Engine mechanism - Crankshaft front oil seal assembly

5. Remove crankshaft front oil seal.

(a) Cut oil seal lip with blade.

(b) Prize out oil seal with flat screwdriver whose sharp end is

winded with tape.

Note: check crankshaft is damaged after removing oil

seal, and repair with abrasive paper (#400) if it

is damaged.

6. Install crankshaft front oil seal.

(a) Coat a little MP grease on new oil seal lip.

Note: do not let oil seal lip contact with foreign

matters.

(b) Gently knock new oil seal in with special tool and hammer

until the seal surface is parallel and level with the end sur-

face edge of mounting hole.

Note: wipe off redundant grease on crankshaft.

7. Install damping pulley.

(a) Align the key groove on the pulley with the key on the

crankshaft, and slide pulley in.

(b) Install pulley bolts with special tool.

Torque:  

m

8. Install right engine mounting assembly.

Torque: 

9. Check there is oil leakage.

Cut

position

Prizing out

Special

tool

61

Special

tool

Engine mechanism - Crankshaft rear oil seal assembly

Replacement

1. Remove transmission assembly.

2. Remove clutch assembly and flywheel components.

Fix crankshaft with special tool, remove clutch assembly at

first, and then remove flywheel components.

3. Remove crankshaft rear oil seal.

(a) Cut oil seal mouth with blade.

(b) Prize out oil seal with flathead screwdriver whose sharp

end is winded with tape.

Note: check crankshaft is damaged after removing oil

seal, and repair with abrasive paper (#400) if it is

damaged.

4. Install crankshaft rear oil seal [4G18-1002130].

(a) Coat a little MP grease on new oil seal lip.

Note: do not let oil seal lip contact with foreign

matters.

(b) Gently knock new oil seal in with special tool and hammer

until the seal surface is parallel and level with the end sur-

face edge of mounting hole.

Note: wipe off redundant grease on crankshaft.

5. Install flywheel components and clutch assembly.

(a) Fix crankshaft with special tool.

(b) Clean bolts and bolt holes.

(c) Coat bolts with adhesive.

Adhesive:  thread locking adhesive 1234 (Kesaixin 1234)

(d) Install flywheel components.

As sequences shown in the diagram, tighten bolts at sev-

eral times.

Torque: 

(e) Install clutch assembly.

6. Install transmission assembly.

Special

tool

Cut

position

Special

tool

62

Crankshaft rear oil seal assembly

Engine mechanism - Cylinder cover gasket components

Replacement

1. Take measures to prevent gasoline leaking.

2. Remove timing chain assembly.

3. Remove camshaft.

As sequences shown in the diagram, evenly loosen at

several times, and remove 19 bearing cover bolts, and then

remove 9 bearing covers of intake camshaft and exhaust

camshaft.

4. Remove cylinder head assembly.

(a) Remove warm air water outlet pipe from cylinder head.

(b) As shown in the diagram, evenly loosen 10 cylinder head

bolts with 10mm dual hexagonal sleeves at several times,

and then remove 10 cylinder head bolts and plain washer.

Notes:

Be careful not to let washer fall into cylinder head.

 Incorrect disassembling sequence will cause cylin-

der head warp or chap.

5. Remove cylinder head gasket components

[4G18-1003160].

6. Install cylinder head gasket components.

Put new cylinder head gasket on the cylinder body.

Notes:

Pay attention to installation direction.

Gently put down cylinder head to avoid damaging

cylinder head gasket.

7. Install cylinder head assembly.

Hint: Lock up cylinder head bolts as 2 steps.

(a) Coat a thin layer of engine oil at bolt thread and the bottom

of bolt head.

(b) As shown in the diagram, evenly tighten 10 cylinder head

bolts and plain washer with 10mm dual hexagonal sleeves

at several times.

Torque:  

63

Cylinder cover gasket components

Engine mechanism - Cylinder cover gasket components

(c) Tighten each cylinder head bolt in turn again.

Torque:  

m

(d) Install heating air water outlet pipe components.

Torque: 

8. Install camshaft.

(a) Coat engine oil on camshaft journal.

(b) Put 2 camshafts on cylinder head and with cylinder 1 cam-

shaft end toward the direction shown in the diagram.

(c) Check forward remarks and figures of all bearing cover, and

tighten the bolts as sequences shown in the diagram.

Torque:

Camshaft front bearing cover: 

Camshaft bearing cover:  

9. Check idle speed and ignition timing.

10.

Check compression pressure.

11.

Check CO/HC.

64