SECTION 6A - ENGINE MECHANICAL (6VE1 3.5L)

Service Precautions

General Description

Engine Cleanliness and Care

General Information on Engine Service

Cylinder Block

Cylinder Head

Valve Train

Intake Manifold

Exhaust Manifold

Pistons and Connecting Rods

Crankshaft and Bearings

Engine Control Module (ECM)

Engine Diagnosis

Hard Starting

Engine Compression Test Procedure

Rough Engine Idling or Engine Stalling

Rough Engine Running

Hesitation

Engine Lacks Power

Engine Noisy

Abnormal Combustion

Engine Oil Consumption Excessive

Fuel Consumption Excessive

Lubrication Problems

Engine Oil Pressure Check

Malfunction Indicator Lamp

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 - Service Operations

Removal

Installation

Camshaft

Removal

Inspection and Repair

Installation

Cylinder Head

Cylinder Head and Associated Parts

Removal

Disassembly

Clean

Inspection and Repair

Reassembly

Installation

Engine Assembly

Removal

Installation

Engine Assembly Repair

Cylinder Block and Associated Parts

Piston, Connecting Rod and Associate Parts

Crankshaft and Associated Parts

Disassembly

Inspection and Repair

Main Bearing Clearance

Reassembly

Main Data and Specifications

General Specifications

Torque Specifications

Special Tools

Service Precautions

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL

RESTRAINT SYSTEM (SRS). REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN

ORDER TO DETERMINE WHETHER YOU ARE

PERFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING. WHEN YOU

ARE PERFORMING SERVICE ON OR NEAR THE

SRS COMPONENTS OR THE SRS WIRING, REFER

TO THE SRS SERVICE INFORMATION. FAILURE TO

FOLLOW WARNINGS COULD RESULT IN

POSSIBLE AIR BAG DEPLOYMENT, PERSONAL

INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM

REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

HOLDEN will call out those fasteners that require a

replacement after removal. HOLDEN will also call

out the fasteners that require thread lockers or

thread sealant. UNLESS OTHERWISE SPECIFIED,

do not use supplemental coatings (Paints, greases,

or other corrosion inhibitors) on threaded fasteners

or fastener joint interfaces. Generally, such

coatings adversely affect the fastener torque and

the joint clamping force, and may damage the

fastener. When you install fasteners, use the

correct tightening sequence and specifications.

Following these instructions can help you avoid

damage to parts and systems.

General Description

Engine Cleanliness and Care

An automobile engine is a combination of many

machined, honed, polished and lapped surfaces with

tolerances that are measured in the thousandths of a

millimeter (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.

•

liberal coating of engine oil should be applied to

all friction areas during assembly to protect and

lubricate the surfaces on initial operation.

• Whenever valve train components, pistons, piston

rings, connecting rods, rod bearings, and

crankshaft journal bearings are removed fo

service, they should be retained in order and

should be reinstalled in the same locations and

with the same mating surfaces as when removed.

• The battery cables should be disconnected before

any major work is performed on the engine.

Failure to disconnect the battery may result in

damage to wiring harness or other electrical parts.

• The six cylinders of this engine are identified by

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

cylinders 2, 4 and 6, as counted from crankshaft

pulley side to flywheel side.

General Information on Engine Service

The following information on engine service should be

noted carefully, as it is important in preventing damage

and contributes to reliable engine performance.

• When raising or supporting the engine for any

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

the small clearance between the oil pan and the

oil pump strainer. Jacking against the oil pan may

cause damage to the oil pick-up unit.

• The 12-volt electrical system is capable o

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.

•

ny time the intake air duct or air cleaner is

removed, the intake opening should be covered.

This will protect against accidental entrance o

foreign material into the cylinder which could

cause extensive damage when the engine is

started.

Cylinder Block

The 75°V−type six cylinder block is made of aluminum

die-cast casting. It has a rear plate integrated structure

and employs a deep skirt. The cylinder liner is cast and

the liner inner diameter and crankshaft journal diameter

are classified into grades. The crankshaft is supported

by four bearings of which the width is different between

No.2, No.3 and No.1, No.4; the width of No.3 bearing in

the block is different in order to support the thrust

bearing. The bearing caps are made of nodular cast

iron and each bearing cap uses four main 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 a V-type design. The ports are of the

cross-flow type.

Valve Train

Intake and exhaust camshaft on the both side of banks

are driven through a camshaft drive gear, driven by a

timing belt. The valves are operated by the camshaft

and the valve clearances are adjusted by selecting a

suitable thickness shim.

Intake Manifold

The intake manifold system is composed of the

aluminum cast common chamber and intake manifold

with six fuel injectors.

Exhaust Manifold

The exhaust manifold is made of nodular cast iron.

Pistons and Connecting Rods

Aluminum pistons are used and the grade must be

selected that meets the cylinder bore diameter. Each

piston has two compression rings and one oil ring. The

piston pin is made of chromium steel and is offset 1mm

toward the thrust side. The thrust pressure of the 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 size

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 Control Module (ECM)

The ECM location is on the common chamber.

Engine Diagnosis

Hard Starting

1. Starting Motor Does Not Turn Over

Troubleshooting Procedure

Turn on headlights and starter switch.

Symptom Possible Cause Action

Headlights go out or dim

considerably Battery run down or under charged Recharge or replace battery

Terminals poorly connected Clean battery posts and terminals

and connect properly

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 ignition coil from any spark plug. Connect the spark plug tester 5−8840−0383−0, crank the engine, and

check if a spark is generated in the spark plug tester. Before cranking the engine, make sure that the spark plug tester

is properly grounded. To avoid electrical shock, do not touch the part where insulation of the ignition coil is broken

while the engine is running.

Symptom Possible Cause Action

Spark jumps across gap Spark plug defective Clean 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 (E ngine 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 Repair

Engine Control Module cable

disconnected or defective Repair or replace

3. Trouble In Fuel System

Symptom Possible Cause Action

Starting motor turns over and spark

occurs but engine does not start Fuel tank empty Fill

Water in fuel system Clean

Fuel filter clogged Replace filter

Fuel pipe clogged Clean or replace

Fuel pump defective Replace-

Fuel pump circuit open Repair or replace

Evaporative Emission Control

System circuit clogged Repair or replace

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

section

4. Engine Lacks Compression

Symptom Possible Cause Action

Engine lacks compression Spark plug loosely fitted Tighten to specified torque

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

Incorrect valve clearances Check and adjust valve clearances

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

Symptom Possible Cause Action

Trouble in fuel injection system Idle air control valve defective Replace

Throttle shutting off incomplete Replace

Throttle position sensor circuit open

or shorted Repair or replace

Fuel injector circuits open or shorted Repair or replace

Fuel injectors damaged Replace

Fuel pump relay defective Replace

Mass Airflow Sensor circuit open or

poor connections Repair or replace

Mass Airflow Sensor defective Replace

Engine Coolant Temperature Sensor

circuit open or poor connections Repair or replace

Engine Coolant Temperature Sensor

defective Replace

Intake Air Temperature sensor circuit

open or poor connections Repair or replace

Intake Air Temperature sensor

defective Replace

Vehicle Speed Sensor circuit open or

shorted Repair or replace

Vehicle Speed Sensor defective Replace

Trouble in emission control system EGR valve defective Replace

EGR valve circuit open or poor

connection Repair or replace

Engine Control Module defective Replace

Canister purge valve circuit open or

poor connections Repair or replace

Canister purge valve defective Replace

Evaporative Emission Canister Purge

control valve defective Replace

Trouble in ignition system Refer to “Hard Start"

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

Incorrect valve clearances Check and adjust valve clearances

Positive Crankcase Ventilation valve

defective or clogged Replace

Rough Engine Running

Symptom Possible Cause Action

Engine misfires periodically Ignition coil layer shorted Replace

Spark plugs fouling Clean or install correct heat range

plug

Spark plug(s) insulator nose leaking Replace

Fuel injector(s) defective Repair or replace

Engine control module faulty Replace

Engine knocks periodically Spark plugs running too hot Install correct heat range plug

Engine control module faulty Replace

Engine lacks power Spark plugs fouled Clean or replace

Fuel injectors defective Repair or replace

Mass Airflow Sensor or Intake Airflow

Sensor circuit defective Repair or replace

Engine Coolant Temperature Sensor

or Engine Coolant Temperature

Sensor circuit defective

Repair or replace

Engine Control Module faulty Replace

Intake Air Temperature Sensor or

Intake Air Temperature Sensor circuit

defective

Repair or replace

Throttle Position Sensor or Throttle

Position Sensor circuit defective Repair or replace

Hesitation

Symptom Possible Cause Action

Hesitation on acceleration Throttle Position Sensor adjustment

incorrect Replace throttle valve assembly

Throttle Position Sensor circuit open

or shorted Repair or replace

Excessive play in accelerator linkage Adjust or replace

Mass Airflow Sensor circuit open or

poor connections Repair or replace

Mass Airflow Sensor defective Replace

Intake Air Temperature (IAT) Sensor

circuit open or poor connections Repair or replace

IAT Sensor defective Replace

Hesitation at high speeds

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

Fuel pipe clogged Clean or replace

Fuel filter clogged Replace

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 repair or replace

Fuel Injector defective Replace

Cable of Multiport Fuel Injection

System circuit open or poor

connections

Repair or replace

Hesitation at high speeds Engine Control Module defective Replace

Throttle Position Sensor cable

broken or poor connections Repair or replace

Throttle Position Sensor defective Replace

Engine Coolant Temperature Sensor

circuit open or shorted Repair or replace

Engine Coolant Temperature Sensor

defective Replace

Mass Airflow Sensor circuit open or

poor connections Repair or replace

Mass Airflow Sensor defective Replace

IAT Sensor circuit open or poor

connections Repair or replace

IAT Sensor defective Replace

Throttle valve not fully opened Check and adjust or replace

Air Cleaner Filter clogged Replace filter element

Power supply voltage too low Check and correct or replace

Engine Lacks Power

Symptom Possible Cause Action

Trouble in fuel system Fuel Pressure Control Valve not

working correctly Replace

Fuel injector clogged Clean or replace

Fuel pipe clogged Clean

Fuel filter clogged or fouled Replace

Fuel pump drive circuit not working

correctly Repair 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

Engine Control Module supplied poor

voltage Repair circuit

Throttle Position Sensor cable

broken or poor connections Repair or replace

Throttle Position Sensor defective Replace

Mass Airflow Sensor not working

correctly Replace

Manifold Absolute Pressure Sensor

not working correctly Replace

Intake Air Temperature Sensor not

working correctly Replace

Engine Coolant Temperature Sensor

circuit open or shorted Repair or replace

Engine Coolant Temperature Sensor

defective Replace

Engine Control Module defective Replace

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

Air duct kinked or flattened Repair or replace

Exhaust system clogged Repair or replace

Ignition failure ———— Refer to Hard Start Troubleshooting

Guide

Heat range of spark plug inadequate Install the correct heat range spark

plugs

Ignition coil defective Replace

Symptom Possible Cause Action

Engine overheating Level of Engine Coolant too low Replenish

Fan clutch defective Replace

Thermostat defective Replace

Engine Coolant pump defective 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 Check exhaust system and replace

defective parts

Throttle Position Sensor adjustment

incorrect Replace with Throttle Valve ASM

Throttle Position Sensor circuit open

or shorted Repair 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 recom mended pressures

Brake drag Adjust

Clutch slipping Adjust or replace

Level of oil in engine crankcase too

high Correct level of engine oil

EGR valve defective Replace

Engine Noisy

Abnormal engine noise often consists of various noises originating in rotating parts, sliding parts and other moving

parts of the engine. It is, therefore, advisable to locate the source of noise systematically.

Symptom Possible Cause Action

Noise from crank journals or from

crank bearings

(Faulty crank journals and crank

bearings usually make dull noise that

becomes more evident when

accelerating)

Oil clearance increased due to worn

crank journals or crank bearings Replace crank bearings and

crankshaft or regrind crankshaft and

install the undersize bearing

Crankshaft out of round Replace crank bearings and

crankshaft or regrind crankshaft and

install the undersize bearing

Crank bearing seized Crank bearing seized Replace crank

bearings and crankshaft or regrind

crankshaft and install the undersize

bearing

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.

Symptom Possible Cause Action

Noise from connecting rods or from

connecting rod bearings

(Faulty connecting rods or

connecting rod bearings usually

make an abnormal noise slightly

higher than the crank bearing noise,

which becomes more evident when

engine is accelerated)

Bearing or crankshaft pin worn Replace connecting rod bearings and

crankshaft or regrind crankshaft pin

and install the undersize bearing

Crankpin out of round Replace connecting rod bearings and

crankshaft or regrind crankshaft pin

and install the undersize bearing

Connecting rod bent 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.

Symptom Possible Cause Action

Piston and cylinder noise

(Faulty piston or cylinder usually

makes a combined mechanical

thumping noise which increases

when engine is suddenly accelerated

but diminishes gradually as the

engine warms up)

Piston clearance increased due to

cylinder wear Check and repair engine assembly

as required

Piston seized Check and repair engine assembly

as required

Piston ring broken Check and repair engine assembly

as required

Piston defective Check and repair engine assembly

as required

Troubleshooting Procedure

Short out each spark plug and listen for change in engine noise.

Symptom Possible Cause Action

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 assembly

Troubleshooting Procedure

The slapping sound stops when spark plug on bad cylinder is shorted out.

Symptom Possible Cause Action

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 if required

the timing cover. Check alignment of

cover

Valve noise Valve clearance incorrect Check and adjust as required

Valve and valve guide seized Replace valve and valve guide

Valve spring broken or weakened Replace

Valve seat off–positioned Repair

Camshaft worn out Replace

Crankshaft noise Crankshaft end play excessive (noise

occurs when clutch is engaged) Replace thrust bearing and check the

crankshaft for wear

Engine knocking Preignition due to use of spark plugs

of inadequate heat range Install the correct heat range spark

plugs

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 tensioner and/or drive

belt

Abnormal Combustion

Symptom Possible Cause Action

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 Airflow (MAF) Sensor circuit

open or defective Repair or replace

MAF Sensor defective Replace

Engine Coolant Temperature (ECT)

Sensor circuit open or shorted Repair or replace

ECT Sensor defective Replace

Throttle Position Sensor adjustment

incorrect Readjust

Throttle Position Sensor defective Replace

Throttle Position Sensor connector

poor connections Reconnect

Vehicle Speed Sensor cable poor

connections or defective Repair or replace

Vehicle Speed Sensor loosely fixed Tighten attaching screws to correct

torque specification

Vehicle Speed Sensor in wrong

contact or defective Replace

Engine Control Module cable poor

connections or defective Repair or replace

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

Heated Oxygen Sensor defective Replace

Signal vacuum hose loosely fitted or

defective Repair or replace

EGR Valve circuit open or shorted Repair or replace

EGR Valve defective Replace

ECT Sensor circuit open or shorted Repair or replace

Canister Purge Valve circuit open or

shorted Repair or replace

Canister Purge Valve defective Replace

ECT Sensor defective Replace

Positive Crankcase Ventilation (PCV)

valve and hose clogged Repair or replace

Evaporator system Refer to Section 6E

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

Trouble in cylinder head parts Carbon deposits in combustion

chamber Remove carbon

Carbon deposit on valve, valve seat

and valve guide Remove carbon

Engine Oil Consumption Excessive

Symptom Possible Cause Action

Oil leaking Oil pan drain plug loose Retighten or replace gasket

Crankcase fixing bolts loosened Retighten

Oil pan setting bolts loosened Retighten

Oil pan gasket broken Replace gasket

Front cover retaining bolts loose or

gasket broken Retighten or replace gasket

Head cover fixing bolts loose or

gasket broken Retighten or replace gasket

Oil filter adapter cracked Replace

Oil filter 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 Ventilation Valve

clogged Clean or replace

Engine/Transmission coupling failed Replace oil seal

Oil leaking into combustion

chambers due to poor seal in valve

system

Valve stem oil seal defective Replace

Valve stem or valve guide worn Replace valve and valve guide

Oil leaking into combustion

chambers due to poor seal in

cylinder parts

Cylinders and pistons worn

excessively Check and repair engine assembly

as required

Piston ring gaps incorrectly

positioned Repair

Piston rings set with wrong side up Correct

Piston ring sticking Check and repair engine assembly

as required

Piston ring and ring groove worn Replace pistons and rings

Return ports in oil rings clogged Clean piston and replace rings

Positive Crankcase Ventilation

System malfunctioning Positive Crankcase Ventilation Valve

clogged Clean

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

viscosity

Continuous high speed driving and/or

severe usage such as trailer towing Continuous high speed operation

and/or severe usage will normally

cause increased oil consumption

Fuel Consumption Excessive

Symptom Possible Cause Action

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 to Section 6E

Returning of accelerator control

sluggish Repair

Fuel system leakage Repair or replace

Clutch slipping Adjust or replace

Brake drag Check and adjust

Selection of transmission gear

incorrect Caution operator of incorrect gear

selection

Lubrication Problems

Symptom Possible Cause Action

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

Relief valve sticking Replace

Oil pump not operating properly Repair or replace

Oil pump strainer clogged Clean or replace strainer

Oil pump worn Replace

Oil pressure gauge defective Repair 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 Check and repair engine assembly

as required

Oil not reaching valve system Oil passage in cylinder head or

cylinder body clogged Clean

Engine Oil Pressure Check

1. Check for dirt, fuel 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 Indicator Lamp (MIL) illuminates by self diagnostic system when

the system checks the starting of engine, or senses malfunctions. ”CHECK ENGINE" MIL does not illuminate at the

starting of engine.

Symptom Possible Cause Action

“CHECK ENGINE" MIL does not

illuminate at the starting of engine Bulb defective Replace

MIL circuit open Repair or replace

Command signal circuit to operate

self diagnostic system shorted Repair or replace

Engine Control Module (ECM) cable

loosely connected, disconnected or

defective

Repair or replace

ECM defective Replace

“CHECK ENGINE" MIL illuminates,

and stays on Deterioration of heated oxygen

sensor internal element Replace

Heated oxygen sensor connector

terminal improper contact Repair or replace

Heated oxygen sensor lead wire

shorted Repair

Heated oxygen sensor circuit open Repair or replace

Deterioration of engine coolant

temperature sensor internal element Replace

Engine coolant temperature sensor

connector terminal improper contact Repair or replace

Engine coolant temperature sensor

lead wire shorted Repair

Engine coolant temperature sensor

circuit open Repair or replace

Throttle position sensor open or

shorted circuits Repair or replace

Deterioration of crankshaft position

sensor Replace

Crankshaft position sensor circuit

open or shorted Repair or replace

Vehicle speed sensor circuit open Repair or replace

Intake air temperature sensor circuit

open or shorted Repair or replace

Fuel injector circuit open or shorted Repair or replace

ECM driver transistor defective Replace ECM

Malfunctioning of ECM RAM

(Random Access Memory) or ROM

(Read Only Memory)

Replace ECM

Cylinder Head Cover LH

Removal

1. Disconnect the battery ground cable.

2. Disconnect the positive crankcase ventilation

hose.

3. Remove the camshaft angle sensor connector.

4. Remove the ground cable fixing bolt attaching the

cylinder head cover.

5. Ignition coil connector and ignition coil.

• Disconnect the three connectors (1) from the

ignition coils.

• Remove the wiring harness bracket bolt on the

cylinder head cover.

• Remove fixing bolts (2) on the ignition coils (3).

060RW078

Legend

(1) Ignition Coil Connector

(2) Bolt

(3) Ignition Coil Assemblies

6. Remove the fixing bolt for the fuel injector harness

bracket.

7. Remove eight fixing bolts, then remove the

cylinder head cover.

010RW001

Installation

1. Clean the sealing surface of cylinder head and

cylinder head cover to remove oil and any

remaining sealing materials completely.

• Apply a 2-3 mm bead of sealant TB-1207B o

equivalent at eight places at the arched area o

the camshaft bracket on the front and rea

sides.

• Install cylinder head cover.

NOTE: The cylinder head cover must be installed within

5 minutes after sealant application to prevent hardening

of sealant.

• Tighten bolts to the specified torque.

Torque: 9 N⋅m (0.9 kg⋅m/7 lb ft)

010RW006

2. Install fuel injection harness bracket and tighten

the bolt to the specified torque.

Torque: 8 N⋅m (0.8 kg⋅m/6 lb ft)

3. Connect the ignition coil connector and ignition

coil, then tighten bolt to the specified torque.

Torque: 4 N⋅m (0.4 kg⋅m/3 lb ft)

060RW078

Legend

(1) Ignition Coil Connector

(2) Bolt

(3) Ignition Coil Assembly

4. Connect the ground cable and tighten bolts to the

specified torque.

Torque: 9 N⋅m (0.8 kg⋅m/6 lb ft)

5. Connect the camshaft angle sensor connector.

6. Install the positive crankcase ventilation hose.

7. Reconnect the battery ground cable.

Cylinder Head Cover RH

Removal

1. Disconnect the battery ground cable.

2. Remove the air cleaner duct assembly.

3. Disconnect the ventilation hose from the cylinde

head cover.

4. Disconnect the three ignition coil connectors from

the ignition coils and remove the wiring harness

bracket bolts on the cylinder head cover, then

remove the ignition coil fixing bolts on the ignition

coils and remove the ignition coils.

5. Remove the heater pipe fixing bolts from the

bracket.

6. Disconnect the fuel injector wiring harness

connector then remove fuel injector harness

bracket bolt.

7. Remove the EGR pipe.

8. Remove the eight fixing bolts, then the cylinde

head cover.

010RW002

Installation

1. Clean the sealing surface of cylinder head and

cylinder head cover to remove oil and sealing

materials completely.

• Apply a 2-3 mm bead of sealant TB-1207B o

equivalent at eight places at the arched area o

the camshaft bracket on the front and rea

sides.

• Install the cylinder head cover.

• Tighten the bolts to the specified torque.

Torque: 9 N⋅m (0.9 kg⋅m/7 lb ft)

NOTE: The cylinder head cover must be installed

within 5 minutes after sealant application to

prevent premature hardening of sealant.

014RW019

2. Install the exhaust gas recirculation pipe and

tighten to specified torque.

Torque:

Exhaust manifold side: 29 N⋅m (3.0 kg⋅m/21 lb ft)

Flare nut: 44 N⋅m (4.5 kg⋅m/33 lb ft)

Cylinder head side: 20 N⋅m (2.0 kg⋅m/14 lb ft)

3. Tighten the fuel injector harness bracket bolts to

the specified torque, then reconnect the fuel

injector wiring harness connector.

Torque: 8 N⋅m (0.8 kg⋅m/5.7 lb ft)

4. Install heater pipe bolt to the specified torque.

Torque: 20 N⋅m (2.0 kg⋅m/14 lb ft)

5. Connect the ignition coil connector and tighten the

ignition coil fixing bolts to specified torque.

Torque: 4 N⋅m (0.4 kg⋅m/3 lb ft)

6. Connect the ventilation hose to cylinder head.

7. Install the air cleaner duct assembly.

Common Chamber

Removal

1. Disconnect the battery ground cable.

2. Remove the air cleaner du ct assembly.

3. Disconnect the two conne ctors from the ECM.

• Remove the fixing bolts on the common

chamber.

• Remove the fixing bolts for ground cable, then

remove the ECM.

060RW025

4. Remove the accelerator control cable from the

accelerator control cable bracket by sliding the

lock in direction A, then rotating the ratchet ring in

the direction of the arrow 90°

RTW46ASH000201

Legend

(1) Cable Bracket

(2) Ratchet ring

(3) Outer Cap

(4) Lock

(5) Paint Mark

(6) Arrow Mark

5. Remove the accelerator control cable from the

throttle body.

6. Disconnect the brake vacuum booster hose from

common chamber.

7. Disconnect the connectors from the manifold

absolute pressure sensor, idle air control valve,

throttle position sensor, solenoid valve and the

electric vacuum sensing valve (VSV).

8. Disconnect the vacuum hose on the canister VSV

and positive crankcase ventilation hose, fuel rail

assembly with pressure control valve bracket.

9. Remove the ventilation hose from the throttle

valve and intake duct and remove the water hose.

10. Remove the exhaust gas recirculation valve

assembly fixing bolt and nut on common chamber.

11. Remove the two bolts from the common chambe

rear side and remove the fuel hose bracket.

12. Remove the common chamber four bolts and fou

nuts, then remove the common chamber.

025RW001

Legend

(1) Common Chamber

(2) Throttle Valve Assembly

(3) Bolt

13. Remove the four throttle body fixing bolts.

Installation

1. Install throttle body and tighten the bolts to the

specified torque.

Torque: (Bolt size M8)

25 N⋅m (2.5 kg⋅m/18 lb ft)

2. Install the fuel hose bracket and tighten the bolts

to specified torque.

Torque: 10 N⋅m (1.0 kg⋅m/89 lb in)

3. Install the common chamber and tighten the bolts

and nuts 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 the ventilating hose to the throttle valve and

intake duct.

5. Connect the vacuum hoses on canister VSV and

the positive crankcase ventilation hose. Tighten

the bolts for the fuel rail assembly and the

pressure control valve bracket.

Torque: 25 N⋅m (2.5 kg⋅m/18 lb ft)

6. Ensure each connector is co rrectly installed.

7. Connect the vacuum booster ho se.

8. Install the ECM and tighten the four bolts to the

specified torque.

Torque: 10 N⋅m (1.0 kg⋅m/7 lb ft)

• Connect the two connectors.

• Tighten the two ground cable bolts to the

specified torque.

Torque: 10 N⋅m (1.0 kg⋅m/7 lb ft)

9. Install the accelerator control cable to the

accelerator cable bracket.

• Rotate the ratchet ring in the direction of the

arrow 90°.

• Confirm that the marking of the outer cap must

be at the upper side.

• Confirm the ratchet ring is locked.

060RW093

Legend

(1) Cable Bracket

(2) Ratchet ring

(3) Outer Cap

(4) Lock

(5) Paint Mark

(6) Arrow Mark

10. Install the cable clips to accelerator control cable.

11. Install air cleaner duct assembly.

Exhaust Manifold LH

Removal

1. Disconnect the battery ground cable.

2. Disconnect the O2 sensor connector.

3. Remove the torsion bar. Refer to removal

procedure in Front Suspension section.

4. Remove the front exhaust pipe three stud nuts

from the exhaust side and two nuts from rear end

of the front exhaust pipe.

RTW36FSH000201

5. Remove the two heat protector fixing bolts, then

remove the heat protector.

6. Remove the bolt on the engine LH side for the ai

conditioner (A/C) compressor bracket and remove

the two bolts for the A/C compressor, then move

the A/C compressor to front side.

7. Remove the exhaust manifold eight fixing nuts and

remove the exhaust manifold from the engine.

Installation

1. Install the exhaust manifold and tighten the

exhaust manifold fixing nuts to the specified

torque ensuring new nuts are used.

Torque: 52 N⋅m (5.3 kg⋅m/38 lb ft)

2. Install the heat protector.

3. Install the exhaust front pipe and tighten the 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)

4. Install the torsion bar and readjust the vehicle

height. Refer to installation and vehicle height

adjustment procedure for Front Suspension.

5. Set the A/C compressor to the normal position and

tighten the two bolts for the A/C compressor and

the bolt attaching the A/C compressor bracket to

the specified torque.

Torque: 40 N⋅m (4.1 kg⋅m/30 lb ft)

6. Reconnect the O2 sensor connector.

7. Install the air cleaner duct assembly.

Exhaust Manifold RH

Removal

1. Disconnect the battery ground cable.

2. Remove the front exhaust pipe three attaching

stud nuts and the two nuts, then remove the front

exhaust pipe.

RTW36FSH000101

3. Remove the steering shaft. Refer to removal

procedure in Steering section.

4. Remove the heat protector two fixing bolts, then

the heat protector.

5. Remove the EGR pipe.

6. Remove the exhaust manifold eight fixing nuts,

then the exhaust manifold.

Installation

1. Install the exhaust manifold and tighten the bolts

to the specified torque.

Torque: 52 N⋅m (5.3 kg⋅m/38 lb ft)

2. Install EGR pipe.

Torque: 29 N⋅m (3.0 kg⋅m/22 lb ft)

3. Install heat protector

4. Install the front exhaust pipe and tighten the three

stud nuts and the 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 steering shaft. Refer to installation

procedure in Steering section.

Crankshaft Pulley

Removal

1. Disconnect the battery ground cable.

2. Remove the air cleaner assembly.

3. Remove the radiator upper fan shroud from the

radiator.

4. Move the drive belt tensioner to the loose side,

using a wrench, then remove the 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 the cooling fan assembly four fixing nuts,

then the cooling fan assembly.

6. Remove the crankshaft pulley assembly using

5−8840−0133−0 crankshaft holder, then by

holding the crankshaft pulley, remove the cente

bolt and pulley.

Installation

1. Install the crankshaft pulley using 5−8840−0133−0

crankshaft holder, then hold the crankshaft pulley

and tighten the center bolt to the specified torque.

Torque: 167 N⋅m (17.0 kg⋅m/123 lb ft)

2. Install the cooling fan assembly and tighten the

bolts/nuts to the specified torque.

Torque: 25 N⋅m (2.5 kg⋅m/18 lb ft) for fan pulle

and fan bracket.

Torque: 10 N⋅m (1.0 kg⋅m/7 lb ft) for fan and

clutch assembly.

3. Move the drive belt tensioner to the loose side

using wrench, then install the drive belt to the

normal position.

4. Install the radiator upper fan shroud.

5. Install the air cleaner assembly.

6. Reconnect the battery.

Timing Belt - Service Operations

Removal

NOTE: The following information describes the service

procedures to replace a timing belt prior to breakage.

However, the service procedures are the same except

the timing marks will all have to be placed in their

respective positions individually.

NOTE: To assist in the installation of an un-broken

timing belt, it is recommended that the timing marks

listed in steps 1 to 7 in the installation procedure be

aligned prior to removal of the timing belt. Due to the

ratios of the timing gears, it may take up to six turns of

the crankshaft to align the timing marks.

1. Disconnect the battery ground cable.

2. Remove the air cleaner assembly.

3. Remove the radiator upper fan shroud from the

radiator.

4. Move the drive belt tensioner to the loose side

using a wrench, then remove the 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 the four nuts attaching the cooling fan

assembly, then remove the cooling fan assembly.

6. Remove the cooling fan drive pulley assembly.

7. Remove the idle pulley assembly.

8. Remove the drive belt tensioner assembly.

9. Remove the power steering pump assembly.

10. Remove the crankshaft pulley assembly using

5−8840−0133−0 crankshaft holder, then by

holding the crankshaft pulley, remove the cente

bolt and pulley.

11. Remove the right-hand side timing belt cover then

the left-hand side timing belt cover.

12. Remove the lower timing belt cover.

13. Remove the tensioner pusher assembly.

CAUTION: The timing belt tensioner push rod

prevents air from entering the oil chamber. Ensure

the rod is facing upward when stored.

014RW011

Legend

(1) Up Side

(2) Down Side

(3) Direction For Installation

(4) Locking Pin

14. Remove the cylinder head covers, refer to

Cylinder Head Cover RH and

Cylinder Head Cover LH.

15. Ensure the timing marks are aligned, then remove

the timing belt.

Installation

NOTE: NEW BELT CARE

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

core could be damaged. The timing belt should

not be bent at a radius less than 30 mm.

2. Do not allow oil or other chemical substances to

come in to contact with the timing belt. A timing

belt that has been contaminated with oil o

chemicals will have its life shortened.

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

screwdriver or any other tool during installation.

4. Store the timing belt in a cool and dark place.

Never expose the timing belt to direct sunlight o

heat.

NOTE: For correct timing belt installation, the letters on

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

front of the vehicle.

014RW006

Legend

(1) Timing Belt

(2) Engine Rotation Direction

(3) Cylinder Head Side

014RY00043

Legend

(7) Alignment Mark on Oil Pump.

(8) Alignment Mark on Timing Belt

(9)

lignment Mark (notch) on Crankshaft Timing

Pulley

(10)

lignment Mark (groove) on Crankshaft Timing

Pulley.

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) Tensioner Pulley

014R100015

1. Align the mark (notch) of the crankshaft timing

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

2. Install the timing belt to the crankshaft gear and

align the mark (groove) on the crankshaft timing

gear pulley (3) with the alignment mark (white

dots) on the timing belt (4).

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

3. Align the alignment mark on the RH bank

camshaft drive gear pulley (2) to the alignment

mark of the cylinder head cover RH (3).

NOTE: When aligning the timing marks, use a wrench

to turn the camshaft drive gear pulley.

lign the alignment mark (white line) on the timing

belt (1) with alignment mark on the RH bank

camshaft drive gear pulley (2) and install the

timing belt to the camshaft drive gear pulley.

014RW00004

Legend

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

(2) Alignment Mark on Camshaft Drive Gear Pulley.

(3) Alignment Mark on Cylinder Head Cover RH.

5. 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 the timing belt has been installed to each pulley, to

prevent the belt from coming off the pulley after

installation.

lign the alignment mark on the LH bank camshaft

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

cylinder head cover LH (3).

lign the alignment mark (white line) on the timing

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

camshaft drive gear pulley (2).

014RW00005

Legend

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

(2) Alignment Mark on Camshaft Drive Gear Pulley.

(3) Alignment Mark on Cylinder Head Cover LH

8. Secure the belt with a double clip or equivalent

clip.

9. Install the crankshaft pulley temporarily and

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

10. Turn the crankshaft pulley clockwise to allow

some belt slack between the crankshaft timing

pulley and the RH bank camshaft drive gea

pulley.

NOTE: When reusing the tensioner, compress the pin

with approximately 100Kg of force to retract the

rod then, insert a locking pin manufactured from

1.4 mm piano wire or similar.

11. Compress and pin the timing belt tensioner, then

install the tensioner assembly and tighten the

attaching bolts to the specified torque.

Torque: 25 N⋅m (2.5 Kg⋅m/18 lb ft)

NOTE: Install the tensioner while pushing the tensioner

pulley towards the belt.

014RW011

Legend

(1) Up Side

(2) Down Side

(3) Direction for Installation

(4) Locking Pin

12. Pull the locking pin out from the tensioner and

ensure that the push rod projection is about 5 mm,

as shown.

6V003

Legend

(1) Tensioner Pulley

(2) Direction Of Rotation

(3) Crankshaft Pulley

(4) Tensioner Assembly

13. Remove the double clips or equivalent clips, from

the timing belt pulleys, then turn the crankshaft

pulley clockwise by hand six turns and recheck

the timing marks.

NOTE: The timing marks on the belt are for initial

installation only. The crankshaft timing mark, oil pump

cover timing mark and camshaft timing mark will be in

their timing setting positions every six crankshaft

revolutions.

14. Remove the crankshaft pulley installed in step 9.

15. Install the timing belt cover and tighten all

attaching 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

16. Install the crankshaft pulley using 5-8840-0133-0

crankshaft holder, then hold the crankshaft pulley

and tighten the center bolt to the specified torque.

Torque: 167 N⋅m (17.0 kg⋅m/123 lb ft)

17. Install the fan pulley bracket and tighten fixing the

bolts to the specified torque.

Torque: 22 N⋅m (2.2 kg⋅m/16 lb ft)

18. Install the power steering pump assembly and

tighten to the bolts 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)

19. Install the cooling fan assembly and tighten the

bolts/nuts to the specified torque.

Torque: 22 N⋅m (2.2 kg⋅m/16 lb ft) for fan pulle

and fan bracket.

Torque: 10 N⋅m (1.0 kg⋅m/7 lb ft) for fan and

clutch assembly.

20. Move the drive belt tensioner to loose side using

wrench, then install the drive belt to the 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

21. Install the radiator upper fan shroud.

22. Install the air cleaner assembly.

23. Reconnect the battery.

Camshaft

Removal

1. Disconnect the battery ground cable.

2. Remove the crankshaft pulley.

• Refer to removal procedure for

Crankshaft Pulley in this manual.

3. Remove the timing belt.

• Refer to removal procedure for Timing Belt in

this manual.

4. Remove the appropriate cylinder head cover.

• Refer to removal procedure for

Cylinder Head Cover LH and

Cylinder Head Cover RH in this manual.

5. Remove the twenty fixing bolts attaching the inlet

and exhaust camshaft brackets, then remove the

camshaft brackets.

014RW027

6. Remove the camshaft assembly.

7. Remove the fixing bolt for the camshaft drive gea

pulley.

8. Remove the three fixing bolts attaching the

camshaft drive gear retainer, then remove the

camshaft drive gear assembly.

014RW026

Legend

(1) Right Bank

(2) Left Bank

(3) Timing Mark on Retainer

9. Remove the camshaft assembly.

Inspection and Repair

1. Use a micrometer and measure the camshaft lobe

height and uneven wear. Replace the camshaft i

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 and 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, then slowly

rotate the camshaft and measure the runout with a

dial indicator. Replace the camshaft if the runout

exceeds the specified limit.

Run Out

Limit: 0.1 mm (0.0039 in)

014RW044

4. Clean the camshaft brackets and the cylinde

head journals.

5. Install the brackets and tighten in numerical orde

to the specified torque before measuring the

camshaft bracket inside diameter.

Torque: 10 N⋅m (1.0 kg⋅m/7 lb ft)

014RW031

6. Measure the camshaft bracket housing inside

diameter by measuring the inside diameter of the

camshaft journals in two directions as shown.

a. Subtract the camshaft outside diameter from

the camshaft bracket housing inside diameter.

014RW037

7. Replace the cylinder head and/or the camshaft, i

the measured oil clearance exceeds the specified

limit.

Oil Clearance

Standard :

0.027 mm−0.078 mm (0.0011 in−0.0031 in)

Limit: 0.11 mm (0.0043 in)

8. 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

NOTE: Remove the camshaft assembly from the

cylinder head prior to the installation procedure. This is

to allow for the lubrication of the camshaft and journals.

Installation

1. Install the camshaft drive gear assembly into the

cylinder head and tighten the three attaching bolts

to the specified torque.

Torque: 10 N⋅m (1.0 kg⋅m/7 lb ft)

2. Tighten the bolt for the camshaft drive gea

assembly pulley to the specified torque.

Torque: 98 N⋅m (10.0 kg⋅m/72 lb ft)

014RW060

3. Tighten the sub gear setting bolt by using

5−8840−2443−0 gear spring lever to turn the sub

gear to the right direction until it aligns with the M5

bolt hole between camshaft driven gear and sub

gear.

4. Insert a suitable M5 bolt and tighten firmly to

prevent the sub gear from moving while installing

the camshaft assembly.

014RW041

pply engine oil to the camshaft journal and

bearing surface of camshaft brackets.

6. Install the camshaft assembly and camshaft

brackets, then tighten the bracket fixing bolts

firmly at this stage in numerical order shown is

step 8.

lign the timing mark on the intake camshaft (one

dot for the right bank, two dots for the left bank)

and the exhaust camshaft (one dot for right bank,

two dots for the left bank) to the timing mark on

the 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

8. Tighten the ten bolts in numerical order on one

side camshaft to the specified torque.

• Repeat for the other camshaft.

Torque: 10 N⋅m (1.0 kg⋅m/7 lb ft)

014RW031

9. Remove the M5 bolt installed in step 4.

10. Check and adjust the valve clearances as

required. Refer to Valve Clearances in Cylinde

Head Section.

11. Install the appropriate cylinder head cover.

• Refer to the installation procedure for the

Cylinder Head Cover LH and

Cylinder Head Cover RH in this manual.

12. Install the timing belt.

• Refer to the installation procedure fo

TIMING BELT in this manual.

13. Install the crankshaft pulley.

• Refer to the installation procedure fo

CRANKSHAFT PULLEY in this manual.

Cylinder Head

Cylinder Head 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

Removal

1. If required, remove the engine hood.

2. Disconnect the battery ground cable.

3. Drain the radiator coolant and the engine oil.

4. Remove the timing belt.

• Refer to removal procedure for Timing Belt in

this manual.

5. Remove the appropriate exhaust manifold.

• Refer to removal procedure for

Exhaust Manifold LH and

Exhaust Manifold RH in this manual.

6. Remove the appropriate cylinder head cover.

• Refer to removal procedure for

Cylinder Head Cover LH and

Cylinder Head Cover RH in this manual.

7. Remove the common chamber.

• Refer to removal procedure fo

Common Chamber in this manual.

8. Remove the eight bolts attaching the cylinde

head to the block, then remove the cylinder head

assembly.

014RW028

Legend

(1) Cylinder Head

(2) Cylinder Head Bolt

(3) Camshaft

Disassembly

NOTE: During disassembly, be sure that the valve train

components are kept together and Identified so that

they can be reinstalled in their original locations.

1. Remove the camshaft assembly. Refer to

Camshaft in this section.

2. Remove the valve clearance adjusting shim (4)

and the tappet (5).

3. Use the 5−8840−2446−0 valve spring compresso

and 5−8840−2547−0 valve spring compresso

adapter to remove the split collar (6).

014RW042

4. Remove the valve spring.

5. Remove the valve.

6. Remove the oil controller and spring lower seat.

7. Repeat steps 2 to 6 for the remaining valve train

components.

Clean

Cylinder head

Carefully remove all varnish, soot and carbon from the

cylinder head. Do not use a motorized wire brush on

any gasket surface.

Inspection and Repair

Cylinder Head

1. Inspect the cylinder head gasket and mating

surfaces for leaks, corrosion or blow-by. If the

gasket has failed, determine the cause of the

failure.

−Insufficient torque on head bolts

−Improper installation

−Loose or warped cylinder head

−Missing dowel pins

–Engine overheating

−Warped case surface

2. Inspect the cylinder head for cracks, especially

between the valve seats and in the exhaust ports.

3. Inspect the cylinder head deck and water jackets

for corrosion, sand particles in the head and

porosity.

CAUTION:

• Do not attempt to weld the cylinder head.

Replace if it is corroded, cracked or damaged.

• Do not reuse the cylinder head bolts.

4. Inspect the cylinder head deck, common chambe

and exhaust manifold mating surfaces fo

distortion. 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 cylinder head i

it requires machining beyond the repairable limit.

5. Inspect the water jacket sealing plugs and seating

surfaces for corrosion.

NOTE: It is recommended that all water jacket sealing

plugs be replaced when servicing the cylinder head.

Head and manifold surfaces

Standard: 0.05 mm (0.002 in) or less

Distortion 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)

Distortion limit: 0.2 mm (0.0079 in)

Maximum repairable limit: 133.0 mm (5.2362 in)

011RW019

Valve Spring

CAUTION: Visually inspect the valve springs and

replace them if damage or abnormal wear is

evident.

1. Using a vernier, measure the free length

(un-compressed length) of the valve spring. The

spring must be replaced if the free length is below

the specified limit.

Standard: 44.6 mm (1.756 in)

Limit: 43.6 mm (1.717 in)

014RS004

2. Using a flat surface and a steel square, measure

the valve spring to ensure it is not distorted and is

perpendicular to the base of the spring, replace

the valve spring if the measured value exceeds

the specified limit.

Limit: 2 mm (0.079 in)

014RS005

3. Using a spring tester to compress the valve spring

to the installed height and measure the

compressed spring tension. Replace the springs i

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)

LNW21BSH056701

Valve Guide

NOTE: Take care not to damage the valve seat contact

surface, when removing carbon from the valve head

and base of the valve stem. Carefully inspect the valve

stem for scratches or abnormal wear. If these

conditions are present, the valve, valve guide and valve

seat insert must be replaced as a complete set.

1. Measure the valve stem diameter in two directions

as shown with a micrometer. If the valve stem

diameter is less than the specified limit, the valve,

valve guide and valve seat insert 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 inner diameter of the valve guide with

a micrometer. Subtract the measured oute

diameter of the valve stem from the measured

inner diameter of the valve guide. If the value

exceeds the specified limit, the valve, valve guide

and valve seat insert must be replaced as a set.

Inside Diameter of the Valve Guide

Inlet clearance

Standard : 0.023mm−0.056mm

(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 the valve guide replacement tool 5-8840-

2442-0, drive the valve guide from the cylinde

head, from the combustion chamber side.

014RS008

pply engine oil to the outside of the new valve

guide and using the valve guide replacement

tool 5-8840-2442-0, insert in a new valve guide

into the cylinder head, from the camshaft side

until the valve guide height is at the specified

height from the cylinder head upper face.

Valve guide upper end height: 13.0 mm (0.5118

in)

(Measured from the cylinder head upper face)

014RW046

3. Check the valve guide inner clearance, if the

clearance is less than the specified clearance the

valve guide will require reaming to obtain the

specified clearance. Ream the inside diameter o

valve guide using a sharp 6 mm reamer.

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.

NOTE: If the valve seat insert requires replacement,

the valve, valve seat insert and valve guide must be

replaced as a complete set.

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 valve seat contact

surface is damaged or rough or, if the valve seat

contact width exceeds the specified 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 and Valve

1. Measure the contact surface angle on the valve

seat.

2. If the measured value exceeds the limit, replace

the valve, valve guide and valve seat as a set.

Valve contact surface angle: 45°

014RS012

Valve Seat Insert Correction

1. Carefully, remove the carbon from the valve seat

insert surface.

2. Use a valve cutter to minimize scratches and othe

rough areas. Remove only the scratches and

rough areas and take care not to cut away too

much or the unblemished areas of the valve seat

surface.

Valve seat angle degree: 90°

014RW059

pply valve cutting compound to the valve seat

insert surface

4. Insert the valve into the valve guide.

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

insert.

6. Check that the valve contact width is correct.

Replace the valve, valve insert and valve guide if it

is not within the specified limit.

7. Check that the valve seat insert surface is in

contact with the entire circumference of the valve.

014RS014

Valve Seat Insert Replacement

CAUTION: Use extreme care not to damage the

cylinder head in the following operation.

NOTE: If the valve seat insert requires replacement,

the valve, valve guide and valve seat insert must be

replaced as a complete set.

1. Arc weld a welding rod at several points around

the valve seat insert.

llow the rod to cool for a few minutes. This will

cause the valve seat to shrink.

3. Strike the rod and pull the valve seat insert out o

the cylinder head.

014RS015

4. Carefully, clean the section around the valve seat

insert area of the cylinder head.

5. Heat the section around the valve seat insert in

the cylinder head with steam or some other means

to cause expansion. Cool the valve seat with dry

ice or some other means.

6. Insert the valve seat insert into the cylinder head

horizontally, ensuring it is fully seated in the

cylinder head.

Standard fitting interference: 0.14 mm−0.09 mm

(0.0055 in−0.0035 in)

fter insertion, use a valve seat grinder to cut the

seating face. Carefully note the seating angle, the

contact width, and the depression of the valve

seat insert contact area.

8. Lap the valve and the valve seat together to obtain

a uniform finish

Reassembly

1. Install the valve spring lower seat (2), then using

the oil controller installer 5−8840−0623−0, install a

new oil controller (3) over the valve guide (1).

014RW058

pply clean engine oil to the outside of the valve

stem and install the valve to the valve guide.

3. Attach the valve spring to the lower spring seat.

NOTE: The painted area of the valve spring should be

facing downward.

014RS020

4. Install the lower valve spring seat, valve spring

and the upper valve spring seat, then using the

5−8840−2446−0 valve spring compressor and

5−8840−2547−0 valve spring compressor adapter,

install the split collars to the upper valve spring

seat.

014RW042

5. Install the tappet with the shim.

6. Install the camshaft assembly.

• Refer to installation procedure for Camshaft in

this manual.

djust the valve clearances. Refer to

Valve Clearances in this Section.

Valve Clearance Adjustments

NOTE: To adjust the valve clearance, apply clean

engine oil to the cam (1) and the adjusting shim (2).

1. With the cylinder head assembled to the cylinde

block, rotate the camshaft two turns by, using the

timing pulley tightening bolt.

2. Measure the valve clearance when the nose o

cam is opposite to the maximum cam lift as

shown.

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

To select the correct size adjusting shim;

• Add the thickness of the shim removed to the

measured valve clearance

• Subtract the appropriate valve clearance

• This will give the final figure, which is the

thickness of the shim required.

Based on this formula, select the most suitable sized

shim from the 41 available. The shims are available in

intervals of 0.02 mm (0.0008 in) from 2.40 mm (0.0945

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

selected then recheck the valve clearance to confirm

the correct shim was selected.

Replacement of Shim

1. Insert the valve clearance adjusting tool,

5−8840−2444−0.

014RW082

2. Rotate the camshaft and allow the adjusting tool

to push down on the edge of tappet.

014RW083

3. Push out the shim with a flat blade screwdriver.

014RW084

4. Insert the shim selected and rotate the camshaft in

the opposite direction. Recheck the valve

clearances to confirm the correct shim is selected.

5. Repeat the process if necessary.

Installation

1. Ensure the cylinder head and block are clean and

free of oil and old head gasket material.

2. Place cylinder head gasket on the cylinder block.

NOTE: There is discrimination mark "R" (1) for the right

bank and "L" (2) for the left bank on the cylinder head

gasket. Do not reuse cylinder head gasket or bolts.

011RW005

lign the dowel pin hole in the cylinder head to the

dowel pin on the cylinder block, then carefully

install the cylinder head assembly to the cylinde

block.

NOTE: Take care not to damage the head gasket.

4. Tighten two new cylinder head bolts by hand to

prevent the cylinder head assembly from moving.

5. Install the remaining new cylinder head bolts and

tighten in the numerical order to the specified

torque in stage 1, using the cylinder head bolt

wrench 9−8511−4209−0.

NOTE: Do not reuse the cylinder head bolts or apply

any lubricant to the bolts.

Cylinder Head Bolt Torque:

Stage 1: 29 N⋅m (3.0 kg⋅m/21 lb ft)

014RW029

6. Tighten the cylinder head bolts in the numerical

order to the final specified torque.

Cylinder Head Bolt Torque:

Final: 64 N⋅m (6.5 kg⋅m/47 lb ft)

7. Install the common chamber.

• Refer to the installation procedure fo

Common Chamber in this manual.

8. Install the appropriate exhaust manifold.

• Refer to the installation procedure for

Exhaust Manifold LH and

Exhaust Manifold RH in this manual.

9. Install the timing belt.

• Refer to the installation procedure for

Timing Belt in this manual.

10. Install the crankshaft pulley.

• Refer to the installation procedure fo

Crankshaft Pulley in this manual.

11. Fill the cooling system with the correct coolant.

Refer to Cooling System.

12. Fill the engine with the recommended grade and

quantity of oil. Refer to Section 0B.

Engine Assembly

Removal

1. Disconnect the battery ground and positive cables,

then remove the battery from the vehicle.

2. Place an alignment mark on the engine hood and

hinges and remove the hood.

3. Drain the radiator coolant and if required, drain the

engine oil.

4. Remove the accelerator control cable from the

accelerator control cable bracket by, sliding the

lock towards direction A, then rotate the ratchet

ring (2) in the direction of the arrow (6) 90°

RTW46ASH000201

5. To remove the ECM from the common chamber;

•. Disconnect the two connectors from the ECM,

•. Remove the fixing bolts for the ground cable,

• Remove the fixing bolts on the common

chamber then remove the ECM.

060RW025

6. Disconnect the air duct from the air cleaner cover.

7. Remove the air cleaner assembly.

8. Disconnect the canister vacuum hose.

9. Disconnect the brake vacuum booster hose.

10. Disconnect the three engine harness connectors.

11. Disconnect the wiring harness connector to the

transmission on engine left side.

12. Disconnect the shift on the fly wiring harness

connector from the front side of the front axle and

remove the transmission harness bracket from the

engine left side.

13. Disconnect the ground cable between the engine

and chassis.

14. Disconnect the wiring harness connector from the

starter motor.

15. Disconnect the wiring harness connector from the

generator.

16. Disconnect the coolant reserve tank hose from the

radiator.

17. Remove the radiator upper and the lower hoses.

18. Remove the upper fan shroud and if required,

remove the radiator.

19. Remove the four fixing nuts attaching the cooling

fan assembly and remove the cooling fan

assembly.

20. Move the drive belt tensioner to the loose side

using a wrench, then remove the drive belt.

850RW001

21. Remove the power steering pump fixing bolts,

then the power steering pump. Place the powe

steering pump along with hoses on the body side

and secure with tie wire or similar.

22. Remove the air conditioning compressor fixing

bolts from the bracket and place the compresso

along with the piping on the body side.

23. Remove the four O2 sensor wiring harness

connectors (two each bank) from the front exhaust

pipe.

24. Remove the LH and RH front exhaust pipes. Refe

to Section 6F.

25. Remove the flywheel dust covers.

26. Disconnect the two heater hoses from the engine.

27. Disconnect the fuel hose connector at the engine.

CAUTION: Plug the fuel pipe on the engine side and

the fuel hose from the fuel tank side.

28. Remove the transmission assembly. Refer to the

MUA5G Transmission or

AW30-40LE Transmission.

NOTE: Support the engine using an engine hoist or

similar.

29. Remove the four fixing bolts attaching the left-

hand and right-hand engine mounts to the

chassis.

30. Using an engine hoist or similar, lift the engine

from the vehicle taking care that all hoses, wiring

harnesses, cables and ancillary equipment are

clear from the engine assembly.

Installation

CAUTION: When assembling the engine to the

transmission, confirm that the dowels have been

installed in their specified locations on the engine.

Also, take care that the dowel positions are

different between the manual transmission and the

automatic transmission. Otherwise, the

transmission may be damaged.

012RS009

1. Using an engine hoist or similar, install the engine

assembly and tighten the engine mount to chassis

fixing bolts to the specified torque.

Torque: 41 N⋅m (4.2 kg⋅m/30 lb ft)

2. Install the transmission assembly. Refer to

MUA5G Transmission or

AW30-40LE Transmission.

3. Reconnect the fuel hose to the fuel pipe at the

engine.

4. Reconnect the two heater hoses to the engine.

5. Install the flywheel dust covers.

6. Install the exhaust pipe and temporally tighten the

two (each bank) rear exhaust flange nuts then

tighten the three stud nuts (each bank) between

the exhaust manifold and the exhaust pipe, finally

tighten the rear side stud nuts to the specified

torque. For further information, refer to

Section 6F.

Torque: 67 N⋅m (6.8 kg⋅m/49 lb ft)

7. Reconnect the O2 sensor connectors.

8. Install the cooling fan assembly and tighten the

bolts/nuts to the specified torque.

Torque: 25 N⋅m (2.5 kg⋅m/18 lb ft) for fan pulle

and fan bracket.

Torque: 10 N⋅m (1.0 kg⋅m/7 lb ft) for fan and

clutch assembly.

9. Install the air conditioner compressor to the engine

and tighten the fixing bolts to the specified torque.

Torque: 43 N⋅m (4.4 kg⋅m/32 lb ft)

10. Install the power steering pump then, tighten the

fixing bolts to the specified torque.

Torque:

M8 bolts: 25 N⋅m (2.5 kg⋅m/18 lb ft)

M10 bolts: 43 N⋅m (4.4 kg⋅m/32 lb ft)

11. Move the drive belt tensioner to the loose side

using a wrench then, install the drive belt to the

normal position.

12. Install the upper fan shroud.

13. If removed, refit the radiator and reconnect the

radiator upper and lower hoses.

14. Reconnect the coolant reserve tank hose to the

radiator.

15. Reconnect the generator harness connector.

16. Reconnect the starter harness connector.

17. Reconnect the wiring harness connector to

transmission.

18. Reconnect the shift on the fly wiring harness

connector at the front of the front axle and install

the transmission harness bracket to the engine left

side.

19. Reconnect the three engine harness connectors.

20. Reconnect the vacuum booster hose.

21. Reconnect the canister vacuum hose.

22. Install the air cleaner assembly.

23. Reconnect the air duct.

24. Reconnect the accelerator cable to throttle valve

on the common chamber.

25. Install the ECM

• Tighten the four bolts.

Torque: 10 N⋅m (1.0 kg⋅m/7 lb ft)

• Connect the two connectors.

• Tighten the two ground cable bolts.

26. Install engine hood to the original position.

• Refer to installation procedure for

Body section in this manual.

27. Install accelerator control cable to accelerato

cable bracket.

• Rotate the ratchet ring in direction an arrow 90°

• Confirm that the marking on the outer cap must

be on the upper side.

• Slider the lock in direction B.

• Confirm that the ratchet ring is locked.

RTW46ASH000201

Legend

(1) Cable Bracket

(2) Ratchet ring

(3) Outer Cap

(4) Lock

(5) Paint Mark

(6) Arrow Mark

28. Install the cable clips to the accelerator control

cable.

29. Fill the cooling system with the recommended

coolant. Refer to Section 0B.

30. Fill the engine with the recommended grade and

quantity of engine oil. Refer to Section 0B.

Engine Assembly Repair

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

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

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

NOTE: When disassembling the cylinder block, ensure

that all parts such as piston and connecting rod

assemblies, crankshaft main bearing caps and

bearings are retained as a set and are identified so they

can be installed in their original location.

1. Remove the cylinder head assembly and head

gasket. Refer to Cylinder Head in this Section.

2. Remove the crankcase and the oil pan by

removing the 20 fixing bolts, then remove the fou

fixing bolts from within the crankcase.

013RW004

3. Remove the oil pipe and O-ring and the oil straine

and O-ring.

4. Remove the oil pump assembly.

050RW002

Legend

(1) Oil Pump

(2) Oil Strainer

(3) Oil Gallery

(4) From Oil Filter

(5) To Oil Filter

5. Remove the eight bolts attaching the oil gallery to

the cylinder block and remove the oil gallery.

6. Remove the eight crankcase side bolts.

012RS007

7. Remove the piston and the connecting rod

assemblies, keeping them in the order removed.

NOTE: If required, measure the thrust clearance before

removing the piston and connecting rod assembly.

Refer to Inspection in this Section.

8. Remove any ridge or carbon build up from the top

end of the cylinder.

9. Remove the flywheel.

10. Remove the rear main oil seal retainer assembly.

11. Remove the main bearing caps and the

crankshaft.

NOTE: If required, measure the crankshaft thrust

clearance prior to removing the crankshaft. Refer to

Inspect and Repair Crankshaft.

Piston and Connecting Rods

1. Remove the piston rings with a piston ring

expander. Arrange the removed piston rings in the

cylinder number order.

015RS022

2. 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 in

the order removed and as a set. If reusing the original

parts, all parts they 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

Inspection and Repair

1. Remove any remaining particles of the cylinde

head gasket adhering to the upper surface of the

cylinder block.

NOTE: Be very careful not to allow any material to

accidentally drop into the cylinder block and do not

scratch the cylinder block.

2. Carefully remove any remaining sealant from the

oil pump assembly, rear main oil seal retainer and

crankcase assembly or adhering to the block.

3. Wipe the cylinder block clean or clean the block in

a commercially available parts cleaner.

4. Visually inspect the cylinder block for excessive

wear or cracks. If necessary, use a crack detecto

to perform a crack test and/or a hydraulic (or ai

pressure) test. If cracking or other damage is

detected, the cylinder block must either be

repaired or replaced.

Distortion

1. Using a straight−edge and a feeler gauge, check

the cylinder head surface of the cylinder block fo

any signs of distortion.

2. The cylinder block must be reground or replaced i

distortion of the cylinder head surface exceeds the

specified limit.

Distortion limit: 0.15 mm (0.0059 in)

Maximum repairable limit: 0.15 mm (0.0059 in)

012RS00

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 three points.

012RS005

Cylinder Bore Inside 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)

Limit: 93.530 mm (3.6823 in)

If the measurement exceeds the specified limit, the

cylinder block must be replaced.

NOTE: For information on piston diameter, please refer

to the section Piston and Connecting Rod Assembly

in this Section.

NOTE: The "Grade" mark (1) is stamped at the position

illustrated.

012RS006

Main Bearing Clearance

1. Remove the crankshaft and remove the main

bearings.

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

crankshaft main journal, bearing caps and the

crankcase where the bearings are located.

3. Check the bearings for any damage or excessive

wear.

NOTE: The bearings must be replaced as a set if

damage or excessive wear is discovered during

inspection.

4. Install the upper bearings and the thrust washers

to their original positions and carefully install the

crankshaft.

5. Install the lower bearings to the original bearing

cap.

pply a small piece of plastigauge to the

crankshaft journal unit.

NOTE: Do not place the plastigauge on the oil hole.

015RS005

7. Install the main bearing caps, oil gallery and

crankcase bolts in the order shown, and tighten

each bolt in numerical order to the specified

torque.

NOTE: Do not apply engine oil to the main bearings or

the crankcase 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

8. Remove all the main bearing fixing bolts in the

reverse order and remove the main bearing caps.

9. Measure the width of the plastigauge and

determine the oil clearance. If the oil clearance

exceeds the specified limit, replace the main

bearings as a set and/or grind the crankshaft and

fit the undersize bearings.

NOTE: The crankshaft may need replacement if

undersize bearings are not available.

Standard : 0.019 mm−0.043 mm

(0.0007 in−0.0017 in)

Limit: 0.08 mm (0.0031 in)

015RS008

10. Clean the plastigauge from the bearings and the

crankshaft and remove the crankshaft and the

bearings.

Crankshaft

1. Place a dial indicator as shown in the illustration

and measure the crankshaft thrust clearance. I

the thrust clearance exceeds the specified limit,

replace the thrust bearings as a set and inspect

the crankshaft thrust faces for wear.

Thrust Clearance

Standard: 0.06 mm−0.24 mm

(0.0024 in−0.0094 in)

Limit: 0.30 mm (0.0118 in)

NOTE: This operation requires the crankshaft to be

installed. Refer to Installation of crankshaft in this

section.

015RS003

2. Inspect the surface of the crankshaft journal and

crank pins for excessive wear and damage.

Inspect the oil seal contact surfaces for excessive

wear and damage. Inspect the oil ports fo

obstructions.

3. Carefully place the crankshaft on V−blocks. Slowly

rotate the crankshaft and measure the runout. I

the crankshaft runout exceeds the specified limit,

the crankshaft must be replaced.

Runout: 0.04 mm (0.0016 in)

4. Using a micrometer, measure the diameter and

uneven wear of the main journal and the 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)

015RS0

015RS009

Crankshaft Bearing Selection

Crankshaft bearing selection is based on the measured

diameters of the crankshaft journals and the bearing

inserts.

1. The grade mark (1) for the cylinder block journals

are stamped on the lower face of the cylinde

block.

RTW31BSH00070

2. The crankshaft journal diameter grade mark (1) is

also stamped on the No.1 crankshaft balancer (2).

3. Match the cylinder block journal grade marks and

the crankshaft journal grade marks in the table

below to determine the correct crankshaft bearing

size.

NOTE: The size color code is painted on the side of the

crankshaft bearings.

015R200005

RTW31BSH000601

Grade

Mark Cylinder Block

Journal Crank Shaft Journal

Diameter Grade

Mark

Color Code Oil Clearance

(Reference)

63.918-63.925

(2.5165-2.5167) 2 Blue 0.024-0.043

(0.0009-0.0017)

1 68.994-69.000

(2.7163-2.7165) 63.926-63.933

(2.5168-2.5170) 1 Brown 0.022-0.041

(0.0009-0.0016)

63.918-63.925

(2.5165-2.5167) 2 0.023-0.042

(0.0009-0.0016)

2 68.987-68.993

(2.7160-2.7163) 63.926-63.933

(2.5168-2.5170) 1 Green 0.021-0.040

(0.0008-0.0016)

63.918-63.925

(2.5165-2.5167) 2 0.022-0.041

(0.0009-0.0016)

3 68.980-68.986

(2.7157-2.7160) 63.926-63.933

(2.5168-2.5170) 1 Yellow 0.020-0.039

(0.0008-0.0015)

Piston and Connecting Rod Assemblies

Piston Diameter

Carefully clean away all carbon adhering to the piston

head and in the piston ring grooves.

NOTE: Do not use a wire brush to clean the pistons.

1. 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.

2. Measure the piston outside diameter with a

micrometer at the piston grading position and at a

right angle to the piston pin.

• Distance from the head of the piston to the

piston grading position.

Piston grading position: 43.0 mm (1.6929 in)

015RV014

• Refer to the size mark (1) for the correct piston

outside diameter.

Outside diameter at:

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)

015RS025

3. Measure the cylinder bore inside diameter (refer to

Cylinder Block.

Piston Rings (8)

1. To measure the piston ring end -gap;

• Insert the piston ring into the bore.

• Push the ring by with the piston at a right angle

to the cylinder wall and at a point where the

cylinder bore diameter is the smallest.

• Measure the ring end gap.

015RS026

NOTE: No.1 compression ring must be set in the

direction of origin. No. 2 compression ring positioning

mark (1) is painted.

015RS027

Compression Ring End Gap:

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)

Limit: 0.15mm (0.0059 in)

2. Measure the clearance between the piston ring

groove and the piston ring with a feeler gauge. I

the piston ring groove/piston ring clearance

exceeds the specified limit, the piston and rings

must be replaced.

Compression Ring Clearance

Standard: 0.016 mm−0.038 mm

(0.0006 in. −0.0015 in)

015RS028

Piston Pin (9)

NOTE: Do not reuse the old piston pin.

1. Use a micrometer to measure the new piston pin

outside diameter in both directions at the three

different positions shown.

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.

NOTE: To calculate the interference fit, subtract the

connecting rod small end diameter from the piston pin

diameter.

Piston pin interference:

0.023 mm−0.038 mm (0.0009 in−0.0015 in)

015RS029

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

it. If the pin rotates smoothly with no backlash, the

clearance is normal. If there is backlash o

roughness, measure the inside diameter of the

piston. 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 (11)

1. Check the connecting rod alignment If either the

bend or the twist of the connecting rod 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 and/or the crankshaft 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. Remove the connecting rod cap nuts and the rod

caps.

NOTE: Arrange the removed rod caps in the cylinder

number order.

4. Clean the connecting rod bearings and the

crankshaft journals.

NOTE: Carefully check the connecting rod bearings. If

only one bearing is found to be damaged or badly worn,

the bearings must be replaced as a set.

5. Reinstall the bearings in their original positions

and apply plastigauge to the crank pin.

015RS032

6. Reinstall the rod caps to their original positions

and tighten the rod cap nuts to the specified

torque.

Torque: 54 N⋅m (5.5 kg⋅m/40 lb ft)

NOTE: Do not allow the crankshaft to rotate.

7. Carefully remove the rod caps.

8. Measure the width of the plastigauge 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

9. Clean the plastigauge from the bearings and the

crankshaft pins.

Con−rod Bearing Selection

Select 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

Size Mark Big end Bore

Diameter Crankshaft Pin

Diameter

Connecting Rod

Bearing Thickness

(Reference)

Color of

Size Mark Oil Clearance

(Reference)

A 56.994-57.000

(2.2439-2.2441) 1.512-1.516

(0.0595-0.0597) Yellow 0.025-0.054

(0.0010-0.0021)

B 56.988-56.994

(2.2436-2.2439) 1.508-1.512

(0.0594-0.0595) Green 0.027-0.056

(0.0011-0.0022)

C 56.982-56.988

(2.2434-2.2436)

53.922-53.937

(2.1229-2.1235) 1.504-1.508

(0.0592-0.0594) Pink 0.029-0.058

(0.0011-0.0023)

Reassembly

1. Install the main bearings to the cylinder block

ensuring they are positioned correctly.

NOTE: Do not apply engine oil to the back faces of the

main bearings.

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.

pply clean engine oil to the upper and lower main

bearing faces.

3. Carefully, position the crankshaft on to the

bearings.

pply clean engine oil to the thrust washer, then

assemble the thrust washer to the No. 3 bearing

journal.

NOTE: The oil grooves must face the crankshaft.

015RS013

5. Install the crankshaft main bearing caps and apply

clean engine oil to the thread and seating surface

of each main bearing cap fixing bolt.

NOTE: Install bearing caps in the order of cylinder

numbers, starting with cylinder block front side.

6. Tighten the main bearing fixing bolts to the

specified torque.

Torque: 39 N⋅m (4.0 kg⋅m/29 lb ft)

NOTE: After tightening the main bearing bolts, ensure

the crankshaft rotates smoothly.

7. Install the piston rings and align the piston ring

end gaps.

015RS019

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

Legend

(1) Piston Front Mark

(2) Piston Grade

(3) Connecting Rod Front Mark

8. Apply clean engine oil to the cylinder bores, the

connecting rod bearings, rings and the crankshaft

journals.

NOTE: Do not apply engine oil to the bearing back

faces and connecting rod bearing fitting surfaces.

9. Insert the piston/connecting rod assemblies into

each cylinder using a piston ring compressor.

NOTE: When installing the piston, the piston front

mark, must face the front of the engine. The bearing

cap number must be the same as the connecting rod

umber. n

10. Apply engine oil to the thread and the seating

surface of each connecting rod cap nut.

11. Tighten the connecting rod cap nuts to the

specified torque.

Torque: 54 N⋅m (5.5 kg⋅m/40 lb ft)

NOTE: After tightening the nuts, make sure that the

crankshaft rotates smoothly.

12. Remove any oil on the cylinder block and the

retainer sealing surface.

13.

pply sealant (TB1207B or equivalent) to the rea

main oil seal retainer sealing surface.

015RW002

Legend

(1) Around Bolt Holes

(2) Around Dowel Pin

14. Install the seal to the retainer and apply clean

engine oil to the oil seal lip. Align the dowel pin in

the cylinder block with the corresponding location

hole in the retainer and install the retainer to the

block.

NOTE: The oil seal retainer must be installed within 5

minutes after sealant application before the sealant

hardens.

15. Tighten the retainer fixing bolts in numerical orde

to the specified torque.

Torque: 18 N⋅m (1.8 kg⋅m/13 lb ft)

015RW001

NOTE: If replacing the seal with the retainer already

installed to the block, apply clean engine oil to the oil

seal lip and install the seal using 5−8840−2286−0

installer.

015RS017

16. Remove any oil on the cylinder block and the oil

pump mounting surface.

17.

pply sealant (TB1207B or equivalent) to the oil

pump mounting surface.

051RW002

Legend

(1) Around Bolt Holes

(2) Around Dowel Pin

18.

pply clean engine oil to the oil seal lip and install

the oil pump assembly to the cylinder block.

NOTE: The oil pump assembly must be installed within

5 minutes after sealant application to prevent

premature hardening of sealant.

19. Tighten the oil pump assembly fixing bolts in

numerical order to the specified torque.

Torque: 25 N⋅m (2.5 kg⋅m/18 lb ft)

20. Clean the contact surface of the oil gallery and the

main bearing cap.

21.

pply clean engine oil to the oil gallery fixing bolts

and then, tighten the bolts in numerical order in

two stages.

Torque:

Stage 1: 29 N⋅m (3.0 kg⋅m/21 lb ft)

Stage 2: Turn the bolt 55° − 65°

22. Install the cylinder crankcase side bolts and

tighten in numerical order to the specified torque.

Torque: 39 N⋅m (4.0 kg⋅m/29 lb ft)

NOTE: Do not apply the oil to the cylinder crankcase

bolts.

012RS007

23. Install oil pipe with O-ring and tighten fixing bolts

to the specified torque.

Torque: 25 N⋅m (2.5 kg⋅m/18 lb ft)

24. Install the oil strainer with the O-ring and tighten

the bolts to the specified torque.

Torque: 25 N⋅m (2.5 kg⋅m/18 lb ft)

25. Ensure the oil pan and crankcase sealing surfaces

are clean and dry.

26.

pply a continuous bead, 4.5 mm (0.7 in) wide o

TB1207C sealant or equivalent to the oil pan

sealing surface and install the oil pan to the

crankcase.

NOTE: The oil pan must be installed within 5 minutes

after sealant application to prevent premature

hardening of sealant.

013RW003

27. Tighten fixing bolts in numerical order to the

specified torque.

Torque: 25 N⋅m (2.5 kg⋅m/18 lb ft)

013RW002

28. Ensure the crankcase and cylinder block sealing

surfaces are clean and dry.

29.

pply a continuous bead, 4.5 mm (0.7 in) wide o

TB1207C sealant or equivalent to the crankcase

sealing surface and install the crankcase and oil

pan assembly to the cylinder block.

NOTE: The crankcase must be installed within 5

minutes after sealant application to prevent premature

hardening of sealant.

30. Tighten the fixing bolts in numerical order to the

specified torque.

Torque: 10 N⋅m (1.0 kg⋅m/1 lb ft)

013RW010

013RW004

31. Clean the flywheel holes in the crankshaft.

32. Clean the crankshaft and flywheel mounting

surface.

33. Install the flywheel and tighten the fixing bolts in

numerical order 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

34. Install the cylinder head. Refer to Cylinder Head

in this Section.

35. Install the appropriate exhaust manifold. Refer to

the installation procedure for

Exhaust Manifold LH and

Exhaust Manifold RH in this manual.

36. Install the common chamber. Refer to the

installation procedure for Common Chamber in

this manual.

Main Data and Specifications

General Specifications

Item Specifications

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 Cast in the cylinder block

Total piston displacement 3494 cc

Cylinder bore x stroke 93.4 mm x 85.0 mm

(3.6772 in × 3.3465 in)

Compression ratio 8.6

Compression pressure at 300 rpm 1.37 MPa (14.0 Kg/cm2)

Engine idling speed rpm Non adjustable (750)

Valve clearance Intake: 0.28 mm (0.11 in)

Exhaust: 0.30mm (0.12 in)

Oil capacity 5.3 litres

Ignition timing Non adjustable (12° BTDC at idle rpm)

Spark plug PK16PR11, RC10PYP4, K16PR-P11

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

Torque Specifications

Ignition Coil, Spark Plug, Crankshaft Angle Sensor and Under Cover N⋅m (kg⋅m/lb ft)

RTW460LF000101

Cylinder Head Cover, Cylinder Head, Camshaft Bracket, Common Chamber and ECM N⋅m (kg⋅m/lb ft)

RTW46ALF000601

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)

RTW46ALF000701

Connecting Rod and Water Pump N⋅m (kg⋅m/lb ft)

E06RW042

Engine Mount N⋅m (kg⋅m/lb ft)

RTW36ALF000101

Special Tools

ILLUSTRATION PART NO.

PART NAME ILLUSTRATION PART NO.

PART NAME

5-8840-0011-0

(J-21687-02)

Remover; tie rod end

5-8840-2445-0

(J-42985)

Installer; Camshaft

oil seal

5-8840-0203-0

(J-36390)

Wrench; Oil filter (79φ)

5-8840-2545-0

(J-39206)

Installer; Pilot bearing

5-8840-2446-0

(J-8062)

Compressor;

Valve spring (1)

5-8840-2547-0

(J-42898)

Adapter; Compressor,

Valve spring (2)

5-8840-0133-0

(J-8614-01)

Holder; Crankshaft

5-8840-0623-0

(J-37281)

Remover; Oil controller

5-8840-2153-0

(J-37228)

Seal cutter

5-8840-0624-0

(J-38537)

Installer; Oil controller

5-8840-2286-0

(J-39201)

Installer; Rear oil seal

5-8840-2005-0

(J-29107)

Universal pitman arm

remover

5-8840-2287-0

(J-39202)

Installer; Oil pump

oil seal

ILLUSTRATION PART NO.

PART NAME

9-8511-4209-0

(J-24239-1)

Cylinder head bolt wrench

5-8840-2442-0

(J-42899)

Replacer; Valve guide

(1,2)

5-8840-2548-0

(J-42687)

Installer; Valve guide (1)

5-8840-2549-0

(J-37985-1)

Remover; Valve guide (2)

5-8840-2444-0

(J-42689)

Adjusting Tool; Valve

clearance

5-8840-2443-0

(J-42686)

Lever; Gear spring

5-8840-2447-1

(J-43041)

Holder; Universal