket and unscrew the mounting bolts and nuts (LH/RH)
from the engine mounting.

RH Mounting Nut Rear Bracket

Front Bracket LH Mounting Bolt

ENGINE ASSEMBLY
ACTYON 2008.07
01-38 1113-01

14.Carefully separate the engine assembly from the vehicle.

15.Installation should follow the removal procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
 1452-01 01-39

NO. FUNCTION
1 Bolt (M8 X 40, 3 pieces)........................................ 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
2 Bolt (M8 X 70, 2 pieces)........................................ 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
3 Bolt (M8 X 85, 1 piece).......................................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
4 Alternator Bracket

1. Disconnect the negative battery cable.

2. Remove the drive belt.
3. Remove the alternator.
4. Unscrew the alternator carrier bolts and remove the carrier.

- Apply 3 Nm of torque when mounting the bolt (1) apply 25 Nm of torque when mounting
the bolts (2), and (3) and then tighten the bolt (1) with 25 Nm of torque.

5. Installation should follow the removal procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
01-40 1113-01

1. Unscrew the upper engine mount nut or bolt and remove the engine.

2. Unscrew the lower nuts.

3. Remove the hydraulic engine mounting insulator.

4. Installation should follow the removal procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
 1130-07 01-41

1. Removal of cooling fan

NO. FUNCTION NO. FUNCTION

1 Poly V-Belt (2,155 mm) 3 Belt Tensioner
2 Belt Tensioning Pulley

1. Release the belt tension by turning the

stud on the cap with 12 sided wrench or
spanner counterclock-wise.
2. Remove the poly v-belt.

- Check the belt for damage and

tensioning pulley bearing point for wear
and replace them if necessary.

3. Install the belt after prying the tensioning

pulley.

- Belt Tensioning Pulley

- Crankshaft Belt Pulley
- A/C Compressor Pulley
- Generator Pulley
- Power Steering Pump Pulley
- Water Pump Pulley

ENGINE ASSEMBLY
ACTYON 2008.07
01-42 1130-07

1. Rotate the engine and

check the belt for damage.

If one of the following types of damages is

found, replace the belt.

1. Rubber lumps in the base of rib.

2. Dirt or grit ingrained.

3. Pointed rib.
4. Belt cord visible in the base of rib.

5. Cord torn out at the side.

6. Outer cords frayed.

ENGINE ASSEMBLY
ACTYON 2008.07
 1130-07 01-43

7. Rib detached from the base of belt.

8. Splits across the rib.

9. Sections of rib torn out.

10.Splits across several ribs.

11.Splits across the back of the belt.

ENGINE ASSEMBLY
ACTYON 2008.07
01-44 1332-18

1. Removal of tensioning device shock absorber

NO. FUNCTION
1 Bolt (M8 x 75, 2 pieces) + Washer ........................ 22.5 - 27.5 Nm (16.6 - 0.3 lb-ft)
2 Bolt (M8 x 25, 1 pieces) + Washer ........................ 22.5 - 27.5 Nm (16.6 - 0.3 lb-ft)
3 Tensioning Device
4 Stud bolt
5 Tensioning Arm

1. Turn the stud bolt to counterclockwise.

2. Insert the pin into the hole in tensioning
arm.
3. Unscrew the bolts (1, 2) and remove the
tensioning device.

(16.6 - 20.3 lb-ft)

4. Installation should follow the removal
procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
 1332-18 01-45

NO. FUNCTION
1 End Cover
2 Bolt ............................................................................ 40.5 - 9.5 Nm (29.9 - 6.5 lb-ft)
3 Tensioning Pulley
4 Bolt (M8 X 25) + Washer .......................................... 22.5 - 7.5 Nm (16.6 - 0.3 lb-ft)
5 Tensioning Device
6 Bolt (M8 X 35) + Washer .......................................... 22.5 - 7.5 Nm (16.6 - 0.3 lb-ft)
7 Shock Absorber

1. Remove the end cover (1).

2. Remove the bolt (2) and remove the tensioning pulley (3).

(29.9 - 36.5 lb-ft)

3. Unscrew the bolts (4,6) and remove the shock absorber (7).

(16.6 - 20.3 lb-ft)

ENGINE ASSEMBLY
ACTYON 2008.07
01-46 1221-01

NO. FUNCTION
1 Spark Plug Cover
2 Spark Plug Connector
3 Bolt (M6 X 45 : 4 pieces, M6 X 60 : 6 pieces) .................... 9 - 11 Nm (80 - 97 lb-in)
4 Cylinder Head Cover
5 Gasket ...........................................................................................................Replace

ENGINE ASSEMBLY
ACTYON 2008.07
 1221-01 01-47

1. Remove the intake air duct.

(80 - 97 lb-ft)

2. Remove the spark plug cover.

(80 - 97 lb-ft)

- Release 3 screws from the spark plug

cover and remove the cover for G23D
Engine coil.

3. Remove the spark plug connector and

ignition cable.
4. Unscrew the bolts (3) and remove the
head cover and the gasket.
(80 - 97 lb-ft)

- Replace the gasket with a new one if

necessary.
5. Installation should follow the removal
procedure in the reverse order.
6. Check for oil leaks by operating the engine.

ENGINE ASSEMBLY
ACTYON 2008.07
01-48 1221-02

1. Removal of cylinder head cover

2. Removal of thermostat housing assembly
3. Removal of engine hanger bracket

NO. FUNCTION
1 Bolt (M6 X 16, 3 pieces) ..................................................... 9 - 11 Nm (80 - 97 lb-in)
2 Camshaft Adjuster
3 Bolt (M8 X 35, 2 pieces) ....................................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
4 Bolt (M6 X 22, 6 pieces) ..................................................... 9 - 11 Nm (80 - 97 lb-in)
5 Front Cover (E20 : G23D.943)
6 Sleeve
7 O-Ring ..........................................................................................................Replace
8 Thermostat Housing.

ENGINE ASSEMBLY
ACTYON 2008.07
 1221-02 01-49

1. Disconnect the camshaft adjuster

connector and remove the camshaft
adjuster.

(80 - 97 lb-ft)

2. Remove the cylinder head front cover.

(16.6 - 20.3 lb-ft)

- Apply the sealant at the mating
surface of the cylinder head and the
front cover.

3. Remove the O-Ring.

- Replace the O-ring with new one and

apply the sealant.

4. Installation should follow the removal

procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
01-50 1221-02

1. Removal of cylinder head cover

2. Removal of cylinder head front cover
3. Removal of intake manifold
4. Removal of cylinder head lower line (intake manifold side)

NO. FUNCTION
Cylinder Head Bolt (M12 X 100, 10 pieces) ........................ 1ststep 55 Nm (41 lb-ft)
1 .................. 2nd step 90° rotation added
................ 3rd step 90 ° rotation addedio
3 Bolt (M8 X 35, 4 pieces) ......................................... 22.5 - 27.5 Nm (16.6 - 0.3 lb-ft)
4 Camshaft Bearing cap
5 Cylinder Head
6 Gasket ..........................................................................................................Replace
7 Dowel Sleeve..................................................................................................... Note
7 Dowel Sleeve...................................................................................................... Note

ENGINE ASSEMBLY
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 1221-02 01-51

- A9912 0080B (617 589 00 10 00) Allen

Wrench Socket
- A9913 0080B (116 589 20 33 00)
Sliding Hammer
- A9913 0061B (116 589 01 34 00)
Threaded Pin
1. Rotate the crankshaft so that the piston of
number 1 cylinder is at ATDC 20.

2. Put the holding pin A9913 0052B (111

589 03 15 00) into the cam-shaft bearing
cap.

3. Put the alignment marks (arrows) on the

timing chain and camshaft sprocket.
4. Remove the chain tensioner.

(53 - 65 lb-ft)

5. Remove the exhaust camshaft sprocket.

(13 - 16 lb-ft)
2nd step: 60° ± 5°

- The flange bolt is designed to be used

only once, so always replace with new
one.

ENGINE ASSEMBLY
ACTYON 2008.07
01-52 1221-02

6. Remove the camshaft adjuster.

(13 - 16 lb-ft)
2nd step: 60° ± 5°

- The flange bolt is designed to be used

only once, so always replace with new
one.

- Flange Shaft
- Flange Bolt
- Compression Spring
- Adjust Piston
- Camshaft Sprocket
- Seal Cover
- Nut

7. Remove the guide rail pin using the

sliding hammer A9913 0080B (116 589
20 33 00) (02) and the threaded pin
A9913 0061B (116 589 01 34 00) (03).

- Apply the sealant on guide rail pin

when installation.

8. Unscrew the bolts (A).

(16.6 - 20.3 lb-ft)

- Bolt (A) : (M8 X 35, 4 pieces)

ENGINE ASSEMBLY
ACTYON 2008.07
 1221-02 01-53

9. Remove the cylinder head bolts in the

reverse order of the numerics (No.10
→ No.1) using allen wrench socket
A9912 0080B (617 589 00 10 00).
- Tighten the bolts as numerical order with
specified torque (No.1 → No.10).

2nd step: +90 °

3rd step: +90 °

- Operate during engine cooling.

10.Remove the No. 1 bearing cap of the

exhaust camshaft.

(16.6 - 20.3 lb-ft)

11.Carefully remove the cylinder head.
12.Check the cylinder head mating surface
and clean the crankcase head bolt
mounting hole.
13.Replace the cylinder head gasket with
new one.
14.Check the length of the cylinder head bolt.

When New 100 mm

Length (L)
Max. Length 105 mm

- Replace the bolt if the measured length

exceed the max. length.

15.Installation should follow the removal

procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
01-54 1332-01

1. Removal of viscous clutch

2. Removal of cylinder head front cover
3. Removal of tensioning device
4. Removal of water pump
5. Removal of oil filter element
6. Removal of oil pan
7. Removal of generator bracket

NO. FUNCTION
1 Bolt (M8 X 60, 3 pieces) ........................................ 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
2 Bolt (M8 X 75, 1 piece) .......................................... 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
3 Seal
4 Timing Gear Case Cover
5 O-Ring
6 Sleeve.

ENGINE ASSEMBLY
ACTYON 2008.07
 1332-01 01-55

- A9913 0080B (116 589 20 33 00)

Sliding Hammer
- A9913 0061B (116 589 01 34 00)
Threaded Pin

1. Remove the power steering belt pulley

and A/C compressor bracket.
2. Remove the oil line from power steering
pump.
3. Rotate the crankshaft so that the piston of
number, cylinder is at ATDC 20 °.

4. Put the alignment marks (arrows) on the

timing chain and camshaft sprocket.
5. Remove the chain tensioner.

(53 - 65 lb-ft)
6. Remove the intake and exhaust camshaft
sprocket (remove the camshaft adjuster
assembly in E23 engine).

(13 - 16 lb-ft)
2nd step: 60° ± 5°

- The flange bolt is designed to be used

only once, so always replace with new
one.

7. Remove the guide rail pin using the

sliding hammer A9913 0080B (116 589
20 33 00) (02) and the threaded pin
A9913 0061B (116 589 01 34 00) (03).

- Apply the sealant on guide rail pin

when installation.

ENGINE ASSEMBLY
ACTYON 2008.07
01-56 1332-01

8. RUnscrew the bolts (A).

(16.6 - 20.3 lb-ft)

9. Remove the belt pulley and vibration

damper.

(148 + 15 lb-ft)
2nd step: 90° ± 10°
10.Unscrew the bolts (1, 2) on timing gear
case cover and remove the timing gear
case cover.

(16.6 - 20.3 lb-ft)

- Be careful not to damage the cylinder

head gas-ket.

11.Remove the radial shaft seal.

- Installation note replace the seal with

new one.
12.Clean the timing gear case cover and
crankcase sealing surface.
13.Replace the O-ring with new one and
apply the sealant on the sealing surface.

- Be careful not to stain the oil chamber

of chain tensioner with the sealant.
14.Installation should follow the removal
precedure in the reverse order.
15.Warm up the engine and check for oil
leaks.

ENGINE ASSEMBLY
ACTYON 2008.07
 1124-17 01-57

1. Removal of the automatic transmission drive plate or flywheel

NO. FUNCTION
1 Bolt (M6 x 20, 6 pieces) .................................................... 9 - 11 Nm (80 - 97 lb-in)
2 Radial Shaft Seal
3 Rear Cover
4 leeve
5 Bolt (M6 x 85, 2 pieces) ..................................................... 9 - 11 Nm (80 - 97 lb-in)
6 Washer

ENGINE ASSEMBLY
ACTYON 2008.07
01-58 1124-17

- W9911 0020B (601 589 03 43 00)

Crankshaft Rear Seal Installer
1. Unscrew the bolts (1) and (5) and
remove the closing cover by pulling the
rear cover lug (arrows).

- Be careful not to damage the oil pan

gasket.

2. Clean the sealing surface of the

crankcase and the rear sealing cover.
3. Check the radial shaft seal and replace it
if necessary.
4. Apply the Loctite 573 to the rear cover
sealing surface.
5. Apply the engine oil to the dust lip of the
radial shaft seal.

- Do not use the grease.

6. Install the crankshaft rear radial seal and
the crankshaft sealing rear cover, using
crankshaft rear seal installer W9911
0020B (601 589 03 43 00).

7. Install the crankshaft sealing rear cover

mounting bolts and remove the
crankshaft rear seal installer W9911
0020B (601 589 03 43 00).

(80 - 97 lb-ft)
8. Installation should follow the removal
procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
 1130-07 01-59

1. Removal of cooling fan and viscous clutch

2. Removal of fan shroud
3. Removal of drive belt

NO. FUNCTION
Vibration Damper Center 1st step 200+20 Nm (148 + 15 lb-ft) 2nd step 90°+
1 10° rotation added
2 Vibration Damper Disk
5 Vibration Damper Assembly
6 Key
5 Bolt (M6 x 85, 2 pieces) ..................................................... 9 - 11 N·m (80
- 97 lb-in)

ENGINE ASSEMBLY
ACTYON 2008.07
01-60 1130-07

▶ Components

NO. FUNCTION

1 Center Bolt (M18 x 50)

2 Center Bolt Washer
3 Vibration Damper and Pulley Assembly
4 Key
5 Crankshaft Front Seal
6 Timing Gear Case Cover
7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil Pump Driven)
9 Crankshaft
10 Oil Pan
11 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)

▷ Service Data Standard

Permissble Deviation of Radial Runout 0.6 mm

The Vibration Damper Axial Ruout 0.6 mm

ENGINE ASSEMBLY
ACTYON 2008.07
 1130-07 01-61

- A9910 0150B (602 589 00 40 00)

Engine Lock

1. Adjust the piston of number 1 cylinder to

the TDC.

2. Remove the start motor and install the

engine lock A9910 0150B (602 589 00 40
00) to the flywheel ring gear.
3. Remove the vibration damper center bolt.

(148 + 15 lb-ft)
2nd step: 90° ± 10°

4. Remove the vibration damper assembly

using the puller.
5. Installation should follow the removal
procedure in the reverse order.

- If possible, don't separate the vibration

damper and the pulley.

ENGINE ASSEMBLY
ACTYON 2008.07
01-62 1131-02

1. Removal of belt pulley and vibration damper

1. Center Bolt (M18 x 50)

- 1st step 200 + 20 45 Nm (148 +15 lb-ft)
.................................. 2nd step 90 ° + 10°
2. Center Bolt Washer
3. Crankshaft Front Seal Installer
4. Crankshaft Front Seal
5. Key

- A9911 0060B (601 589 03 14 00)

Crankshaft Front Seal Installer

1. Remove the radial seal with a screw driver.

- Use a clean cloth not to damage the

radial seal mounting hole and the
crankshaft.

2. Coat the radial sealing lip with engine oil.

3. Using the crankshaft front seal installer
A9911 0060B (601 589 03 14 00),
assemble the radial seal.
4. Align the sleeve groove and the woodruff
key and tighten the center bolt until the
center bolt and the damper disk stop in
the movement.

(148 + 15 lb-ft)
2nd step: 90° ± 10°
5. Remove the crankshaft front seal installer
A9911 0060B (601 589 03 14 00), and
install the belt pulley and the vibration
damper.
6. Check for leaks while operating the
engine.

ENGINE ASSEMBLY
ACTYON 2008.07
 1124-16 01-63

1. Removal of flywheel or drive plate

NO. FUNCTION
1 Special Tool
2 Special Tool
3 Crankshaft Rear Seal

- W9911 0020B (601 589 03 43 00)

Crankshaft Rear Seal Installer

1. Remove the radial seal with a screw driver.

- Use a clean cloth not to damage the

radial seal mounting hole and the
crankshaft.

2. Install the special tool (2) to the crankshaft.

3. Apply the engine oil on the special tool (2).

- Do not use the grease.

4. Install the radial seal on the inner parts

assembler.
5. Press in the special tool (1) until the radial
seal is stopped.
6. Check for leaks while operating the
engine.

ENGINE ASSEMBLY
ACTYON 2008.07
01-64 1130-01

1. Removal of engine
2. Removal of cylinder head
3. Removal of timing gear case cover
4. Removal of crankcase sealing rear cover
5. Removal of oil pan
6. Removal of baffle plate
7. Removal of oil pump

NO. FUNCTION
Bearing Cap Bolt
(M8 X 55 - 10 pieces)
1
................. 1ststep 55 Nm (41 lb-ft)
............2nd step 90 ° rotation added
2 Bearing Cap
3 Upper Main Bearing
4 Lower Main Bearing
5 Upper Thrust Bearing
6 Lower Thrust Bearing
7 Crankshaft.

▶ Service Data Standard (Crankshaft Main Bearing Gap)

▶ Service Data Standard (Connecting Rod Bearing Gap)

ENGINE ASSEMBLY
ACTYON 2008.07
 1130-11 01-65

AND THE MAIN BEARING

NO. FUNCTION NO. FUNCTION

1 Upper Main Bearing A Crankcase Side

2 Upper Thrust Bearing B Bearing Cap Side (Oil Pan Side)
3 Crankshaft
4 Lower Main Bearing
5 Lower Thrust Bearing

▷ (1) - (8) Weight Balance/Color Marking Point

▷ j1 - j5 Journal Main Bearing #1 - #5
- Color Dot Marking

▷ The color dot marking are put on the (1),

(2), (4), (6), (8), and it indicates the
diameter of crankshaft journal by color as
below.

ENGINE ASSEMBLY
ACTYON 2008.07
01-66 1130-11

▶ Selection of Crankshaft Main Bearing

▷ Crankcase Side
There are seven punching marks on the
mating surface to oil pan. This mark is
correspondent to the bearing distinguished
by color. Select the relevant bearing
according to the punching mark when
repaired.

▷ Crankshaft Bearing Cap Side

Select the crankshaft main bearing
according to the marking letter on the
crank shaft main journal when repaired.

▶ Service Data

ENGINE ASSEMBLY
ACTYON 2008.07
 1130-11 01-67

1) Removal & Installation

1. Unscrew the connecting rod bearing cap
bolt and remove the bearing cap.

- Make sure that the upper and lower

bearing shells do not change each
other.
- Coat the bearing shell with engine oil.
- Install the bearing cap according to the
consecutive number.

2. Unscrew the crankshaft bearing cap

bolts and separate the upper and lower
bearing shells and thrust washers.

- Remove the bearing cap from front

(pulley side) to rear.
- Make sure that the upper and lower
bearing shells do not change each
other and coat with engine oil.
- The oil grooves (arrows) in the thrust
Part No. : 601 030 00 62 2.15 mm washers must face outward and insert
Part No. : 601 030 01 62 2.20 mm the thrust bearing into the bearing cap.
Part No. : 601 030 02 62 2.25 mm - There are five kinds of thrust washers
Part No. : 601 030 03 62 2.30 mm by thick-ness.
Part No. : 601 030 04 62 2.40 mm Select the proper washer when
repaired.
3. Remove the crankshaft.
4. Installation should follow the removal
procedure in the reverse order.
5. After completion of the installation, check
for the rotating condition of the crankshaft.

- Make sure the crankshaft bearing cap

properly seated in place in the crankcase
side. When perfectly installed, the
projected part (arrow) locates in the left
side (intake manifold side).
- Assemble so that the projected part of the
cap and crankcase face the same
direction.

ENGINE ASSEMBLY
ACTYON 2008.07
01-68 1130-11

2) Inspection
1. If the length 'L' of the crankshaft bearing
cap bolt exceeds 63.8 mm, replace it.

2. Make sure the crankshaft bearing cap is

properly seated on the cylinder block
(arrows).

3. Measure and record the inner diameter

of the crankshaft bearing.

- Measure at 2 points (1, 2).

- Measure 'A', 'B' and 'C' as shown. If
average value of 'B' and 'C' is less than
value 'A', then the average value of 'B'
and 'C' is actual average value.
If average value of 'B' and 'C' is more
than value 'A' is actual average value.

ENGINE ASSEMBLY
ACTYON 2008.07
 1130-11 01-69

4. Measure and record the diameter of the

crankshaft bearing journal.

- Record the mean value when

measured at 3 points (A,B,C).
- Measure the inner diameter of bearing
and the diameter of journal and if it is
out of the standard data, replace the
bearing shell.

ENGINE ASSEMBLY
ACTYON 2008.07
01-70 1130-09

1. Removal of manual or automatic transmission

NO. FUNCTION
Flywheel Mounting Bolt
(M10 x 22, 8 pieces)
1
..1st step 45 + 5 Nm (33 + 3.7 lb-ft)
2nd step 90 ° + 10 °
2 Plate
3 Driven Plate (A/T)
4 Dowel Pin

▶ Service Data Standard (Stretch Bolt)

1) Removal & Installation Procedure

1. Unscrew the flywheel mounting bolt.

(33 + 3.7 lb-ft)

2nd step: 90° ± 10°
- Replace the bolt when the stretch side diameter (d) of the flywheel mounting bolt is less
than 8.0mm.
- For the flywheel mounting bolt tightening, keep the socket wrench and Tommy-bar to
be 90 ° and tighten as specified.
2. Remove the flywheel for manual transmission vehicles, or the driven plate (3), and plate (2)
for Auto transmission vehicle.
3. Installation should follow the removal procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
 1311-31 01-71

1. Bolt (M6 X 16, 3 pieces)

9 - 11 Nm (80 - 97 lb-in)
2. Cylinder Head Front Cover
3. Bolt 35 Nm (26 lb-ft)
4. Armature
5. RollPin
6. Nut (M20 X 1.5)
60 - 70 Nm (44 - 52 lb-ft)
7. Seal Cover
8. Camshaft Sprocket
9. Adjust Piston
10.Conical Spring
11.Flange Bolt (M7 X 13, 3 pieces)
1stStep 18 - 22 Nm
(13 - 16 lb-ft)
2nd Step 60 ° ± 5 °Rotation
Added
12.Flange Shaft
13.Compression Spring
14.Control Piston
15.Circlip
16.Oil Gallery
17.Straight Pin
18.Intake Camshaft
Y49 Magnetic Actuator
(2 - Pin Connector)

1. Turn the crankshaft and position the no.1

cylinder piston at ATDC 20 °.

- Turn the crankshaft in the direction of

engine rotation.

2. Remove the cylinder head front cover.

ENGINE ASSEMBLY
ACTYON 2008.07
01-72 1311-31

3. Put the alignment marks (arrows) on the

camshaft sprocket and the timing chain.

4. Insert the holding pin A9913 0052B (111

589 03 15 00) into the no.1 and no.6
bearing cap hole on camshaft to secure
intake and exhaust camshaft.
5. Remove the chain tensioner.
6. Unscrew the exhaust sprocket bolt and
remove the exhaust camshaft sprocket.

(13 - 16 lb-ft)
2nd step: 60° ± 5°

- The flange bolt is designed to be used

only once, so always replace with new
one.

7. Unscrew the bolt (3) from the armature

(4) and re ove the roll pin, and remove
the armature.

8. Unscrew the nut (6) and remove the seal

cover (7).

(44 - 52 lb-ft)

- Put the locking slot of nut toward

armarture.

9. Take off the timing chain from intake

camshaft sprocket.

ENGINE ASSEMBLY
ACTYON 2008.07
 1311-31 01-73

10.Remove the adjuster piston (9) and

conical spring (10) from intake camshaft
sprocket.
11.Unscrew the bolt (11) and remove the
flange shaft.

(13 - 16 lb-ft)
2nd step: 60° ± 5°

- The flange bolt is designed to be used

only once, so always replace with new
one.

12 Installation should follow the removal

procedure in the reverse order.
13.Check and adjust the camshaft timing.

ENGINE ASSEMBLY
ACTYON 2008.07
01-74 1311-31

1) Camshaft Sprocket Bolt

▶ Intake Flange Shaft Bolt

(13 - 16 lb-ft)
2nd step: 60° ± 5°

- The sprocket bolts are designed to be

used only once, so always replace with
new one.

C. M7 x 13 Collar Bolt Torx-T30

E. 6.8 mm
16.Flange Shaft
18.Control Piston
22.Intake Camshaft

▶ Exhaust Camshaft Sprocket Bolt

(13 - 16 lb-ft)
2nd step: 60° ± 5°

- The sprocket bolts are designed to be

used only once, so always replace with
new one.

E. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
13a. Camshaft Sprocket
22a. Exhaust Camshaft

ENGINE ASSEMBLY
ACTYON 2008.07
 1221-21 01-75

1. Removal of cylinder head cover

2. Removal of camshaft adjust actuator and cylinder head front cover

NO. FUNCTION
Bolt (M7 X 13, 3 pieces)
1 ..................... 1st Step 18 - 22 Nm (13 - 16 lb-ft)
..................... 2nd Step 60 ° ± 5 ° Rotation Added
2 Exhaust Camshaft Sprocket
Timing Chain
3 4a. Intake Camshaft Spocket (E20)
4b. Camshaft Adjuster and Camshaft Sprocket (E23)
5 Bearing Cap Bolt (20 pieces) ........................ 22.5 - 27.5 Nm (16.6 - 20.3 lb-ft)
6 Camshaft Bearing Cap
7 Wrench

ENGINE ASSEMBLY
ACTYON 2008.07
01-76 1221-21

1. Turn the crankshaft and position the no.1

cylinder piston at ATDC 20 °.
2. Put the alignment marks (arrows) on the
camshaft sprocket and the timing chain.
3. Remove the chain tensioner.

40 Nm
Screw Plug
(30 lb-ft)
Tensioner 72 - 88 Nm
Assembly (53 - 65 lb-ft)
4. Remove the exhaust camshaft sprocket.

(13 - 16 lb-ft)
2nd step: 60° ± 5°

- The sprocket bolt is designed to be

used only once, so always replace with
new one.

5. Take off the timing chain from intake

camshaft sprocket, and secure it not to
fall down into the timing gear case.

6. Using the wrench (7), turn the camshaft

until there is no resistence in camshaft
bearing area.

7. Remove the bearing cap, and remove the

intake and the exhaust camshaft.
(44 - 52 lb-ft)

- Check the numbers on the bearing cap

not to be mixed up.

ENGINE ASSEMBLY
ACTYON 2008.07
 1221-21 01-77

8. Apply the engine oil on the valve tappet

and camshaft bearing.
9. Installation should follow the removal
procedure in the reverse order.

- Base circle of cam should cantact with

the valve tappet.
- Install the camshaft bearing caps
according to the numbers on the
cylinder head cast and bearing cap.

10.Check the camshaft timing position.

ENGINE ASSEMBLY
ACTYON 2008.07
01-78 1221-21

CAMSHAFT TIMING POSITION

1. Removal of cylinder head cover
2. Removal of cylinder head front cover

NO. FUNCTION

1 Holding Pin A9913 0052B (111 589 03 15 00)

2 Intake Camshaft Sprocket
3 Camshaft Bearing Cap
4 Timing Chain
5 Exhaust Camshaft Sprocket
Bolt (M7 X 13, 3 pieces)
6 ..................... 1st step 18 - 22 Nm (13 - 16 lb-ft)
.........................2nd step 60 ° ± 5 °rotation added
7 StratePin

ENGINE ASSEMBLY
ACTYON 2008.07
 1221-21 01-79

1) Inspection Procedure

- A9913 0052B (111 589 03 15 00)

Holding Pin

1. Position the NO.1 cylinder piston to

ATDC 20 °by turning the crankshaft.

- When the ATDC 20 ° mark on

vibration damper is aligned with timing
gear case cover, the intake and ex-
haust cam of cylinder will make the
slope to the center and will face up. In
this way, the insert hole in NO.1 and
NO.4 camshaft bearing cap will match
in line with the flange hole for
camshaft sprocket.

2. Check the timing as below procedure

- Check if the holding pin A9913 0052B
(111 589 03 15 00) can be inserted
into the NO.1 and NO.4 bearing cap
- hole.
At this condition, check if the ATDC
20° mark on vibration damper aligns
with the marker on the timing gear
case.

ENGINE ASSEMBLY
ACTYON 2008.07
01-80 1221-21

2) Adjustment Procedure
1. Position the NO.1 cylinder to ATDC 20 °.
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Adjust the timing position with inserting the holding pin A9913 0052B (111 589 03 15 00)
into the NO.1 and NO.4 camshaft bearing cap hole and flange hole while rotating the
camshaft by using wrench.
5. Install the chain to the intake camshaft sprocket.
6. Install the chain to the exhaust camshaft sprocket and tighten the bolt.
(13 - 16 lb-ft)
2nd step: 90° ± 5°
- The sprocket bolt is designed to be used only once, so replace with new one.
7. Install the chain tensioner.

40 Nm
Screw Plug
(30 lb-ft)
Tensioner 72 - 88 Nm
Assembly (53 - 65 lb-ft)

8. Check the camshaft timing.

ENGINE ASSEMBLY
ACTYON 2008.07
 1211-32 01-81

1. Removal of camshaft
2. Removal of spark plug

NO. FUNCTION NO. FUNCTION

1 Valve Cotter 6 Connecting Hose A9912 0012B (DW110 - 090)
2 Valve Spring Retainer 7 Thrust Piece A9917 0121B (111 589 25 63 00)
3 Valve Spring 8 Lever Pusher A9917 0111B (111 589 18 61 00)
4 Valve Stem Seal 9 Supporting Bar A9917 0101B (111 589 01 59 00)
5 Lower Retainer

ENGINE ASSEMBLY
ACTYON 2008.07
01-82 1211-32

- A9917 0101B (111 589 01 59 00)

Supporting Bar
- A9917 0111B (111 589 18 61 00) Lever
Pusher
- A9917 0121B (111 589 25 63 00)
Thrust Piece
- A9910 0150B (602 589 00 40 00)
Engine Lock
- A9912 0012B (DW110 - 090)
Connecting Hose
1. Place the supporting bar A9917 0101B
(111 589 01 59 00) (a) at the camshaft
bearing cap and tighten them with the
bearing cap bolt.

(16.6 - 20.3 lb-ft)

2. Turn the crankshaft to position the each

cylinder piston at TDC.

(13 - 16 lb-ft)
2nd step: 90° ± 5°

- Remove the valve spring only at TDC.

- Always rotate the crankshaft by holding
the chain to prevent from timing chain
damage and tangling, and for smooth
rotation.

3. Remove the valve tappet using the valve

tappet remover.
4. Install the connecting hose A9912 0012B
(DW110 - 090) (c) to the spark plug hole.

ENGINE ASSEMBLY
ACTYON 2008.07
 1211-32 01-83

5. Install the engine lock A9910 0150B

(602 589 00 40 00) to the ring gear to
prevent the crankshaft from rotating.
6. Blow up with compressed air.

7. Install the supporting bar A9917 0101B

(111 589 01 59 00) (d) and the lever
pusher A9917 0111B (111 589 18 61 00)
(a).
8. Mount the thrust piece A9917 0121B
(111 589 25 63 00) (b) vertically to the
valve spring retainer (2).
9. Press the valve spring (3) by using the
lever pusher A9917 0111B (111 589 18
61 00) (a).
10.Remove the valve cotter (1) using the
pincette.
11.Remove the upper retainer (2) and the
valve spring (3).

12.Remove the valve stem seal (4) and

replace if necessary.

- Check the valve stem seal for damage

and replace if necessary.

13.Remove the lower retainer (5).

- Check the retainer for damages and

replace with a new one if necessary.

14.Installation should follow the removal

procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
01-84 1211-32

▶ Test (Upper and Lower Valve Tappet and Valve Cotter)

- Upper Valve Spring Retainer

Size (d) 8.5

(mm) (D) 12.3

- Lower Valve Spring Retainer

Size
(a) 0.8 - 1.0
(mm)

- Valve Cotter

Size (B) 9.0

(mm) (H) 9.2 - 9.8

ENGINE ASSEMBLY
ACTYON 2008.07
 1211-30 01-85

1. Removal of valve spring

NO. FUNCTION

1 Drift 119 589 00 43 00

2 Valve Stem Seal
3 Protective Sleeve
4 Timing Chain
5 Exhaust Camshaft Sprocket
- A9917 0171B (119 589 00 43 00) Drift

1. Remove the valve stem seal (2) using

the pliers.

- Check the valve stem seal for damage

and replace if necessary.

2. Coat the valve stem seal with oil and

assemble it with the protective sleeve.
3. Insert the valve stem seal by pressing it
with the drift A9917 0171B (119 589 00
43 00).

ENGINE ASSEMBLY
ACTYON 2008.07
01-86 1532-19

NO. FUNCTION

1 Screw Plug ...................................................................................... 40 Nm (30 lb-ft)

2 Seal
3 Filler Pin
4 Compression Spring
5 Snap Ring
6 Thrust Pin
7 Chain Tensioner Housing .................................................. 72 - 88 Nm (53 - 65 lb-ft)
8 Seal

ENGINE ASSEMBLY
ACTYON 2008.07
 1532-19 01-87

1) Removal Procedure
1. Position the number 1 cylinder to ATDC
20 ° .

- Remove the oil filler cap at adjustment

position, and check whether the intake
camshaft cam's lobe (arrow) stays in
the upper side.

2. Cover the generator with a clean cloth.

3. Release the tension by unscrewing the
screw plug once.

- In case that the tension is reduced by

unscrewing the screw plug, reinstall
after completely removing the chain
tensioner. If the chain tensioner is
tightened again without completely
reducing its tension, then the snap ring
doesn't return to the original position
and the tension gets exceeded.

4. Carefully unscrew the screw plug (1),

and remove the seal (2).

- For the removal of screw plug, be

careful that it can be jumped out due to
the force of compression spring.
- Remove the screw plug only when the
seal and compression spring are
damaged.
5. Carefully remove the filler pin (3),
compression spring (4), snap ring (5),
and the thrust pin (6).
6. Remove the chain tensioner housing (7)
and the seal (8).

ENGINE ASSEMBLY
ACTYON 2008.07
01-88 1532-19

2) Installation Procedure
1. Connect the thrust pin (6) and the snap ring
(5) to the chain tensioner housing (7).

- Remove the oil filler cap at adjustment

When connecting the thrust pin, push in
the thrust pin far enough so that it
doesn't protrude at the chain tensioner
housing.

2. Install the chain tensioner housing (7),

thrust pin (6), snap ring (5), and the seal
(8).

(53 - 65 lb-ft)
3. Insert the compression spring (4) with the
filler pin (3) into chain tensioner housing.
4. Lightly apply the grease to the seal (2)
and install the screw plug (1).

5. Check for leaks by operating the engine.

ENGINE ASSEMBLY
ACTYON 2008.07
 1311-01 01-89

1) Sectional View

NO. FUNCTION NO. FUNCTION

1 Screw Plug 13 Chain Tensioner Housing

2 Ball (Nonreturn Valve) 14 Seal
3 Compression Spring 15 Timing Gear Case Cover
4 Ball Guide 16 Cylinder Head
5 Seal (Aluminum) 17 Bolt / Washer
6 Filler Pin 18 Tensioning Rail

7 Compression Spring 19 Cylinder Head Gasket

8 Snap Ring 20 Timing Chain
9 Thrust Pin Tensioning Rail Base
21 (Sliding Surface)
10 Ball (Nonreturn Valve)
11 Compression Spring A Oil Supply Hole
12 Thrust Piece B Chain Tensioner Oil Storage Hole

ENGINE ASSEMBLY
ACTYON 2008.07
01-90 1311-01

2) Removal And Installation

1. Removal of cylinder head cover
2. Removal of spark plug

NO. FUNCTION NO. FUNCTION

1 Pin 5 Link
2 New Timing Chain 6 Center Plate
3 Timing Chain (Used) 7 Outer Plate
4 Wedge
5 Seal (Aluminum)

- A9913 0010B (000 589 58 43 00)

Chain Assembly
- A9913 0052B (111 589 03 15 00)
Holding Pin

1. Position the NO.1 cylinder to ATDC 20°.

ENGINE ASSEMBLY
ACTYON 2008.07
 1311-01 01-91

2. Insert the holding pin A9913 0052B (111

589 03 15 00) to the intake and exhaust
camshaft flange not to rotate camshaft.
3. Remove the chain tensioner.

4. Mount the wedges to both sides of the

camshaft sprocket as shown in the
figure.

5. Cover the chain housing with a clean

cloth, and grind off the timing chain pin
from the intake camshaft sprocket with
the grinder.

6. Remove the outer plate (7) with the

screw driver and remove the link (5).

ENGINE ASSEMBLY
ACTYON 2008.07
01-92 1311-01

7. Connect the new timing chain (2) to the

used timing chain (3) with the link (5),
center plate (6, thickness 1.6 mm), and
the outer plate (7).
8. Rotate the crankshaft in the direction if
engine revolution by pressing the new
timing chain against the exhaust camshaft
sprocket to prevent it to be tangled.

- Be sure to remove the wedge before

cranking the engine.

9. Take out the used timing chain out from

the chain housing.
10.Connect both separators of the new
timing chain with the link (5) and the
center plate (6).
11.Install the jaw (a) and the thrust piece (b)
to the assembly tool as shown in the
figures.

12.Place the outer plate (7, thickness 1.2

mm) inside the thrust piece (b).

ENGINE ASSEMBLY
ACTYON 2008.07
 1311-01 01-93

13.Install the chain assembly A9913 0010B

(000 589 58 43 00)above the link and
tighten the spindle (c) until a block is felt.
14.Place the chain assembly A9913 0010B
(000 589 58 43 00).

15.Replace the thrust piece (b) as shown in

the figure.

16.Install the chain assembly A9913 0010B

(000 589 58 43 00) to the link pin and
tighten the spindle (c).

17.Rivet the link pin.

Check the condition and it again if
necessary.
18.Install the chain tensioner.

40 Nm
Screw Plug
(30 lb-ft)
Tensioner 72 - 88 Nm
Assembly (53 - 65 lb-ft)

19.Check the camshaft timing position.

ENGINE ASSEMBLY
ACTYON 2008.07
01-94 1311-04

1. Removal of cylinder head

NO. FUNCTION NO. FUNCTION

1 Sliding Rail Pin 3 Timing Gear Case Cover

2 Sliding Rail
3 Timing Chain (Used) 3 Timing Chain (Used)
1. Remove
4 the timing gear case cover (3).
Wedge 4 Wedge
5 Seal (Aluminum) 5 Seal (Aluminum)
- Be careful not to damage the gasket.

2. Remove the sliding rail (1) from the sliding rail pin (2).

- Replace the plastic guide (2) if it is damaged.

- For installation, exactly align the plastic guide (2) with the sliding rail (1).

3. Installation should follow the removal procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
 1311-09 01-95

1. Removal of cylinder head front cover

NO. FUNCTION

1 Bolt (M6 X 45, 2 pieces) 9 - 11 Nm (80 - 97 lb-in)

2 Guide Rail
3 Timing Chain (Used)
4 Wedge
5 Seal (Aluminum)

ENGINE ASSEMBLY
ACTYON 2008.07
01-96 1311-09

- A9913 0052B (111 589 03 15 00)

Holding Pin

1. Position the number 1 cylinder to ATDC

20 ° guide rail.
2. Install the holding pin A9913 0052B (111
589 03 15 00) into the no.1 and no.6
bearing cap hole.
3. Remove the chain tensioner.

40 Nm
Screw Plug
(30 lb-ft)
Tensioner 72 - 88 Nm
Assembly (53 - 65 lb-ft)

4. Unscrew the bolt (1) and remove the

guide rail.

(80 - 97 lb-ft)
5. Installation should follow the removal
procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
 1311-05 01-97

1. Removal of timing gear case cover

NO. FUNCTION

1 Guide Rail Pin

2 Guide Rail
3 Timing Gear Case Cover
4 Wedge
1. Remove the timing gear case cover (3).
5 Seal (Aluminum)

- Be careful not to damage the gasket when removing / installing the timing gear case cover.

2. Remove the guide rail (2) from the guide rail pin (1).

- Replace the plastic guide (2) if damaged.

- Connect the plastic guide (2) and the guide rail (1) by aligning them accurately when
installing.

3. Installation should follow the removal procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
01-98 1130-04

1. Removal of oil pan

2. Removal of tensioning rail
3. Removal of crank case guide rail

NO. FUNCTION

1 Oil Pump Chain Tensioner

2 Oil Pump Chain Bushing

3 Oil Pump Chain Spring
4 Crankshaft Sprocket
5 Key
6 Bolt (M8 x 20, 1 piece) / Washer ..................................... 29 - 35 Nm (21 - 26 lb-ft)

7 Oil Pump Sprocket

8 Oil Pump
9 Oil Pump Roller Chain
10 Timing Chain
5 Seal (Aluminum)

ENGINE ASSEMBLY
ACTYON 2008.07
 1130-04 01-99

- W9911 0050B (615 589 01 33 00)

Crankshaft Sprocket Puller

1. Put the assembly mark at the crankshaft

sprocket (4) and the timing chain (10)
with the paint (arrow).

- Align the assembly marks on

crankshaft sprocket and timing chain.
Also, align the assembly marks on
camshaft sprocket and timing chain
when installing.

2. Unscrew the bolt (6) and remove the oil

pump sprocket (7) from the oil pump.

(21 - 26 lb-ft)

3. Remove the oil pump roller chain (9).

4. Remove the oil pump chain tensioner
(1), oil pump chain bushing (3), and the
oil pump chain spring (2).
5. Remove the crankshaft sprocket (4)
using crankshaft sprocketpuller W9911
0050B (615 589 01 33 00).

- Make sure not to lose the crankshaft

pulley key (5) when removing.
- Install the crankshaft sprocket (4) after
warming it up.

6. Installation should follow the removal

procedure in the reverse order.

ENGINE ASSEMBLY
ACTYON 2008.07
01-100 1130-20

1. Removal of engine
2. Removal of cylinder head
3. Removal of oil pan
4. Removal of oil pump
5. Removal of baffle plate

NO. FUNCTION

1 Connecting Rod Bearing Cap

2 Connecting Rod
Connecting Rod Bolt (M9 x 52, 8 pieces) .......................... 1st step 40 Nm (30 lb-ft)
3 ............................................ 2nd step 90°
4 Piston
5 Snap Ring
6 Piston Pin

ENGINE ASSEMBLY
ACTYON 2008.07
 1130-20 01-101

1) Removal Procedure
1. Unscrew the connecting rod bolt (3) and
remove the cap.
2. Remove the connecting rod and the
piston upward.

- Make sure that the bearing cap and

shell are not changed each other.

3. Removethe snapring (5) and

pulloutthepiston pin (6).

- Remove the snap ring using a clean

cloth as shown in the right picture so
that the piston, piston ring, and the
snap ring don't get damaged.

2) Installation Procedure
1. Check the piston ring gap and apply the
engine oil to the piston pin and the
connecting rod bushing.
2. Connect the piston and the connecting
rod by pressing in the piston pin (6) and
install the snap ring to the groove.
3. Clean the cylinder bore, connecting rod
bearing journal, connecting rod bearing
shell and the piston and coat them with
engine oil.
4. Install the piston ring.
5. Install the piston so that the arrow on the
piston head faces to the forward of the
vehicle.
6. After aligning the connecting rod and the
bearing cap mark (// or a number), tighten
the bolts.

(30 lb-ft)
2nd step: 90°
- Apply the engine oil to the bearing
cap upper and lower bearing shells.
7. Check if the crankshaft rotates without
any trouble by rotating it.

ENGINE ASSEMBLY
ACTYON 2008.07
01-102 1130-13

1. Removal of piston

NO. FUNCTION

1 Connecting Rod Bushing

2 Oil Gallery
3 Balance Weight
Connecting Rod Bearing Cap Bolt (M9 x 52, 8 pieces) ...... 1ststep 40 Nm (30 lb-ft)
4 ....................... 2nd step 90°
5 Fit Sleeve
6 Upper Connecting Rod Bearing

7 Lower Connecting Rod Bearing

8 Bearing Shell Lug

9 Marking [Indication (//) or Numbers]
Connecting Rod Bearing Cap Bolt (M9 x 52, 8 pieces) ...... 1ststep 40 N·m (30
4 lb-ft)
........................ 2
5 Fit Sleeve

ENGINE ASSEMBLY
ACTYON 2008.07
 1130-13 01-103

▶ Service Data Standard

ENGINE ASSEMBLY
ACTYON 2008.07
01-104 1130-13

1) Inspection
1. Measure the basic bore of the connecting
rod bearing.

- If the basic bore exceeds the value of

51.614 mm, replace the bearing or
check the connecting rod.

2. Check connecting rod bolts.

Length When 51.7 - 52 mm

New (L)
Max. Length (L) 52.9 mm
1st step : 40 Nm
Tightening Torque (30 lb-ft)
2nd step : 90°

- If the length exceeds max. length,

replace it.

3. Check the assembly mark (indication//or

number: arrow) of the connecting rods
and the bearing cap when installing.

- Make sure it doesn't exceed over 4g

with other connecting rods when
replacing the connecting rods.
- Check if the connecting rod and the
bearing cap are accurately seated on
the groove when replacing the bearing.

ENGINE ASSEMBLY
ACTYON 2008.07
 1130-21 01-105

1. Removal of piston

NO. FUNCTION
Piston Compression Ring
1 (Top Ring)
Piston Compression Ring
2 (2nd Ring)
3 Piston Oil Ring
4 Spring
5 Spacer
6 SideRail

1. Measure the piston ring's gap.

Groove 1 0.20 - 0.40 mm

End Gap
of the Groove 2 0.20 - 0.40 mm
Piston Ring
Groove 3 0.20 - 0.45 mm

Gap Between Groove 1 0.028 - 0.060 mm

the Piston and Groove 2 0.010 - 0.045 mm
the
Piston Ring Groove 3 0.010 - 0.045 mm

- If out of specification, replace the piston

ring.

2. Remove the piston ring with a pliers.

3. For installation, position the piston ring to

be the 'TOP' mark on the piston ring
upward and arrange the piston ring ends
to be 120 ° part.
4. Adjust the hook spring joint in the oil ring
180 ° way from the ring end.

ENGINE ASSEMBLY
ACTYON 2008.07
01-106 1532-24

Oil pan assembly

Oil pan

Oil pan

ENGINE ASSEMBLY
ACTYON 2008.07
 1532-24 01-107

1. Remove the drain plug and drain the oil

completely.

2. Unscrew the bolts and remove the oil pan

and gasket.

- Arrange the bolts according to each

size.

3. Clean the inside of oil pan and sealing

surface, then apply the sealant.
4. Replace the gasket with new one.
5. Install the oil pan with gasket, and tighten
each bolt in specified torque.

6. Check for oil leaks while running the

engine.

ENGINE ASSEMBLY
ACTYON 2008.07
01-108 1532-00

NO. FUNCTION NO. FUNCTION

1 Oil Filter Cover 25 Nm (18 lb-ft) 4 Oil Drain Plug
2 O-Ring Replace 5 Oil Filter Bypass Valve
3 Oil Filter Element

- A9910 0050A (103 589 02 09 00) Oil Filter Remover

1. Install the oil filter remover A9910 0050A (103 589 02 09 00) on the oil filter cover.

- Make the screw cover removable by tightening the bolt at the side of the oil filter remover
103 589 02 09 00.

2. Install the wrench to the upper bolt in the oil filter remover A9910 0050A (103 589 02 09 00)
and remove the oil cover by turning it.
3. Remove the oil filter element.

- Work with a cloth under the vehicle when removing the oil filter element to not drain the oil.

ENGINE ASSEMBLY
ACTYON 2008.07
 1532-00 01-109

4. Remove the drain plug and drain the

engine oil.

- Leave the oil filler cap open to ease the

engine oil discharge.

5. Tighten the engine oil drain plug after

cleaning it.

- Replace the seal washer with new one.

6. Replace the O-ring in the oil filter cover

with new one.

- Apply the engine oil to the O-ring.

7. Insert new oil filter element into the oil

filter housing.
8. Temporarily tighten the oil filter cover.
Install the Oil filter remover A9910 0050A
(103 589 02 09 00), and then completely
tighten it.

9. Fill up engine oil through the engine oil

filler opening (3).
10.Check for oil leaks at normal engine
temperature after starting the engine.
11.Stop the engine and wait 5 minutes.
Check the oil level and fill up as specified
if necessary.

ENGINE ASSEMBLY
ACTYON 2008.07
01-110 1532-00

1. Removal of oil pan

1. Unscrew the three bolt (1) and remove

the oil pump.

(16.6 - 20.3 lb-ft)

2. Remove the oil pump from the cylinder

block.

ENGINE ASSEMBLY
ACTYON 2008.07
 1532-00 01-111

1. Removal of oil pan

NO. FUNCTION NO. FUNCTION

1 Screw Plug ....... 50 Nm (37 lb-ft) 3 Guide Pin
2 Compression Spring 4 Piston
3 Oil Filter Element
1. Remove the screw plug (1).

2. Remove the spring (2), guide pin (3) and the piston (4).
3. Installation should follow the removal procedure in the reverse order.

- Don't use the seal for the screw plug.

ENGINE ASSEMBLY
ACTYON 2008.07
01-112 1532-00

1. Removal of timing gear case cover

NO. FUNCTION
1 Oil Non-return Valve

▶ Functions
The non-return valve prevents the oil in the chain tensioner from drying up. In other words, it
stops oil-returning in order to prevent the oil in the chain tensioner from getting dry. As a result,
the chain tensioner can be activated with oil in itself.

1. Remove the non-return valve using a

2. pliers.
Insert new non-return valve with hand.

ENGINE ASSEMBLY
ACTYON 2008.07
 1532-00 01-113

NO. FUNCTION

1 Oil Dipstick Level Gauge

2 Oil Dipstick Guide Tube

3 O-Ring
4 Bolt (M6 X 16, 1 piece) ....................................................... 9 - 11 Nm (80 - 97 lb-in)
5 Clamp

1. Pull out the oil dipstick level gauge (1).

2. Unscrew the bolt (4) and remove the oil dipstick guide tube (2).
(80 - 97 lb-ft)
- It is very hard to remove the oil dipstick guide tube without special tool. If it is not
necessary, do not remove the guide tube.
3. Installation should follow the removal procedure in the reverse order.
4. Check for leaks by starting the engine.

ENGINE ASSEMBLY
ACTYON 2008.07
01-114 1311-31

1. Draining of the coolant

NO. FUNCTION

1 Core Plug .................................................Replace

2 Oil Dipstick Guide Tube

3 O-Ring
4 Bolt (M6 X 16, 1 piece) ....................................................... 9 - 11 N·m (80
- 97 lb-in)
5 Clamp

ENGINE ASSEMBLY
ACTYON 2008.07
 1311-31 01-115

- W9911 0010B (102 589 00 15 00) Drift

1. Remove the intake and exhaust manifolds.

2. Pull back the core plug until the end of one
side comes out using the screw driver.

3. Pull out the plug carefully using a pliers.

4. Clean the sealing surface and apply

Loctite 241.

5. Press in new plug using a drift.

- Wait for about 45 minutes before filling

the coolant so that the Loctite 241
hardens.

6. Warm up the engine and check the

coolant for leaks.

ENGINE ASSEMBLY
ACTYON 2008.07
01-116 1124-01

▶ Group Code Letter and Cylinder Bore Size

1) The group code letters are carved on the surface of the piston crown and in the mating
surface of the crankcase.

ENGINE ASSEMBLY
ACTYON 2008.07
 1124-01 01-117

▶ Service Data Standard

▶ Measurement of Cylinder Bore

1. Clean the cylinder wall.

2. Using a internal diameter gauge, measure
the bore size in axial and transverse
direction at three points (1,2,3).
- 1, 2, 3 Measuring Points
A. Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c. Location of the Oil Ring at BDC

▶ Chamfer Angle

ENGINE ASSEMBLY
ACTYON 2008.07
01-118 1311-31

▶ Service Data Standard

ENGINE ASSEMBLY
ACTYON 2008.07
 1311-31 01-119

▶ Service Data Standard

1. Chamfer angle : 75 °

2. Polish the lower chamfered area evenly

with a grinder after finishing the
chamfering with a suitable tool (e.g.,
hand milling cutter).

ENGINE ASSEMBLY
ACTYON 2008.07
01-120 1211-02

1. Removal of valves

▶ Service Data Standard

- Do not exceed 0.4 mm for the milling of the mating surface of crankcase and cylinder head.

ENGINE ASSEMBLY
ACTYON 2008.07
 1211-02 01-121

▶ Measurement of Mating Surfac

1. Measure the height (H) of the cylinder head (refer to Service data standard).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing and the valve system
(refer to Service data standard).
7. Mill the cylinder head valve seat (refer to Service data standard).

▶ Universal Tool

Surface Grinding Machine Sceledum, Type RTY Roaro Schio / Italy

ENGINE ASSEMBLY
ACTYON 2008.07