SECTION 6A - ENGINE MECHANICAL

Service Precaution

General Description

Engine Diagnosis

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

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

Techline

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

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.

ISUZU will call out those fasteners that require a

replacement after removal. ISUZU 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 (ten thousandths of an inch). 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 friction areas is part of the

repair procedure. This is considered standard shop

practice even if not specifically stated.

DA liberal coating of engine oil should be applied to all

friction areas during assembly to protect and lubricate

the surfaces on initial operation.

DWhenever valve train components, pistons, piston

rings, connecting rods, rod bearings, and crankshaft

journal bearings are removed for service, they should

be retained in order.

DAt the time of installation, they should be installed in

the same locations and with the same mating

surfaces as when removed.

DBattery 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.

DThe 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:

DWhen 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

strainer, jacking against the oil pan may cause

damage to the oil pick–up unit.

DThe 12–volt electrical system is capable of damaging

circuits. When performing any work where electrical

terminals could possibly be grounded, the ground

cable of the battery should be disconnected at the

battery.

DAny 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 skint. 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 in the center. The intake and exhaust 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.

Intake 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 chromium steel is offset 1mm toward the thrust 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 crankshaft is made of Ductile cast–iron. Pins 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 crankshaft is fed through full–flow oil filter 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 juornals on the connecting rod

for piston cleaning. The oil pan flange is dealed with liquid

packing 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.

Condition Possible cause Correction

Headlights go out or dim

considerably

Battery run down or under charged Recharge or replace battery

cons

era

yTerminals poorly connected Clean battery posts and terminals

and connect properly

Starting motor coil circuit shorted Overhaul or replace

Starting motor defective Overhaul or replace

2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start

Spark Test

Disconnect an igniton 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 igniton coil is

broken while the engine is running.

Condition Possible cause Correction

Spark jumps across gap Spark plug defective Clean, adjust spark gap or replace

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 incorrect Adjust

Engine lacks compression Refer to item 4 (Engine lacks

compression)

No sparking takes place 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 replace

3. Trouble In Fuel System

Condition Possible cause Correction

Starting motor turns over and spark

occurs but engine does not start

Fuel tank empty Fill

occurs

eng

oes no

.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 replace

Multiport Fuel Injection System faulty Refer to “Electronic Fuel Injection”

section

4. Engine Lacks Compression

Condition Possible cause Correction

Engine lacks compression Spark plug loosely fitted or spark

plug gasket defective Tighten to specified torque or replace

gasket

Valve timing incorrect Adjust

Cylinder head gasket defective Replace gasket

Valve incorrectly seated Lap valve

Valve stem seized Replace valve and valve guide

Valve spring weakened or broken Replace

Cylinder or piston rings worn Overhaul engine

Piston ring seized Overhaul engine.

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 the starter

engaged until the compression gage needle reaches

the maximum level. Note the reading.

9.Repeat the test with each cylinder.

If the compression pressure obtained falls below the

limit, engine overhaul is necessary.

Limit; 1000 kPa (145 psi)

Rough Engine Idling or Engine Stalling

Condition Possible cause Correction

Trouble in fuel injection system Idle air control valve defective Replace

Throttle shutting off incomplete Correct or replace

Throttle position sensor circuit open

or shorted Correct or replace

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 replace

MAF Sensor defective Replace

Manifold Absolute Pressure (MAP)

Sensor circuit open or poor

connections

Correct or replace

MAP Sensor defective Replace

Engine Coolant Temperature (ECT)

Sensor circuit open or poor

connections

Correct or replace

ECT Sensor defective Replace

Intake Air Temperature (IAT) sensor

circuit open or poor connections Correct or replace

IAT sensor defective Replace

Knock Sensor (KS) cable broken or

poor connections Correct or replace

KS defective Replace

KS Module circuits open or ground Correct or replace

KS Module defective Replace

Vehicle Speed Sensor (VSS) circuit

open or shorted Correct or replace

VSS defective Replace

Trouble in emission control system Powertrain Control Module defective Replace

Exhaust Gas Recirculation (EGR)

Valve circuit open or poor

connections

Correct or replace

EGR Valve faulty Replace

Canister purge valve circuit open or

poor connections Correct or replace

Canister purge valve defective Replace

Evaporative Emission Canister

Purge control valve defective Replace

Trouble in ignition system Refer to “Hard Start”

Condition CorrectionPossible cause

Others Engine lacks compression Refer to “Hard Start”

Valve incorrectly seated Lap valve

Air Cleaner Filter clogged Replace filter element

Valve timing incorrect Readjust

Idle air control valve broken Replace

Fast idle solenoid defective Replace

Positive Crankcase Ventilation valve

defective or clogged Replace

Rough Engine Running

Condition Possible cause Correction

Engine misfires periodically Ignition coil layer shorted Replace

Spark plugs fouling Clean or install hotter type plug

Spark plug(s) insulator nose leaking Replace

Fuel injector(s) defective Replace

Powertrain control module faulty Replace

Engine knocks periodically Spark plugs running too hot Install colder type spark plugs

Powertrain control module faulty Replace

Engine lacks power Spark plugs fouled Clean

Fuel injectors defective Replace

Mass Air flow Sensor or Intake

Airflow Sensor circuit defective Correct or replace

Manifold Absolute Pressure (MAP)

Sensor or Manifold Absolute

Pressure Sensor circuit defective

Correct or replace

Engine Coolant Temperature (ECT)

Sensor or ECT Sensor circuit

defective

Correct or replace

Powertrain Control Module faulty Replace

Intake Air Temperature (IAT) Sensor

or IAT Sensor circuit defective Correct or replace

Throttle Position Sensor (TPS) or

TPS circuit defective Correct or replace

Knock Sensor (KS) or KS circuits

defective Correct or replace

KS Module or KS Module circuits

defective Correct or replace

Hesitation

Condition Possible cause Correction

Hesitation on acceleration Throttle Position Sensor (TPS)

adjustment incorrect Replace throttle valve assembly

TPS circuit open or shorted Correct or replace

Excessive play in accelerator linkage Adjust or replace

Mass Air flow (MAF) Sensor circuit

open or poor connections Correct or replace

MAF Sensor defective Replace

Manifold Absolute Pressure (MAP)

Sensor circuit open or shorted Correct or replace

MAP Sensor defective Replace

Intake Air Temperature (IAT) Sensor

circuit open or shorted Correct or replace

Knock Sensor (KS) Circuit open or

poor connections Correct or replace

KS defective Replace

KS Module circuits open or shorted Correct or replace

KS Module defective Replace

IAT Sensor defective Replace

Hesitation at high speeds Fuel tank strainer clogged Clean or replace

(Fuel pressure too low) Fuel pipe clogged Clean or replace

Fuel filter clogged Replace

Defective fuel pump system Check and replace

Fuel Pressure Control Valve leaking Replace

Hesitation at high speeds

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

Multiport Fuel Injection System

shorted or open

Check and correct or replace

Fuel Injector defective Replace

Cable of Multiport Fuel Injection

System circuit open or poor

connections

Correct or replace

Condition CorrectionPossible cause

Hesitation at high speeds Powertrain Control Module defective Replace

Throttle Position Sensor (TPS) cable

broken or poor connections Correct or replace

TPS defective Replace

Engine Coolant Temperature (ECT)

Sensor circuit open or shorted Correct or replace

ECT Sensor defective Replace

Mass Air flow (MAF) Sensor circuit

open or poor connections Correct or replace

MAF Sensor defective Replace

MAP Sensor cable broken or poor

connections Correct or replace

MAP Sensor defective Replace

IAT Sensor circuit open or poor

connections Correct or replace

IAT Sensor defective Replace

KS circuit open or poor connections Correct or replace

KS defective Replace

KS Module circuit open or shorted Correct or replace

KS 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

Engine Lacks Power

Condition Possible cause Correction

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 replace

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 Sensor not working

normally Replace

Manifold Absolute Pressure Sensor

not working normally Replace

Intake Air Temperature Sensor not

working normally Replace

Engine Coolant Temperature (ECT)

Sensor circuit open or shorted Correct or replace

ECT 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

Ignition failure ———— Refer to Hard Start Troubleshooting

Guide

Heat range of spark plug inadequate Install spark plugs of adequate heat

range

Ignition coil defective Replace

Condition CorrectionPossible cause

Engine overheating Level of Engine Coolant too low Replenish

Fan clutch defective Replace

Incorrect fan installed Replace

Thermostat defective Replace

Engine Coolant pump defective Correct or replace

Radiator clogged Clean or replace

Radiator filler cap defective Replace

Level of oil in engine crankcase too

low or wrong engine oil Change or replenish

Resistance in exhaust system

increased Clean exhaust system or replace

defective parts

Throttle Position Sensor (TPS)

adjustment incorrect Replace with Throttle Valve ASM

TPS circuit open or shorted Correct or replace

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 Tire inflation pressure abnormal Adjust to recommended pressures

Brake drag Adjust

Clutch slipping Adjust or replace

Level of oil in engine crankcase too

high Correct level of engine oil

Exhaust Gas Recirculation Valve

defective Replace

Engine Noisy

Abnormal engine noise often consists of various noises

originating in rotating parts, sliding parts and other mov- ing parts of the engine. It is, therefore, advisable to locate

the source of noise systematically.

Condition Possible cause Correction

Noise from crank journals or from

crank bearings

(Faulty crank journals and crank

Oil clearance increased due to worn

crank journals or crank bearings Replace crank bearings and

crankshaft or regrind crankshaft and

install the undersize bearing

bearings usually make dull noise that

becomes more evident when

accelerating)

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

Troubleshooting Procedure

Short out each spark plug in sequence using insulated

spark plug wire removers. Locate cylinder with defective bearing by listening for abnormal noise that stops when

spark plug is shorted out.

Condition Possible cause Correction

Noise from connecting rods or from

connecting rod bearings

(Faulty connecting rods or

Bearing or crankshaft pin worn Replace connecting rod bearings

and crankshaft or regrind crankshaft

pin and install the undersize bearing

connecting rod bearings usually

make an abnormal noise slightly

higher than the crank bearing noise,

which becomes more evident when

Crankpin out of round Replace connecting rod bearings

and crankshaft or regrind crankshaft

pin and install the undersize bearing

which

becomes

evident

when

engine is accelerated) 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

Troubleshooting Procedure

Abnormal noise stops when the spark plug on the cylinder

with defective part is shorted out.

Condition Possible cause Correction

Piston and cylinder noise

(Faulty piston or cylinder usually

k bid hil

Piston clearance increased due to

cylinder wear Replace piston and cylinder body

es a com

mec

thumping noise which increases Piston seized Replace piston and cylinder body

when engine is suddenly accelerated

but diminishes

raduall

as the Piston ring broken Replace piston and cylinder body

but

diminishes

gradually

the

engine warms up) Piston defective Replace pistons and others

Troubleshooting Procedure

Short out each spark plug and listen for change in engine

noise.

Condition Possible cause Correction

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

Troubleshooting Procedure

The slapping sound stops when spark plug on bad cylin-

der is shorted out.

Condition Possible cause Correction

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

pulley or replace timing belt

Tensioner bearing defective Replace

Timing belt defective Replace

Timing pulley defective Replace

Timing belt comes in contact with

timing cover Replace timing belt and timing cover

Valve noise Valve clearance incorrect Replace adjusting shim

Valve and valve guide seized Replace valve and valve guide

Valve spring broken or weakened Replace

Valve seat off–positioned 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”

Others Water pump defective Replace

Drive belt slipping Replace auto tentioner or drive belt

Abnormal Combustion

Condition Possible cause Correction

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 replace

MAF Sensor defective Replace

Manifold Absolute Pressure (MAP)

Sensor circuit open or shorted Correct or replace

MAP Sensor defective Replace

Engine Coolant Temperature (ECT)

Sensor circuit open or shorted Correct or replace

ECT Sensor defective Replace

Throttle Position Sensor (TPS)

adjustment incorrect Readjust

TPS defective Replace

TPS connector poor connections Reconnect

Vehicle Speed Sensor (VSS) cable

poor connections or defective Correct or replace

VSS loosely fixed Fix tightly

VSS in wrong contact or defective Replace

Powertrain Control Module cable

poor connections or defective Correct or replace

Trouble in emission control system Heated Oxygen (O2) Sensor circuit

open Correct or replace

O2 Sensor defective Replace

Signal vacuum hose loosely fitted or

defective Correct or replace

Exhaust Gas Recirculation (EGR)

Valve circuit open or shorted Correct or replace

EGR Valve defective Replace

Engine Coolant Temperature (ECT)

Sensor circuit open or shorted Correct or replace

Canister Purge Valve circuit open or

shorted Correct or replace

Canister Purge Valve defective Replace

ECT Sensor defective Replace

Positive Crankcase Ventilation

(PCV) valve and hose clogged Correct or replace

Evaporator system Refer to Section 6E

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

Condition CorrectionPossible cause

Trouble in cylinder head parts Carbon deposits in combustion

chamber Remove carbon

Carbon deposit on valve, valve seat

and valve guide Remove carbon

Engine Oil Consumption Excessive

Condition Possible cause Correction

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 cooler adapter cracked Replace

Oil cooler center bolt loose Retighten

Oil cooler O–ring broken Replace

Oil cooler piping loose or broken Retighten or replace

Oil filter adapter cracked Replace

Oil filter attaching bolt loose or rubber

gasket broken Retighten or replace oil filter

Oil cooler broken Replace

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

Positive Crankcase V entilation V alve

clogged Clean

Engine/Transmission coupling failed Replace oil seal

Oil leaking into combustion

chambers due to

oor seal in valve

Valve stem oil seal defective Replace

chambers

due

oor

seal

valve

system Valve stem or valve guide worn Replace valve and valve guide

Oil leaking into combustion

chambers due to poor seal in cylinder

Cylinders and pistons worn

excessively Replace cylinder body assembly and

pistons

par

sPiston 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 V entilation V alve

clogged Clean

Condition CorrectionPossible cause

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

cause increased oil consumption

Fuel Consumption Excessive

Condition Possible cause Correction

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

Returning of accelerator control

sluggish Correct

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 (EGR) flow due to

trouble in EGR system

Refer to “Abnormal Combustion”

Lubrication Problems

Condition Possible cause Correction

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

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

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.

c.Refer to the “Maintenance and Lubrication” section

of this manual.

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 In-

dicator Lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses

malfunctions.

Condition Possible cause Correction

“CHECK ENGINE” MIL does not

illuminate at the starting of engine

Bulb defective Replace

ill

e a

e s

ng o

eng

ne MIL circuit open Correct or replace

Command signal circuit to operate

self diagnostic system shorted Correct or replace

Powertrain Control Module (PCM)

cable loosely connected,

disconnected or defective

Correct or replace

PCM defective Replace

Condition CorrectionPossible cause

“CHECK ENGINE” MIL illuminates,

and stays on Deterioration of heated oxygen

sensor internal element Replace

Heated oxygen (O2) sensor

connector terminal improper contact Reconnect properly

O2 sensor lead wire shorted Correct

O2 sensor circuit open Correct or replace

Deterioration of Engine Coolant

Temperature (ECT) sensor internal

element

Replace

ECT sensor connector terminal

improper contact Reconnect properly

ECT sensor lead wire shorted Correct

ECT sensor circuit open Correct or replace

Throttle position sensor open or

shorted circuits Correct or replace

Deterioration of crankshaft position

sensor Replace

Crankshaft position sensor circuit

open or shorted Correct or replace

Vehicle speed sensor circuit open Correct or replace

Manifold absolute pressure sensor

circuit open or shorted Correct or replace

Intake air temperature sensor circuit

open or shorted Correct or replace

Fuel injector circuit open or shorted Correct or replace

PCM driver transistor defective Replace PCM

Malfunctioning of PCM RAM

(Random Access Memory) or ROM

(Read Only Memory)

Replace PCM

Cylinder Head Cover LH

Removal

1.Disconnect battery ground cable.

2.Drain engine coolant from faucet bottom of radiator.

3.Remove engine cover from the dowels on the

common chamber.

F06RW018

4.Remove air cleaner duct assembly (3) and air cleaner

element (4).

130RW001

Legend

(1) Positive Crankcase Ventilation Hose Connector

(2) Intake Air Temperature Sensor

(3) Air Cleaner Duct Assembly

(4) Air Cleaner Element

(5) Mass Air Flow Sensor

NOTE: Disconnect the mass air flow (MAF) sensor

connector, intake air temperature (IA T) sensor connector,

and positive crankcase ventilation (PCV) hose before

hand the air cleaner duct assembly is removed.

5.Disconnect following wiring connectors and bonding

cable:

DManifold Absolute Pressure (MAP) sensor

DVacuum Switching Valve (VSV) for Induction Air

Control Valve (IACV) actuator

DIgnition coils for left bank

DFuel injectors for left bank

DIdle air control (IAC) valve

DThrottle position sensor (TPS)

DBonding cable

DOthers as necessitated

6.Disconnect following vacuum hoses:

DBrake master VAC

DCanister

DVSV for IACV actuator

DDuty solenoid valve

DPCV

7.Disconnect radiator upper and lower hoses

8.Remove engine harness from the cylinder head

cover.

9.Remove the upper fan guide.

10.Remove cooling fan and clutch assembly.

11.Remove drive belt by pushing down the auto

tensioner using spanner as illustrated.

F06RW019

Legend

(1) Crankshaft Pulley

(2) Generator

(3) Auto Tensioner

(4) Idle Pulley

(5) Cooling Fan Pulley

(6) Power Steering Oil Pump

(7) Drive Belt

(8) Air Conditioner Compressor

12.Remove power steering oil pump pulley.

13.Remove fan pulley and bracket assembly.

14.Remove idle pulley assembly.

15.Remove auto tensioner assembly.

16.Remove crankshaft pulley using 5–8840–0133–0

crankshaft holder.

17.Remove timing belt covers from the right bank side to

the left bank side in order.

18.Remove ignition coil assemblies for the left side bank.

060RW018

Legend

(1) Ignition Coil Connectors

(2) Bolts

(3) Ignition Coil Assemblies

19.Remove cylinder head cover assembly.

Installation

1.Install cylinder head cover.

DClean the sealing surface of cylinder head and

cylinder head cover to remove oil and sealing

materials completely.

DApply sealant (TB-1207B or equivalent) of bead

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

camshaft bracket on front and rear sides.

DThe cylinder head cover must be installed within 5

minutes after sealant application to prevent

premature hardening of sealant.

014RW144

DTighten bolts to the specified torque.

Torque : 9 N·m (0.9 Kg·m/78 lb in)

010RW008

2.Install ignition coil assemblies and tighten the fixing

bolts to the specified torque.

Torque : 4 N·m (0.4 Kg·m/35 lb in)

3.Install timing belt covers from left bank side to right

bank side, and tighten the fixing bolts and nut to the

specified torque.

Torque : 19 N·m (1.9 Kg·m/14 lb ft)

4.Install crankshaft pulley and tighten the fixing bolt

using 5–8840–0133–0 crankshaft holder to the

specified torque.

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

5.Install auto tensioner assembly and tighten the fixing

bolts to the specified torque.

Torque :

Shorter Bolt : 20 N·m (2.0 Kg·m/14 lb ft)

Longer Bolt : 39 N·m (4.0 Kg·m/29 lb ft)

6.Install idle pulley and bracket assembly and tighten

the fixing bolt to the specified torque.

Torque : 52 N·m (5.3 Kg·m/38 lb ft)

7.Install fan pulley and bracket assembly and tighten

the fixing bolts and nut to the specified torque.

Torque : 22 N·m (2.2 Kg·m/16 lb ft)

8.Install power steering oil pump pulley and tighten the

fixing bolt to the specified torque.

Torque : 78 N·m (8.0 Kg·m/58 lb ft)

9.Install drive belt by pushing down the auto tensioner

using spanner as shown in the removal step of drive

belt.

10.Install cooling fan and clutch assembly and tighten

the fixing bolts to the specified torque.

Torque : 10 N·m (1.0 Kg·m/87 lb in)

11.Install upper fan guide and clip both side and tighten

the fixing bolts to the specified torque.

Torque : 4 N·m (0.4 Kg·m/35 lb in)

12.Install engine harness and tighten the fixing bolts of

the retaining clip and bracket to the specified torque.

Torque : 4 N·m (0.4 Kg·m/35 lb in)

13.Connect radiator upper and lower hoses and clip

them securely.

14.Connect vacuum hoses of those which were

disconnected in the removal step.

15.Connect wiring connectors and bonding cable of

those which were disconnected in the removal step.

16.Install air cleaner element and air cleaner duct

assembly, and clip the both end securely.

17.Connect Mass Air Flow (MAF) sensor connector,

Intake Air Temperature (IAT) sensor connector and

Positive Crankcase Ventilation (PCV) hose.

18.Install engine cover mating with the dowels.

Cylinder Head Cover RH

Removal

1.Disconnect battery ground cable.

2.Remove battery from the vehicle.

3.Drain engine coolant from faucet bottom of radiator.

4.Remove engine cover from the dowels on the

common chamber.

F06RW018

5.Remove air cleaner duct assembly (3) and air cleaner

element (4).

130RW001

Legend

(1) Positive Crankcase Ventilation Hose Connector

(2) Intake Air Temperature Sensor

(3) Air Cleaner Duct Assembly

(4) Air Cleaner Element

(5) Mass Air Flow Sensor

NOTE: Disconnect the mass air flow (MAF) sensor

connector, intake air temperature (IA T) sensor connector,

and positive crankcase ventilation (PCV) hose before

hand the air cleaner duct assembly is removed.

6.Disconnect following wiring connectors and bonding

cable:

DExhaust Gas Recirculation (EGR) valve

DFuel injectors for right bank

DIgnition coils for right bank

DBonding cable

DOthres as necessitated

7.Disconnect radiator upper and lower hoses.

8.Remove engine harness from the cylinder head

cover.

9.Remove the upper fan guide.

10.Remove cooling fan and clutch assembly.

11.Remove drive belt by pushing down the auto

tensioner using spanner as illustrated.

F06RW019

Legend

(1) Crankshaft Pulley

(2) Generator

(3) Auto Tensioner

(4) Idle Pulley

(5) Cooling Fan Pulley

(6) Power Steering Oil Pump

(7) Drive Belt

(8) Air Conditioner Compressor

12.Remove fan pulley and bracket assembly.

13.Remove idle pulley assembly.

14.Remove auto tensioner assembly.

15.Remove crankshaft pulley using 5–8840–0133–0

crankshaft holder.

16.Remove timing belt covers for right bank side.

17.Reomve timing belt covers for right bank side.

060RW001

Legend

(1) Ignition Coil Connectors

(2) Bolts

(3) Ignition Coil Assemblies

18.Remove ignition coil assemblies for the right side

bank.

19.Remove cylinder head cover assembly.

Installation

1.Install cylinder head cover.

DClean the sealing surface of cylinder head and

cylinder head cover to remove oil and sealing

materials completely.

DApply sealant (TB-1207B or equivalent) of bead

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

camshaft bracket on front and rear sides.

DThe cylinder head cover must be installed within 5

minutes after sealant application before the sealant

hardens.

014RW143

DTighten bolts in turn to the specified torque.

Torque : 8.8 N·m (0.9 Kg·m/78 lb in)

010RW007

2.Install ignition coil assemblies and tighten the fixing

bolts to the specified torque.

Torque : 4 N·m (0.4 Kg·m/35 lb in)

3.Install timing belt cover and tighten the fixing bolts and

nut to the specified torque.

Torque : 19 N·m (1.9 Kg·m/14 lb ft)

4.Install crankshaft pulley and tighten the fixing bolt

using 5–8840–0133–0 crankshaft holder to the

specified torque.

Torque : 167 N·m (17 Kg·m/123 lb ft)

5.Install auto tensioner assembly and tighten the fixing

bolts to the specified torque.

Torque :

Shorter Bolt : 20 N·m (2.0 Kg·m/14.8 lb ft)

Longer Bolt : 39 N·m (4.0 Kg·m/28.8 lb ft)

6.Install idle pulley assembly and tighten the fixing bolt

to the specified torque.

Torque : 52 N·m (5.3 Kg·m/38.4 lb ft)

7.Install fan pulley and bracket assembly and tighten

the fixing bolts and nut to the specified torque.

Torque : 22 N·m (2.2 Kg·m/16.2 lb ft)

8.Install drive belt by pushing down the auto tensioner

using spanner as shown in the removal step of drive

belt.

9. Install cooling fan clutch assembly and tighten the

fixing bolts to the specified torque.

Torque : 10 N·m (1.0 Kg·m/88.5 lb in)

10.Install upper fan guide and clip both side and tighten

the fixing bolts to the specified torque.

Torque : 4 N·m (0.4 Kg·m/35.4 lb in)

11.Install engine harness and tighten the fixing bolts of

the retaining clip and brackets to the specified torque.

Torque : 4 N·m (0.4 Kg·m/35.4 lb in)

12.Connect radiator upper and lower hoses and clip

them securely.

13.Connect wiring connectors and bonding cable of

those which were disconnected in the removal step.

14.Install air cleaner element and air cleaner duct

assembly, and the clip both end securely.

15.Connect Mass Air Flow (MAF) sensor connector,

Intake Air Temperature (IAT) sensor connector and

Positive Crankcase Ventilation (PCV) hose.

16.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 accelerator pedal cable from throttle

body and cable bracket.

4. Disconnect vacuum booster hose from common

chamber.

5. Disconnect connector from manifold absolute

pressure sensor, idle air control valve, throttle

position sensor, solenoid valve, electric vacuum

sensing valve, and EGR valve.

6. Disconnect vacuum hose on canister Vacuum

Switching Valve (VSV) and positive crankcase

ventilation hose, fuel rail assembly with pressure

control valve bracket.

7. Remove ventilation hose from throttle valve and

intake duct and remove water hose.

8. Remove the four throttle body fixing bolts.

9. Remove exhaust gas recirculation valve assembly

fixing bolt and nut on common chamber and

remove EGR valve assembly.

10. Remove two bolts from common chamb er rear side

for remove fuel hose bracket.

11. Remove com mon chambe r four b olts an d four nuts

then remove the common chamber.

025RW001

Legend

(1) Common Chamber

(2) Throttle Valve 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 bolts 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. Connect accelerator pedal cable.

10. 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 battery ground cable.

2.Remove air cleaner duct assembly.

130RW001

Legend

(1) Positive Crankcase Ventilation Hose Connector

(2) Intake Air Temperature Sensor

(3) Air Cleaner Duct Assembly

(4) Air Cleaner Element

(5) Mass Air Flow Sensor

3.Disconnect heated oxygen (O2) sensor connector.

4.Remove exhaust front pipe three stud nuts from

exhaust side and two nuts from rear end of exhaust

front pipe.

150RX014

Legend

(1) O2 Sensor

(2) Exhaust Front Pipe LH

5.Remove heat protector two fixing bolts then the heat

protector.

6.Remove a bolt on engine LH side for air conditioner

(A/C) compressor bracket and loosen two bolts for

A/C compressor then move A/C compressor to front

side.

7.Remove exhaust manifold eight fixing nuts and

remove exhaust manifold from the engine.

Installation

1.Install exhaust manifold and tighten exhaust manifold

fixing nuts to the specified torque with new nuts.

Torque: 57 N·m (5.8 Kg·m/42 lb ft)

2.Install heat protector.

3.Install exhaust front pipe and tighten three stud nuts

and two nuts to the specified torque.

Torque :

Stud nuts: 67 N·m (6.8 Kg·m/49 lb ft)

Nuts: 43 N·m (4.4 Kg·m/32 lb ft)

150R014

Legend

(1) O2 Sensor

(2) Exhaust Front Pipe LH

4.Set A/C compressor to normal position and tighten

two bolts and a bolt to the specified torque.

Torque : 40 N·m (4.1 Kg·m/30 lb ft)

5.Reconnect O2 sensor connector.

6.Install air cleaner duct assembly.

Exhaust Manifold RH

Removal

1.Disconnect battery ground cable.

2.Remove torsion bar. Refer to removal procedure in

Front Suspension section.

3.Remove exhaust front pipe three stud nuts and two

nuts then disconnect exhaust front pipe.

150RX015

Legend

(1)Exhaust Front Pipe RH

(2)Heated Oxygen (O2) Sensor

4.Remove heat protector two fixing bolts then the heat

protector.

5.Remove exhaust gas recirculation (EGR) pipe fixing

bolt and nut from exhaust manifold, remove a nut

from EGR valve and a bolt from rear side of cylinder

head for bracket of EGR pipe then remove the EGR

pipe.

056RW001

Legend

(1)EGR Valve

(2)EGR Pipe

6.Remove exhaust manifold eight fixing nuts then the

exhaust manifold.

Installation

1.Install exhaust manifold and tighten bolts to the

specified torque.

Torque : 57 N·m (5.8 Kg·m/42 lb ft)

2.Install the EGR pipe, tighten bolt and nut on exhaust

manifold to specified torque.

Torque : 28 N·m (2.9 Kg·m/21 lb ft)

Tighten nut to EGR valve to the specified torque.

Torque : 44 N·m (4.5 Kg·m/33 lb ft)

Tighten the bolt for EGR pipe bracket to specified

torque.

Torque : 25 N·m (2.5 Kg·m/18 lb ft)

3.Install heat protector

4.Install exhaust front pipe and tighten three stud nuts

and two nuts to the specified torque.

Torque:

Stud nuts: 67 N·m (6.8 Kg·m/49 lb ft)

Nuts: 43 N·m (4.4 Kg·m/32 lb ft)

5.Install the torsion bar and readjust the vehicle height.

Refer to installation and vehicle height adjustment

procedure for Front Suspension.

Crankshaft Pulley

Removal

1.Disconnect battery ground cable.

2.Remove air cleaner assembly.

130RW001

Legend

(1) Positive Crankcase Ventilation Hose Connector

(2) Intake Air Temperature Sensor

(3) Air Cleaner Duct Assembly

(4) Air Cleaner Element

(5) Mass Air Flow Sensor

3.Remove radiator upper fan shroud from radiator.

4. Move serpentine belt tensioner to loose side using

wrench then remove serpentine belt.

850RW001

Legend

(1) Crankshaft Pulley

(2) Cooling Fan Pulley

(3) Tensioner

(4) Generator

(5) Air Conditioner Compressor

(6) Power Steering Oil Pump

(7) Serpentine Belt

5.Remove cooling fan assembly four fixing nuts, then

the cooling fan assembly.

6.Remove crankshaft pulley assembly using

5-8840-0133-0 crankshaft holder, hold crankshaft

pulley then remove center bolt and pulley.

Installation

1.Install crankshaft pulley using 5-8840-0133-0

crankshaft holder, hold the crankshaft pulley and

tighten center bolt to the specified torque.

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

2.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 bracket.

Torque : 10 N·m (1.0 Kg·m/88.5 lb in) for fan and

clutch assembly.

3.Move serpentine belt tensioner to loose side using

wrench, then install serpentine belt to normal

position.

4.Install radiator upper fan shroud.

5.Install air cleaner assembly.

Timing 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

Legend

(1)Crankshaft Pulley

(2)Cooling Fan Pulley

(3)Tensioner

(4)Generator

(5)Air Conditioner Compressor

(6)Power Steering Oil Pump

(7)Drive Belt

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 pusher.

CAUTION:The pusher prevents air from entering

the oil chamber. Its rod must always be facing

upward.

014RW011

Legend

(1)Up Side

(2)Down Side

(3)Direction For Installation

(4)Locking Pin

14.Remove timing belt.

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 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. Never

expose the belt direct sunlight or heat.

Techline

Installation

NOTE: For correct belt installation, the letter on the belt

must be able to be read as viewed from the front of the

vehicle.

014RY00042

Legend

(1) Crankshaft Timing Pulley

(2) RH Bank Camshaft Drive Gear Pulley

(3) Water Pump Pulley

(4) Idle Pulley

(5) LH Bank Camshaft Drive Gear Pulley

(6) Tension Pulley

014RY00043

(7) Alignment Mark on Oil Pump.

(8) Alignment Mark on Timing Belt

(9) Alignment Mark (notch) on Crankshaft Timing

Pulley.

(10) Alignment Mark (groove) on Crankshaft Timing

Pulley.

014RW006

Legend

(1) Timing Belt

(2) Engine Rotation Direction

(3) Cylinder Head Side

1.Install timing belt.

1. 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).

NOTE: When timing marks are aligned, No.2 piston will

be on Top Dead Center.

014RW003

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

Techline

2. Align the alignment mark on the RH bank

camshaft drive gear pulley (2) to the alignment

mark of the cylinder head cover RH (3).

3. 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 from the front of the vehicle) and put the

timing belt on the camshaft drive gear pulley.

Secure the belt with a double clip or equivalent

clip.

014RW00004

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.

4. Align the alignment mark on the LH bank

camshaft drive gear pulley (2) to the alignment

mark of the cylinder head cover LH (3).

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

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

camshaft drive gear pulley (2).

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.

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

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.

6. 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.

2.Install pusher and tighten bolt to the specified torque.

Torque : 25 N·m (2.5 Kg·m/18 lb ft)

1. Install the pusher while pushing the tension pulley

to the belt.

2. Pull out pin from the pusher.

NOTE: When reusing the pusher, press the pusher with

approximately 100Kg to retract the rod, and insert a pin

(1.4 mm piano wire).

014RW011

Legend

(1) Up Side

(2) Down Side

(3) Direction for Installation

(4) Locking Pin

3. Remove double clips or equivalent clips, from

timing belt pulleys.

Turn the crankshaft pulley clockwise by two turns.

3. Install timing belt cover.

Remove crankshaft pulley that was installed in step

1 item 5.

Tighten bolts to the specified torque.

Torque: 19 N·m (1.9 Kg·m/14 lb ft)

020RW004

Legend

(1) Timing Belt Cover RH

(2) Timing Belt Cover LH

(3) Timing Belt Cover Lower

020RW003

Legend

(1) Timing Belt Cover

(2) Rubber Bushing

(3) Sealing Rubber

(4) Cylinder Body

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 (17.0 Kg·m/123 lb ft)

5.Install fan pulley bracket and tighten fixing bolts to the

specified torque.

Torque : 22 N·m (2.2 Kg·m/16 lb ft)

6.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)

7.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 bracket.

Torque : 10 N·m (1.0 Kg·m/88.5 lb in) for fan and

clutch assembly.

8.Move drive belt tensioner to loose side using wrench,

then install drive belt to normal position.

850RW001

Legend

(1) Crankshaft Pulley

(2) Cooling Fan Pulley

(3) Auto Tensioner

(4) Generator

(5) Air Conditioner Compressor

(6) Power Steering Oil Pump

(7) Idle Pulley

(8) Drive Belt

9.Install radiator upper fan shroud.

10.Install air cleaner assembly.

Camshaft

Removal

1.Disconnect battery ground cable.

2.Remove crankshaft pulley.

DRefer to removal procedure for Crankshaft Pulley in

this manual.

3.Remove timing belt.

DRefer to removal procedure for Timing Belt in this

manual.

4.Remove cylinder head cover LH.

DRefer to removal procedure for Cylinder Head

Cover LH in this manual.

5.Remove cylinder head cover RH.

DRefer 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

Legend

(1) Right Bank

(2) Left Bank

(3) Timing Mark on Retainer

Installation

1.Install camshaft drive gear assembly and tighten

three bolts to the specified torque.

Torque : 10 N·m (1.0 Kg·m/89 lb in)

2.Tighten bolt for camshaft drive gear assembly pulley

to the specified torque.

Torque : 98 N·m (10.0 Kg·m/72 lb ft)

3.Tighten sub gear setting bolt.

1. Use the 5–8840–2443–0 gear spring lever to turn

sub gear to right direction until it aligns with the M5

bolt hole between camshaft driven gear and sub

gear.

2. Tighten the M5 bolt to a suitable torque to prevent

the sub gear from moving.

014RW041

4.Install camshaft assembly and camshaft brackets,

tighten twenty bolts on one side bank to the specified

torque.

1. Apply engine oil to camshaft journal and bearing

surface of camshaft bracket.

2. Align timing mark on intake camshaft (one dot for

right bank, two dot 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).

014RW020

Legend

(1) Intake Camshaft Timing Gear for Right Bank

(2) Intake Camshaft Timing Gear for Left Bank

(3) Exhaust Camshaft Timing Gear

(4) Discrimination Mark

(LI: Left bank intake, RI: Right bank intake)

(LE: Left bank exhaust, RE: Right bank

exhaust)

014RW023

Legend

(1) Right Bank Camshaft Drive Gear

(2) Left Bank Camshaft Drive Gear

(3) Timing Mark on Drive Gear

(4) Dowel Pin

014RW024

Legend

(1)Right Bank

(2)Left Bank

(3)Alignment Mark on Camshaft Drive Gear

(4)Alignment Mark on Camshaft

(5)Alignment Mark on Retainer

3.Tighten twenty bolts on numerical order an one

side bank as shown in the illustration.

Torque : 10 N·m (1.0 Kg·m/89 lb in)

014RW031

5.Install cylinder head cover RH.

DRefer to installation procedure for CYLINDER

HEAD COVER RH in this manual.

6.Install cylinder head cover LH.

DRefer to installation procedure for CYLINDER

HEAD COVER LH in this manual.

7.Install timing belt.

DRefer to installation procedure for TIMING BELT in

this manual.

8.Install crankshaft pulley.

DRefer to installation procedure for CRANKSHAFT

PULLEY in this manual.

9.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.

DRefer to removal procedure for Crankshaft Pulley in

this manual.

6.Remove timing belt.

DRefer to removal procedure for Timing Belt in this

manual.

7.Remove cylinder head cover LH.

DRefer to removal procedure for Cylinder Head

Cover LH in this manual.

8.Remove cylinder head cover RH.

DRefer to removal procedure for Cylinder Head

Cover RH in this manual.

9.Remove common chamber.

DRefer 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

Legend

(1) Cylinder Head

(2) Cylinder Head Bolt

(3) Camshaft

Installation

1.Install cylinder head assembly to cylinder block.

1. 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

2. Align dowel pin hole to dowel pin on the cylinder

block.

3. Tighten two bolts temporarily by hand to prevent

the cylinder head assembly from moving.

4. Using 9–8511–4209–0 cylinder head bolt wrench,

tighten bolts in numerical order as shown in the

illustration to the specified torque.

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/21 lb ft)

Final : 64 N·m (6.5 Kg·m/47 lb ft)

014RW029

2.Install common chamber.

DRefer to installation procedure for Common

Chamber in this manual.

3.Install cylinder head cover RH.

DRefer to installation procedure for Cylinder Head

Cover RH in this manual.

4.Install cylinder head cover LH.

DRefer to installation procedure for Cylinder Head

Cover LH in this manual.

5.Install timing belt.

DRefer to installation procedure for Timing Belt in this

manual.

6.Install crankshaft pulley.

DRefer 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.

DDrain engine coolant.

3.Remove cylinder head assembly.

DRefer to removal procedure for Cylinder Head in

this manual.

4.Remove camshaft.

DRefer 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.

DRefer to installation procedure for Camshaft in this

manual.

6.Install cylinder head assembly.

DRefer 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

Legend

(1)Cylinder Head

(2)Crankcase with Oil Pan

(3)Oil Pipe

(4)Oil Strainer

(5)Oil Gallery

(6)Piston with Connecting Rod Assembly

1.Remove cylinder head assembly.

DRefer to removal procedure for Cylinder Head in

this manual.

2.Remove crankcase with Oil Pan.

DRefer to removal procedure for Oil Pan and

Crankcase in this manual.

3.Remove oil strainer fixing bolts, remove oil strainer

assembly with O-ring.

050RW002

Legend

(1)Oil Pump

(2)Oil Strainer

(3)Oil Gallery

(4)From Oil Filter

(5)To Oil Filter

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.

DApply engine oil to cylinder bore, connecting rod

bearing and crank pin.

When installing the piston, its front mark must face

the engine front side.

DThe bearing cap number must be the same as

connecting rod number.

DApply engine oil to the thread and seating surface of

each nut.

DTighten nuts to the specified torque.

Torque : 54 N·m (5.5 Kg·m/40 lb ft)

DAfter 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 surfaces.

015RW003

Legend

(1)Piston Front Mark

(2)Piston Grade

(3)Connecting Rod Front Mark

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/21 lb ft)

2nd step : 55°–65°

051RS009

3.Install oil pipe with O-ring.

Torque : 10 N·m (1.0 Kg·m/89 lb in)

4.Install oil strainer assembly with O-ring.

Torque : 25 N·m (2.5 Kg·m/18 lb ft)

5.Install crankcase with Oil Pan.

DRefer to installation procedure for Oil Pan and

Crankcase in this manual.

6.Install cylinder head assembly.

DRefer to installation procedure for Cylinder Head in

this manual.

Crankshaft and Main Bearings

Removal

F06RW010

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)Cylinder Body Side Bolt

(10)Oil Gallery

(11)Flywheel

(12)Rear Oil Seal Retainer

(13)Connecting Rod Cap

(14)Crankshaft Main Bearing Cap

(15)Crankshaft and Main Bearing

1.Remove engine assembly.

DRefer to removal procedure for Engine Assembly in

this manual.

2.Remove timing belt.

DRefer to removal procedure for Timing Belt in this

manual.

3.Remove oil pan and crankcase.

DRefer to removal procedure for Oil Pan and

Crankcase in this manual.

4.Remove oil pipe with O-ring.

5.Remove oil strainer assembly with O-ring.

6.Remove oil pump assembly.

DRefer 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.

DRefer 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.

DInstall main bearing in the cylinder block and main

bearing cap respectively.

Apply new engine oil to upper and lower main

bearings.

NOTE:

DDo not apply engine oil to the bearing back faces.

DMake sure that main bearings are in correct position.

DInstall crankshaft with care.

DApply engine oil to the thrust washer.

DInstall thrust washer on No.3 journal.

DOil grooves in thrust washer must face the

crankshaft.

015RS012

015RS013

2.Install crankshaft main bearing caps.

DApply engine oil to the thread and seating surface of

each bearing cap fixing bolt.

NOTE:

DDo not apply engine oil to the bearing back faces.

DInstall bearing caps in the order of numbers, starting

with cylinder block front side.

DTighten main bearing fixing bolts to the specified

torque.

Torque : 39 N·m (4.0 Kg·m/29 lb ft)

DAfter tightening the bolts, make sure that the

crankshaft rotates smoothly.

3.Install connecting rod caps.

DThe cap number must be same as connecting rod

number.

DApply engine oil to the thread and seating surface of

each nut.

DTighten nuts to the specified torque.

Torque : 54 N·m (5.5 Kg·m/40 lb ft)

DAfter tightening the nuts, make sure that the

crankshaft rotates smoothly.

4.Install rear oil seal retainer.

DRemove oil on cylinder block and retainer fitting

surface.

DApply sealant (TB1207B or equivalent) to retainer

fitting surface as shown in illustration.

DThe oil seal retainer must be installed within 5

minutes after sealant application before the sealant

hardens.

015RW002

Legend

(1) Around Bolt Holes

(2) Around Dowel Pin

DApply engine oil to oil seal lip and align a dowel pin

hole in the cylinder block with that in the retainer.

DT ighten retainer fixing bolts to the specified torque.

Torque : 18 N·m (1.8 Kg·m/13 lb ft)

015RW001

5.Install flywheel.

DClean tapped holes in the crankshaft.

DRemove oil on crankshaft and flywheel fitting

surface.

NOTE:

DDo not reuse the bolts.

DDo not apply oil or thread lock to the bolts.

DTighten fixing bolts to the specified torque.

Torque : 54 N·m (5.5 Kg·m/40 lb ft)

015RS018

6.Install oil gallery.

DClean contact surface of oil gallery and main

bearing cap.

Apply engine oil to oil gallery fixing bolts and tighten

the bolts in two steps, in the order shown in

illustration.

Torque :

1st step : 29 N·m (3.0 Kg·m/21 lb ft)

2nd step : 55°–65°

7. Install cylinder body side bolts and tighten bolts in

order to the specified 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.

DRemove oil on cylinder block and oil pump mounting

surface.

DApply sealant (TB1207B or equivalent) to the oil

pump mounting surface.

DThe oil pump assembly must be installed within 5

minutes after sealant application before the sealant

hardens.

DApply engine oil to oil seal lip.

DInstall 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

Legend

(1) Around Bolt Holes

(2) Around Dowel Pin

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 oil pipe with O-ring, tighten fixing bolts to the

specified torque.

Torque : 25 N·m (2.5 Kg·m/18 lb ft)

11.Install crankcase.

DRemove oil on crankcase mounting surface and dry

the surface.

DProperly 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.

DThe crankcase must be installed within 5 minutes

after sealant application before the sealant

hardens.

DTighten fixing bolts to the specified torque.

Torque : 10 N·m (1.0 Kg·m/89 lb in)

013RW010

013RW004

12.Install oil pan

DRemove oil on oil pan mounting surface and dry the

surface.

DProperly 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.

DThe oil pan must be installed within 5 minutes after

sealant application to prevent premature hardening

of sealant.

DTighten fixing bolts to the specified torque.

Torque : 25 N·m (2.5 Kg·m/18 lb ft)

013RW003

013RW002

13.Install timing belt.

DRefer to installation procedure for Timing Belt in this

manual.

14.Install engine assembly.

DRefer to installation procedure for Engine in this

manual.

Rear Oil Seal

Removal

1.Remove transmission assembly (Auto).

DRefer to removal procedure for Transmission

section - 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

5–8840–2286–0.

015RS017

2.Install flywheel.

DClean tapped holes in the crankshaft.

DRemove oil on the crankshaft and flywheel

mounting surface.

DTighten 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

3.Install transmission (Auto).

DSee Transmission section - 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

515RX013

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 accelerator cable and automatic cruise

control cable from throttle valve on common

chamber.

7.Disconnect air duct with air cleaner cover.

8.Remove air cleaner assembly.

9.Disconnect canister vacuum hose.

10.Disconnect vacuum booster hose.

11.Disconnect three engine harness connectors.

12.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.

13.Disconnect ground cable between engine and frame.

14.Disconnect bonding cable connector on the back of

right dash panel.

15.Disconnect bonding cable terminal on the left bank.

16.Disconnect starter harness connector from starter.

17.Disconnect generator harness connector from

generator.

18.Disconnect coolant reserve tank hose from radiator.

19.Remove radiator upper and lower hoses.

20.Remove upper fan shroud.

21.Remove cooling fan assembly four fixing nuts, then

the cooling fan assembly.

22.Move drive belt tensioner to loose side using wrench

then remove drive belt.

23.Remove power steering pump fixing bolts, then

power steering pump. Place the power steering pump

along with piping on the body side.

24.Remove air conditioning compressor fixing bolts from

bracket and place the compressor along with piping

on the body side.

25.Remove O2 sensor harness connectors from exhaust

front pipe.

26.Remove three exhaust pipe fixing nuts from each

bank.

27.Remove two exhaust pipe fixing nuts from each

exhaust pipe, then move exhaust pipe to rear side of

vehicle.

28.Remove flywheel dust covers.

29.Disconnect two heater hoses from engine.

30.Disconnect fuel hoses from right side of transmission.

CAUTION:Plug fuel pipes on engine side and fuel

hoses from fuel tank.

31.Remove transmission assembly (Auto).

Refer to Transmission section - manual.

32.Support the engine by engine hoist.

33.Remove two left side engine mount fixing bolts from

engine mount on chassis side.

34.Remove two right side engine mount fixing bolts from

engine mount on chassis side.

35.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 posi-

tions, the transmission may be damaged the trans-

mission.

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 (Auto).

Refer to Transmission section - 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

Legend

(1) Exhaust Front Pipe RH

(2) O2 Sensor

150RX014

Legend

(1) O2 Sensor

(2) Exhaust Front Pipe LH

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 bracket.

Torque : 10 N·m (1.0 Kg·m/88.5 lb in) for fan and

clutch assembly.

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 bolts : 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

Legend

(1)Crankshaft Pulley

(2)Cooling Fan Pulley

(3)Tensioner

(4)Generator

(5)Air Conditioner Compressor

(6)Power Steering Oil Pump

(7)Drive Belt

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 accelerator cable and automatic cruise

control cable to throttle valve on common chamber.

035RW007

Legend

(1)Throttle Valve Assembly

(2)Throttle Lever

(3)Idle Air Control Valve

(4)Throttle Position Sensor

27.Install engine hood to the original position.

DRefer to installation procedure for Body section in

this manual.

28.Install accelerator pedal cable.

Cylinder Head

Cylinder Head and Associated Parts

011RW008

Legend

(1) Spark Plug

(2) Cylinder Head Bolt

(3) Camshaft Drive Gear Pulley Fixing Bolt

(4) Camshaft Drive Gear Pulley

(5) Camshaft Bracket Fixing Bolt

(6) Camshaft Bracket

(7) Camshaft Exhaust

(8) Camshaft Intake

(9) Retainer Fixing Bolt

(10) Retainer Assembly

(11) Tappet with Shim

(12) Split Collar

(13) Valve Spring and Spring Upper Seat

(14) Valve

Disassembly

NOTE:

DDuring disassembly, be sure that the valve train

components are kept together and identified so that

they can be reinstalled in their original locations.

DBefore 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).

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

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

side (8).

3.Remove tappet with shim (11).

4.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

5.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:

DDo not attempt to weld the cylinder head. Replace

it.

DDo 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.Install Spark plug and tighten all the spark plugs to

specified torque.

Torque: 18 N·m (1.8 Kg·m/13 lb ft)

2.Tighten sub gear setting bolt.

1. Use 5–8840–2443–0 gear spring lever to turn sub

gear to right direction until the M5 bolt aligns with

the hole between camshaft driven gear and sub

gear.

2. Tighten the M5 bolt to a suitable torque to prevent

the sub gear from moving .

014RW025

3.Install camshaft drive gear assembly and tighten

three bolts to the specified torque.

Torque: 10 N·m (1.0 Kg·m/89 lb in)

4.Install camshaft assembly and camshaft brackets,

tighten twenty bolts on one side bank to the specified

torque.

1. Apply engine oil to camshaft journal and bearing

surface of camshaft bracket.

2. 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).

014RW020

Legend

(1) Intake Camshaft Timing Gear for Right Bank

(2) Intake Camshaft Timing Gear for Left Bank

(3) Exhaust Camshaft Timing Gear

(4) Discrimination Mark

LI: Left Bank Intake

RI: Right Bank Intake

LE: Left Bank Exhaust

RE: Right Bank Exhaust

014RW023

Legend

(1) Right Bank Camshaft Drive Gear

(2) Left Bank Camshaft Drive Gear

(3) Timing Mark on Drive Gear

(4) Dowel Pin

014RW024

Legend

(1) Right Bank

(2) Left Bank

(3) Alignment Mark on Camshaft Drive Gear

(4) Alignment Mark on Camshaft

(5) Alignment Mark on Retainer

3. Tighten twenty bolts in numerical order on one

side bank as shown in the illustration.

Torque: 10 N·m (1.0 Kg·m/89 lb in)

014RW031

5.Tighten bolt for camshaft drive gear assembly pulley

to the specified torque.

Torque: 98 N·m (10.0 Kg·m/72 lb ft)

Valve Spring, Oil Controller, Valve, Valve Guide

Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts

014RW039

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

Disassembly

1.Remove camshaft bracket fixing bolts (1).

2.Remove camshaft assembly (intake).

3.Remove camshaft assembly (Exhaust side).

4.Remove shim (4) and tappet (5).

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.Measure the free height of the springs. The springs

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 spring tester to compress the springs 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 head. Carefully inspect the valve 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 of 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.Measure the inside diameter of the valve guide with a

micrometer . Subtract the measured outer diameter of

the valve stem from the measured inner 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 Vale 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 Replacement

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, ream 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 limit.

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. T ake care not

to cut away unblemished areas of the valve seat

surface.

Valve seat angle degree: 90°

014RW059

3.Apply abrasive compound to the valve seat insert

surface.

4.Insert the valve into the valve 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 entire 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 camshaft side.

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.

DRefer 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

Legend

(1) Cam

(2) Shim

(3) Tappet

Valve Clearance Standard Value (cold)

Intake: 0.23 mm–0.33 mm

(0.0091 in–0.0130 in)

Exhaust: 0.25 mm–0.35 mm

(0.0098 in–0.0138 in)

Selection of Adjusting Shim

Shim to be selected = (Thickness of removed shim) +

(Valve clearance measurement – Standard valve)

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 (0.0945 in)

through 3.2mm (0.1260 in) thick). Install the shim and

check valve clearance.

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

014RW040

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) Camshaft Drive Gear

(10) Oil Seal

Disassembly

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

using the 5–8840–2447–0 universal holder.

014RW060

2. Remove twenty fixing bolts from inlet and exhaust

camshaft bracket on one side bank, then camshaft

brackets (2).

014RW027

3.Remove camshaft assembly (3), (4).

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

gear retainer (8), then camshaft drive gear 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 micrometer to measure the diameter and the

uneven wear of the camshaft journals.

Replace the camshaft if the diameter or the uneven

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 measure 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/89 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/89 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/89 lb in)

2.Tighten sub gear setting bolt.

1. Use 5–8840–2443–0 to turn sub gear to right

direction until the M5 bolt hole aligns between

camshaft driven gear and sub gear.

2. Tighten M5 bolt suitable torque for prevent

moving the sub gear.

014RW041

3.Install camshaft assembly and camshaft brackets,

tighten twenty bolts on one side bank to the specified

torque.

1. Apply engine oil to camshaft journal and bearing

surface of camshaft bracket.

2. 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).

014RW020

Legend

(1) Intake Camshaft Timing Gear for Right Bank

(2) Intake Camshaft Timing Gear for Left Bank

(3) Exhaust Camshaft Timing Gear

(4) Discerning Mark

LI: Left Bank Intake

RI: Right Bank Intake

LE: Left Bank Exhaust

RE: Right Bank Exhaust

014RW023

Legend

(1) Right Bank Camshaft Drive Gear

(2) Left Bank Camshaft Drive Gear

(3) Timing Mark on Drive Gear

(4) Dowel Pin

014RW024

Legend

(1) Right Bank

(2) Left Bank

(3) Alignment Mark on Camshaft Drive Gear

(4) Alignment Mark on Camshaft

(5) Alignment Mark on Retainer

3. Tighten twenty bolts in numerical order on one

side bank as shown in the illustration.

Torque: 10 N·m (1.0 Kg·m/89 lb in)

014RW031

4.If the oil seal requires replacement, use the

5–8840–2445–0 to install the oil seal.

014RW034

5.Tighten bolt for camshaft drive gear pulley to the

specified torque using the 5–8840–2447–0 universal

holder.

Torque: 98 N·m (10.0 Kg·m/72 lb ft)

014RW060

Crankshaft

Crankshaft and Associated Parts

013RW009

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

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

sealing flange surface of crankcase.

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

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

5.Remove oil pump assembly (5).

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 thrust

clearance exceeds the specified limit, replace the

thrust bearings as a set.

Thrust Clearance

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

crankshaft main journal.

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.Install main bearing caps, oil gallery and crank case

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/21 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.Measure the plastigage width and determine the oil

clearance. If the oil clearance exceeds the specified

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 crankshaft and measure the runout. If the

crankshaft runout exceeds the specified limit, the

crankshaft must be replaced.

Runout : 0.04 mm (0.0016 in)

015RS007

2.Measure the diameter and the uneven wear of main

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 (1) and the crankshaft journal.

015RS010

2.Diameter size mark (1).

The diameter size marks are stamped on the No.1

crankshaft balancer as shown in the illustration.

015RS011

NOTE: Take care to ensure the bearings are positioned

correctly.

015RS012

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

1 Size

Mark Main Bearing

Bore Diameter Crank Shaft Main

Journal Diameter 2 Size

Mark

Crank

Shaft

Bearing

Size Mark

(Upper

Side)

Crank

Shaft

Bearing

Size Mark

(Lower

Side)

Oil Clearance

(Reference)

68.994-69.000 63.918-63.925

(2.5165-2.5167) 2 Blue Blue 0.030-0.049

(0.0012-0.0019)

(2.7163-2.7165) 63.926-63.933

(2.5168-2.5170) 1

Brown

0.028-0.047

(0.0011-0.0019)

68.987-68.993 63.918-63.925

(2.5165-2.5167) 2

Brown

0.029-0.048

(0.0011-0.0019)

(2.7160-2.7163) 63.926-63.933

(2.5168-2.5170) 1

Green

0.027-0.046

(0.0011-0.0018)

68.980-68.986 63.918-63.925

(2.5165-2.5167) 2

Green

0.028-0.047

(0.0011-0.0019)

(2.7157-2.7160) 63.926-63.933

(2.5168-2.5170) 1 Yellow Yellow 0.026-0.045

(0.0010-0.0018)

Reassembly

1.Crankshaft

DInstall the main bearings to the cylinder block and

the main bearing caps.

DBe sure that they are positioned correctly.

DApply new engine oil to the upper and lower main

bearing faces.

NOTE: Do not apply engine oil to the main bearing back

faces.

015RS012

DCarefully mount the crankshaft.

DApply engine oil to the thrust washer.

DAssemble the thrust washer to the No.3 bearing

journal. The oil grooves must face the crankshaft.

015RS013

2.Rear oil seal

DRemove the oil from the cylinder block and the

retainer mounting surface.

DApply 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

Legend

(1) Around Bolt Holes

(2) Around Dowel Pin

DApply engine oil to the oil seal lip.

DAlign the cylinder block dowel pin holes with the rear

retainer dowel pins.

DTighten 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 very careful not to disengage the 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. Remove the oil from the crankshaft and flywheel

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)

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

lock to the bolt.

015RS018

4.Piston and connecting rod assembly (8)

DApply engine oil to the cylinder bores, the

connecting rod bearings and the crankshaft pins.

Check to see that the piston ring end gaps are

correctly positioned.

015RX003

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

DInsert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor. The

front marks must be facing the front of the engine.

DMatch the numbered caps with the numbers on the

connecting rods. Align the punched marks on the

connecting rods and caps.

DApply engine oil to the threads and seating faces of

the nuts.

DTighten the nuts.

Torque: 54 N·m (5.5 Kg·m/40 lb ft)

After tightening the cap nuts, check to see that the

crankshaft rotates smoothly.

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

DTighten 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.

1.Completely remove all residual sealant, lubricant

and moisture from the sealing surfaces. The

surfaces must be perfectly dry.

2.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.

3.The crankcase assembly must be installed within

5 minutes after sealant application to prevent

premature hardening of the sealant.

4.Tighten the bolts and nuts to the specified torque.

Torque : 10 N·m (1.0 Kg·m/89 lb in)

013RW010

Legend

(1)Portion Between Bolt Holes

(2)Bolt Hole Portion

11.Install cylinder head assembly, refer to “Cylinder

head” in this manual.

Piston and Connecting Rod

Piston, Connecting Rod and Associate Parts

015RW019

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)Piston Ring

(9)Piston Pin

(10)Piston

(11)Connecting Rod

(12)Connecting Rod Cap

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).

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

DRemove 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

Legend

(1) Press Ram

(2) Piston

(3) Connecting Rod

(4) Piston Pin

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.

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

DInsert the piston ring into the bore.

DPush the ring by the piston, at a right angle to the

wall, into the point at which the cylinder bore

diameter is the smallest.

DMeasure the ring end gap.

Compression Ring

1st ring

Standard: 0.300 mm–0.400 mm

(0.0118 in–0.0157 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

DPositioning 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 ring groove / piston ring clearance exceeds 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 and pin does not conform to the specified value,

the connecting rod must be replaced.

Standard : 0.023 mm–0.038 mm (0.0009

in–0.0015 in)

015RS029

3.Insert the new pin into the piston and rotate it. If the

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 measure the thrust clearance at the

large end of the connecting rod If the clearance

exceeds the specified limit, the connecting rod must

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

entire 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

1 Size Mark Big end Bore

Diameter Crankshaft Pin

Diameter Connecting Rod

Bearing Thickness

(Reference)

Color of

Size

Mark Oil Clearance

(Reference)

A56.994-57.000

(2.2439-2.2441) 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) 53.922-53.937

(2.1229-2.1235) 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)

Reassembly

1.Install connecting rod

2.Install piston

3.Install piston pin

DApply 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.

DAttach the piston to the connecting rod with the

piston front mark and the connecting rod front mark

on the same side.

015RS036

DWith 5–8840–0551–0 Piston pin service set and a

press, press fit the piston pin.

NOTE: Heat the connecting rod small end to a suitable

temperature to ensure smooth installation.

015RX001

Legend

(1) Press Ram

(2) Piston

(3) Connecting Rod

(4) Piston Pin

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

DInstall piston rings in the following sequence.

1. Oil ring

1. Expander ring

2. Upper side rail

3. Lower side rail

2. 2nd compression ring

3. 1st compression ring

DThe 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

DAfter installation, apply engine oil to the entire

circumference of the piston rings. Check to see that

all the rings rotate smoothly.

015RS038

5.Install piston and connecting rod assembly.

DInsert the bearings into the connecting rods and

caps. Apply new engine oil to the bearing faces and

nuts.

DTighten 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.

DRefer to “Cylinder Head” in this manual.

Cylinder Block

Cylinder Block and Associated Parts

012RW010

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) Cylinder Block

Disassembly

1.Remove cylinder head assembly.

2.Remove cylinder head gasket.

3.Remove crankcase 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 bolts.

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.

DThe ”Grade” mark (1) is stamped at the position

illustrated.

012RS006

Reassembly

1.Install cylinder block.

2.Install crankshaft.

DInstall the main bearings to the cylinder block and

the main bearing caps.

DBe sure that they are positioned correctly.

DApply new engine oil to the upper and lower main

bearing faces.

NOTE: Do not apply engine oil to the bearing back faces.

015RS012

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.

DCarefully mount the crankshaft.

DApply engine oil to the thrust washer.

DAssemble the thrust washer to the No. 3 bearing

journal. The oil grooves must face the crankshaft.

015RS013

3.Install rear oil seal retainer.

DRemove oil on cylinder block and retainer fitting

surface.

DApply sealant (TB1207B or equivalent) to retainer

fitting surface as shown in illustration.

DThe oil seal retainer must be installed within 5

minutes after sealant application before the sealant

hardens.

015RW002

Legend

(1) Around Bolt Holes

(2) Around Dowel Pin

DApply engine oil to oil seal lip and align a dowel pin

hole in the cylinder block with that in the retainer.

DT ighten retainer fixing bolts to the specified torque.

Torque: 25 N·m (2.5 Kg·m/18.4 lb ft)

015RW001

4.Install flywheel

1. Thoroughly clean and remove the oil from the

threads of crankshaft.

2. Remove the oil from the crankshaft and flywheel

mounting faces.

3. Mount the flywheel on the crankshaft and then

install the washer.

4. 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.

DApply 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.

DCheck to see that the piston ring end gaps are

correctly positioned.

015RX003

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

DInsert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor.

DThe 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.

1.Completely remove all residual sealant, lubricant

and moisture from the sealing surfaces. The

surfaces must be perfectly dry.

2.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.

3.The oil pan must be installed within 5 minutes

after sealant application to prevent premature

hardening of sealant.

4.Tighten the bolts and nuts to the specified torque.

Torque : 10 N·m (1.0 Kg·m/89 lb in)

013RW010

Legend

(1)Portion Between Both Holes

(2)Bolt Hole Portions

12.Install cylinder head gasket.

13.Install cylinder head assembly. Refer to “Cylinder

Head” in this manual.

Main Data and Specification

General Specification

Item

Specifications

Item

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

Cylinder liner type Casted in cylinder drive

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 14.0 Kg/cm@

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, PK16PR11, 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 Under cover N·m (Kg·m/lb ft)

E06RX008

Cylinder head cover, Cylinder head, Camshaft bracket, Common chamber, EGR valve and EGR pipe

N·m (Kg·m/lb ft)

E06RW043

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/lb ft)

E06RW039

Connecting rod and Water pump N·m (Kg·m/lb ft)

E06RW042

Engine mount N·m (Kg·m/lb ft)

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 controller

5–8840–0624–0

(J–38537)

Installer; Oil controller

5–8840–2445–0

(J–42985)

Installer; Camshaft oil

seal

5–8840–2545–0

(J–39206)

Installer; Pilot bearing

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–0133–0

(J–8614–01)

Holder; Crankshaft

5–8840–2153–0

(J–37228)

Seal cutter

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

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–2443–0

(J–42686)

Lever; Gear spring

5–8840–2447–0

(J–43041)

Holder; Universal