SECTION 6A - ENGINE MECHANICAL

Service Precaution

General Description

Engine Diagnosis

Drive Belt (Serpentine Belt)

Removal

Inspection and Repair

Installation

Cylinder Head Cover LH

Removal

Installation

Cylinder Head Cover RH

Removal

Installation

Common Chamber

Removal

Installation

Exhaust Manifold LH

Removal

Installation

Exhaust Manifold RH

Removal

Installation

Crankshaft Pulley

Removal

Installation

Timing Belt — Broken Belt

Removal

Installation

Timing Belt Replacement — Service Operation

Removal

Installation

Camshaft

Removal

Installation

Cylinder Head

Removal

Installation

Valve Stem Oil Controller, Valve Spring

and Valve Guide

Removal

Installation

Piston, Piston Ring and Connecting Rod

Removal

Installation

Crankshaft and Main Bearings

Removal

Installation

Rear Oil Seal

Removal

Installation

Engine Assembly

Removal

Installation

Cylinder Head

Cylinder Head and Associated Parts

Disassembly

Clean

Inspection and Repair

Reassembly

Valve Spring, Oil Controller, Valve, Valve

Guide

Valve Spring, Oil Controller, Valve, Valve

Guide and Associated Parts

Disassembly

Inspection and Repair

Reassembly

Valve Clearance Adjustments

Camshaft

Camshaft and Associated Parts

Disassembly

Inspection and Repair

Reassembly

Crankshaft

Crankshaft and Associated Parts

Disassembly

Inspection and Repair

Reassembly

Piston and Connecting Rod

Piston, Connecting Rod and Associate Parts

Disassembly

Inspection and Repair

Reassembly

Cylinder Block

Cylinder Block and Associated Parts

Disassembly

Inspection and Repair

Reassembly

Main Data and Specification

Special Tool

Techline

SERVICE PRECAUTION

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL

RESTRAINT SYSTEM (SRS), REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN

ORDER TO DETERMINE WHETHER YOU ARE

PERFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING. WHEN YOU

ARE PERFORMING SERVICE ON OR NEAR THE

SRS COMPONENTS OR THE SRS WIRING, REFER

TO THE SRS SERVICE INFORMATION. FAILURE TO

FOLLOW WARNINGS COULD RESULT IN POSSIBLE

AIR BAG DEPLOYMENT, PERSONAL INJURY, OR

OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

HOLDEN will call out those fasteners that require a

replacement after removal. HOLDEN will also call

out the fasteners that require thread lockers or

thread sealant. UNLESS OTHERWISE SPECIFIED,

do not use supplemental coatings (Paints, greases,

or other corrosion inhibitors) on threaded fasteners

or fastener joint interfaces. Generally, such

coatings adversely affect the fastener torque and

the joint clamping force, and may damage the

fastener. When you install fasteners, use the correct

tightening sequence and specifications. Following

these instructions can help you avoid damage to

parts and systems.

GENERAL DESCRIPTION

Engine Cleanliness And Care

An automobile engine is a combination of many

machined, honed, polished and lapped surfaces with

tolerances that are measured in the thousandths of a

millimeter. Accordingly, when any internal engine parts

are serviced, care and cleanliness are important.

Throughout this section, it should be understood that

proper cleaning and protection of machined surfaces

and f rict ion a reas i s part o f the repair pr ocedure. T his is

considered standard shop practice even if not

specifically stated.

• A libe ral c oatin g of engin e oil shoul d be ap plied to all

friction areas during assembly to protect and lubricate

the surfaces on initial operation.

• Whenever valve train components, pistons, piston

rings, connecting rods, rod bearings, and crankshaft

journal bearings are removed for service, they should

be retained in order.

• At the time of installation, they should be installed in

the same locations and with the same mating

surfaces as when 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.

• The six cylinders of this engine are identified by

numbers; Right side cylinders 1, 3 and 5, Left side

cylinders 2, 4 and 6, as counted from crankshaft

pulley side to flywheel side.

General Information on Engine Service

The following information on engine service should be

noted carefully, as it is important in preventing damage

and contributing to reliable engine performance:

• When raising or supporting the engine for any

reason, do not use a jack under the oil pan. Due to

the small clearance between the oil pan and the oil

pump str ainer, jackin g against the oil pan may ca use

damage to the oil pick–up unit.

• The 12 –v olt el ec tric al sy st em is capabl e o f da maging

circuits. When performing any work where electrical

terminals could possibly be grounded, the ground

cable of the battery should be disconnected at the

battery.

• Any time the intake air duct or air cleaner is removed,

the intake opening should be covered. This will

protect against accidental entrance of foreign

material into the cylinder which could cause

extensive damage when the engine is started.

Cylinder Block

The cylinder block is made of aluminum die–cast

casting for 75°V–type six cylinders. It has a rear plate

integrated structure and employs a deep skirt. The

cylinder liner is cast and the liner inner diameter and

crankshaft journal diameter are classified into grades.

The crankshaft is supported by four bearings of which

width of No.3 bearing on the body side is different in

order to support the thrust bearing. The bearing cap is

made of nodular cast iron and each bearing cap uses

four bolts and two side bolts.

Cylinder Head

The cylinder head, made of aluminum alloy casting

employs a pent–roof type combustion chamber with a

spark plug i n the center. The intake and exhaus t valves

are placed in V–type design. The ports are cross–flow

type.

Valve Train

Intake and exhaust camshaft on the both side of banks

are driven through an camshaft drive gear by timing

belt. The valves are operated by the camshaft and the

valve clearance is adjusted to select suitable thickness

shim.

Int a ke Manifold

The intake manifold system is composed of the

aluminum cast common chamber and intake manifold

attached with six fuel injectors.

Exhaust Manifold

The exhaust manifold is made of nodular cast iron.

Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade

that meets the cylinder bore diameter. Each piston has

two compression rings and one oil ring. The piston pin is

made of c hr omium s tee l i s offset 1mm toward the thr ust

side, and the thrust pressure of piston to the cylinder

wall varies gradually as the piston travels. The

connecting rods are made of forged steel. The

connecting rod bearings are graded for correct seze

selection.

Crankshaft and Bearings

The crank shaft is m ade of Duc tile cas t–iron. Pi ns and

journals are graded for correct size selection for their

bearing.

Engine Lubrication

The oil discharged by a trochoid–type oil pump driven

by the crank shaft is f ed through full –flow oil filt er and to

the oil gallery provided under the crankshaft bearing

cap. The oil is then led to the crankshaft journals and

cylinder head. The crank pins are lubricated with oil

from crankshaft journals through oil holes. Also, an oil

jet is fed to each cylinder from crankshaft journals on

the connecting rod for piston cleaning. The oil pan

flange is dealed wit h liquid pack ing only; do not deform

or damage the flange surface during removal or

installation.

ENGINE DIAGNOSIS

Hard Starting

1. Starting Motor Does Not Turn Over

Troubleshooting Procedure

Turn on headlights and starter switch.

2. Ignition Trouble — Starter Motor Turns Over But

Engine Does Not Start

Spark Test

Disconnect an ignition coil from any spark plug. Connect

the spark plug tester J–26792 (ST–125), start the

engine, and check if a spark is generated in the spark

plug tester. Before starting the engine, make sure that

the spark plug tester is properly grounded. To avoid

electrical shock, do not touch the part where insulation

of the ignition coil is broken while the engine is running.

3. Trouble In Fuel System

Condition Possible cause Correcti on

Headlights go out or dim

considerably Battery run down or under charged Recharge or replace battery

Terminals poorly connected Clean battery posts and terminals

and connect properly

Starter motor coil circuit shorted Overhaul or replace

Starter motor defective Overhaul or replace

Condition Possible cause Correcti on

Spark jumps across gap Spark plug defective Clean, adjust s park gap or replac e

Ignition timing incorrect Refer to Ignition System

Fuel not reaching fuel injector(s) or

engine Refer to item 3 (Trouble in fuel

system)

Valve timing inco rrec t Adjus t

Engine lacks compression Refer to item 4 (Engine lacks

compression)

No spark Ignition coil disconnected or broken Connect properly or replace

Electronic Ignition System with

module Replace

Poor connections in engine harness Correct

Powertrain Control Module cable

disconnected or defective Correct or replac e

Condition Possible cause Correcti on

Starting motor turns over and spark

occurs but engine does not start. Fuel tank empty Fill

Water in fuel system Clean

Fuel filter clogged Replace filter

Fuel pipe clogged Clean or replace

Fuel pump defective Replace

Fuel pump circuit open Correct or replace

Evaporative Emission Control

System circuit clogged Correct or replac e

Multiport Fuel Injection System

faulty Refer to “Electronic Fuel Injection"

section

4. Engine Lacks Compression

Engine Compression Test Procedure

1. Start and run the engine until the engine reaches

normal operating temperature.

2. Turn the engine off.

3. Remove all the spark plugs.

4. Remove ignition coil fuse (15A) and disable the

ignition system.

5. Remove the fuel pump relay from the relay and fuse

box.

6. Engage the starter and check that the cranking

speed is approximately 300 rpm.

7. Install cylinder compression gauge into spark plug

hole.

8. With the throttle valve opened fully, keep th e starter

engaged until the compression gage needle

reaches the maximum level. Note the reading .

9. Repeat the test with each cylinder.

If th e co mpression pr essure obtained fa ll s be l ow the

limit, engine overhaul is necessary.

Limit; 1000 kPa (145 psi)

Condition Possible cause Correcti on

Engine lacks compression Spark plug loosely fitted or spark

plug gasket defective Tighten to specified torque or

replace gas k et

Val ve tim ing inco rrec t Adjus t

Cylinder head gasket defective Replace gasket

Valve in correctly seated Lap va lve

Val ve ste m sei ze d Replac e valv e and va lv e guid e

Val ve sp ring weakened or broken Replac e

Cylinder or piston rings worn Overhaul engine

Piston ring seized Overhaul engine.

Rough Engine Idling or Engine Stalling

Condition Possible cause Correcti on

Fault in fuel injection system Throttle blade sticking Correct or replace

Throttle position sensor circuit open

or shorted Correct or replac e

Fuel injector circuits open or shorted Correct or replace

Fuel injectors damaged Replace

Fuel pump relay defective Replace

Mass Air Flow (MAF) Sensor circuit

open or poor connections Correct or replac e

Mass Air Flow (MAF) Sensor

defective Replace

Manifold Absolute Pressure Sensor

circuit open or poor connections Correct or replac e

Manifold Absolute Pressure Sensor

defective Replace

Engine Coolant T emperature Sensor

circuit open or poor connections Correct or replac e

Engine Coolant T emperature Sensor

defective Replace

Intake Air Temperature sensor

circuit open or poor connections Correct or replac e

Intake Air Temperature sensor

defective Replace

ION Sensing Module cable broken

or poor connec tions Correct or replac e

ION Sensing Module defective Replace

Vehicle Speed Sensor circuit open

or shorted Correct or replac e

Vehicle Speed Sensor defective Replace

Fault in emission control system Powertrain Control Module defective Replace

Exhaust Gas Recirculation Valve

circuit open or poor connections Correct or replac e

Exhaust Gas Recirculation Valve

faulty Replace

Canister purge valve circuit open or

poor connections Correct or replac e

Canister purge valve defective Replace

Evaporative Emission Canister

Purge control valve defective Replace

Ignition system Fault Refer to “Hard Start"

Rough Engine Running

Others Engine lacks compression Refer to “Hard Start"

Valve in correctly seated Lap va lve

Air Cleaner Filter clogged Replace filter element

Val ve tim ing inco rrec t Readj us t

Idle air control valve broken Replace

Fast idle solenoid defective Replace

Positive Crankcase Ventilation valve

defective or clogged Replace

Condition Possible cause Correcti on

Engine misfires periodically Ignition coil layer shorted Replace

Spark plugs fouling Clean or install hotter type plug

Defective spark plug(s) Replace

Fuel injector(s) defective Replace

Powe rt rain cont ro l mod ule faulty Repl ac e

Engine knocks periodically Spark plugs - incorrect heat range Install colder type spark plugs

Powertrain control module fault Replace

ION Sensing module fault Replace

Engine lacks power Spark plugs fouled Clean

Fuel injectors defective Replace

Mass Air Flow (MAF) Sensor or

Intake Airflow Sensor circuit

defective

Correct or replac e

Manifold Absolute Pressure (MAP)

Sensor or Manifold Absolute

Pressure Sensor circuit defective

Correct or replac e

Engine Coolant T emperature Sensor

or Engine Coolant Temperature

Sensor circuit defective

Correct or replac e

Powertrain Control Module fault Replace

Intake Air Temperature Sensor or

Intake Air Temperature Sensor

circuit defective

Correct or replac e

Throttle Position Sensor or Throttle

Position Sensor circuit defective Correct or replac e

ION Sensing Module or ION

Sensing Module circuits defective Correct or replac e

Condition Possible cause Correcti on

Hesitation

Condition Possible cause Correcti on

Hesitation on acceleration Throttle Position Sensor adjustment

incorrect Replace throttle valve assembly

Throttle Position Sensor circuit open

or shorted Correct or replac e

Mass Air Flow (MAF) Sensor circuit

open or poor connections Correct or replac e

Mass Air Flow (MAF) Sensor

defective Replace

Manifold Absolute Pressure (MAP)

Sensor circuit open or shorted Correct or replac e

MAP Sensor defective Replace

Intake Air Temperature (IAT) Sensor

circuit open or poor connections Correct or replac e

ION Sensing Module circuit open or

poor connections Correct or replac e

ION Sensing Module defective Replace

IAT Sensor defective Replace

Hesitation at high speeds

(Fuel pressure too low) Fuel tank strainer clogged Clean or replace

Fuel pipe clogged Clean or replace

Fuel filter clogged Replace

Defecti ve fuel pump syst em Check and re pla ce

Fuel Pressure Control Valve leaking Replace

Hesitation at high speeds

(Fuel injector not working normally) Power supply or ground circuit for

Fuel Injection System shorted or

open

Check and co rrec t or replace

Fuel Injector defective Replace

Fuel Injection System harness

circuit open or poor connections Correct or replac e

Hesitation at high speeds Powertrain Control Module defective Replace

Throttle Position Sensor cable

broken or poor connections Correct or replace

Throttle Position Sensor defective Replace

Engine Coolant T emperature Sensor

circuit open or shorted Correct or replace

Engine Coolant T emperature Sensor

defective Replace

Mass Air Flow (MAF) Sensor circuit

open or poor connections Correct or replac e

Mass Air Flow (MAF) Sensor

defective Replace

MAP Sensor cable broken or poor

connections Cor rect or replac e

MAP Sensor defective Replace

IAT Sensor circuit open or poor

connections Cor rect or replac e

IAT Sensor defective Replace

ION Sensing Module circuit open or

poor connections Correct or replac e

ION Sensing Module defective Replace

Throttle valve not fully opened Check and correct or replace

Air Cleaner Filter clogged Replace filter element

Power supply voltage too low Check and correct or replace

Condition Possible cause Correcti on

Engine Lacks Power

Condition Possible cause Correcti on

Trouble in fuel system Fuel Pressure Control Valve not

working normally Replace

Fuel injector clogged Clean or replace

Fuel pipe clogged Clean

Fuel filter clogged or fouled Replace

Fuel pump drive circuit not working

normally Correct or replac e

Fuel tank not sufficiently breathing

due to clogged Evaporative

Emission Control System circuit

Clean or replace

Water in fuel system Clean

Inferior quality fuel in fuel system Use fuel of specified octane rating

Powertrain Control Module supplied

poor voltage Correct circuit

Throttle Position Sensor cable

broken or poor connections Correct or replace

Throttle Position Sensor defective Replace

Mass Air Flow (MAF) Sensor not

working normally Replace

Manifold Absolute Pressure Sensor

not working normally Replace

Intake Air Temperature Sensor not

working normally Replace

Engine Coolant T emperature Sensor

circuit open or shorted Correct or replace

Engine Coolant T emperature Sensor

defective Replace

Powertrain Control Module defective Replace

Trouble in intake or exhaust system Air Cleaner Filter clogged Replace filter element

Air duct kinked or flattened Correct or replace

TWC defective Repair

Ignition failure ———— Refer to Hard Start Troubleshooting

Guide

Heat range of spark plug incorrect Install spark plugs of correct heat

range

Ignition coil defective Replace

Engine overheating Level of Engine Coolant too low Replenish

Fan clutch defective Replace

Incorrect fan installed Replace

Thermos tat defectiv e Replac e

Engine Coolant pump defective Correct or replace

Radiator clogged Clean or replace

Radiator filler cap defective Replace

Level of oil in eng ine crankc as e too

low or wrong engine oil Change or replenish

Resistance in exhaust system

increased Clean exhaust system or replace

defective parts

Throttle Position Sensor adjustment

incorrect Replace with Throttle Valve ASM

Throttle Position Sensor circuit open

or shorted Correct or replac e

Cylinder head gasket damaged Replace

Engine overcooling Thermostat defective Replace (Use a thermostat set to

open at 82°C (180°F))

Engine lacks compression ———— Refer to Hard Start

Others tyre inflation pressure abnormal Adjust to recommended pressures

Brake drag Adjust

Clutch slipping Adjust or replace

Level of oil in eng ine crankc as e too

high Correct lev el of engine oil

Exhaust Gas Recirculation Valve

defective Replace

Condition Possible cause Correcti on

Engine Noisy

Abnorma l engine noise oft en consists of var ious noises

originating in rotating parts, sliding parts and other

moving parts of the en gine. It is , therefore , advis able to

use a systematical approach to locating the source of

noise .

Troubleshooting Procedure

Remove ea ch s park plu g HT lead in s eq uence usin g an

insulate d s park p lug le ad removing tool . Lo ca te c yl in der

with defective bearing by listening for any abnormal

noise that stops when spark plug lead is removed.

Troubleshooting Procedure

Abnormal noise stops when the spark plug on the

cylinder with defective part is shorted out.

Condition Possible cause Correcti on

Noise from crank journals or from

crank bearings

(Faulty crank journals and crank

bearings usually make dull noise

that becomes more evident when

accelerating)

Oil cl earance incr eased due to worn

crank journals or crank bearings Replace crank bearings and

crankshaft or regrind crankshaft and

install the undersize bearing

Crankshaft out of round Replace crank bearings and

crankshaft or regrind crankshaft and

install the undersize bearing

Crank bearing seized Crank bearing seized Replace crank

bearings and crankshaft or regrind

crankshaft and install the undersize

bearing

Condition Possible cause Correcti on

Noise from connecting rods or from

connecting rod bearings

(Faulty connecting rods or

connecting rod bearings usually

make an abnormal noise slightly

higher than the c rank bearing nois e,

which becomes more evident when

engine is acce le ra ted)

Bearing or crankshaft pin worn Replace connecting rod bearings

and crankshaft or regrind crankshaft

pin and install the undersize bearing

Crankpin out of round Replace connecting rod bearings

and crankshaft or regrind crankshaft

pin and install the undersize bearing

Connecting rod bent Correct or replace

Connecting rod bearing seized Replace connecting rod bearings

and crankshaft or regrind crankshaft

pin and install the undersize bearing

Condition Possible cause Correcti on

Piston and cylinder noise

(Faulty piston or cylinder usually

makes a combined mechanical

thumping noise which increases

when engine is suddenly

accelerated but diminishes gradually

as the engine warms up)

Piston clearance increased due to

cylinder wear Replace piston and cylinder body

Piston seized Replace piston and cylinder body

Piston ring broken Replace piston and cylinder body

Piston defective Replace pistons and others

Troubleshooting Procedure

Short out each spark plug and listen for change in

engine noise.

Troubleshooting Procedure

The slapping sound stops when spark plug on bad

cylinder is shorted out.

Condition Possible cause Correcti on

Piston pin noise

(Piston makes noise each time it

goes up and down)

Piston pin or piston pin hole worn Replace piston, piston pin and

connecting rod assy

Condition Possible cause Correcti on

Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the

tension pulley or replace timing belt

Tensione r beari ng defe cti v e Replac e

Timing belt defective Replace

Timing pulley defective Replace

Timing belt comes in contact with

timing cove r Replace timing belt and timing cover

Valve noise Valve clearance incorrect Replace adjusting shim

Valve and valve guide seized Replace valve and valve guide

Val ve sp ring brok en or weaken ed Replac e

Val ve se at off–posit ioned Correct

Camshaft worn out Replace

Crankshaft noise Crankshaft end play excessive

(noise occurs when clutch is

engaged)

Replace thrust bearing

Engine knocking Preignition due to use of spark plugs

of inadequate heat range Install Spark Plugs of adequate heat

range

Carbon deposits in combustion

chambers Clean

Fuel too low in octane rating Replace fuel

Wide Open Throttle enrichment

system failure Refer to Section 6E

Selection of transmission gear

incorrect Caution operator of incorrect gear

selection

Engine overheating Refer to “Engine Lacks Power"

Other s Water pump defectiv e Replac e

Drive belt slipping Replace auto tentioner or drive belt

Abnormal Combustion

Condition Possible cause Correcti on

Trouble in fuel system Fuel pressure control valve

defective Replace

Fuel filter clogged Replace

Fuel pump clogged Clean or replace

Fuel tank or fuel pipe clogged Clean or replace

Fuel injector clogged Clean or replace

Fuel pump relay defective Replace

Power supply cable for fuel pump

broken or poor connections Reconnect, correct or replace

Mass Air Flow (MAF) Sensor circuit

open or defective Correct or replac e

MAF Sensor defective Replace

Manifold Absolute Pressure Sensor

circuit open or shorted Correct or replace

Manifold Absolute Pressure Sensor

defective Replace

Engine Coolant Temperature (ECT)

Sensor circuit open or shorted Correct or replac e

ECT Sensor defective Replace

Throttle Position Sensor adjustment

incorrect Readjust

Throttle Position Sensor defective Replace

Throttle Position Sensor connector

poor connections Reconnect

Vehicle Speed Sensor cable poor

connections or defective Correct or replac e

Vehicle Speed Sensor loosely fixed Fix tightly

Vehicle Speed Sensor in wrong

contact or defective Replace

Powertrain Control Module cable

poor connections or defective Correct or replac e

Engine Oil Consumption Excessive

Trouble in emission control system Heated Oxygen Sensor circuit open Correct or replace

Heated Oxygen Sensor defective Replace

Signal vacuum hose loosely fitted or

defective Correct or replace

EGR Valve circuit open or shorted Correct or replace

Exhaust Gas Recirculation Valve

defective Replace

ECT Sensor circuit open or shorted Correct or replace

Canister Purge Valve circuit open or

shorted Correct or replac e

Canister Purge Valve defective Replace

ECT Sensor defective Replace

Positive Crankcase Ventilation

(PCV) valve and hose clogged Co rre ct or replace

Evaporator system Refer to Section 6E

Trouble in ignition system ———— Refer to “Engine Lacks Power"

Trouble in cylinder head parts Carbon deposits in combustion

chamber Remove carb on

Carbon deposit on valve, valve seat

and valve guide Remove carb on

Condition Possible cause Correcti on

Oil leaking Oil pan drain plug loose Retighten or replace gasket

Crankcase fixing bolts loosened Retighten

Oil pan setting bolts loosened Retighten

Oil pan gasket broken Replace gasket

Front cover retaining bolts loose or

gasket broken Retighten or replace gasket

Head cover fixing bolts loose or

gasket broken Retighten or replace gasket

Oil filter adapter cracked Replace

Oil filter attachings bolt loose or

rubber gasket broken Retighten or replace oil filter

Crankshaft front or rear oil seal

defective Replace oil seal

Oil pressure unit loose or broken Retighten or replace

Blow–by gas hose broken Replace hose

Posit ive Cr ankc ase Venti latio n Valve

clogged Clean

Engine/Transmission coupling failed Replace oil seal

Oil leaking into combustion

chambers due to poor seal in valve

system

Valve stem oil seal defective Replace

Valve stem or valve guide worn Replace valve and valve guide

Condition Possible cause Correcti on

Fuel Consumption Excessive

Lubrication Problems

Oil leaking into combustion

chambers due to poor seal in

cylinder parts

Cylind ers and pis to ns worn

excessively Replace cylinder body assembly

and pistons

Piston ring gaps incorrectly

positioned Correct

Piston rings set with wrong side up Correct

Piston ring sticking Replace cylinder body assembly

and pistons

Piston ring and ring groove worn Replace pistons and others

Return ports in oil rings clogged Clean piston and replace rings

Positive Crankcase Ventilation

System malfunctioning Positive Crankcase Ventilation Valve

clogged Clean

Others Improper oil viscosity Use oil of recommended S.A.E.

viscosity

Continuous high speed driving and/

or severe usage such as trailer

towing

Continuous high speed operation

and/or severe usage will normally

caus e increased oil consumption

Condition Possible cause Correcti on

Trouble in fuel system Mixture too rich or too lean due to

trouble in fuel injection system Refer to “Abnormal Combustion"

Fuel cut function does not work Refer to “Abnormal Combustion"

Trouble in ignition system Misfiring or abnormal combustion

due to trouble in ignition system Refer to “Hard Start" or “Abnormal

Combustion"

Others Engine idle speed too high Reset Idle Air Control Valve

Fuel system leakage Correct or replace

Clutch slipping Correct

Brake drag Correct

Selection of transmission gear

incorrect Caution operator of incorrect gear

selection

Excessive Exhaust Gas

Recirculation flow due to trouble in

Exhaust Gas Recirculation system

Refer to “Abnormal Combustion"

Condition Possible cause Correcti on

Oil pressure too low Wrong oil in use Replace with correct engine oil

Relief valve sticking Replace

Oil pump not operating properly Correct or replace

Oil pump strainer clogged Clean or replace strainer

Oil pump worn Replace

Oil pressure gauge defective Correct or replace

Crankshaft bearing or connecting

rod bearing worn Replace

Condition Possible cause Correcti on

Engine Oil Pressure Check

1. Check for dirt, gasoline or water in the engine oil.

a Check the viscosity of the oil.

b Change the oil if the viscosity is outside the

specified standard - Refer to Section 0B

2. Check the engine oil level.

The level should fall somewhere between the “ADD"

and the “FULL" marks on the oil level dipstick.

If the oil level does not reach the “ADD" mark on the

oil level dipstick, engine oil must be added.

3. Remove the oil pressure unit.

4. Install an oil pressure gauge.

5. Start the engine and allow the engine to reach

normal operating temperature (About 80°C).

6. Measure the oil pressure.

Oil pressure should be:

392–550 kPa (56.9–80.4 psi) at 3000 rpm.

7. Stop the engine.

8. Remove the oil pressure gauge.

9. Install the oil pressure unit.

10. Start the engine and check for leaks.

Malfunction Indicator Lamp

The instrument panel “CHECK ENGINE" Malfunction

Indicator Lamp (MIL) illuminates by self diagnostic

system when the system checks the starting of engine,

or senses malfunctions.

Should the MIL illuminate while driving, or fail to

illuminate for three seconds when the ignition is first

turned ON, refer to Section 6C1 - Emissions and

Driveability.

Oil contamination Wrong oil in use Replace with correct engine oil

Oil filter clogged Replace oil filter

Cylinder head gasket damage Replace gasket

Burned gases leaking Replace piston and piston rings or

cylinder body assembly

Oil not reaching valve system Oil passage in cylinder head or

cylinder body clogged Clean or correct

Condition Possible cause Correcti on

DRIVE BELT (SERPENTINE BELT)

033R100002

EndOFCallout

REMOVAL

1. Disconnect the battery negative cable.

2. Remove the two bolts form upper side fan guide and

four clamps (4) from side of the fan guide for

remove the upper fan guide (1).

3. Remove the four nuts (3) from the fan pulley and

remove the cooling fan with the fan clutch (2).

Legend

(1) Upper Fan Guide

(2) Cooling Fan and Fan Clutch

(3) Nut

(4) Clamp

(5) Drive Belt (Serpentine belt)

4. Move the drive belt tensioner to loose side using

wrench then remove drive belt (5).

850RW001

EndOFCallout

CAUTION:

1. Do not bend or twist the belt, otherwise its core

could be damaged. The belt should not be bent

at a radius less then 30 mm.

2. Do not allow oil or other chemical substances to

come in contact with the belt. They will shorten

the life.

3. Do not attempt to pry or stretch the belt with a

screw driver or any other tool during

installation.

4. Store the belt in a cool and dark place. Never

expose the belt direct sunlight or heat.

Legend

(1) Crankshaft Pulley

(2) Cooling Fan Pulley

(3) Tensioner

(4) Generator

(5) Ai r Conditioner Compressor

(6) P ower Steering Oi l Pum p

(7) D riv e (ser pe ntine) Belt

INSPECTION AND REPAIR

1. Replace the drive belt, if found the worn or

damaged on the belt during inspection.

2. Inspect the belt life indicator, replace the drive belt if

the belt life indicator indicate with out limited.

850R100002

EndOFCallout

Legend

(1) Automatic Drive Belt Tensioner

(2) Drive Belt Tension Lower Limit

(3) Tension Pulley; Drive Belt Tensioner

(4) Driv e Bel t Life Indic ator

(5) Drive Belt Tensioner Higher Limit

INSTALLATION

1. Move the drive belt tensioner to loose side using

wrench, then install the drive belt to normal position.

850RW001

EndOFCallout

2. Install the cooling fan with the fan clutch and tighten

the four nuts.

Torque : 10 N·m (1.0 k g·m/87 lb i n) for fan a nd fan

clutch.

Torque : 22 N·m (2.2 kg·m/16 lb ft) for fan pulley

and fan bracke t.

3. Install the upper fan guide.

Tighten the two bolts to specified torque.

Torque : 4 N·m (0.4 kg·m/35 lb in)

4. Connect the battery negative cable.

Legend

(1) Crankshaft Pulley

(2) Cooling Fan Pulley

(3) Tensioner

(4) Generator

(5) Ai r Conditioner Compressor

(6) P ower Steering Oi l Pum p

(7) D riv e (ser pe ntine) Belt

CYLINDER HEAD COVER LH

REMOVAL

1. Disconnect battery ground cable.

2. Remove engine cover from the dowels on the

common chamber.

F06RY001

3. Disconnect positive crankcase ventilation hose.

4. Remove ground cable fixing bolt on cylinder head

cover.

5. Ignition coil connector and ignition coil.

• Disconn ec t th e three c onn ec tors fr om t he ig nit ion

coils.

• Remove harness bracket bolt on cylinder head

cover.

• Remove fixing bolts on ignition coils.

060RY022

EndOFCallout

6. Disconnect fuel injector harness connector then

remove fuel injector harness bracket bolt.

7. Remove eight fixing bolts, then the cylinder head

cover.

010RW001

Legend

(1) Ignition Coil Connector

(2) Bolt

(3) Ig nition Coil Assemblies

INSTALLATION

1. Install cylinder head cover.

• Clean the sealing surface of cylinder head and

cylinder head cover to remove oil and sealing

materials completely.

• Apply sealant (TB-1207B or equivalent) of bead

diameter 2-3 mm at eight place of arched area of

camshaft bearing cap on front and rear sides.

• The cylinder head cover must be installed with in

5 minutes after sealant application to prevent

hardning of sealant.

• Tighten bolts to the specified torque.

Torque : 9 N·m (0.9 kg·m/80 lb in)

010RW008

2. Install fuel injection harness bracket and tighten bolt

to the specified torque.

Torque : 9 N·m (0.9 kg·m/80 lb in)

3. Connect ignition coil connector and ignition coil,

then tighten bolt to the specified torque.

Torque : 4 N·m (0.4 kg·m/35 lb in)

060RY022

EndOFCallout

CAUTION: Ignition coil assembly #6 is 4mm shorter

than ignition coil assemblies #1 to #5. Fitting #6

coil to the incorrect cylinder will result in misfire

DTC’s being set.

060R100117

EndOFCallout

4. Connect ground cable and tighten bolts to the

specified torque.

Torque : 9 N·m (0.9 kg·m/80 lb in)

5. Install positive crankcase ventilation hose.

6. Install engine cover mating with the dowels.

Legend

(1) Ignition Coil Connector

(2) Bolt

(3) Ig nition Coil Assembly

Legend

(1) Long Type Ignition Coil Assemblies (# 1 ∼ # 5)

(2) Short Type Ignition Coil Assembly (# 6)

CYLINDER HEAD COVER RH

REMOVAL

1. Disconnect battery ground cable.

2. Remove engine cover from the dowel on the

common chamber.

F06RY001

3. Disconnect ventilation hose from cylinder head

cover.

4. Disconnect three ignition coil connectors from

ignition coils and remove harness bracket bolts on

cylinder head cover then remove ignition coil fixing

bolts on ignition coils and remove ignition coils.

5. Disconnect fuel injector harness connector then

remove fuel injector harness bracket bolt.

6. Remove eight fixing bolts then the cylinder head

cover.

010RW002

INSTALLATION

1. Install cylinder head cover.

• Clean the sealing surface of cylinder head and

cylinder head cover to remove oil and sealing

materials completely.

Apply sealant (TB-1207B or equivalent) bead

(diameter 2-3 mm) at eight places of arched

areas of camshaft bracket on front and rear

sides.

• The cylinder head cover must be installed within

5 minutes after sealant application to prevent

premature hardening of sealant.

• Tighten bolts to the specified torque.

Torque : 9 N·m (0.9 kg·m/78 lb in)

014RW019

2. Tighten fuel injector harness bracket bolts to

specified torque then reconnect fuel injector

harnes s co nnector.

Torque : 7.8 N·m (0.8 kg·m/5.7 lb ft)

3. Connect ignition coil connector and tighten ignition

coil fixing bolts to specified torque.

Torque : 4 N·m (0.4 kg·m/35 lb in)

4. Connect ventilation hose to cylinder head.

5. Install engine cover mating with the dowels.

COMMON CHAMBER

Removal

1. Disconnect battery ground cable.

2. Remove the air cleaner duct assembly.

013RY00001

Legend

(1) Positive Crankcase Ventilation Hose Connector

(2) Intake Air Temperature Sensor

(3) Air Cleaner Duct As sembly

(4) Air Flow Sensor

3. Disconnect vacuum booster hose from common

chamber.

4. Disconnect connector from manifold absolute

pressure sensor, idle air control valve, throttle

position sensor, solenoid valve, electric vacuum

sensing valve, and EGR valve.

5. Disconnect vacuum hose on canister Vacuum

Switching Valve (VSV) and positive crankcase

ventilation hose, fuel rail assembly with pressure

control valve bracket.

6. Remove ventilation hose from throttle valve and

intake duct and remove water hose.

7. Remove the four throttle body fixing bolts.

8. Remove exhaust gas recirculation valve assembly

fixing bolt and nut on common chamber and

remove EGR valve assembly.

9. Remove two bolts from common chamber rear side

for remove fuel hose bracket.

10. Remove common chamber four bolts and four nuts

then remove the common chamber.

025RW001

Legend

(1) Common Chamber

(2) Throttle Body Assembly

(3) Bolt

Installation

1. Install throttle body and tighten bolts to the specified

torque.

Torque : (Bolt size M8)

25 N.m (2.6 kg·m/18 lb ft)

2. Install fuel hose bracket and tighten bolts to

specified torque.

Torque : 10 N.m (1.0 kg·m/89 lb in)

3. Install common chamber and tighten bol ts and n uts

to the specified torque.

Torque :

Bolt : 18 N.m (1.8 kg-m/13 lb ft.)

Nut : 18 N.m (1.8 kg·m/13 lb ft)

4. Install ventilating hose to throttle valve and intake

duct.

5. Install exhaust gas recirculation valve assembly

and tighten bolt and nut to specified torque.

Torque : 25 N.m (2.5 kg·m/18 lb ft)

6. Connect vacuum hoses on canister VSV and

positive crankcase ventilation valve. Tighten bolts

for fuel rail assembly with pressure control valve

bracket to specified torqu e.

Torque : 25 N.m (2.5 kg·m/18 lb ft)

7. Connect each connector without fail.

8. Connect vacuum booster hose.

9. Install air cleaner duct assembly.

013RY00001

Legend

(1) Positive Crankcase Ventilation Hose Connector

(2) Intake Air Temperature Sensor

(3) Air Cleaner Duct As sembly

(4) Air Flow Sensor

EXHAUST MANIFOLD LH

REMOVAL

1. Disconnect the battery ground cable.

2. Raise the vehicle and support it with chassis stands.

3. Remove the left side wheel and tyre assembly.

4. Remove the inner fender skirt.

5. Disconnect the O2 sensor connector.

6. Remove the 3 stud nuts from the exhaust pipe

flange.

7. Remove the 2 bolts from the rear end of the front

exhaust pipe with catalytic converter.

8. Remove the front exhaust pipe with catalytic

converter rubber support.

9. Move the front exhaust pipe with catalytic converter

to the rear.

150RY00039

EndOFCallout

10. Remove the exhaust manifold heat protector.

11. Remove the 8 exhaust manifold fixing nuts and the

exhaust manifold from the engine.

027RY00006

EndOFCallout

INSTALLATION

1. Install the exhaust manifold and exhaust manifold

gasket.

• Do not reuse the old exhaust manifold nuts.

Use new nuts and tighten to the specified torque.

Torque: 57 N·m (5.8 kg·m/42 lb ft)

2. Install the exhaust manifold heat protector.

3. Fix th e front exhaus t pipe with ca talytic conver ter to

the exhaust manifold flange stud bolts and

hand-tighten the nuts.

4. Hang the fr ont exhaust pipe with c atalytic con verter

on the chassis (pipe to rubber support/rubber

support to chassis).

5. Hand-tighten the 2 bolts at the rear end of the front

exhaust pipe.

6. Tighten the exhaust pipe flange stud nuts.

Torque : 67 N·m (6.8 kg·m/49 lb ft)

7. Tighten the 2 bolts at the rear end of the front

exhaust pipe.

Torque : 43 N·m (4.4 kg·m/32 lb ft)

8. Connect the O2 sensor connector.

9. Install the i nner fender skirt.

10. Install the left side wheel and tyre assembly.

Legend

(1) Exhaust Front Pipe LH

(2) Bolt

(3) Rubber Support

(4) Stud Nut

(5) O2 Sensor

Legend

(1) Exhaust Manifold Heat Protector

(2) Exhaust Manifold

EXHAUST MANIFOLD RH

REMOVAL

1. Disconnect the battery ground cable.

2. Raise the vehicle and support it with chassis stands.

3. Remove the right side wheel and tyre assembly.

4. Remo ve the mud fender skir t.

5. Disco nne ct the O2 sensor connector (5).

6. Remove the 3 stud nuts (6) from the exhaust pipe

flange.

7. Remove t he 2 bolts (4) from the rear end of the left

side front exhaust pipe with catalytic converter.

8. Remove the 4 nuts (1) from the front end of the

silencer.

9. Remove the 2 nuts (3) from the rear end of the

silencer.

10. Remove the rubber support (8) from the right-front

exhaust pipe.

11. Mov e the front exhaust pi pe (7), the center exhaust

pipe (9) and the silencer assembly (2) to the rear.

150RY00040

12. Remove the exhaust gas recirculation (EGR) pipe

fixing bolts from the exhaust manifold.

13. Remove the EGR pipe bracket and bolt from the

rear side of the cylinder head.

14. Loosen the nut between the EGR pipe and the EGR

valve.

F06RY00036

EndOFCallout

15. Remove the exhaust manifold heat protector.

16. Remove the 8 exhaust manifold fixing nuts and the

exhaust manifold from the engine.

INSTALLATION

1. Install the exhaust manifold and exhaust manifold

gasket.

• Do not reuse the old exhaust manifold nuts.

Use new nuts and tighten to the specified torque.

Torque: 57 N·m (5.8 kg·m/42 lb ft)

2. Install the exhaust manifold heat protector.

3. Install the EGR pipe between the exhaust manifold

and the EGR valve.

Tighten the fixing nuts and bolts to the specified

torque.

• Exhaust manifold (2)

Torque: 28 N·m (2.9 kg·m/21 lb ft)

• Rear cylinder head (1)

Torque: 44 N·m (4.5 kg·m/33 lb ft)

• EGR pipe and EGR valve.

Torque: 25 N·m (2.5 kg·m/18 lb ft)

4. Fix th e front exhaus t pipe with ca talytic conver ter to

the exhaust manifold flange stud bolts and

hand-tighten the nuts.

5. Hang the fr ont exhaust pipe with c atalytic con verter

from the chassis (pipe to rubber support/rubber

support to chassis).

6. Fix the front end of silencer and hand-tighten the 4

nuts.

7. Fix the end of the left side front exhaust pipe and

hand-tighten the bolts.

8. Fix the rear end of the silencer to the rear exhaust

pipe bolts and hand tighten the nuts.

9. Tighten the exhaust pipe flange stud nuts.

Torque: 67 N·m (6.8 kg·m/49 lb ft)

10. Tighten the front end silencer nuts.

Torque: 15 N·m (1.5 kg·m/11 lb ft)

11. Tighten the fixing bolts at the end of the left-side

front exhaust pipe.

Torque: 43 N·m (4.4 kg·m/32 lb ft)

12. Tighten the nuts at the rear of the silencer.

Torque: 43 N·m (4.4 kg·m/32 lb ft)

Legend

(1) Pipe Fixing Nut

(2) Bracket and Bolt

(3) Pipe Fixing Bolt

CRANKSHAFT PULLEY

REMOVAL

1. Disconnect the battery ground cable.

2. Remove the upper fan guide.

3. Remove the serpentine belt.

• Refer to the removal procedure for Drive Belt

(Serpentine Belt) in this manual.

4. Remove the 4 cooling fan fixing nuts and the cooling

fan with clutch assembly.

5. Remove the fan pulley bracket (2 nuts and 1 bolt)

and the fan pulley bracket.

6. Use the crankshaft holder (J-8614-01), to hold the

crankshaft pulley.

7. Remove the crankshaft center bolt and the pulley.

INSTALLATION

1. Use the crankshaft holder (J-8614-01), to hold the

crankshaft pulley.

2. Tighten center bolt to the specified torque.

Torque : 167 N·m (17.0 kg·m/123 lb ft)

3. Install the fan pulley bracket and tighten the nuts

and bolt to the specified torque.

Torque : 22 N·m (2.2 kg·m/16 lb ft)

4. Install the fan wit h clutch assem bly to the fan pulley

bracket.

Torque : 22 N·m (2.2 kg·m/16 lb ft)

5. Use a wrench to force the auto-tensioner pulley

toward the bottom of the engine.

Place the serpentine belt over the pulley.

6. Install the upper fan guide.

TIMING BELT - BROKEN BELT

REMOVAL

1. Disconnect battery ground cable.

2. Remove air cleaner assembly.

3. Remove radiator upper fan shroud from radiator.

4. Move drive belt tensioner to loose side using

wrench then remove drive belt.

850RW001

EndOFCallout

5. Remove cooling fan assembly four nuts, then the

cooling fan assembly.

6. Remove cooling fan drive pulley assembly.

7. Remove idle pulley assembly.

8. Remove serpentine belt tensioner assembly.

9. Remove power steering pump assembly.

10. Remove crankshaft pulley assembly using 5–8840–

0133–0 crankshaft holder, hold crankshaft pulley

remove center bolt, then the pulley.

11. Remove right side timing belt cover then left side

timing belt cover.

12. Remove lower timing belt cover

13. Remove timing belt tensioner.

CAUTION: The prevent air entering the oil chamber.

The tensioner must be stored with the rod facing

upward.

014R100020

EndOFCallout

14. Remove broken timing belt.

15. Remove the cylinder head covers - refer to 6A-24

NOTE: NEW BELT CARE

1. Do not bend or twist the new belt, otherwise its

core could be damaged. The belt should not be

bent at a radius less than 30 mm.

2. Do not allow oil or other chemical substances to

come in contact with the belt. They will shorten

the life.

3. Do not attempt to pry or stretch the belt with a

screw driver or any other tool during

installation.

4. Store timing belt in a cool and dark place. Ne ver

expose the belt to direct sunlight or heat.

Legend

(1) Crankshaft Pulley

(2) Cooling Fan Pulley

(3) Tensioner

(4) Generator

(5) Air Conditioner Compressor

(6) Power Steering Oil Pump

(7) Drive Belt

Legend

(1) U p Si de

(2) Down Side

(3) Direction For Installation

(4) Locking Pin

(5) Apply a force of 980 N (220 lb) when

compressing the pusher rod.

INSTALLATION

014R100015

NOTE: For correct belt installation, the lettering on

the belt must be able to be read as viewed from the

front of the vehicle. Any attempt to use belts with

different markings will void these service

procedures.

014RW006

EndOFCallout

Legend

(1) Timing Belt

(2) Engine Rotation Direction

(3) Cy li nde r Head Side

1. Install timing belt.

a Align the mark (notch) of crankshaft timing

pulley (2) with mark on oil pump (1).

Align the mark (groove) on the crankshaft timing

pulley (3) with alignment mark (white dots line)

on the timing belt (4).

When ti ming marks a re a ligned, No.2 p iston will

be on Top Dead Center.

014RW003

EndOFCallout

b Rotate the camshaft drive gear pulley on the

right-han d bank to positi on the cam lobes for #1

cylinder as shown in the diagram on page xxx-

The alignment mark on the Camshaft Drive

Gear pulley should be at the 12o’clock position

relative to the cylinder head-block mounting

face.

c Align the alignment mark (white line) on the

timing belt (1) with alignment mark on the RH

bank camshaft drive gear pulley (2) (on the left

side as viewed fr om the fron t of the veh icle ) and

put the timing belt on the camshaft drive gear

pulley.

Secure the belt with a double clip or equivalent

clip.

014RW00004

EndOFCallout

d Rotate the camshaft drive gear pulley on the

left-hand bank to position the cam lobes for #2

cylinder as shown in the diagram on page xxx-

The alignment mark on the Camshaft Drive

Gear pulley should be at the 12o’clock position

relative to the cylinder head-block mounting

face.

e Align the alignment mark (white line) on the

timing belt (1) with alignment mark on the RH

bank camshaft drive gear pulley (2) (on the left

side as viewe d fro m the front of the veh icle) and

put the timing belt on the camshaft drive gear

pulley.

Secure the belt with a double clip or equivalent

clip.

f When aligning the timing marks, use a wrench

to turn the camshaft drive gear pulley, then set

the timing mark between timing belt and

camshaft drive gear pulley and put the timing

belt on the camshaft drive gear pulley.

Secure the belt with a double clip or equivalent

clip.

Legend

(1) Alignment Mark on Oil Pump

(2) Groove on Crankshaft Timing Pulley

(3) Alignment Mark on Crankshaft Timing Pulley

(4) Alignment Mark on Timing Belt

Legend

(1) Alignment Mark on Timing Belt (White line).

(2) Alignment Mark on Camshaft Drive Gear

Pulley.

(3) Alignemnt Mark on Cylinder Head Cover RH.

NOTE: It is recommended for easy installation that

the belt be secured with a double clip or equivalent

clip after it is installed the timing belt to each pulley.

014RW00005

EndOFCallout

g Install crankshaft pulley temporarily and tighten

center bolt by hand (do not use a wrench).

Turn the crankshaft pulley clockwise to give

some belt slack between the crankshaft timing

pulley and the RH bank camshaft drive gear

pulley.

NOTE: When reusing the tensioner, compress the

tensioner rod with approximately 980N force and

insert a holding pin (1.4 mm piano wire).

2. Install timing belt tensioner and tighten bolt to the

specified torque.

Torque : 25 N·m

a Install the tensioner while pushing the tension

pulley to the belt.

b Pull out pin from the tensioner.

NOTE: After release the push rod from the locking

pin, the rod projection is approximate 5 mm.

014R100020

EndOFCallout

014R100032

EndOFCallout

Legend

(1) Alignment Mark on Timing Belt (White line).

(2) Alignment Mark on Camshaft Drive Gear

Pulley.

(3) Alignemnt Mark on Cylinder Head Cover LH.

Legend

(1) Direction for Installation

(2) Locking Pin

(3) Apply 980 N to compress the tensioner rod

Legend

(1) Tensioner Pulley

(2) Crankshaft Pulley Rotation Direction

(3) Crankshaft Pulley

(4) Tension Assembly

c Remove double clips or equivalent clips, from

timing belt pulleys.

Turn the crankshaft pulley by six turns and

check for timing mark alignment.

NOTE: The crankshaft pulley timing mark, oil pump

cover timing mark and camshaft lobes will be in

their timing setting positions every six (6)

crankshaft revolutions.

NOTE: The markings on the timing belt are for

installation only and will not realign every six turns.

3. Install timing belt covers

Remo ve crankshaft p ulley that was installed in step

1 item 5.

Tighten bolts to the specified torque.

Torque: 19 N·m

020RW004

EndOFCallout

020RW003

EndOFCallout

4. Install crankshaft pulley using 5–8840–0133–0, hold

the crankshaft pulley and tighten center bolt to the

specified torque.

Torque : 167 N·m

5. Install fan pulley bracket and tighten fixing bolts to

the specified torque.

Torque : 22 N·m

6. Install power steering pump assembly and tighten to

the specified torque.

Torque :

M8 bo l t : 22 N· m

M10 bolt : 46 N·m

7. Install cooling fan assembly and tighten bolts/nuts to

the specified torque.

Torque : 22 N·m for fan pulley and fan bracket.

Torque : 10 N·m for fan and clutch assembly.

Legend

(1) Timing Belt Cover RH

(2) Timing Belt Cover LH

(3) Timing Belt Cover Lower

Legend

(1) Timing Belt Cover

(2) Rubber Bushing

(3) Sealing Rubber

(4) Cylinder Bod y

8. Move drive belt tensioner to loose side using

wrench, then install drive belt to normal position.

850RW001

EndOFCallout

9. Install radiator upper fan shroud.

10. Install air cleaner assembly.

Legend

(1) Crankshaft Pulley

(2) Cooling Fan Pulley

(3) Auto Tensioner

(4) Generator

(5) Air Conditioner Compressor

(6) Power Steering Oil Pump

(7) Id le Pu lley

(8) Drive Belt

TIMING BELT REPLACEMENT - SERVICE OPERATION

REMOVAL

1. Follow steps 1) through to 12) of the Timing Belt

Replacement - Broken Belt procedure - refer 6A-34

2. Rotate the crankshaft until the following marks are

aligned:

• The mark (notch) of crankshaft timing pulley (2)

with mark on oil pump (1).

• The alignment mark on the RH bank camshaft

drive gear pulley (2) to the alignment mark of the

cylinder head cover RH (3).

• The alignment mark on the LH bank camshaft

drive gear pulley (2) to the alignment mark of the

cylinder head cover LH (3).

NOTE: It It may require up to three revolutions of

the crankshaft to achieve alignment of all marks.

3. Remove the timing belt tensioner and carefully

remove the timing belt, ensuring the Camshaft

Drive Gear Pulleys do not turn.

INSTALLATION

NOTE:

1. Do not bend or twist the belt, otherwise its core

could be damaged. The belt should not be bent

at a radius less than 30 mm.

2. Do not allow oil or other chemical substances to

come in contact with the belt.

3. Do not attempt to pry or stretch the belt with a

screw driver or any other tool during

installation.

4. Store timing belt in a coo l and dark place . Never

expose the belt to direct sunlight or heat.

NOTE: For correct belt installation, the lettering on

the belt must be able to be read as viewed from the

front of the vehicle.

NOTE: Any attempt to use belts with different

markings to those shown below will void these

service procedures.

014RW006

Legend

(1) Timing Belt

(2) Engine Rotation Direction

(3) Cy li nde r Head Side

014R100015

4. Ensure that the alignment marks on the crankshaft

and camshaft drive gear pulleys are aligned with

their respective marks as shown above.

5. Align the mark (groove) on the crankshaft timing

pulley (3) with alignment mark (white dots line) on

the timing belt (4)

6. Align the alignment mark (white line) on the timing

belt (1) with alignment mark on the RH bank

camshaft drive gear pulley (2) and put the timing

belt on the camshaft drive gear pulley. Secure the

belt with a double cl ip or equiv al ent cl ip .

7. Align the alignment mark (white line) on the timing

belt (1) with the alignment mark on the LH bank

camshaft drive gear pulley (2).

5. When aligning the timing marks, use a wrench to

turn the camshaft drive gear pulley, and put the

timing belt on the camshaft drive gear pulley.

Secure the belt with a double clip or equivalent clip.

6. Install crankshaft pulley temporarily and tighten

center bolt by hand (do not use a wrench).

7. Turn the crankshaft pulley clockwise to give some

belt slack between the crankshaft timing p ulley and

the RH bank camshaft drive gear pulley.

8. Compress and pin the timing belt tensioner push

rod, then install timing belt tensioner and tighten bolt

to the specified torque.

Torque : 25 Nm

9. Remove the timing belt tensioner push rod locking

pin, and ensure that the push rod projection is about

5 mm., as shown above.EndOFCallout

10. Remove double clips or equivalent clips, from timing

belt pul le ys .

11. Turn the cranks haft pulley by th ree turns an d check

for timing mark alignment.

NOTE: The timing marks on the belt are for initial

installation only. Due to the gear ratio between the

camshaft drive gear pulley and the camshaft driven

gear, the belt markings cannot be used to recheck

timing accuracy.

Legend

(1) Direction for Installation

(2) Locking Pin

(3) Apply 980 N to compress the tensioner rod

Legend

(1) Tensioner Pulley

(2) Crankshaft Pulley Rotation Direction

(3) Crankshaft Pulley

(4) Tensioner Assembly

12. Install timing belt cover. and tighten bolts to the

specified torque.

Torque: 19 N·m (1.9 kg·m/14 lb ft)

020RW004

EndOFCallout

020RW003

EndOFCallout

13. Install crankshaft pulley using 5–8840–0133–0, hold

the crankshaft pulley and tighten center bolt to the

specified torque.

Torque : 167 N·m (17.0 kg·m/123 lb ft)

14. Install fan pulley bracket and tighten fixing bolts to

the specified torque.

Torque : 22 N·m (2.2 kg·m/16 lb ft)

15. Install power steering pump assembly and tighten to

the specified torque.

Torque :

M8 bolt : 22 N·m (2.2 kg·m/16 lb ft)

M10 bolt : 46 N·m (4.7 kg·m/34 lb ft)

16. Install cooling fan assembly and tighten bolts/nuts to

the specified torque.

Torque : 22 N·m (2.2 kg·m/16 lb ft) for fan pulley

and fan bracke t.

Torque : 10 N·m (1.0 kg·m/87 lb in) for fan and

clutch assembly.

17. Move drive belt tensioner to loose side using

wrench, then install drive belt to normal position.

850RW001

EndOFCallout

18. Install radiator upper fan shroud.

19. Install air cleaner assembly.

Legend

(1) Timing Belt Cover RH

(2) Timing Belt Cover LH

(3) Timing Belt Cover Lower

Legend

(1) Timing Belt Cover

(2) Rubber Bushing

(3) Sealing Rubber

(4) Cyl inder Body

Legend

(1) Crankshaft Pulley

(2) C oo li ng Fan Pul ley

(3) A uto Ten sion er

(4) Generator

(5) Ai r Conditioner Compressor

(6) P ower Steering Oi l Pum p

(7) Idle Pulley

(8) Driv e Be l t

CAMSHAFT

REMOVAL

1. Disconnect battery ground cable.

2. Remove crankshaft pulley.

• Refer to removal procedure for Crankshaft Pulley

in this manual.

3. Remove timing belt.

• Refer to removal procedure for Timing Belt in this

manual.

4. Remove cylinder head cover LH.

• Refer to removal procedure for Cylinder Head

Cover LH in this manual.

5. Remove cylinder head cover RH.

• Refer to removal procedure for Cylinder Head

Cover RH in this manual.

6. Remove twenty fixing bolts from inlet and exhaust

camshaft bracket on one side bank, then camshaft

brackets.

014RW027

7. Remove camshaft assembly.

8. Remove fixing bolt for camshaft drive gear pulley.

9. Remove three fixing bolts from camshaft drive gear

retainer, then camshaft drive gear assembly.

014RW026

EndOFCallout

INSTALLATION

1. Install camshaft drive gear assembly and tighten

three bolts to the specified torque.

Torque : 10 N·m

Legend

(1) R ight Ban k

(2) Left Bank

(3) Timing Mark on Retainer

2. Tighten sub gear setting bolt.

a Use the 5–8840–2443–0 gear spring lever to

turn s ub ge ar to r ig ht di recti on un til i t ali gn s with

the M5 bolt hole between camshaft driven gear

and sub gear.

b Tighten the M5 bolt to a suitable torque to

prevent the sub gear from moving.

014RW041

3. Align the timing m ark on the r etain er and dowel pin

of the camshaft drive gear.

4. Install camshaft assembly and camshaft brackets,

tighten twenty bolts on one side bank to the

specified torque.

a Apply engine oil to camshaft journal and bearing

surface of camshaft bracket.

b Align timing mark on intake camshaft (one dot

for right ba nk , two dot f or lef t ban k) an d exha us t

camsha ft (one dot for right bank, two dots for

left bank) to timing ma rk on cams haft dr ive gear

(one dot).

014R100016

EndOFCallout

014R100025

EndOFCallout

Legend

(1) Alignment Mark on the Camshaft Gear

(2) Alignment Mark on the Camshaft Drive Gear

Legend

(1) Discrimination Mark for Right Bank Intake

Camshaft Ge ar

(2) Alignment Mark for Right Bank (One Dot)

(3) Camshaft Timing Gear for Right Bank Intake

014R100026

EndOFCallout

014R100027

EndOFCallout

014R100023

EndOFCallout

014R100024

EndOFCallout

Legend

(1) Alignment Mark for Left Bank (Two Dots)

(2) Discrimination Mark for Left Bank Intake

Camshaft Gear

(3) Camshaft Timing Gear for Left Bank Intake

Legend

(1) Discrimination Mark

LE : Left Bank Exhau st

RE : Right Bank Exhaust

(2) Alignment Mark

One Dot for Right Bank

Two Dots for Left Bank

(3) Camshaft Timing Gear for Exhaust

Legend

(1) Timing Mark on the Camshaft Drive Gear for

Right Bank Exhau st Cams ha ft

(2) Timing Mark on the Camshaft Drive Gear for

Right Bank Intake Camsha ft

(3) Dowel Pin

Legend

(1) Timing Mark on the Camshaft Drive Gear for

Left Bank Intake Camshaft

(2) Timing Mark on the Camshaft Drive Gear for

Left Bank Exhaust Camshaft

(3) Dowel Pin

c Tighten the twenty bolts in numerical order on

one bank as shown in the illustration.

Torque : 10 N·m (1.0 kg·m/87 lb in)

014RW031

5. Tighten the bolt for camshaft drive gear assembly

pulley fixing to the specified torque.

Torque : 98 N·m (10.0 kg·m/72 lb ft)

6. Install cylinder head cover RH.

• Refer to installation procedure for CYLINDER

HEAD COVER RH in this manual.

7. Install cylinder head cover LH.

• Refer to installation procedure for CYLINDER

HEAD COVER LH in this manual.

8. Install timing belt.

• Refer to installation procedure for TIMING BELT

in this manual.

9. Install crankshaft pulley.

• Refer to installation procedure for CRANKSHAFT

PULLEY in this manual.

10. Install accelerator pedal cable.

CYLINDER HEAD

REMOVAL

1. Remove engine hood.

2. Disconnect battery ground cable.

3. Drain radiator coolant.

4. Drain engine oil.

5. Remove crankshaft pulley.

• Refer to removal procedure for Crankshaft Pulley

in this manual.

6. Remove timing belt.

• Refer to removal procedure for Timing Belt in this

manual.

7. Remove cylinder head cover LH.

• Refer to removal procedure for Cylinder Head

Cover LH in this manual.

8. Remove cylinder head cover RH.

• Refer to removal procedure for Cylinder Head

Cover RH in this manual.

9. Remove common chamber.

• Refer to removal procedure for Common

Chamber in this manual.

10. Remove cylinder head assembly.

1. Loosen eights bolts for tight cylinder head.

2. Remove cylinder head assembly.

014RW028

EndOFCallout

INSTALLATION

1. Install cylinder head assembly to cylinder block.

a Put cylinder head gasket on the cylinder block.

NOTE: There is discrimination mark “R" for right

bank and “L" for left bank on the cylinder head

gasket as shown in the illustration.

Do not reuse cylinder head gasket.

011RW005

b Align dowel pin hole to dowel pin on the cylinder

block.

c Tighten two bolts temporarily by hand to prevent

the cylinder head assembly from moving.

d Using 9–8511–4209–0 cylinder head bolt

wrench, tighten bolts in numerical order as

shown in the illustration to the specified torque.

Legend

(1) Cylinder Head

(2) Cylinder Head Bolt

(3) Camshaft

NOTE: Do not reuse cylinder head bolts.

Do not apply any lubricant to the cylinder head

bolts.

Torque :

Temporary : 29 N·m (3.0 kg·m/22 lb ft)

Final : 64 N·m (6.5 kg·m/47 lb ft)

014RW029

2. Install common chamber.

• Refer to installation procedure for Common

Chamber in this manual.

3. Install cylinder head cover RH.

• Refer to installation procedure for Cylinder Head

Cover RH in this manual.

4. Install cylinder head cover LH.

• Refer to installation procedure for Cylinder Head

Cover LH in this manual.

5. Install timing belt.

• Refer to installation procedure for Timing Belt in

this manual.

6. Install crankshaft pulley.

• Refer to installation procedure for Crankshaft

Pulley in this manual.

7. Install accelerator pedal cable.

VALVE STEM OIL CONTROLLER ,

VALVE SPRING AND VALVE GUIDE

REMOVAL

1. Disconnect battery ground cable.

2. Drain engine oil.

• Drain engine coolant.

3. Remove cylinder head assembly.

• Refer to removal procedure for Cylinder Head in

this manual.

4. Remove camshaft.

• Refer to removal procedure for Camshaft in this

manual.

5. Remove tappets with shim.

NOTE: Do not damage shim surface.

6. Remove valve springs using 5–8840–2446–0 valve

spring compressor and 5–8840–2547–0 valve

spring compressor adapter then remove upper

valve spring seat and lower seat.

014RW042

7. Remove oil controller using 5–8840–0623–0 oil

controller remover, remove each valve stem oil

controller.

8. Remove valve guide using 5–8840–2549–0 valve

guide replacer.

INSTALLATION

1. Install valve guide using 5–8840–2442–0 valve

guide installer.

2. Install oil controller using 5–8840–0624–0 oil

controller installer.

3. Install lower valve spring seat, valve spring and

upper valve spring seat then put split collars on the

upper spring seat, using 5–8840–2446–0 valve

spring compressor and 5–8840–2547–0 valve

spring compressor adapter to install the split collars.

4. Install tappet with shim.

5. Install camshaft assembly.

• Refer to installation procedure for Camshaft in

this manual.

6. Install cylinder head assembly.

• Refer to installation procedure for Cylinder Head

in this manual .

7. Fill engine oil until full level.

8. Fill engine coolant.

PISTON, PISTON RING AND CONNECTING ROD

REMOVAL

F06RW011

EndOFCallout

1. Remove cylinder head assembly.

• Refer to removal procedure for Cylinder Head in

this manual.

2. Remo ve cr an kc as e wit h Oi l Pan .

• Refer to removal procedure for Oil Pan and

Crankcase in this manual.

Legend

(1) Cylinder Head

(2) Crankcase with Oil Pan

(3) Oil Pipe

(4) Oil Strainer

(5) Oil Gallery

(6) Piston with Connecting Rod Assembly

3. Remove oil strainer fixing bolts, remove oil strainer

assembly with O-ring.

050RW002

EndOFCallout

4. Remove three fixing bolts, oil pipe with O-ring.

5. Remove eight fixing bolts, oil gallery.

6. Remove piston with connecting rod assembly,

before removing the bearing cap, remove carbon on

the top of cylinder bore and push piston with

connecting rod out from the top of cylinder bore.

INSTALLATION

1. Install piston with connecting rod assembly.

• Apply engine oil to cylinder bore, connecting rod

bearing and crank pin.

When installing the piston, its front mark must

face the engine front side.

• The bearing cap number must be the same as

connecting rod number.

• Apply engine oil to the thread and seating surface

of each nut.

• Tighten nuts to the specified torque.

Torque : 54 N·m (5.5 kg·m/40 lb ft)

• After tightening the nuts, make sure that the

crankshaft rotates smoothly.

NOTE: Do not apply engine oil to the bearing back

faces and connecting rod bearing fitting sur faces .

015RW003

EndOFCallout

2. Install oil gallery and tighten the bolts in two steps, in

the order shown in illustration.

Torque :

1st step : 29 N·m (3.0 kg·m/22 lb ft)

2nd step : 55°–65°

051RS009

3. Install oil pipe with O-ring.

Torque : 10 N·m (1.0 kg·m/87 lb in)

4. Install oil strainer assembly with O-ring.

Torque : 25 N·m (2.5 kg·m/18 lb ft)

Legend

(1) Oil Pump

(2) Oil Strainer

(3) Oil Gallery

(4) From Oil Filter

(5) To Oil Filter

Legend

(1) P is ton Fro nt Mar k

(2) Piston Grad e

(3) Connecting Rod Front Mark

5. Install crankcase with Oil Pan.

• Refer to installation procedure for Oil Pan and

Crankcase in this manual.

6. Install cylinder head assembly.

• Refer to installation procedure for Cylinder Head

in this manual.

CRANKSHAFT AND MAIN BEARINGS

REMOVAL

F06RY00023

EndOFCallout

1. Remove engine assembly.

• Refer to removal procedure for Engine Assembly

in this manual.

2. Remo ve tim ing belt.

• Refer to removal procedure for Timing Belt in thismanual.

3. Remove oil pan and crankcase.

• Refer to removal procedure for Oil Pan andCrankcase in this manual.

4. Remove oil pipe with O-ring.

5. Remove oil strainer assembly with O-ring.

6. Remove oil pump assembly.

Legend

(1) Engine Assembly

(2) Crankshaft Pulley

(3) Timing Belt Cover

(4) Timing Belt

(5) Crankcase with Oil Pan

(6) Oil Pipe

(7) Oil Strainer

(8) Oil Pump Assembly

(9) C yli nde r Bod y Side Bol t

(10) Oil Gallery

(11) Flywheel

(12) Rear Oil Seal Retainer

(13) Connecting Rod Cap

(14) Crankshaft Main Bearing Cap

(15) Crankshaft and Main Bearing

• Refer to removal procedure for Oil Pump in this

manual.

7. Remove cylinder body side bolts.

8. Remove oil gallery.

9. Remove flywheel.

10. Remove rear oil seal retainer.

• Refer to removal procedure for Rear Oil Seal in

this manual.

11. Remove connecting rod caps.

12. Remove crankshaft main bearing caps.

13. Remove crankshaft and main bearings.

INSTALLATION

1. Install crankshaft and main bearings.

• Install main bearing in the cylinder block and

main bearing cap respectively.

Apply new engine oil to upper and lower main

bearings.

NOTE:

• Do not apply engine oil to the bearing back faces.

• Make sure that main bearings are in correct

position.

• Install crankshaft with care.

• Apply engine oil to the thrust washer.

• Install thrust washer on No.3 journal.

• Oil grooves in thrust washer must face the

crankshaft.

015RS012

015R100033

2. Install crankshaft main bearing caps.

• Apply engine oil to the thread and seating surface

of each bearing cap fixing bolt.

NOTE:

• Do not apply engine oil to the bearing back faces.

• Install bearing caps in the order of numbers, starting

with cylinder block front side.

• Tighten main bearing fixing bolts to the specified

torque.

Torque : 39 N·m (4.0 kg·m/29 lb ft)

• After tightening the bolts, make sure that the

crankshaft rotates smoothly.

3. Install connecting rod caps.

• The cap number must be same as connecting rod

number.

• Apply engine oil to the thread and seating surface

of each nut.

• Tighten nuts to the specified tor que.

Torque : 54 N·m (5.5 kg·m/40 lb ft)

• After tightening the nuts, make sure that the

crankshaft rotates smoothly.

4. Install rear oil seal retainer.

• Remove oil on cylinder block and retainer fitting

surface.

• Apply sealant (TB1207B or equivalent) to retainer

fitting surface as shown in illustration.

• The oil seal retainer must be installed within 5

minutes after sealant application before the

sealant harde ns .

015RW002

EndOFCallout

• Apply engine oil to oil seal lip and align a dowel

pin hole in the cylinder block with that in the

retainer.

• Tighten retainer fixing bolts to the specified

torque.

Torque : 18 N·m (1.8 kg·m/13 lb ft)

015RW001

5. Install flywheel.

• Clean tapped holes in the crankshaft.

• Remove oil on crankshaft and flywheel fitting

surface.

NOTE:

• Do not reuse the bolts.

• Do not apply oil or thread lock to the bolts.

• Tighten fixing bolts to the specified torque.

Torque : 54 N·m (5.5 kg·m/40 lb ft)

015RS018

For manual transmission.

015RV015

For automatic transmission.

6. Install oil gallery.

• Clean contact surface of oil gallery and main

bearing ca p.

Apply engine oil to oil gallery fixing bolts and

tighten the bolts in two steps, in the order shown

in illustr ati on .

Legend

(1) Around Bolt Holes

(2) Around Dowel Pin

Torque :

1st step : 29 N·m (3.0 kg·m/22 lb ft)

2nd step : 55°–65°

7. Install cylinder body side bolts and tighten bolts in

order to the speci fi ed torque.

Torque : 39 N·m (4.0 kg·m/29 lb ft)

NOTE: Do not apply the oil to the bolts.

012RS007

8. Install oil pump assembly.

• Remove oil on cylinder block and oil pump

mounting su rfa ce .

• Apply sealant (TB1207B or equivalent) to the oil

pump mounting surface.

• The oi l pum p a ssembly m us t b e i ns talled wi thin 5

minutes after sealant application before the

sealant harde ns .

• Apply engine oil to oil seal lip.

• Install oil pump in the cylinder block and tighten

fixing bolts to the specified torque.

Torque : 25 N·m (2.5 kg·m/18 lb ft)

051RW002

EndOFCallout

051RW001

9. Install oil strainer with O-ring, tighten to the specified

torque.

Torque : 25 N·m (2.5 kg·m/18 lb ft)

10. Install o il pipe w ith O-ring, t ighten fixing bolts to the

specified torque.

Torque : 25 N·m (2.5 kg·m/18 lb ft)

11. Install crankcase.

• Remove oil on crankcase mounting surface and

dry the surfa ce .

• Properly apply a 4.5 mm (0.7 in) wide bead of

sealant (TB1207C or equivalent) to the

crankcase mounting surface. The bead must be

continuous.

Legend

(1) Around Bolt Holes

(2) Around Dowel Pin

• The crankcase must be installed within 5 minutes

after sealant application before the sealant

hardens.

• Tighten fixing bolts to the specified torque.

Torque : 10 N·m (1.0 kg·m/87 lb in)

013RW010

013RW004

12. Install oil pan

• Remove oil on oil pan mounting surface and dry

the surface.

• Properly apply a 4.5 mm (0.7 in) wide bead of

sealant (TB1207C or equivalent) to the oil pan

mounting surface. The bead must be continuous.

• The oil pan must be installed within 5 minutes

after sealant application to prevent premature

hardening of sealant.

• Tighten fixing bolts to the specified torque.

Torque : 25 N·m (2.5 kg·m/18 lb ft)

013RW003

013RW002

13. Install timing belt.

• Refer to installation procedure for Timing Belt in

this manual.

14. Install engine assembly.

• Refer to installation procedure for Engine in this

manual.

REAR OIL SEAL

REMOVAL

1. Remove transmission assembly.

• Refer to removal procedure for Transmission

section in this manual.

2. Remove flywheel.

3. Remove rear oil seal using a seal remover.

NOTE: Take care not to damage the crankshaft or

oil seal retainer when removing oil seal.

INSTALLATION

1. Apply engine oil to oil seal lip and install oil seal

using 5–8 840– 228 6–0 .

015RS017

2. Instal l flywheel.

• Clean tapped holes in the crankshaft.

• Remove oil on the crankshaft and flywheel

mounting su rfa ce .

• Tighten fixing bolts to the specified torque.

NOTE: Do not reuse the bolts and do not apply oil

or thread lock to the bolts.

Torque : 54 N·m (5.5 kg·m/40 lb ft)

015RS018

For manual transmission.

015RV015

For automatic transmission.

3. Install transmission.

• See Transmission section in this manual.

CAUTION: When assembling the engine and

transmission, confirm that dowels have been

mounted in the specified positions at the engine

side. Take care that dowel positions are different

between the manual transmission and the

automatic transmission.

Otherwise, the transmission may be damaged.

012RS009

ENGINE ASSEMBLY

REMOVAL

F06RY00016

1. Disconnect battery ground and positive cable.

2. Remove battery.

3. Make alignment mark on the engine hood and

hinges before removal in order to return the hood to

original position exactly.

4. Remove engine hood.

5. Drain radiator coolant.

6. Disconnect Ion sensing module harness

connectors, and manifold absolute pressure sensor

harness connectors from sensor on common

chamber.

7. Disconnect throttle position sensor harness

connectors from throttle body.

8. Disconnect air duct with air cleaner cover.

9. Remove air cleaner assembly.

10. Disconnect canister vacuum hose.

11. Disconnect vacuum booster hose.

12. Disconnect three engine harness connectors.

13. Disconnect harness connector to transmission (left

front side of engine compartment), disconnect shift

on the fly harness connector from front side of front

axle and remove transmission harness bracket from

engine left side.

14. Disconnect ground cable between engine and

frame.

15. Disconnect bonding cable connector on the back of

right dash panel.

16. Disconnect bonding cable terminal on the left bank.

17. Disconnect starter harness connector from starter.

18. Disconnect generator harness connector from

generator.

19. Disconnect coolant reserve tank hose from radiator.

20. Remove radiator upper and lower hoses.

21. Remove upper fan shroud.

22. Remove cooling fan assembly four fixing nuts, then

the cooling fan assembly.

23. Move drive belt tensioner to loose side using

wrench then remove drive belt.

24. Remove power steering pump fixing bolts, then

power steering pump. Place the power steering

pump along with piping on the body side.

25. Remove air conditioning compressor fixing bolts

from bracket and place the compressor along with

piping on the body side.

26. Remove four O2 sensor harness connectors (two

each bank) from exhaust front pipe.

27. Remove three exhaust pipe fixing nuts from each

bank.

28. Remove two exhaust pipe fixing nuts from each

exhaust pipe, then move exhaust pipe to rear side

of vehicle.

29. Remove flywheel dust covers.

30. Disconnect two heater hoses from engine.

31. Disconnect fuel hoses from right side of

transmission.

CAUTION: Plug fuel pipes on engine side and fuel

hoses from fuel tank.

32. Remove transmission assembly. Refer to

Transmission section in this manual.

33. Support the engine by engine hoist.

34. Remove t wo l eft s id e en gine m oun t fix i ng b olts from

engine mount on chassis side.

35. Remove two right side engine mount fixing bolts

from engine mount on chassis side.

36. Remove engine assembly.

INSTALLATION

CAUTION: When assembling the engine and

transmission, confirm that dowels have been

mounted in the specified positions at the engine

side. Take care that dowel positions are different

between the manual transmission and the

automatic transmission.

If the engine is assembled in the condition that the

dowels have not been mounted in the specified

positions, the transmission may be damaged the

transmission.

012RS009

1. Install engine assembly. Tighten engine mount fixing

bolts to frame to the specified torque.

Torque: 41 N·m (4.2 kg·m/30 lb ft)

2. Reconnect fuel hose to fuel pipe on engine.

3. Install transmission assembly. Refer to

Transmission section in this manual.

4. Reconnect two heater hoses to engine.

5. Install flywheel dust covers.

6. Install exhaust pipe and temporally tighten two

(each bank) rear exhaust flange nuts then tighten

three stud nuts (each bank) between exhaust

manifold and exhaust pipe, finally tighten rear side

nuts to the specified torque.

Torque:

Nuts: 43 N·m (4.4 kg·m/32 lb ft)

Stud nuts: 67 N·m (6.8 kg·m/49 lb ft)

150RX015

EndOFCallout

150RX014

EndOFCallout

7. Reconnect O2 sensor connector.

8. Install cooling fan assembly and tighten bolts/nuts to

the specified torque.

Torque : 22 N·m (2.2 kg·m/16 lb ft) for fan pulley

and fan bracke t.

Legend

(1) Exhaust Front Pipe RH

(2) O2 Sensor

Legend

(1) O2 Sensor

(2) Exhaust Front Pipe LH

Torque : 10 N·m (1.0 kg·m/87 lb in) for fan and

clutch ass embly.

9. Install air conditioner compressor to engine and

tighten to the specified torque.

Torque :

M8 bolts : 22 N·m (2.2 kg·m/16 lb ft)

M10 bolts : 43 N·m (4.4 kg·m/32 lb ft)

10. Install power steering pump, tighten fixing bolt to the

specified torque.

Torque :

M8 bolt s : 22N·m (2.2 kg·m/16 lb ft)

M10 bolts : 46 N·m (4.7 kg·m/34 lb ft)

11. Move drive belt tensioner to loose side using

wrench, then install drive belt to normal position.

850RW001

EndOFCallout

12. Install upper fan shroud.

13. Reconnect radiator upper and lower hoses.

14. Reconnect coolant reserve tank hose to radiator.

15. Reconnect generator harness connector.

16. Reconnect starter harness connector.

17. Reconnect bonding cable terminal on left bank

18. Reconnect bonding cable terminal on the back of

right dash panel.

19. Reconnect ground cable between engine and

chassis.

20. Reconnect harness connector to transmission and

install transmission harness bracket on engine left

side.

21. Reconnect three engine harness connectors.

22. Reconnect vacuum booster hose.

23. Reconnect canister vacuum hose.

24. Install air cleaner assembly.

25. Reconnect air duct.

26. Reconnect throttle position sensor harness

connector.

025R100010

EndOFCallout

27. Reconnect manifold absolute pressure sensor

harnes s co nnectors .

Legend

(1) Crankshaft Pulley

(2) Cooling Fan Pulley

(3) Tensioner

(4) Generator

(5) Air Conditioner Compressor

(6) Power Steering Oil Pump

(7) Id le Pu lley

(8) Drive Belt

Legend

(1) Throttle Position Sensor Connector

(2) T hr ott le Val ve Ass emb ly

28. Reconnect ion sensing module connectors as

shown in the illustration.

060RY00003

EndOFCallout

29. Install engine hood to the original position.

• Refer to installation procedure for Body section in

this manual.

Legend

(1) Green Connector

(2) Blue Connector

CYLINDER HEAD

CYLINDER HEAD AND ASSOCIATED PARTS

011RW008

EndOFCallout

DISASSEMBLY

NOTE:

• During disassembly, be sure that the valve train

components are kept together and identified so that

they can be reinstalled in their original locations.

• Before removing the cylinder head from the engine

and before disassembling the valve mechanism,

perform a compression test and note the results.

1. Remove camshaft drive gear pulley fixing bolt (3),

then pulley (4).

Legend

(1) Spark Plug

(2) Cylinder Head Bolt

(3) Camshaft Drive Gear Pulley Fixing Bolt

(4) Camsh aft Drive Gear Pulley

(5) Camshaft Bracket Fixing Bolt

(6) Camshaft Bracket

(7) Camshaft Exhaust

(8) Cam s haft Intake

(9) Retainer Fixing Bolt

(10) Retainer Assembly

(11) Tappet with Shim

(12) Split Collar

(13) Valve Spring and Spring Upper Seat

(14) Valve

2. Remove camshaft bracket fixing bolt (5), camshaft

bracket (6), then camshaft exhaust (7), and intake

side (8).

3. Remove the cylinder head assembly.

4. Remove tappet with shim (11).

5. Use the 5–8840–2446–0 valve spring compressor

and 5–8840–2547–0 valve spring compressor

adapter to remove the split collar (12), valve spring

with upper seat (13) and valve (14).

014RW042

6. Remove spark plug (1).

CAUTION: Do not remove the spark plugs when the

head and plugs are hot. Clean dirt and debris from

spark plug recess areas before removal.

CLEAN

Cylinder head

Carefully remove all varnish, soot and carbon from the

bare metal. Do not use a motorized wire brush on any

gasket sealing surface.

INSPECTION AND REPAIR

1. Cylinder head gasket and mating surfaces for leaks,

corrosion and blow–by. If the gasket has failed,

determine the cause.

– Insufficient torque on head bolts.

– Improper installation

– Loose or warped cylinder head

– Missing dowel pins

– Warped case surface

2. Cylinder head for cracks, especially between valve

seats and in the exhaust ports.

3. Cylinder head deck for corrosion, sand particles in

head and porosity.

CAUTION:

• Do not attempt to weld the cylinder head. Replace

it.

• Do not reuse cylinder head bolts.

4. Cylinder head deck, common chamber and exhaust

manifold mating surfaces for flatness. These

surfaces may be reconditioned by milling. If the

surfaces are “out of flat" by more than specification,

the surface should be ground to within

specifications. Replace the head if it requires

machining beyond the repairable limit.

Head surface and manifold surface

Standard: 0.05 mm (0.002 in) or less

Warpage limit: 0.2 mm (0.0079 in)

Maximum Repairable limit: 0.2 mm (0.0079 in)

Head height

Standard height : 133.2 mm (5.2441 in)

Warpage limit : 0.2 mm (0.0079 in)

Maximum Repairable limit : 133.0 mm (5.2362 in)

011RW019

5. Water jacket sealing plugs seating surfaces.

REASSEMBLY

1. Reassemble the valve, valve seat, valve spring and

split collars.

Refer to the reassembly procedure for valve spring,

oil controller, valve, valve guide in this manual.

2. Install the cylinder head assembly to cylinder block.

Refer to the installation procedure for cylinder head

in this manual.

3. Install the camshaft assembly.

Refer to the installation procedure for camshaft in

this manual.

4. Install the s park plug and tighte n all the spark plu gs

to specified torque.

Torque: 18 N·m (1.8 kg·m/13 lb ft)

VALVE SPRING, OIL CONTROLLER, VALVE, VALVE GUIDE

VALVE SPRING, OIL CONTROLLER, VALVE, VALVE GUIDE AND ASSOCIATED

PARTS

014RW039

EndOFCallout

DISASSEMBLY

1. Remove camshaft bracket fixing bolts (1).

2. Remo ve ca ms haft asse mbl y (intake).

3. Remo ve ca ms haft asse mbl y (Exhaus t si de).

4. Remo ve sh im (4 ) and tappet (5).

Legend

(1) Camshaft Bracket Fixing Bolts

(2) Camshaft Assembly Inlet

(3) Camshaft Assembly Exhaust

(4) Shim

(5) Tappet

(6) Split Collar

(7) Spring Upper Seat

(8) Valve Spring

(9) Oil Controller

(10) Spring Lower Seat

(11) Valve Guide

(12) Valve

5. Use 5–8840–2446–0 valve spring compressor and

5–8840–2547–0 valve spring compressor adapter

to remove split collar.

014RW042

6. Remove valve spring.

7. Remove valve.

8. Remove oil controller and spring lower seat.

9. Remove the valve guide using the 5–8840–2442–0

valve guide replacer.

INSPECTION AND REPAIR

Valve Spring

CAUTION: Visually inspect the valve springs and

replace them if damage or abnormal wear is

evident.

1. Measur e the free height of th e springs. The s prings

must be replaced if the free height is below the

specified limit.

Standard : 44.6 mm (1.7559 in)

Limit : 43.6 mm (1.7165 in)

014RS004

2. Measure the valve spring squareness with a steel

square and replace the valve springs if the

measured value exceeds the specified limit.

Limit : 2 mm (0.0787 in)

014RS005

3. Using a sprin g te st er to compres s th e sprin gs to the

installed height, measure the compressed spring

tension, and replace the springs if the measured

tension is below the specified limit.

At installed height: 35.0 mm (1.38 in)

Standard: 196 N (44 lb)

Limit: Less than 181 N (41 lb)

014RS006

Valve Guide

CAUTION: Take care not to damage the valve seat

contact surface, when removing carbon adhering to

the valve h ead. Carefully inspect the valv e stem for

scratchs or abnormal wear. If these conditions are

present, the valve and the valve guide must be

replaced as a set.

1. Measure the valve stem diameter with a

micrometer. If the valve stem diameter is less than

the specified limit, the valve and the valve guide

must be replaced as a set.

Diameter o f Valve Stem

Intake

Standard : 5.977 mm–5.959 mm

(0.2353 in–0.2346 in)

Limit : 5.90 mm (0.2323 in)

Exhaust

Standard : 5.952 mm–5.970 mm

(0.2343 in–0.2350 in)

Limit : 5.90 mm (0.2323 in)

014RS007

2. Measur e the ins ide diame ter of t he val ve guide with

a micrometer. Subtract the measured outer

diameter of the v alve ste m fr om the m eas ured inn er

diameter of the valve guide. If the value exceeds the

specified limit, the valve and the valve guide must

be replaced as a set.

Inside Diameter of the Valve Guide

Inlet clearance

Standard : 0.023 mm–0.056 mm

(0.0009 in–0.0002 in)

Limit : 0.20 mm (0.00787 in)

Exhaust clearance

Standard : 0.030 mm–0.063 mm

(0.0012 in–0.0025 in)

Limit : 0.20 mm (0.00787 in)

Valve Guide Replacemen t

1. Using Valve guide replacer: 5–8840–2442–0, drive

out the valve guide from the combustion chamber

side.

014RS008

2. Apply engine oil to the outside of the valve guide.

Using valve guide replacer 5–8840–2442–0, drive in

a new valve guide from the camshaft side, and

check the valve guide height.

Valve guide upper end height: 13.0 mm (0.5118 in)

(Measured from the cylinder head upper face)

014RW046

3. Check the clearance. If the clearance is less than

the specified value, ream the inside diameter of

valve guide. Using a sharp 6 mm reamer, rea m the

valve guide to obtain the specified clearance.

Valve Seat

1. Measure the protrusion of the valve stem when a

new valve is installed in the cylinder head. If the

protrusion of the valve stem exceeds the limit,

replace the valve seat insert or the cylinder head

assembly.

Protrusion of valve stem

Intake

Standard: 39.32 mm (1.5480 in)

Limit: 39.47 mm (1.5539 in)

Exhaust

Standard: 39.30 mm (1.5472 in)

Limit: 39.45 mm (1.5531 in)

014RW047

2. Measure the valve seat contact width. Make the

necessary corrections if the seat contact surface is

damaged or rough or if the contact width wear

exceeds the limi t.

Valve seat contact width

Standard: 1.1 mm (0.0433 in)

Limit: 1.7 mm (0.0669 in)

014RS011

Contact Surface Angle on Valve Seat on

Valve

1. Measure contact surface angle on valve seat.

2. If the measured value exceeds the limit, replace

valve, valve guide and valve seat as a set.

Valve contact surface angle: 45°

014RS012

Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert

surface.

2. Use a valve cutter to minimize scratches and other

rough areas. This will bring the contact width back to

the standard value. Remove only the scratches

and rough areas. Do not cut away too much. Take

care not to cut away unblemished areas of the valve

seat surface.

Valve seat angle degree: 90°

014R100036

3. Apply abrasive compound to the valve seat insert

surface.

4. Inse rt the valv e into the val v e guide .

5. Turn the valve while lapping it to fit the valve seat

insert.

6. Check that the valve contact width is correct.

7. Check that the valve seat insert surface is in contact

with the entyre circumference of the valve.

014RS014

Valve Seat Insert Replacement

1. Arc weld the rod at several points. Be careful not to

damage the aluminum section.

2. Allow the rod to cool for a few minutes. This will

cause the valve seat to shrink.

3. Strike the rod and pull it out.

014RS015

4. Carefully clean the valve seat press–fit section on

the cylinder head side.

5. Heat the press–fit section with steam or some other

means to cause expansion. Cool the valve seat with

dry ice or some other means.

6. Insert the press–fit section into the valve seat

horizontally.

Standard fitting interference: 0.14 mm–0.09 mm

(0.0055 in–0.0035 in)

7. After insertion, use a seat grinder to grind finish the

seating face. Carefully note the seating angle, the

contact width, and the depression.

8. Lap the valve and the seat.

REASSEMBLY

1. Install valve guide (1) to cylinder head. Apply engine

oil to the outside of the valve guide. Using valve

guide replacer 5–8840–2442–0, drive in a new

valve guide from the camsh aft si de.

2. Install oil controller (3) and spring lower seat (2).

Using oil controller replacer 5–8840–0623–0, drive

in a new oil controller.

014RW058

3. Install valve to valve guide. Before install valve

guide apply engine oil to the outside of the valve

stem.

4. Install valve spring to cylinder head. Attach the

valve spring to the lower spring seat. The painted

area of the valve spring should be facing downward.

014RS020

5. Install lower valve spring seat, valve spring and

upper valve spring seat then put split collars on the

upper spring seat, using the 5–8840–2446–0 valve

spring compressor and 5–8840–2547–0 valve

spring compressor adapter to install the split collars.

014RW042

6. Install tappet with shim.

7. Install camshaft assembly.

• Refer to installation procedure for Camshaft in

this manual.

VALVE CLEARANCE ADJUSTMENTS

NOTE: To adjust valve clearance, apply engine oil

to the cam as well as to the adjusting shim (2) with

the cylinder head built on the cylinder block, give a

few turns to the camshaft by means of timing pulley

tightening bolt, and measure valve clearance when

the nose of cam is just opposite to maximum cam

lift (1) as shown in illistration below.

014RW081

EndOFCallout

Valv e Clear ance Standard Value (co ld)

Intake: 0.28 mm (0.0110 in)

Exhaust: 0.3 mm (0.0118 in)

Selection of Adjusting Shim

Based on the above formula, the best suited shim

should be selected from 41 sorts of shim (differently

thick at 0.02mm (0.0008 in) intervals from 2.40mm

(0.094 5 in) through 3.2mm (0.126 0 in) thick). Install the

shim and check valve clearance.

Legend

(1) Cam

(2) Shim

(3) Tappet

Thickness of removed shim.

+ Valve clearance measurement.

– Standard valve clearance.

Thickness of shim to be selected.

Replacement of Shim

Let the cam push down the edge of tappet by using 5–

8840–2444–0 valve clearance adjusting tool and push

out the shim with a flat blade screw driver as shown in

illustrations below.

014RW082

014RW083

014RW084

CAMSHAFT

CAMSHAFT AND ASSOCIATED PARTS

014R100028

EndOFCallout

Legend

(1) Camshaft Bracket Fixing Bolt

(2) Camshaft Bracket

(3) Camshaft Assembly Intake

(4) Camshaft Assembly Exhaust

(5) Pulley Fixing Bolt

(6) Camshaft Drive Gear Pulley

(7) Retainer Fixing Bolt

(8) Retainer

(9) Cam s haft Driv e Gear

(10) Oil Seal

(11) O–ring

DISASSEMBLY

1. Remove fixing bolt (5) for camshaft drive gear pulley

using the 5–88 40– 244 7–0 unive r sal hold er.

014RW060

2. Remove twenty fixing bolts from inlet and exhaust

camshaft bracket on one side bank, then camshaft

brackets (2).

014RW027

3. R em o ve ca m s ha ft assembly (3 ), (4).

4. Remove three fixing bolts (7) from camshaft drive

gear retainer (8), then camshaft drive gear

assembly.

5. Use the snap ring pliers to remove the snap ring(1).

6. Remove the wave washer(2), sub gear(3) and

spring camshaft gear(4) from the camshaft

assembly(5).

014R100018

EndOFCallout

Legend

(1) Snap Ring

(2) Wave Washer

(3) Sub Gear

(4) Spring; Camshaft Gear

(5) C am s haft Assembly

INSPECTION AND REPAIR

1. Use a micrometer to measure the cam lobe height

and uneven wear. Replace the camshaft if either the

lobe height or the uneven wear exceeds the

specified limit.

Lobe height : 44.709 mm (1.7602 in)

Uneven wear : 0.05 mm (0.0020 in)

014RW043

2. Use a micr ometer to measur e the diameter and th e

uneven wear of the camshaft journals.

Replac e the camsha ft if the di ameter or the uneve n

wear exceeds the specified limit.

Journal Diameter

Standard : 25.972 mm–25.993 mm

(1.0225 in–1.0233 in)

Limit : 25.8 mm (1.0157 in)

Uneven wear : 0.05 mm (0.0020 in)

014RS023

3. Place the camshaft on V–blocks.

Slowly rotate the camshaft and mea sure the runout

with a dial indicator.

Replace the camshaft if the runout exceeds the

specified limit.

Runout

Limit : 0.1 mm (0.0039 in)

014RW044

4. Measure the camshaft journal oil clearance.

1. Measure the camshaft bracket housing inside

diameter.

NOTE: Tighten camshaft bracket (2) to specified

torque before measuring the camshaft bracket

inside diameter .

Torque : 10 N·m (1.0 kg·m/87 lb in)

014RW031

2. Subtract the camshaft outside diameter from the

camshaft bracket housing inside diameter.

Oil Clearance

Standard : 0.027 mm–0.078 mm

(0.0011 in–0.0031 in)

Limit : 0.11 mm (0.0043 in)

014RW037

5. Replace the cylinder head and/or camshaft if the

measured oil clearance exceeds the specified limit.

1. Carefully clean the camshaft journal, the

camshaft bracket, and the cylinder head.

2. Install camshaft assembly and camshaft

brackets (2), tighten twenty bolts (1) on one side

bank to the specified torque.

Torque: 10 N·m (1.0 kg·m/87 lb in)

014RW031

3. Measure the camshaft thrust clearance with a

dial indicator. Replace the camshaft and/or the

cylinder head if the camshaft thrust clearance

exceeds the specified limit.

Camshaft thrust Clearance

Standard : 0.03 mm–0.08 mm

(0.0012 in.–0.0031 in.)

Limit : 0.12 mm (0.0047 mm)

014RW035

REASSEMBLY

1. Install camshaft drive gear assembly and tighten

three bolts to specified torque.

Torque: 10 N·m (1.0 kg·m/87 lb in)

2. Install the spring ; camshaft gear(1) into the

camshaft assembly.

Ensure the clearance is between the right side of

the spring; camshaft gear (1) and the dowel pin (2).

014R100017

3. Align the dowel pin on the sub gear to the clearance

of the spring ; camshaft gear made in step 2 and

install the sub gear (3).

4. Install the wave washer (2). U se snap ring pliers to

install the snap ring (1).

014R100018

5. Tighten sub gear setting bolt.

a Use 5–8840–2443–0 gear spring lever to

pre-load the sub gear. Turn the sub gear in a

clockwise direction until the M5 bolt hole aligns

with the hole in the camshaft driven gear.

b Install the M5 bolt and tighten to a suitable

torque to prevent the sub gear from moving.

014RW041

6. Align the timing m ark on the r etain er and dowel pin

of the camshaft drive gear.

7. Install camshaft assembly and camshaft brackets,

tighten twenty bolts on one side bank to the

specified torque.

a Apply engine oil to camshaft journal and bearing

surface of camshaft bracket.

b Align timing mark on intake camshaft (one dot

for right bank, two dots for left bank) and

exhaust camshaft (one dot for right bank, two

dots for left bank) to timing mark on camshaft

drive gear (one dot).

014R100016

EndOFCallout

014R100025

EndOFCallout

Legend

(1) Alignment Mark on the Camshaft Gear

(2) Alignment Mark on the Camshaft Drive Gear

Legend

(1) Discrimination Mark for Right Bank Intake

Camshaft Ge ar

(2) Alignment Mark for Right Bank (One Dot)

(3) Camshaft Timing Gear for Right Bank Intake

014R100026

EndOFCallout

014R100027

EndOFCallout

014R100023

EndOFCallout

014R100024

EndOFCallout

Legend

(1) Alignment Mark for Left Bank (Two Dots)

(2) Discrimination Mark for Left Bank Intake

Camshaft Gear

(3) Camshaft Timing Gear for Left Bank Intake

Legend

(1) Discrimination Mark

LE : Left Bank Exhau st

RE : Right Bank Exhaust

(2) Alignment Mark

One Dot for Right Bank

Two Dots for Left Bank

(3) Camshaft Timing Gear for Exhaust

Legend

(1) Timing Mark on the Camshaft Drive Gear for

Right Bank Exhau st Cams ha ft

(2) Timing Mark on the Camshaft Drive Gear for

Right Bank Intake Camsha ft

(3) Dowel Pin

Legend

(1) Timing Mark on the Camshaft Drive Gear for

Left Bank Intake Camshaft

(2) Timing Mark on the Camshaft Drive Gear for

Left Bank Exhaust Camshaft

(3) Dowel Pin

c Tighten twenty bolts in numerical order on one

side bank as shown in the illustration.

Torque: 10 N·m (1.0 kg·m/87 lb in)

014RW031

8. If the oil seal requires replacement, use the 5–

8840–2445–0 to install the oil seal.

014RW034

9. If the camshaft end plug requires replacement, use

the 5–8840–2445–0 to install the camshaft end

plug.

014R100031

10. Tighten bolt for camshaft drive gear pulley to the

specified torque using the 5–8840–2447–0

univer s al hol der.

Torque: 98 N·m (10.0 kg·m/72 lb ft)

014RW060

CRANKSHAFT

CRANKSHAFT AND ASSOCIATED PARTS

013RW009

EndOFCallout

DISASSEMBLY

1. Remove cylinder head assembly (1). Refer to

“Cylinder Head" in this manual.

2. Remove crankcase with oil pan (2). Refer to “Oil

Pan and Crankcase" in this manual.

CAUTION: Take care not to damage or deform the

sealin g flang e surfa ce of crank case .

3. Remove oil pipe and O-ring (3).

4. Remove oil strainer and O-ring (4).

5. Remove oil pump assembly (5).

Legend

(1) Cylinder Head Assembly

(2) Crankcase with Oil Pan

(3) Oil Pipe and O-Ring

(4) Oil Strainer and O-Ring

(5) Oil Pump Assembly

(6) Cylinder Block Side Bolts

(7) Oil Gallery

(8) Piston and Connecting Rod Assembly

(9) Flywheel

(10) Rear Oil Seal Retainer and Oil Seal

(11) Main Bearing Cap

(12) Crankshaft

(13) Main Bearing Cap Fixing Bolts

(14) Oil Gallery Fixing Bolts

6. Remove crankcase side bolts (6).

7. Remove oil gallery (7).

8. Remove piston and connecting rod assembly (8).

Refer to “Piston, Piston Ring and Connecting Rod"

in this manual.

9. Remove flywheel (9).

10. Remove rear oil seal retainer (10).

11. Remove main bearing cap (11).

12. Remove crankshaft (12).

INSPECTION AND REPAIR

1. Crankshaft

Set the dial indicator as shown in the illustration and

measure the crankshaft thrust clearance. If the

thrus t c leara nc e ex ceed s the speci fi ed lim it, re pl ace

the thrust bearings as a set.

Thrust Clear ance

Standard : 0.06 mm–0.24 mm

(0.0024 in–0.0094 in)

Limit : 0.30 mm (0.0118 in)

015RS003

Main Bearing Clearance

1. Remove the bearing caps and measure the oil

clearance.

2. Remove the main bearing cap fixing bolts in the

sequence shown in the illustration.

Arrange the removed main bearing caps in the

cylinder number order.

Remove the main bearings.

015RS004

3. Remove the crankshaft.

Remove the main bearings.

4. Clean the upper and lower bearings as well as the

cranksh aft mai n jour na l.

5. Check the bearings for damage or excessive wear.

The bearings must be replaced as a set if damage

or excessive wear is discovered during inspection.

6. Set the upper bearings and the thrust washers to

their original positions.

Carefully install the crankshaft.

7. Set the lower bearings to the bearing cap original

position.

8. Apply plastigage to the crankshaft journal unit as

shown in the illustration.

NOTE: Do not set the plastigage on the oil hole.

015RS005

9. Ins tall ma in bea ring caps, oil g al ler y and cra nk ca se

bolts in the order shown, and tighten each bolt to the

specified torque.

NOTE: Do not apply engine oil to the crank case

side bolts.

Main bearing cap bolts.

Torque: 39 N·m (4.0 kg·m/29 lb ft)

Oil gallery fixing bolts.

Torque:

1st step: 29 N·m (3.0 kg·m/22 lb ft)

2nd step 55°∼ 65°

Crank case side bolts

Torque : 39 N·m (4.0 kg·m/29 lb ft)

NOTE: Do not allow the crankshaft to rotate.

015RS006

10. Remove the main bearing caps in the sequence

shown in the illustration.

015RS004

11. Meas ure the plas tigage width and d etermine th e oil

clearance. If the oil c le aranc e e xc eed s t he s pec if ie d

limit, replace the main bearings as a set and/or

replace the crankshaft.

Standard : 0.019 mm–0.043 mm

(0.0007 in–0.0017 in)

Limit : 0.08 mm (0.0031 in)

015RS008

12. Clean the plastigage from the bearings and the

crankshaft.

Remove the crankshaft and the bearings.

Crankshaft Inspection

Inspect the surface of the crankshaft journal and crank

pins for excessive wear and damage. Inspect the oil

seal fitting surfaces for excessive wear and damage.

Inspect the oil ports for obstructions.

INSPECTION AND REPAIR

1. Carefully set the crankshaft on the V–blocks. Slowly

rotate the crank shaft and measu re the runo ut. If the

crankshaft runout exceeds the specified limit, the

crankshaft must be replaced.

Runout : 0.04 mm (0.0016 in)

015RS007

2. Measur e th e diame t er and the u nev en w ear of m ain

journal and crank pin. If the crankshaft wear

exceeds the specified limit, crankshaft must be

replaced.

Main journal diameter : 63.918 mm–63.933 mm

(2.5165 in–2.5170 in)

Crank pin diameter : 53.922 mm–53.937 mm

(2.1229 in.–2.1235 in.)

Uneven wear limit : 0.005 mm (0.0002 in)

015RS009

Crankshaft Bearing Selection

When installing new crankshaft bearings or replacing

bearings, refer to the selection table below. Select and

install the new crankshaft bearings, paying close

attention to the cylinder block journal hole.

1. Diameter size mark for the cylinder block.

001R100001

2. Diameter size mark for the crankshaft.

The diameter size marks are stamped on the No.1

crankshaft balancer as shown in the illustration.

015R100034

EndOFCallout

NOTE: Take care to ensure the bearings are

positioned correctly.

015RS012

EndOFCallout

Legend

(1) Crankshaft No.1 Balancer

(2) Crankshaft Journal Grade

The grade number stamped 1,2,3,4 journal

from left to right

Legend

(1) Number 1 and 4 main bearing upper and lower

(2) Number 2 and 3 main bearing upper

(3) Number 2 and 3 main bearing lower

REASSEMBLY

1. Crankshaft

• Install the main bearings to the cylinder block and

the main bearing caps.

• Be sure that they are positioned correctly.

• Apply new engine oil to the upper and lower main

bearing faces.

NOTE : Do not apply engi ne oil to th e main bearing

back faces.

015RS012

• Carefully mount the crankshaft.

• Apply engine oil to the thrust washer.

• Assemble the thrust washer to the No.3 bearing

journal. The oil grooves must face the crankshaft.

015R100033

2. Rear oil seal

• Remove the oil from the cylinder block and the

retainer mounting surface.

Main

Bearing

Grade M ark

On Cylinder

Block

Main Bearing Bore

Diameter

mm (in)

Crank Shaft Main

Journal Diameter

mm (in)

Crankshaft

Bearing

Grad e Mark

Crankshaft

Bearing Size

Mark (collor

indicator)

Oil Clearance

(Reference)

mm (in)

168.994-69.000

(2.7163-2.7165)

63.918-63.925

(2.5165-2.5167) 2Blue

0.019–0.043

(0.0007–0.0017)

63.926-63.933

(2.5168-2.5170) 1Brown

268.987-68.993

(2.7160-2.7163)

63.918-63.925

(2.5165-2.5167) 2

63.926-63.933

(2.5168-2.5170) 1Green

368.980-68.986

(2.7157-2.7160)

63.918-63.925

(2.5165-2.5167) 2

63.926-63.933

(2.5168-2.5170) 1Yellow

• Apply sealant (TB–1207B or equivalent) to the

retainer mounting surface, following the pattern

shown in the illustration.

The retainer must be installed within 5 minutes

after sealant application befor the sealant

hardens.

015RW002

EndOFCallout

• Apply engine oil to the oil seal lip.

• Align the cylinder block dowel pin holes with the

rear retainer dowel pins.

• Tighten the rear retainer fixing bolts. New bolts

should be used when installing rear retainer.

Torque: 18 N·m (1.8 kg·m/13 lb ft)

NOTE: Be ver y ca refu l no t t o d ise nga ge t he oil seal

garter spring during installation of the rear retainer.

If the seal was removed from retainer for

replacement, apply engine oil to the oil seal lip and

install the oil seal using 5–8840–2286–0 oil seal

installer.

015RW001

015RS017

3. Flywheel

1. Thoroughly clean and remove the oil from the

threads of crankshaft.

2. R e mo ve th e oi l f ro m th e crankshaf t an d f l ywhe e l

mounting faces.

3. Mount the flywheel on the crankshaft and then

install the washer.

4. Hold the crankshaft to prevent from rotating then

install the bolts in the order shown to the

specified torque.

Torque: 54 N·m (5.5 kg·m/40 lb ft)

Legend

(1) Around Bolt Holes

(2) Around Dowel Pin

NOTE: Do not reuse the bolt and do not apply oil or

thread lock to the bolt.

015RS018

For manual transmission

015RV015

For automatic transmission

4. Piston and connecting rod assembly (8)

• Apply engine oil to the cylinder bores, the

conne cting rod bearings and the cran kshaft pins.

Check to see that the piston ring end gaps are

correctl y pos iti on ed.

015RX003

EndOFCallout

• Insert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor.

The front marks must be facing the front of the

engine.

• Match the numbered caps with the numbers on

the connec ting r ods. Al ign the punch ed m arks on

the conne cting ro ds and caps.

• Apply en gine oil to the thread s and seat ing faces

of the nuts.

• Tighten the nuts.

Torque: 54 N·m (5.5 kg·m/40 lb ft)

After tightening the cap nuts, check to see that

the cranks ha ft rotates smoothly.

Legend

(1) No.1 Compression Ring

(2) No.2 Compression Ring

(3) Oil Ring Side Rail Upper

(4) Oil Ring Side Rail Lower

(5) P is ton Fro nt Mar k

NOTE: Do not apply engine oil to the bearing back

faces.

015RS020

5. Install oil gallery (7) and tighten the bolts in 2 steps,

in the order shown.

1st step: 29 N·m (3.0 kg·m/22 lb ft)

2nd step: 55°∼ 65°

051RS009

6. Cylinder block side bolts

• Tighten all the bolts to the specified torque in the

order shown.

NOTE: Do not apply engine oil to the crank case

side bolts.

Torque: 39 N·m (4.0 kg·m/29 lb ft)

012RS001

7. Install oil pump assembly (5), refer to “Oil pump" in

this manual.

8. Install oil strainer and O-ring (4).

9. Install oil pipe and O-ring (3) and tighten the bolts.

Torque: 25 N·m (2.5 kg·m/18 lb ft)

10. Install crankcase with oil pan.

• Completely remove all residual sealant, lubricant

and moisture from the sealing surfaces. The

surfaces must be perfectly dry.

• Apply a correct width bead of sealant (TB—

1207C or its equivalent) to the contact surfaces of

the oil pan. There must be no gaps in the bead.

• The cra nkcase ass embly mus t be install ed within

5 minutes after sealant application to prevent

premature hardening of the sealant.

1. Tighten the bolts and nuts to the specified

torque.

Torque : 10 N·m (1.0 kg·m/87 lb in)

013RW010

EndOFCallout

11. Install cylinder head assembly, refer to “Cylinder

head" in this manual.

Legend

(1) Portion Between Bolt Holes

(2) Bolt Hole Portion

PISTON AND CONNECTING ROD

PISTON, CONNECTING ROD AND ASSOCIATE PARTS

015RW019

EndOFCallout

DISASSEMBLY

1. Remove cylinder head assembly (1). Refer to

“Cylinder Head Removal" in this manual.

2. Remove cylinder head gasket (2).

3. Remove crankcase with oil pan (3). Refer to“Oil Pan

and Crankcase" in this manual.

4. Remove oil pipe and O-ring (4).

5. Remove oil strainer and O-ring (5).

6. Remove oil gallery (6).

Legend

(1) Cylinder Head Assembly

(2) Cylinder Head Gasket

(3) Crankcase with Oil Pan

(4) Oil Pipe and O-Ring

(5) Oil Strainer and O-Ring

(6) Oil Gallery

(7) Piston and Connecting Rod Assembly

(8) P is ton Rin g

(9) Piston Pin

(10) Piston

(11) Connecting Rod

(12) Connecting Rod Cap

7. Remove connecting rod cap with connecting rod

lower bearing (12).

8. Remove piston and connecting rod assembly (7).

NOTE: Before removing piston and connecting rod

assembly, measure thrust clearance.

015RS031

• Remove any ridge or carbon build up from the top

end of the cylinder.

9. Remove the piston rings (8) with a piston ring

expander. Arrange the removed piston rings in the

cylinder number order.

015RS022

10. Remove the piston pin (9) using 5–8840–0551–0

piston pin service set and piston support with a

press.

NOTE: Keep the parts removed from each cylinder

separate. All parts must be reinstalled in their

original positions. Heating the connecting rod will

permit easy removal of the piston pin.

015RX001

EndOFCallout

11. Piston (10)

12. Connecting rod (11)

INSPECTION AND REPAIR

Pistons

Carefully clean away all the carbon adhering to the

piston head and the piston ring grooves.

NOTE: Never use a wire brush to clean the pistons.

Damage will result. Visually check each piston for

cracking, scoring, and other signs of excessive

wear. If any of the above conditions are found, the

piston must be replaced.

Legend

(1) Press Ram

(2) Piston

(3) Connecting Rod

(4) Piston Pin

Piston Diameter

1. Measure the piston outside diameter with

micrometer at the piston grading position and a right

angle to the piston pin.

Piston grading position (from piston head)

Piston grading position : 43.0 mm (1.6929 in)

015RV014

The size mark (1) for piston outside diameter is

represented as shown in illustration below.

Outside Diameter

Size Mark A : 93.360 mm–93.370 mm

(3.6756 in–3.6760 in)

Size Mark B : 93.371 mm–93.380 mm

(3.6760 in–3.6764 in)

Size Mark C : 93.381 mm–93.390 mm

(3.6764 in–3.6768 in)

015RX002

Measure the cylinder bore inside diameter (refer to

“Cylinder Block" in this manual).

012RS002

Piston Rings

Any worn or damaged part discovered during engine

overhaul must be replaced with a new one.

1. Ring end gap measurement

• Insert the piston ring into the bore.

• Push the ring by the piston, at a right angle to the

wall, into the point at which the cylinder bore

diameter is the smallest.

• Measure the ring end gap.

Compression Ring

1st ring

Standard: 0.300 mm–0.400 mm

(0.0118 in–0.0 157 in)

Limit: 1.0 mm (0.0394 in)

2nd ring

Standard: 0.450 mm–0.600 mm

(0.0177 in–0.0236 in)

Limit: 1.2 mm (0.0472 in)

Oil ring

Standard: 0.150 mm–0.450 mm

(0.0059 in–0.0177 in)

Limit: 1.05 mm (0.0413 in)

015RS026

• Positioning mark (1) is painted as shown in the

illustration.

Marked T : No.1 Compression ring

Marked T2 : No.2 Compression ring

015RS027

2. Measure the clearance between the piston ring

groove and the piston ring with a feeler gauge. If the

piston r ing gr oo ve / pi s ton r ing c l ear ance ex ce eds

the specified limit, the piston must be replaced.

Compression Ring Clearance

Standard : 0.016 mm–0.038 mm

(0.0006 in.–0.0015 in)

Limit : 0.15mm (0.0059 in)

015RS028

Piston Pin

NOTE: Do not reuse the old piston pin.

1. Use a micrometer to measure the new piston pin

outside diameter in both directions at three different

positions.

2. Measure the inside diameter of the connecting rod

small end. If the fitting interference between the

small end an d p in doe s not c onfo rm to the s pec if ied

value, the con nec ting ro d must be repla ce d.

Stan dard : 0.023 mm–0.038 mm (0.0009 in–0.0 015

in)

015RS029

3. Insert the new pin int o the pi ston an d rotate it. If th e

pin rotates smoothly with no backlash, the clearance

is normal. If there is backlash or roughness,

measure the clearance. If the clearance exceeds

the specified limit, the piston must be replaced.

Clearance

Standard : 0.010 mm–0.017 mm

(0.0004 in.–0.0007 in)

Limit : 0.040 mm (0.0016 in)

Connecting Rods

1. Check the connecting rod alignment If either the

bend or the twist exceeds the specified limit, the

connecting rod must be replaced.

Bend per 100 mm (3.937 in)

Limit: 0.15 (0.0059)

Twist per 100 mm (3.937 in)

Limit: 0.20 (0.0078)

015RS030

2. Measure the connecting rod thrust clearance. Use a

feeler gauge to m easure the thrust cle arance at th e

large end of the connecting rod If the clearance

excee ds the s pe ci fie d l imit, th e c onn ec tin g rod m us t

be replaced.

Standard : 0.16 mm–0.35 mm

(0.0063 in.–0.0138 in)

Limit : 0.40 mm (0.0157 in)

015RS031

3. Measure the oil clearance between the connecting

rod and the crankshaft.

1. Remove the connecting rod cap nuts and the

rod caps (12).

Arrange the removed rod caps in the cylinder

number order.

2. Clean the rod bearings and the crankshaft pins.

3. Carefully check the rod bearings. If even one

bearing is found to be damaged or badly worn,

the entyre bearing assembly must be replaced

as a set. Reinstall the bearings in their original

positions. Apply plastigage to the crank pin.

015RS032

4. Reinstall the rod caps (12) to their original

positions.

Tighten the rod cap nuts.

Torque: 54 N·m (5.5 kg·m/40 lb ft)

NOTE: Do not allow the crankshaft to rotate.

5. Remove the rod caps.

6. Measure the width of the plastigage and

determine the oil clearance. If the oil clearance

exceeds the limit, replace the rod bearing as a

set.

Standard : 0.019 mm–0.043 mm

(0.0007 in–0.0017 in)

Limit : 0.08 mm (0.003 in)

015RS008

7. Clean the plastigage from the bearings and the

crankshaft pins.

Con–rod Bearing Selection

Select and install the new connecting rod bearings,

paying close attention to the connecting rod big end

diameter size mark (1).

NOTE: Take care not to confuse the alignment mark

(2) and the size mark (1) during the installation

procedure.

015RS034

REASSEMBLY

1. Install connecting rod

2. Install piston

3. Instal l piston pin

• Apply a thin coat of engine oil to the piston pin.

Try to insert the piston pin into the piston pin hole

with normal finger pressure.

NOTE: When changing piston / connecting rod

combinations, do not change the piston / piston pin

combination and do not reuse the old piston pin.

Connecting

Rod Bearing

Grade Mark

Connecting

Rod

Big end Bore

Diameter Crankshaft Pin

Diameter

Connecting Rod

Bearing Thickness

(Reference)

Color of

Size Ma rk Oil Clearance

(Reference)

A56.994-57.000

(2.2439-2.2441) 53.922-53.937

(2.1229-2.1235)

1.512-1.516

(0.0595-0.0597) Yellow 0.025-0.054

(0.0010-0.0021)

B56.988-56.994

(2.2436-2.2439) 1.508-1.512

(0.0594-0.0595) Green 0.027-0.056

(0.0011-0.0022)

C56.982-56.988

(2.2434-2.2436) 1.504-1.508

(0.0592-0.0594) Pink 0.029-0.058

(0.0011-0.0023)

• Attach the piston to the connecting rod with the

piston front mark and the connecting rod front

mark on the same side.

015RS036

• With 5–8840–0551–0 Piston pin service set and a

press, pres s fit the pist on pin.

NOTE: Heat the connecting rod small end to a

suitable temperature to ensure smooth installation.

015RX001

EndOFCallout

4. Install piston ring with the piston ring expander.

The compression ring must be set with the T mark

(1) facing up.

Marked T : No.1 Compression ring

Marked T2 : No.2 Compression ring

015RS027

• Install piston rings in the following sequence.

1Oil ring

1 Expander ring

2 Upper side rail

3 Lower side rail

2 2nd compr es sion ring

3 1st compression ring

• The compression rings must be set with the T or

T2 mark facing up.

Marked T : No.1 Compression ring

Marked T2 : No.2 Compression ring

• After installation, apply engine oil to the entyre

circumference of the piston rings. Check to see

that all the rings rotate smoothly.

015RS038

Legend

(1) Press Ram

(2) Piston

(3) Connecting Rod

(4) Piston Pin

5. Install piston and connecting rod assembly.

• Insert the bearings into the connecting rods and

caps. Apply new engine oil to the bearing faces

and nuts.

• Tighten the connecting rod cap nuts

Torque : 54 N·m (5.5 kg·m/40 lb ft)

NOTE: Do not apply engine oil to the bearing back

faces.

6. Oil gallery, refer to “Crankshaft and main bearing" in

this manual.

7. Oil strainer and O-ring.

8. Oil pipe and O-ring.

9. Install crankcase with oil pan, refer to “Oil pan and

Crankcase" in this manual.

10. Install cylinder head gasket.

11. Install Cylinder head assembly.

• Refer to “Cylinder head" in this manual.

CYLINDER BLOCK

CYLINDER BLOCK AND ASSOCIATED PARTS

012RW010

EndOFCallout

DISASSEMBLY

1. Remove cylinder head assembly.

2. Remove cylinder head gasket.

3. Remo ve cr an kcas e with oil pan.

4. Remove oil pipe and O-ring.

5. Remove oil strainer and O-ring.

6. Remove oil pump assembly.

7. Remove crankcase side bol ts.

Legend

(1) Cylinder Head Assembly

(2) Cylinder Head Gasket

(3) Crankcase with Oil Pan

(4) Oil Pipe and O-Ring

(5) Oil Strainer and O-Ring

(6) Oil Pump Assembly

(7) Cylinder Block Side Bolts

(8) Oil Gallery

(9) Piston and Connecting Rod Assembly

(10) Flywheel

(11) Rear Oil Seal Retainer Assembly

(12) Main Bearing Cap

(13) Crankshaft

(14) Cy li nde r Bloc k

Legend

8. Remove oil gallery.

9. Remove piston and connecting rod assembly.

10. Remove flywheel.

11. Remove rear oil seal retainer assembly.

12. Remove main bearing cap.

13. Remove crankshaft.

14. Remove cylinder block.

INSPECTION AND REPAIR

1. Remove the cylinder head gasket and any other

material adhering to the upper surface of the

cylinder block. Be very careful not to allow any

material to accidentally drop into the cylinder block.

Be very careful not to scratch the cylinder block.

2. Carefully remove the oil pump, rear oil seal retainer,

and crankcase assembly installation surface seal.

3. Wipe the cylinder block clean.

4. Visually inspect the cylinder block. If necessary, use

a flaw detector to perform a dye penetrate and

hydraulic (or air pressure) test. If cracking or other

damage is discovered, the cylinder block must

either be repaired or replaced.

Flatness

1. Using a straight–edge and feeler gauge, check that

the upper surface of the cylinder block is not

warped.

CAUTION: Be very careful not to allow any material

to accidentally drop into the upper surface of the

cylinder block. Be very careful not to scratch the

upper surface of the cylinder block.

2. The cylinder block must be reground or replaced if

the warpage exceeds the limit.

Warpage

Limit : 0.15 mm (0.0059 in)

Maximum repairable limit: 0.15 mm (0.0059 in)

012RS004

Cylinder Bore

Use a cylinder gauge to measure the cylinder bore

diameter in both the axial and thrust directions. Each

measurement should be made at six points.

CAUTION: Be very careful not to allow any material

to accidentally drop into the upper surface of the

cylinder block. Be very careful not to scratch the

upper surface of the cylinder block.

Cylinder Bore Inside Diameter

Limit : 93.530 (3.6823)

If the measurement exceed the specified limit, the

cylinder block must be replaced.

Diameter

Grade A : 93.400 mm–93.410 mm

(3.6772 in–3.6776 in)

Grade B : 93.411 mm–93.420 mm

(3.6776 in–3.6779 in)

Grade C : 93.421 mm–93.430 mm

(3.6780 in–3.6783 in)

012RS005

NOTE: For information on piston diameter, please

refer to the section "Inspection of the Piston and

Connecting Rod Assembly" in this manual.

• The cylinder bore "Grade" mark (1) is stamped at the

position illustrated.

012RS006

REASSEMBLY

1. Install cylinder block.

2. Install crankshaft.

• Install the main bearings to the cylinder block and

the main bearing caps.

• Be sure that they are positioned correctly.

• Apply new engine oil to the upper and lower main

bearing faces.

NOTE: Do not apply engine oil to the bearing back

faces.

015RS012

EndOFCallout

• Carefully mount the crankshaft.

• Apply engine oil to the thrust washer.

• Assemble th e thrust washer to the No. 3 bearing

journal. The oil grooves must face the crankshaft.

015R100033

3. Install rear oil seal retainer.

• Remove oil on cylinder block and retainer fitting

surface.

• Apply sealant (TB1207B or equivalent) to retainer

fitting surface as shown in illustration.

Legend

(1) Number 1 and 4 main bearing upper and lower.

(2) Number 2 and 3 main bearing upper.

(3) Number 2 and 3 main bearing lower.

• The oil seal retainer must be installed within 5

minutes after sealant application before the

sealant harde ns .

015RW002

EndOFCallout

• Apply engine oil to oil seal lip and align a dowel

pin hole in the cylinder block with that in the

retainer.

• Tighten retainer fixing bolts to the specified

torque.

Torque: 25 N·m (2.5 kg·m/18 lb ft)

015RW001

4. Instal l flywheel

• Thoroughly clean and remove the oil from the

threads of crankshaft.

• Remove the oil from the crankshaft and flywheel

mounting fac es.

• Mount the flywheel on the crankshaft and then

install the washer.

• Holding the crankshaft stationary, tighten the

flywheel bolts in the order shown.

Torque: 54 N·m (5.5 kg·m/40 lb ft)

NOTE: Do not reuse the bolts and do not apply oil

or thread lock to the bolts.

015RS018

5. Install piston and connecting rod assembly.

• Apply engine oil to the cylinder bores, the

connecting rod bearings and the crankshaft pins.

NOTE: Do not apply engine oil to the bearing back

faces.

Legend

(1) Around Bolt Holes

(2) Around Dowel Pin

• Check to see that the piston ring end gaps are

correctly positioned.

015RX003

EndOFCallout

• Insert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor.

• The front marks (1) must be facing the front of the

engine.

015RS020

6. Install oil gallery and tighten the bolts in 2 steps in

the order shown.

1st step : 29 N·m (3.0 kg·m/22 lb ft)

2nd step : 55°∼ 65°

012RS007

7. Install cylinder block side bolts (1) and tighten

crankcase bolts in sequence shown in the

illustration.

Torque : 39 N·m (4.0 kg·m/29 lb ft)

012RW005

8. Install oil pump assembly. Refer to “Oil Pump" in this

manual.

9. Install oil strainer and O-ring.

10. Install oil pipe and O-ring.

11. Install crankcase with oil pan.

• Completely remove all residual sealant, lubricant

and moisture from the sealing surfaces. The

surfaces must be perfectly dry.

Legend

(1) No.1 Compression Ring

(2) No.2 Compression Ring

(3) Oil Ring Side Rail Upper

(4) Oil Ring Side Rail Lower

(5) Piston Front Mark

• Apply a correct width bead of sealant (TB– 1207C

or its equivalent) to the contact surfaces of the

crankcase. There must be no gaps in the bead.

• The oil pan must be installed within 5 minutes

after sealant application to prevent premature

hardening of sealant.

• Tighten the bolts and nuts to the specified torque.

Torque : 10 N·m (1.0 kg·m/87 lb in)

013RW010

EndOFCallout

12. Install cylinder head gasket.

13. Install cylinder head assembly. Refer to “Cylinder

Head" in this manual.

Legend

(1) Portion Between Both Holes

(2) Bolt Hole Portions

MAIN DATA AND SPECIFICATION

General Specification

Item Specifications

6VD1

Engine type, number of cylinders and arrangement Water cooled, four cycle V6

Form of combustion chamber Pent roof type

Valve mechanism 4-Cams, 4-Valves, DOHC Gear & Belt Drive

Cylinde r liner type Cast in cyli nde r driv e

Total piston displacement 3165 cc

Cylinder bore x stroke 93.4mm x 77.0mm

(3.6772 in x 3.0315 in)

Compression ratio 9.1 : 1

Compression pressure at 300rpm 1373 kpa (14.0 kg/cm2/199 psi)

Engine idling speed rpm Non adjustable (750)

Valve clearance Intake: 0.28 mm (0.11 in)

Exhaust: 0.30mm (0.12in)

Oil capacity 5.3 liters

Ignition timing Non adjustable

16° BTDC at idle rpm

Spark plug K16PR -P11, PK16P R11, RC10PYP4

Plug gap 1.0 mm–1.1 mm(0.0394 in – 0.0433 in)

Torque Specifications

Ignition coil, Spark plug, Crankshaft Position sensor and Undercover N·m (kg·m/lbft)

060R100115

Cylinder head cover, Cylinder head, Camshaft bearing cap, Common chamber,

EGR valve & pipe, Ion Sensing module N·m (kg·m/lbft)

E06R100006

Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, Timing belt

cover, Oil pump, Oil gallery, Oil strainer and Water pump N·m (kg·m/lbft)

E06RW039

Connecting rod and Water pump N·m (kg·m/lbft)

E06RW042

Engine mount N·m (kg·m/lbft)

E06RW040

SPECIAL TOOL

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–0011–0

(J–21687–02)

Remover; tie rod end

5–8840–2441–0

Set Number of Valve

Compressor

5–8840–2446–0

(J–8062)

Compressor; Valve

Spring (1)

5–8840–2547–0

(J–42898)

Adapter; Compressor

Valve Spring (2)

5–8840–0623–0

(J–37281)

Remover; Oil co ntroller

5–8840–0624–0

(J–38537)

Installer; Oi l control ler

5–8840–2445–0

(J–42985)

Installer; Camshaft oil

seal

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–2545–0

(J–39206)

Installer; Pilot bearing

5–8840–0133–0

(J–8614–01)

Holder; Crankshaft

5–8840–2153–0

(J–37228)

Seal cut ter

5–8840–2286–0

(J–39201)

Installer; Real oil seal

9–8511–4209–0

(J–24239–1)

Cylinder head bolt

wrench

5–8840–2442–0

(J–42899)

Replacer; Valve guide

(set) (1,2)

5–8840–2548–0

(J–42687)

Installer; Valve guide (1)

5–8840–2549–0

(J–37985–1)

Remover; Valve guide (2)

5–8840–2444–0

(J–42689)

Adjusting Tool: Valve

clearance

5–8840–2443–0

(J–42686)

Lever; Gear spring

5–8840–2447–0

(J–43041)

Holder; Universal