(G6DB - GSL 3.3)e™ GENERAL ‘SPECIFICATIONS. COMPRESSION VALVE CLEARANCE INSPECTION AND. ADJUSTMENT TROUBLE SHOOTING SPECIAL TOOLS ENGINE AND TRANSAXLE ASSEMBLY REMOVAL INSTALLATION TIMING SYSTEM ‘COMPONENTS REMOVAL DISASSEMBLY. INSPECTION REASSEMBLY. INSTALLATION CYLINDER HEAD ASSEMBLY COMPONENTS REMOVAL. DISASSEMBLY. INSPECTION REASSEMBLY, INSTALLATION EMA- 2 EMA. 8 EMA- 8 EMA-11 EMA- 14 EMA-16 EMA-21 EMA- 22. EMA- 24 EMA - 25 EMA - 30 EMA - 30 EMA- 37 EMA - 38 EMA- 40 EMA. 41 EMA- 42, EMA-47 EMA - 48, Engine ENGINE BLOCK ‘COMPONENTS REMOVAL DISASSEMBLY INSPECTION REASSEMBLY. INSTALLATION, COOLING SYSTEM ‘COMPONENTS ENGINE COOLANT REFILLING AND BLEEDING REMOVAL INSPECTION INSTALLATION, LUBRICATION SYSTEM ‘COMPONENTS OIL AND FILTER. REMOVAL INSPECTION, INSTALLATION, INTAKE AND EXHAUST SYSTEM ‘COMPONENTS REMOVAL INSTALLATION, EMA - 52 EMA - 54 EMA- 55 EMA-56 EMA - 65 EMA - 69 EMA-70 EMA-71 EMA-73 EMA-75 EMA- 76 EMA - 80 EMA- 81 EMA - 84 EMA - 85 EMA - 86 EMA- 89 EMA - 92. EMA - 96EMA -2 ENGINE MECHANICAL SYSTEM GENERAL SPECIFICATION cxcarace Deseri Specifications Limit General Type Vetype, DOHC Number of eylinders 8 Bore 92mm (3.6220in) Stroke 83.8mm (3.2992in) Total displacement 3.34200 (203.860u.in.) Compression ratio 10.4 Firing order 12:3-46-6 Valve timing Intake Opens(ATOC) 14° Closes(ABDC) 62" Exhaust Opens(®8DC) ae Closes(aTDC) & Cylinder head Flatness of gasket surface Less than 0.05mm (0.0018in.) {Less than 0.02mm (0.0008in.) / 150x150} Flatness intake Less than 0.1mm(0.0039in.) of manifold intake [Less than 0.03mm(0.001in)/110x110) mounting ese th Exhaust ‘ess than 0.1mm(0.0039in.) {Less than 0.03mm(0.001in)/110x1 10] Camshaft Cam height LH intake | 46.3mm Camshaft [exhaust | 45.8mm RH Intake | 46.3mm Camshaft [exhaust | 45.8mm Journal outer LHRH intake | No.1: 27.964 ~ 27.980mm (1.1009 ~ 1.1016in.) diameter camshaft No.2,3,4: 23.954 ~ 23.970mm (0.9430 ~ 0.9437in.) Exhaust | No.1: 27.964 ~ 27.980mm (1.1009 ~ 1.1016in.) No.2,3,4: 23.954 ~ 23.970mm (0.9430 ~ 0.9437in.) Bearing ol LHRH intake | No.t: 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.) clearance camshaft No.2,3,4: 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.) Exhaust | No.1: 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.) No.2,3,4: 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.) End play 0.056 ~ 0.064mm (0.0022 ~ 0.0025in.) ValveGENERAL EMA -3 Deserintion specications Cit Vave erat [nate ‘o5 2Tmma 146m) Exhaust 105.50mm (4.1535in.) ‘Stem outer Intake 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.) diameter Exhaust 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.) Face angle i 45.24 45.75° Thickness of Intake 11.56 ~ 1.86mm(0.06142 ~ 0.07323in.) vateheadimar aust 173 28mm0.05811 = 007882n) Vato stom io] lake 0.020 ~ 0.047mm (0.00078 ~ 000188.) orm starance Exhaust 0.030 ~ 0.054mm (0.00118 ~ 0.00212in.) {oossain) Valve gue ier diameter [hike 5.500 = 8.5 T2nm (2165 ~ 02770) Exhaust 5.500 ~5 512mm (0.2165 0.2170) 7 rake $18 = 4.2mm (15887 ~ 6614) Exhaust. 41.8 ~ 42.2mm (1.6457 ~ 1.6614in.) Wave seat contact Exhaust 11.35 ~ 1.65mm(0.05315 ~ 0.06496in.) Seat ange [nate GATS = 45.10 Exheust 475 = 45.10 Valve spring Free length 43.86mm (1.7267in.) Load 19.320.8kg/34.0mm (42.7£1.8 lb/1.3386in) 42.341 3kg/24.2mm (93.3#2.9 Ib/0.9527in) ‘Out of squareness: Less than 1.5 MLA MLA outer intake 34,964 ~ 34,980mm (1.3765 ~ 1.372in.) ciameter Exhaust 34.964 ~ 34,980mm (1.3765 ~ 1.3772in.) Cylinder head | Intake 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.) tappet bore inner T diameter Exhaust 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.) MLA to tappet | Intake 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) (0.07mm(0.0027in.) bore clearance | Exhaust 0.020 ~ 0.064mm (0.0008 ~ 0.0024in.) 0.07 mm(0.0027in.) Valve clearance Intake _ . 0.10 = 0.30mm 0.47 ~ 0.23mm (0.0087 ~ 0.0090in.) (6.0039-0.0118in.) Exhaust 0.20 = 0.40mm 0.27 ~ 0.33mm (0.0106 ~ 0.0123in,) (.0078-00tatin} Cylinder blockEMA -4 ENGINE MECHANICAL SYSTEM Description Specifications Limit Cylinder bore 92.00 ~ 92.03mm (8.6220 ~ 3.6232in,) Less than 0.05mm (0.0019in,) Flatness of gasket surface {Less than 0.02mm (0.0008in.) / 150x150} Piston Piston outer diameter 91.97 ~ 92.00mm(3.6209 ~ 3.6220in.) Piston to oylinder clearance 0.02 ~ 0,04mm(0,0008 ~ 0.00%6in.) Ring groove | No. 1 ring groove ~ 128mm ~ .o4e2in 1.26mm Ring 4.23 ~ 1.25mm (0.0484 ~ 0.0492in.) oorsein) No. 2 ring groove _ - +.26mm 41.22 ~ 1.24mm (0.0480 ~ 0.0488in.) (eosin) Oil ring groove . ~ prea 205mm 2,01 ~ 2.08mm (0.0791 ~ 0.0799in.) oaonn) Piston ring Side clearance [No._1 ring 0.04 ~ 0.076mm (0.0016 ~ 0.003tin.) 0.4mm (0.004in.) No. 2 ring 0.03 ~ 0,07mm (0.0012 ~ 0.0027in.) 0.4mm (0.004in.) Oil ring 0.06 ~ 0.45mm (0.0024 ~ 0.0059in.) (0.2mm (0.008in.) End gap No. 1 ring 0.17 ~ 0.32mm (0.0067 ~ 0.0726in.) 0.6mm (0.0236in.) No. 2 ting 0.32 ~ 047mm (0.0126 ~ 0.0785in,) 0.7mm (0.0275in.) Oil ring 0.20 ~ 0.70mm (0.0078 ~ 0.0275in.) 0.8mm (0.0315in.) Piston pin Piston pin outer diameter 23.001 ~ 23,006mm (0.9055 ~ 0.9057in.) Piston pin hole inner diameter 23,016 ~ 23,02 1mm (0.9061 ~ 0,9063in,) Piston pin hole clearance 0.01 ~ 0.02mm (0.0039 ~ 0.0078in.) Connecting rod small end inner diameter 22.974 ~ 22.985mm (0.9045 ~ 0.9049in.) Connecting rod small end hole clearance 0.016 ~ 0.032mm (0.0006 ~ 0.0012in.) Connecting rod Connecting rod big end innerdiameter Connecting rod bearing oil clearance 58,000 ~ 58.018mm(2.2834 ~2.2842in.) 0.030 ~ 0.048mm (0.0012 ~ 0,0019in.) Side clearance 0.1 = 0.25mm (0.0039 ~ 0.0098in.) Crankshaft Main journal outer diameter 68.942 ~ 68.960mm (2.7142 ~ 2.7149in.) Pin journal outer diameter 54,954 ~ 54.972mm (2.1635 ~ 2.1642in.) Main bearing oil clearance End play Oil pump 0.022 ~ 0.040mm (0.0008 ~ 0.0016in.) 0.10 ~ 0.28mm (0.0039 ~ 0.01 0in.) Relief valve opening pressure ‘450 ~ 550kPa (4.59 ~ 5.6 1kgl!=1',65.28 ~ 79.79psi) Engine oil Oil quantity (Total) il quantity (Oil pan) 6.4L(6.76U.S.qus,5.63lmp.qts) 5.5L(6.81U.S.qus.4.84Imp.ats)GENERAL EMA -5 Description Specifications Limit Oil quantity (Oil filter) 0.4L(0.42U S.qus,0.35Imp.qts) il quantity (Replacement) 5.2L(5.49U.S.qus,4.58imp.ats) Oil quality ‘Above SJ or SL il pressure 130kPa(1.32kgf/0,18.77psi) {at 1000cpm,110°C(230°F)] Cooling system Cooling method Coolant quantity Thermostat Type Forced circulation with electrical fan 8,9L(9.40U.S.qus,7.83imp.ats) Wax pellet type ‘Opening temperature 8242°C (179.6435.6F) Fully openedtem- 95°C (203°F) perature Full ft ‘tomm (0.3937in.) Radiator cap | Main valve opening | 93.16 ~ 122.58kpa pressure (0.95 ~ 1.25kg/cm*, 13.51 ~ 17.78psi) Vacuum vaive opening | 0.98 ~ 4.90 kpa pressure (0.01 ~ 0.05kglem2, 0.14 ~ 0.71 psi) Water temperature sensor Tye Thermister type Resistance 20°C (68°F) 2.31 ~ 2.59K¢ 80°C(176°F) 0.3222 KQEMA -6 ENGINE MECHANICAL SYSTEM TIGHTENING TORQUE Item Quantity Nm kgtm Ibe Crankshaft pulley bolt 1 284.2~3038 | 290~310 | 209.76 ~ 224.22 Timing chain cover bolt B 7 18.62 ~ 21.56 19~22 13.74 ~ 15.91 Timing chain cover bolt C 4 9.80 ~ 11.76 10~ 12 7.23 ~ 8.68 Timing chain cover bolt D 1 | 5880-6880 | 60~70 43.40 ~ 50.63 Timing chain cover bolt E 1 58.80~68.80 | 6.0~7.0 43.40 ~ 50.63 Timing chain cover bolt F 2 2450-2646 | 25-27 18.08 ~ 19.53 Timing chain cover bolt G 4 2456-2352 | 22~24 15.91 ~ 17.36 Timing chain cover bolt H 1 9.80 ~ 11.76 10~ 1.2 7.23 ~ 8.68 Timing chain cover bolt | 1 9.80 ~ 11.76 10-12 7.23 ~ 8.68 Timing chain cover bolt J 1 | 980-1176 1.01.2 7.23 ~ 8.68 Cam to cam guide bolt 4 9.80 ~ 11.76 101.2 7.23 ~ 8.68 Timing chain auto tensioner bolt 2 9.80 ~ 11.76 101.2 7.23 ~ 8.68 Timing chain auto tensioner nut 2 9.80 ~ 11.76 10~ 42 7.23 ~ 8.68 Timing chain tensioner arm bolt 2 18.62 ~ 21.56 1.9~22 13.74 ~ 15.91 Timing chain guide bolt 4 19.60~2450 | 20-25 14.47 ~ 18.08 Oil pump chain cover bolt 3 9.80 ~ 11.76 1.0 = 1.2 7.23 ~ 8.68 il pump chain tensioner bolt 1 9.80 ~ 11.76 10= 12 7.23 ~ 8.68 Oil pump chain guide bolt 2 9.80 ~ 11.76 10~ 12 7.23 ~ 8.68 Oil pump chain sprocket bolt 1 18.62 ~ 21.56 19~22 13.74 ~ 15.91 Lower oil pan bolt 13 | 9.80 ~ 11.76 1.0~ 1.2 7.23 ~ 8.68 Drive belt auto tensioner bolt(M12) 1 96.04~99.96 | 98-102 | 70.88~73.78 Drive belt auto tensioner bolt(M8) 1 17.64 ~ 21.56 1.8 ~ 2.2 13.02 ~ 15.91 Drive belt idler boit 1 53.90~57.82 | 55~59 39.78 ~ 42.67 OCV(oil control valve) bolt 2 9.80 ~ 11.76 10~ 42 7.23 ~ 8.68 Cylinder head bolt 16 | 39.2+120°+ 90° | 4.0+ 120° + 90° | 28.93 120° + 90° Cylinder head bolt 1 18.62 ~ 23.62 19> 24 18.74 ~ 17.36 CWT & exhaust cam sprocket bolt 4 64.68~7644 | 66~7.8 47.74 ~ 56.42 Camshaft bearing cap bolt 32 9.80 ~ 11.76 10~ 1.2 7.23 ~ 8.68 Cylinder head cover bolt 38 9.80 ~ 11.76 10~ 12 7.23 ~ 8.68 Connecting rod bearing bolt 12 19,60 + 90° 2.0 + 90° 14.46 + 90° Main bearing cap bolt 8 49.00 + 90° 5.0 + 90 36.16 + 90° Main bearing cap bolt 8 19.60+ 120° | 20+ 120° 14,46 + 120° Main bearing cap bolt 6 2940~31.36 | 30~32 21.70 ~ 23.14 Oil drain cover bolt 6 9.80 ~ 11.76 1.01.2 7.23 ~ 8.68 Rear oil seal case bolt 6 9.80 ~ 11.76 1.01.2 7.23 ~ 8.68 Baffle plate bolt 12 9.80 ~ 11.76 1.0 = 1.2 7.23 ~ 8.68 Upper oil pan bolt 16 9.80 ~ 11.76 10~ 1.2 7.23 ~ 8.68GENERAL EMA-7 Item Quantity Nm kgtim lof. Knock sensor bolt 2 15.68 ~ 23.52 1624 11.87 ~ 17.36 Drive plate bolt 8 7154-7546 | 73-77 52,80 ~ 55.69 Oi fiter 24.50 25 18.08 Oil drain bolt 1 34.90~ 44.10 | 35-45 25.31 ~ 32.55 Ol pump bolt 3 1960-2352 | 20~24 14.47 ~ 17.36 Oil fiter body bolt 10 9.80 ~ 11.76 10 ~1.2 7.23 ~ 8.68 Oil fiter body cover bolt 1" 9.80 ~ 11.76 10~ 12 7.23 ~ 8.68 Water vent hose bolt 2 9.80 ~ 11.76 10~ 42 7.23 ~ 8.68 Water pump bolt 6 21.56~2352 | 22~24 15.91 ~ 17.36 Water pump bolt 6 9.80 ~ 11.76 10~ 12 7.23 ~ 8.68 Water pump pulley bolt 4 7.84 ~ 9.80 0.8 ~ 1.0 5.78 ~ 7.23 Water temp. control nut 6 18.62 ~ 23.52 19> 24 13.74 ~ 17.36 Water inlet pipe bolt 3 16.66~1960 | 17~20 12.30 ~ 14.47 Air vent pipe bolt 2 9.80 ~ 11.76 10~ 42 7.23 ~ 8.68 Intake manifold bolt 6 18,62 ~ 23.52 19> 24 13.74 ~ 17.36 Intake manifold nut 2 18.62 ~ 23.52 19-24 13.74 ~ 17.36 ‘Surge tank bolt 5 9.80 ~ 11.76 10-12 7.23 ~ 8.68 ‘Surge tank nut 2 9,80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68 Breather pipe bolt 2 9.80 ~ 11.76 10 ~ 42 7.23 ~ 8.68 Surge tank bracket bolt 2 27.44~ 3136 | 28~32 20.25 ~ 23.14 ETC bracket bolt 2 15.68~2548 | 16-26 11.57 ~ 18.80 Exhaust manifold nut 16 39.20~ 4410 | 40~45 28.93 ~ 32.55 Heat proctor bolt 8 1666-2156 | 17-22 12.30 ~ 15.91 Front muffler 2 39,20~ 5880 | 40~60 28,93 ~ 43.40EMA ENGINE MECHANICAL SYSTEM COMPRESSION Gore i the thro is lack of power, excssive oi consump- fon or poor uel econanyy measure the compression proseure 1. Warm up and stop engine. Allow the engine to warm up to normal operating tem- perature. 2. Remove ignition coils. (See EE group - ignition) 3. Remove spark plugs. Using a 16mm plug wrench, remove the 6 spark plugs. 4, Check cylinder compression pressure. a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. . While cranking the engine, measure the com- pression pressure, Grore Always use a fully charged battery to obtain engine speed of 200 rpm or more. d. Repeat steps (a) through (c) for each cylinder, nore This measurement must be done ina short tne as possible Compression pressure 4,283KPa (13.0kgtlcm?, 185psi) Minimum pressure 4,135kPa (11.5kgH/cm?, 164psi) Difference between each cylinder 4100kPa (1.0kgficm?, 15psi) or less e. Ifthe cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low com- pression. + If adding oil helps the compression, itis likely that the piston rings andlor cylinder bore are worn or damaged + If pressure stays low, a valve may be stick- ing or seating is improper, or there may be leakage past the gasket. 5. Reinstall spark plugs. 6. Install ignition coils. (See EE group - ignition) VALVE CLEARANCE INSPECTION AND ADJUSTMENT Wore Inspect and adjust the valve clearance when the en- gine is cold (Engine coolant temperature : 20°C) and cylinder head is installed on the cylinder block. 1. Remove the engine cover. 2. Remove air cleaner assembly.(See page EMA - 16) 3. Remove the surge tank (See page EMA - 92) 4, Remove the cylinder head cover. a. Disconnect the ignition coil connector and re- move the ignition coil b. Disconnect the breather hose(A) from the cylin- der head cover. c. Loosen the cylinder head cover bolts and then remove the cover(A) and gasket. 5. Set No.1 cylinder to TOC/compression.GENERAL EMA -9 a, Tum the crankshaft pulley and align its groove jing mark "T" of the lower timing chain with the b. Check that the mark(A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration. Hf not, turn the crankshaft one revolution (360) 6. Inspect the valve clearance. ‘a. Check only the valve indicated as shown. [No. 1 cylinder : TDC/Compression] measure the valve clearance, RH EXHAUST LH EXHAUST ~ Using a thickness gauge, measure the clear- ance between the tappet and the base circle of camshaft Record the out-of-specification valve clearance measurements, They will be used later to deter- mine the required replacement adjusting tappet. Valve clearance Specification Engine coolant temperature : 20°C [68°F] Limit Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.) Exhaust : 0.20 ~ 0.40mm (0.0079 ~ 0.0187in.) b. Tum the crankshaft pulley one revolution (360°) and align the groove with timing mark "T* of the lower timing chain cover. Gaore Do not rotate engine counterclockwise c. Check only valves indicated as shown. [NO. 4 cylinder: TDC/compression]. Measure the valve clearance,EMA -10 ENGINE MECHANICAL SYSTEM 7. Adjust the intake and exhaust valve clearance. ‘a. Set the No.1 cylinder to the TDC/compression (See page EMA - 9) b. Remove the timing chain.(See page EMA - 24) c. Remove the camshaft bearing caps(A), 9g. Calculate the thickness of @ new tappet so that the valve clearance comes within the specified value. xonrtaes Valve clearance(Engine coolant tempera- ture: 20°C(68°F)) T : Thickness of removed tappet ‘A: Measured valve clearance N: Thickness of new tappet Intake : N = T + [A - 0.20mm(0.0079in.)] Exhaust : N = T+ [A -0.30mm (0.0148in.)] 4. Remove the camshaft assembly(A). h. Select a new tappet with a thickness as close as possible to the calculated value. Wore Shims are available in 41size increments of 0.015mm (0.0006in,) from 3.00mm (0.118in.) 0 3.600mm (0.1417in) somite i. Place anew tappet on the cylinder head. fe. Remove MLAs, _ Measure the thickness of the removed tappet us- Wore ing a micrometer. Appling engine oil at the selected tappet on the pe- riphery and top surface. j. Install the intake and exhaust camshaft. (See page EMA - 50) k. Install the bearing caps. (See page EMA - 51) |. Install the timing chain, (See page EMA - 30) m. Turn the crankshaft two turns in the operat- ing direction(clockwise) and realign crankshaft sprocket and camshaft sprocket timing marks. rn. Recheck the valve clearance. Valve clearance (Engine coolant temperature: 20°C[68°F}) [Specification] Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.) Exhaust : 0.27 ~ 0.3mm (0.0106 ~ 0.0123in.)GENERAL TROUBLESHOOTING EMA ‘Symptom Engine misfire with abnormal internal lower engine noises. Engine misfire with abnormal valve train noise, ‘Suspect area Worn crankshaft bearings. Loose or improperly engine drive plate Remedy Replace the crankshaft and bearings as required. Repair or replace the drive plate as required. Worn piston rings. (Oil consumption may or may not cause the engine to misfire.) Worn crankshaft thrust bearings Stuck valves. (Carbon buildup on the valve stem) Inspect the cylinder for a loss of compression. Repair or replace as required. Replace the crankshaft and bearings as required. Repair or replace as required Excessive worn or mis-aligned timing chain, Replace the timing chain and sprocket as required. Worn camshaft lobes. Replace the camshaft and valve lifters. Engine misfire with coolant consumption. * Faulty cylinder head gasket and/or cranking or other damage to the cylinder head and engine block cooling system. + Coolant consumption may or may not cause the engine to overheat. * Inspect the cylinder head and engine block for damage to the coolant passages and/or a faulty head gasket + Repair or replace as required Engine misfire with excessive oil ‘consumption, Worn valves, guides and/or valve stem oll seals. Repair or replace as required. Worn piston rings. (Oil consumption may or may not cause the engine to misfire) Engine noise on start-up, but only lasting a few seconds. Incorrect oil viscosity, * Inspect the cylinder for a loss of ‘compression. + Repair or replace as required. * Drain the oil + Install the correct viscosity oll Worn crankshaft thrust bearing, * Inspect the thrust bearing and crankshaft. + Repair or replace as required Upper engine noise,regardiess of engine speed. Low oil pressure. Repair or replace as required. Broken valve spring Worn or dirty valve lifters. Stretched or broken timing chain and/or damaged sprocket teeth, Replace the valve spring, Replace the vaive lifter. Replace the timing chain and sprockets. Worn timing chain tensioner, if applicable. Replace the timing chain tensioner as required. Worn camshaft lobes. Worn valve guides or valve stems. * Inspect the camshaft lobes. + Repiace the timing camshaft and valve lifters as required Inspect the valves and valve guides.then repair as required, Stuck valves. (Carbon on the valve stem or valve seat may cause the valve to stay open Inspect the valves and valve guides, then repair as required. Worn drive belt, idler, tensioner and bearing. Replace as required.EMA -12 ENGINE MECHANICAL SYSTEM ‘Symptom ‘Suspect area Remedy Lower engine noise,regardless of engine speed, Low oil pressure, Repair or required Loose or damaged drive plate. Damaged oil pan, contacting the oil pump screen. il pump screen loose, damaged or restricted, Repair or replace the drive plate. *+ Inspect the oil pan, * Inspect the oil pump screen. + Repair or replace as required. * Inspect the oil pump screen. + Repair or replace as required Excessive piston-to-cylinder bore clearance. * Inspect the piston, piston pin and cylinder bore. + Repair as required. Excessive piston pin-to-piston clearance. Excessive connecting rod bearing clearance * Inspect the piston, piston pin and the connecting rod. + Repair or replace as required Inspect the following components and repair as required, + The connecting rod bearings. + The connecting rods. + The crankshaft pin journals. Excessive crankshaft bearing clearance, Inspect the following components, and repair as required, + The crankshaft bearings. + The crankshaft main journals. + The cylinder block, Incorrect piston, piston pin and connecting rod installation * Verify the piston pins and connecting rods are installed correctly. + Repair as required Engine noise under load. Low oil pressure Repair or replace as required. Excessive connecting rod bearing clearance Excessive crankshaft bearing clearance. Inspect the following components andrepair as required *+ The connecting rod bearings. + The connecting rods. + The crankshaft Inspect the following components, andrepair as required. ‘+ The crankshaft bearings. + The crankshaft main journals. + The cylinder block.GENERAL ‘Symptom ‘Suspect area Remedy Engine will not crank-crankshatt will not rotate. Hydraulically locked cylinder. 1, Remove spark plugs and check for fluid. * Coolanvantifreeze in cylinder. 2. Inspect for broken head gasket. + Oil in cylinder, 3. Inspect for cracked engine block + Fuel in cylinder. or cylinder head. 4, Inspect for a sticking fuel injector and/or leaking fuel regulator. Broken timing chain and/or timing chain 1. Inspect timing chain and gears. and/or timing chain gears. 2. Repair as required. Material in cylinder. 1. Inspect cylinder for damaged + Broken valve ‘components and/or foreign materials. + Piston material 2. Repair or replace as required + Foreign material Seized crankshaft or connecting rod bearings. | 1. Inspect crankshaft and connecting rod bearing, 2._Repair as required. Bent or broken connecting rod 1. Inspect connecting rods. 2. Repair as required. Broken crankshaft 4. Inspect crankshaft. 2. Repair as required.EMA -14 ENGINE MECHANICAL SYSTEM SPECIAL TOOLS enc Tool (Number and name) Grankshaft front oll seal installer (09231-36100) Flywheel stopper (08231-36300) Torque angle adapter (09221-44000) Valve stem seal remover (09222-29000) Iustration Y Use Installation of the front oil seal Removal and installation of the flywheel land crankshaft pulley. Installation of bolts & nuts needing an angular method Remover of the valve stem seal Valve stem seal installer (09222-30100) OQ Installation of the valve stem sealGENERAL EMA -15 Tool (Number and name) llustration Use ‘Valve spring compressor & holder (09222-3k000) (09222-36300) Removal and installation of the intakeor exhaust valve A: 09222-3K000 B : 09222-36300 (holder) Crankshaft rear oil seal installer (09231-3¢200) (09231-H1100) Installation of the crankshaft rear oll seal A: 09231-30200 B : 09231-H1100 il pan remover (09215-3c000) XS Removal of oll pan il filter wrench (09263-36100) S Removal and installation of the oil filterEMA -16 ENGINE MECHANICAL SYSTEM ENGINE AND TRANSAXLE 5, Remove front wheels. ASSEMBLY 6, Remove under cover(A) REMOVAL | esc: Ay caution ~ Use fender covers to avoid damaging pant odsurtace + Toavold damage, unplug the wiing connes- tors carcaly whiehalding te connector portion nore * Mark all wiring and hoses fo avoid misconnec- fon + Turn th crankshaft pully 50 that the No.1 piston is at top dead center. (See page EMA - 9) 1, Disconnect the neagative terminal from the battery, 2, Remove the engine cover. revo 3. Remove the air duct 7. Drain the engine coolant. Remove the radiator cap to speed draining. 4, Remove the intake air hose and air cleaner assembly, 8, Remove the upper radiator hose and lower radiator 41) Disconnect the AFS connector(A). hose(A) 2) Disconnect the breather hose(B) from air clean- erhose. 3) Disconnect the ECM connector. (See FL group) 4) Remove the intake air hose(C) and air cleaner(D)ENGINE AND TRANSAXLE ASSEMBLY EMA -17 9. Remove transaxle oil cooler hose. 3) Disconnect RH injector connector(A) and ignition coil connector(8). 10. Remove fuel hose(A) and PCSV(8) hose. 4) Disconnect OCV connector(A) and knock sensor 11. Remove engine wiring. ‘connector(B). 1) Disconnect RH oxygen sensor connector(A). omrtsia 5) Disconnect LH front oxygen sensor connec- tor(A). 2) Disconnect power steering oll pressure sensor connector(A).EMA -18 6) Disconnect alternator connector(A). 7) Disconnect LH ignition coll connector(A), injec- tor connector(B), condenser connector(C) and ground(D), and remove wiring harness protec- tor(€). 8) Disconnect LH CMPS(A) and oil pressure switch connector(8). ENGINE MECHANICAL SYSTEM 9) Disconnect PCSV connector(A) and MAP sensor connector(B). \\ GON 10) Disconnect RH CMPS(A) and OTS connector(B). 11) Disconnect ETC connector(A) and knock sensor connector(B).ENGINE AND TRANSAXLE ASSEMBLY EMA -19 12) Disconnect WTS connector(A). 15. Remove brake vacuum hose(A). 13) Disconnect LH rear oxygen sensor connector(A) 16. Remove power steering pump hose(A). and CPS connector(B). 17. Remove A/C compressor hose, 12, Disconnect the transaxle wire harness connector and remove the transaxle control cable,(See TR group) 18. Drain transaxle oil 43. Disconnect EPS connector. 19. Remove lower arm ball joint. (SeeDS group) 414. Remove heater hose(A) 20. Remove tile rod end ball joint. (See DS group) 21. Remove stabilizer link. (See SS group) 22. After removing a split pin and nut from the steering bar tie rod, disconnect it. (See ST group)EMA -20 ENGINE MECHANICAL SYSTEM 23. Remove power steering return hose(A) and drain 28. Supporting the cross member(A) with a jack, remove power steering oil the stay with the mounting bolts. Tightening torque 187.3~156.9Nm (14.0~16.0kgf.m, 101.3~115.7ib-ft) 24, Remove front roll stopper mounting bolt. 28, Remove drive shaft from transaxle.(See DS group) 25, Remove rear roll stopper mounting bolt 30, Install jack for supporting engine and transaxle as- 26. Remove steering u-joint mounting (See ST group) sembly. 27. Remove front exhaust pipe(A). 31. Remove the engine mounting bracket(A),ENGINE AND TRANSAXLE ASSEMBLY EMA -21 32, Remove the transaxle mounting bracket(A). INSTALLATION | ex0:0801 Installation is in the reverse order of removal. Perform the following + Adjust the shift cable. + Refll the engine with engine ol + Refll the transaxle with fluid + Refll the radiator with engine coolant. * Bleed air from the cooling system with the heater valve open, + Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion. + Inspect for fuel leakage, After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes, Repeat this operation two or three times, then check {or fuel leakage at any point in the fuel line. 33. Jack up the vehicle.EMA -22 ENGINE MECHANICAL SYSTEM TIMING SYSTEM COMPONENT erase 9.8~ 11.76 2, 7 284.2 ~ 303.8 (29.0 ~ 31.0, 209.76 ~ 224.22) 7.84 ~ 9.80 (0.8 ~ 1.0, 5.78 ~ 7.23) 17.64 ~ 21.56 (1.8 ~ 2.3, 3.02 ~ 15.91) 9.8 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) 52.92 ~ 57.82 (6.4 ~ 5.9, 39.06 ~ 42.67) 96.04 ~ 99.96 (8.8 ~ 10.2, 70.85 ~ 73.74) TORQUE : N.m (kgf.m, tbf.ft) 1. Drive belt| 5. Water pump pulley 2. Drive belt tensioner 6. Ollpan 3. Idler 7. Cylinder head cover 4. Damper pulleyTIMING SYSTEM EMA -23 19.60 ~ 24.50 9.80 ~ 11.76 (2.0 ~ 2.5, 14.17 ~ 18.08) (1.0 ~ 1.2, 7.23 ~ 8.68) 18.62 ~ 21.56 (1.9~ 2.2, 13.74 ~ 15.91) 18.62 ~ 21.56 (1.9 ~ 2.2, 13.74 ~ 15.91) 9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) 9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) TORQUE : N.m (kgf.m, Ibf.ft) . Timing chain auto tensioner 13. Crankshaft sprocket 20. Timing chain tensioner arm 14, Timing chain 4. Timing chain cover 8. Timing chain 15. 2. Oil pump chain cover 9. Cam to cam guide 16. 3. Oil pump sprocket 10. Timing chain guide 17 4. Oil pump chain 11. Timing chain auto tensioner 18, 5. Crankshaft sprocket 12. Timing chain tensioner arm 19, 6 7. 9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) 19.60 ~ 24.50 (2.0 ~ 2.5, 14.17 ~ 18.08) ‘Timing chain guide Cam to cam guide Tensioner adapter Gasket il pump chain guide il pump temsioner assemblyEMA -24 ENGINE MECHANICAL SYSTEM REMOVAL | écisseis 4, Remove the alternator(A). Engine removal is required for this procedure. 1, Remove the drive belt(A). 6 3.TIMING SYSTEM EMA -25 7. Remove water pump pulley(A). DISASSEMBLY | Timing chain guide(B) > _ 9.8 Exhaust camshaft sprocket(C) > Intake camshaft sprocket(D). ‘The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain. 6. Install LH timing chain tensioner arm(B), Tightening torque 18,62 ~ 21.56Nm(1.9 ~ 2.2kgfm, 19.74 ~ 15.9406.)EMA -32 9. Install crankshaft sprocket(A)(O/P & RH camshaft drive). 410. Install oil pump chain(B) and oll pump sprocket(A). Tightening torque 18,62 ~ 21.56Nm(1.9 ~ 2.2kgfm, 19.74 ~ 15.9tIb6) 11, Install RH timing chain. ‘To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure. Crankshaft sprocket(A) — Intake camshaft sprocket(8) — Exhaust camshaft sprocket(C) The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain. ENGINE MECHANICAL SYSTEMTIMING SYSTEM 13, Install RH timing chain tensioner arm(8). 14, Install RH timing chain auto tensioner(A) and pull out the pins of hydraulic tensioners(LH & RH) 15, Install RH cam-to-cam guide(A). Tightening torque 9,80 ~ 11.76Nm(1.0 ~ 1.2kgfm, 7.23 ~ 8.68Ibf.f) 16. Install oil pump chain guide(A). Tightening torque 9.80 2kgt.m, 7.23 EMA -33 17. Install oll pump chain tensioner assembly(A), 18. Install oil pump chain cover(A).EMA -34 ENGINE MECHANICAL SYSTEM 19. 20. After rotating crankshaft 2 revolutions in regular direc- tion(clockwise viewed from front), confirm the timing mark. (Wore Always turn the crankshaft clockwise. Install timing chain cover. ‘a. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and ETC. b. Before assembling the timing chain cover, the liq- uid sealant 181217H should be applied on the gap between cylinder head and cylinder block The part must be assembled within 5 minutes after sealant was applied, Bead width : 2.5mm(0.tin.) ©. After applying liquid sealant T81217H on timing The part must be assembled within 5 minutes after sealant was applied. Selant should be applied without discontinuity Bead width : 2.5mm(0.tin.) d. The dowel pins on the cylinder block and holes ‘on the timing chain cover should be used as a reference in order to assemble the timing chain ‘cover to be in exact position. Tightening torque B(17): 18.62 ~ 21.56Nm(1.9 ~ 2.2kgfm, 13.74 ~ 15.91Ib6.) (4): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgtm, 7.23 ~ 8.68lbf.) D(1): 58.80 ~ 68.80Nm(6.0 ~ 7.0kgi:m, 43.40 ~ 50.63ib61) E(1):, 58.80 ~ 68.80Nm(6.0 ~ 7.0kgtm, 43,40 ~ 50.631b¢) F(2): 24.50 ~ 26.46Nm(2.8 ~ 2.7kgfm, 18.08 ~ 19.53Ibt.) G(4): 21.56 ~ 23.52Nm(2.2 ~ 2.4kgfm, 15.91 ~ 17.36Ibf.) H(1): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgfm, 7.23 ~ 8.68Ibf.1) I(1): 9.80 ~ 11.76Nm(1.0 ~ 1.2kg.m, 7.23 ~ 8.68Ibf.t) J(1): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68Ibf.ft) . The fring andior blow out test should not be per- formed within 30 minutes after the timing chain cover was assembled.TIMING SYSTEM EMA -35 21. Using $S1(09231-3C100), install timing chain cover oil seal Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgfm, 7.23 ~ 8.681bt.) 22, Install lower oil pan. ‘a. Using a gasket scraper, remove all the old pack- ing material from the gasket surfaces. b. Before assebling the oil pan, the liquid sealant 781217H should be applied on oil pan. ‘The part must be assembled within 5 minutes after the sealant was applied Bead width : 2.5mm(0.tin.). But marked area(*) to be 5.0mm(0.2in.) Ay caution + Make clean the sealing face before as- sembling two parts. + Remove harmful foreign matters on the sealing face before applying sealant + When applying sealant gasket, sealant must not be protruded into the inside of oil pan. + To prevent leakage of oil, apply sealant gasket ot the inner threads of the bolt holes. c._Install oll pan(A). Uniformly tighten the bolts in several passes. 23, Using SST(09231-3C300) install crankshaft damper pulley(A). Tightening torque 284.2 ~ 303.8Nm(29.0 ~ 31.0kgi.m, 209.76 = 224,221b6.) ‘99291-96300EMA -36 ENGINE MECHANICAL SYSTEM 24, Install cyinder head cover. 2. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover. b. After applying sealant(TB1217H), it should be assembled within 5 minutes. Bead width 2.5mm(0.tin.) cc. The firing andior blow out test should not be per- formed within 30 minutes after the cylinder head cover was assembled. 4. Install the cylinder head cover bolts as following ‘method. Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgfim, 7.23 ~ 8.68lbf-f) A\ caution Do not reuse cylinder Jad cover gasket. . Install ignition coil {Connect RH ignition coil connector(A), condenser connector(8) and install wiring bracket(C), 4g. Install connector bracket(A) from LH cylinder head cover.TIMING SYSTEM EMA -37 INSTALLATION | tscorsce 4, Install drive belt idler(A). 1. Install intake manifold (See page EMA - 96) Tightening torque 52.92 ~ 57.82Nm(6.4 ~ 5.9kgf.m, 39.06 ~ 42.67Ibf ft) 2. Install water pump pulley(A). TT Tightening torque 7.84 ~ 9.80Nm(0.8 ~ 1.0kgf.m, 6.78 ~ 7.23ibf) Sy ee i C SS 1 iis Oe 6 ah Yee rove \ (aARS> STARS Il alterr NY 5. Install alternator vonrwna 6: Install air compressor 3. _ Install drive belt auto tensioner(A). 7. Install power steering pump. “Tightening torque 2~”~—“—SSCS ‘8. Install drive belt(A). Tightening torque . . 96,04 ~ 99.96Nm(9.8 ~ 10.2kgf.m, 70.85 ~ 73.74Ibf.ft) crrksne pulley =~ AIC, pulley ‘cle puley alter 17.64 ~ 21.56Nm(1.8 ~ 2.2kgf.m, 13.02 ~ 15.91Ibf.ft) nator pulley + water pump pulley > P/S pump pulley moving auto tensioner pulley bolt with wrench, After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.EMA -38 ENGINE MECHANICAL SYSTEM CYLINDER HEAD ASSEMBLY COMPONENTS | cecccoco 39.2 (4.0, 28.93) + 120+ 90° 18.62 ~ 23.52 (1.9 ~ 2.4, 13.74 ~ 17.36) TORQUE : N.m (kgf.m, Ibf-ft) 1. RH oylinder head 4, LH cylinder head gasket 2. RH cylinder head gasket 5. Cylinder block 3. LH cylinder headCYLINDER HEAD ASSEMBLY EMA -39 9.80 ~ 11.76 og _ agi8 ag 64.68 ~ 76.44 (6.6 ~ 7.8, 47.74 ~ 56.4) 9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) TORQUE : N.m (kgf.m, Ibfft) 1. Camshaft bearing cap 6. MLA 11. Valve 2. Exhaust camshaft 7. Retainer lock 12, OCV 8. Intake camshaft 8. Retainer 13. Cylinder head 4, Exhaust camshatt sprocket 9. Valve spring 5. CWT assembly 10. Valve stem sealEMA -40 ENGINE MECHANICAL SYSTEM REMOVAL | ccortane Ay cumow © Use ander covers to avold damaging painted sovseee « Bapeld damning th oytnder heed, water i toe cnaine besa partons rope be ee oe tie ops eee ee eee en ee et orn fe ret ett oe « To aol damage unplug the wing connec: ce in ante nekie the connecter parton, nore * Mark all wiring and hoses to avoid misconnec- ton + Tur the crankshaft pulley so thatthe No.1 piston is at top dead center. (See page EMA - 9) Engine removal is required or his procedure 4. Remove exhaust manifold (See page EMA - 94) 2. Remove intake manitold(See page EMA - 92) 3. Remove timing chain.(See page EMA - 24) 4. Remove water temperature control assembly. (See page EMA - 74) 5, Remove camshaft bearing cap(A). Remove camshaft assembly(A). Remove cylinder head bolts, then remove cylinder head 1) Uniformly loosen and remove the 16 cylinder head bolts, in several passes, in the sequence shown, Remove the 16 cylinder head bolts and plate washers. A\ caution Hood warpage or cracking could result from re- moving Bots mn an Incorrect order 2) Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench. Ay caurion Be careful not to damage the contact surfaces of the cylinder head and cylinder block.CYLINDER HEAD ASSEMBLY EMA -41 DISASSEMBLY | ccsccore 2) Remove the spring retainer. 3) Remove the valve spring. Identify MLA, valves and valve springs as they are 4) Remove the valve, removed so that each item can be reinstalled in its original position. 5) Using SST(09222-29000), remove the valve stem seal 1. Remove MLAs(A). 09222-29000 2. Remove valves yore Do not reuse old valve stem seals. 41) Using $ST(09222-3K000, 09222-36300), com- press the valve spring and remove relainerlock. 3. Remove OCV(A) 09222-3K000 "99222-36300EMA -42 ENGINE MECHANICAL SYSTEM INSPECTION CYLINDER HEAD 1. Inspect for flatness. Using a precision straight edge and feeler gauge, ‘measure the surface the contacting the cylinder block and the manifolds for warpage. Flatness of cylinder head gasket surface Standard : Less than 0.05mm(0,002in.)[Less than 0.02mm(0.0008in./150%150] Flatness of manifold gasket surface Standard : Less than 0.03mm(0.00 tin)/110x110 2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. Ifcracked replace the cylinder head. VALVE AND VALVE SPRING 1. Inspect valve stems and valve guides. 1) Using a caliper gauge, measure the inside diam- eter of the valve guide, Valve guide 1.D. Intake / Exhaust : 5.600 ~ §.512mm (0.216 ~ 0.217in.) 2) Using a micrometer, measure the diameter of the valve stem. Valve stem ©.D. Intake : 5.465 ~ 5.480mm (0.2151 ~ 0.2187in.) Exhaust : 5.458 ~ §.470mm (0.2149 ~ 0.2153in.)CYLINDER HEAD ASSEMBLY EMA -43 3) Subtract the vaive stem diameter measurement from the valve guide inside diameter measure- ment. Valve stem-to-guide clearance [Standard] Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0018in.) Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in.) [Limit Intake : 0.07mm (0.0027in.) Exhaust : 0.9mm (0.0035in.) 2. Inspect valves. 1) Check the valve is ground to the correct valve face angle. 2) Check that the surface of the vaive for wear. Ifthe vaive face is worn, replace the valve. 3) Check the valve head margin thickness. Ifthe margin thickness is less than minimum, re- lace the valve. Margin [Standard] Intake : 1.56 ~ 1.86mm(0.06142 ~ 0.07323in.) Exhaust : 1.73 ~ 2.03mm(0.06811 ~ 0.07992in.) 4) Check the valve length Length Intake : 105.27mm (4.1445in) Exhaust : 105.50mm (4.1535in) '5) Check the surface of the valve stem tip for wear. Ifthe valve stem tip is worn, replace the valve. 3 Inspect vaive seats Check the valve seat for evidence of overheating and improper contact with the valve face. If the valve seat is worn, replace cylinder head. Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylin- der head. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face. Inspect valve springs. 1) Using a steel square, measure the out-of-square of the valve spring 2). Using a vernier calipers, measure the free length of the valve spring, Valve spring (Standard) Free height : 43.86mm (1.7267in.) Out-of-square 1.5"EMA -44 ENGINE MECHANICAL SYSTEM MLA 1. Inspect MLA. Using a micrometer, measure the MLA outside diam- ter. MLA ©.D. Intake/Exhaust : 34,964 ~ 34.980mm(1.3765 = 1.3771in) CAMSHAFT 1. Inspect cam lobes. Using a micrometer, measure the cam lobe height. Cam height [Standard value] Intake : 46.3mm (1.8228in.) Exhaust : 45.8 mm (1.8031in.) 2. Using a caliper gauge, measure MLA tappet bore in- nner diameter of cylinder head. ‘Tappet bore 1.D. Intake/Exhaust : 35,000 ~ 35.025mm(1.3779 ~ 1.3789in.) 3. Subtract MLA outside diameter measurement from tappet bore inside diameter measurement, MLA to tappet bore clearance (Standard) Intake/Exhaust : 0.020 ~ 0,061mm(0.0008 ~ 0.0024in.) [Limit Intake/Exhaust : 0.07mm(0.0027in.) If the cam lobe height is less than standard, replace the camshaft 2. Inspect camshatt journal clearance. 1) Clean the bearing caps and camshaft journals. 2) Place the camshafts on the cylinder head. 3) Lay a strip of plastigage across each of the ‘camshaft journal.CYLINDER HEAD ASSEMBLY EMA -45 4) Install the bearing caps. (See page EMA - 51) A\ cauion Do nota the camshaft 5) Remove the bearing caps. 6) Measure the plastigage at its widest point. Bearing oil clearance {Standard value] Intake No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.) 1No.2,3,4,, journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.) Exhaust No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.) No.2,3.4,, journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.) If the oil clearance is greater than maximum, re- place the camshaft. If necessary, replace cylin- der head. 7) Completely remove the plastigage. 8) Remove the camshafts. 3. Inspect camshaft end play. 1) Install the camshafts. (See page EMA - 50) 2). Using a dial indicator, measure the end play while moving the camshaft back and forth. Camshaft end play [Standard value] : 0.056 ~ 0.064mm(0.0022 ~ 0.0028in.) Ifthe end play is greater than maximum, replace: the camshaft. If necessary, replace cylinder head 3) Remove the camshafts.EMA -46 ENGINE MECHANICAL SYSTEM CWT ASSEMBLY 1 Inspect CWT assembly. 1) Check that the CVVT assembly will not turn 2) Apply vinyl tape to the retard hole except the one indicated by the arrow in the illustration, 4) Under the condition of 3), turn the CVVT assem- bly to the advance angle side (the arrow marked direction in the illustration) with your hand. Depending on the air pressure, the CVT assem- bly will urn to the advance side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the casethat the lock pin could be hardly released. 3) Wind tape around the tip of the air gun and apply air of approx. 150kpa(1.Skgficm?, 21psi) to the port of the camshaft (Perform this order to release the lock pin for the maximum delay angle locking.) (nore When the oil splashes, wipe it of witha shop rag '5) Except the position where the lack pin meets at the maximum delay angle, let the CVVT assem- bly turn back and forth and check the movable range and that there is no disturbance. Standard: Movable smoothly in the range about 22.5" 6) Turn the CVVT assembly with your hand and lock it at the maximum delay angle position (counter clockwise).CYLINDER HEAD ASSEMBLY EMA -47 REASSEMBLY NOTE Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace oil seals with new ones. 1. Install ves 1) Using SST(09222-3C 100), push in a new oil seal. Gaore Do not rouso old valve stom soa Incorrect installation of the seal could resuttin oil leak- age past the valve guides. 2) Install the valve, valve spring and spring retainer. NOTE Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then installs the retainer. 3) Using the $$7(09222-3K000, 09222-36300), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor. 09222.3K000 4) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock, 2. Install MLAs. Check that the MLA rotates smoothly by hand. (Gore MLA can be reinstalled in its original position.EMA -48 ENGINE MECHANICAL SYSTEM 3, Install OCV(A). INSTALLATION | cscs Tightening torque Dnore 9.80 ~ 11.76Nm(1.0 ~ 1.2kofm, 7.23 ~ 8.68Ibt.t) ~ —————_s_cv * Thoroughly clean all parts to be assembled. + Always use a new head and manifold gasket. + The cylinder head gasket is a metal gasket. Take care not fo bend it + Rotate the crankshaft, set theNo.1 piston at TDC. (See page EMA - 9) 4. Install the cylinder head gasket on the cylinder block. (Wore + To install OCV with gray colored connector into RH bank. + To install OCV with black colored connector into LH bank. A\ cauriow Snow ~ bo not reuse the OCV when dropped. ateaton a + Boot anes te Bo carat of the instalation drecton « Dotot held the OCV sleeve during servicing “Mion the OGY s nctaled on te engine de mat'move the engine wit helaing the OCV yore.CYLINDER HEAD ASSEMBLY 2 Place the cylinder head carefully in order not to dam- age the gasket with the bottom part of the end. Install cylinder head bolts. 1) Donot apply engine oil on the threads and under the heads of the cylinder head bolts. 2) Using SST(09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown, Tightening torque 39.2Nm (4.0kgf.m, 28.93Ibf.f}+ 120° + 90° 18,62 ~23.52Nm(1 kgfim, 13.74 ~ 17. 361bE. RA) 09221 - 4a000 Install the CVVT and camshaft sprocket. Tightening torque 64.68 ~ 76.44Nm(6.6 ~ 7.8 kgf.m, 47.74 ~ 56.4ibf.f) (Daore * Install camshatt-inlet to dowel pin of CWT as- sembly At this time, attend not fo be installed to oil hole of camshaft-nlet. + Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CWT assembly. + Do not rotate CVVT assembly when camshaft is installed to dowel pin of CVVT assembly.EMA -50 ENGINE MECHANICAL SYSTEM 5, Install camshafts(A), EXHAUST CAMSHAFT (Wore + Apply a light coat of engine oil on camshaft jour- nals. + Assemble the key groove of camshaft rear side to the same level of head top surface. + Be careful the right, left bank, intake, exhaust side before assembling. LH RH 3.3L_ | A: 27mm(1.0630in.) | A: 30mm(1.1811in.) INTAKE CAMSHAFT LH RH A; 27mm(1,0630in,) | A: 30mm(1.1811in,) 33L_ |B: 27mm(1.0630in.) |B: 30mm(1.184 tin.)CYLINDER HEAD ASSEMBLY EMA -51 6. Install camshaft bearing caps, Tightening torque 9.80 ~ 11.76Nm(1 1.2kgfim, 7.23 6albt.A) NOTE Bo careful the right, left bank, intake, exhaust side before assembling. A: L(LH).R(RH) B : I{Intake),None(Exhaust) CC : Journal number A\ caution Rotate the crankshaft not to contact the valves to the pistons by making the pistons below 10mm(0.3937in.) from the top of cylinder block. 7. Install water temperature control assembly.(See page EMA - 77) Install timing chain(See page EMA - 30) 9. Check and adjust valve clearance. (See page EMA - 8) 10, Install the exhaust manifold. (See page EMA - 96) 11. Install the intake manifold. (See page EMA - 96)EMA -52 ENGINE MECHANICAL SYSTEM ENGINE BLOCK COMPONENTS | cxscur 9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) TORQUE : N.m (kgf.m, Ibtft) Piston ring Piston Conneeting rod Connecting rod upper bearing Piston pin a 19.6 (2.0, 14.46) + 90° 9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) Connecting rod lower bearing Connecting rad bearing cap Baffle plate Upper oil pan Cylinder blockENGINE BLOCK EMA -53 aN 9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) 71.84 ~ 75.46 (7.3 ~ 7.7, 52.80 ~ 55.69) yoS 9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) CO = 29,40 ~ 31.36 (3.0 ~ 3.2, 21.70 ~23.14) {—— 19.60 (2.0, 14.46) +120° TORQUE : N.m (kgf.m, Ibf.ft) 1. Oildrain cover 6, Rear oil seal case 2. Crankshaft upper bearing 7. Crankshaft 3. Thrust bearing 8. Crankshaft lower bearing 4, Plate adapter 9. Main bearing cap 5. Drive plate 10. Oil drain cover gasket 11, Rear oll sealEMA -54 ENGINE MECHANICAL SYSTEM REMOVAL | excaosas Ay cumow + Use fender covers to avoid damaging painted surfaces. + To avoid damage, unplug the wiring connec- tors carefully while holding the connector portion. (nore * Mark all wiring and hoses fo avoid misconnec- fon + Inspection the timing belt before removing the oylnder head. + Turn ine crankshaft pulley so that the No.1 piston is at top dead conter. (Soe page EMA - 9) 1. Remove exhaust manifold (See page EMA - 94) 2. Remove intake manifold (See page EMA - 82) 3. Remove timing chain.(See page EMA - 24) 4. Remove water temperature control assembly.(See page EMA - 74) 5. Remove cylinder head.(See page EMA - 40) 6. Remove oll pump.(See page EMA - 84) 7. Remove oil filter assembly.(See page EMA - 85) 8. Remove A/C compressor(A) from engine. 9 10. Remove alternator(A) from engine. Remove power steering pump(A) from engine.ENGINE BLOCK DISASSEMBLY | cscarc 1. Remove drive plate. 2. Remove knock sensor(A). 3, EMA -55 5. Remove rear cil seal case(A). Check the connecting rod end play.(See page EMA - 56) Check the connecting rod oil clearance.(See page EMA - 57) Remove piston and connecting rod assemblies. 1 Using a ridge reamer, remove all the carbon from the top of the cylinder. 2 Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. (ore * Keep the bearings, connecting rod and cap to- getter + Arrange the piston and connecting rod assem- bios nthe correct orderEMA -56 ENGINE MECHANICAL SYSTEM 10, Remove crankshaft main bearing cap and check oil clearance.(See page EMA - 59) 11. Check the crankshaft end play.(See page EMA - 60) 12. Lift the crankshaft(A) out of engine, being careful not, to damage journals. nore Arrange the main bearings and thrust bearings in the correct order. 13. Check fit between piston and piston pin. Try to move the piston back and forth on the piston pin. if any movement is felt, replace piston and piston pin as a set. 14, Remove piston rings. 1) Using a piston ring expender, remove the 2.com- pression rings. 2) Remove 2 side rails and the spacer by hand. (nore ‘Amange the piston ringe inthe comect onder only 15, Disconnect connecting rod from piston. INSPECTION casio CONNECTING ROD AND CRANKSHAFT 1. Check the connecting rod end play. Using a feeler gauge, measure the end play while moving the connecting rod back and forth. Standard end play : 0.1~ 0.25mm(0.004 ~ 0.010in.) * If out-of-tolerance, install a new connecting rod. * If still out-of-tolerance, replace the crankshaft 2. Check the connecting rod bearing oil clearance. 1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassem- bly. 2) Remove 2 connecting rod cap bolts. 3) Remove the connecting rod cap and bearing half. 4) Clean the crank pin and bearing, 5) Place plastigage across the crank pin. 6) Reinstall the bearing half and cap, and torque the bolts, Tightening torque 19.6Nm (2.0kgfm, 14.46Ibf-t) + 90° Daore Do not tum the erankshatENGINE BLOCK EMA -57 7) Remove 2 bolts, connecting rod cap and bearing- halt. 8) Measure the plastigage at its widest point. Standard oil clearance 0.030 ~ 0.048mm(0.0012 ~ 0.0019in.) 9) If the plastigage measures too wide or too nar- row, remove the upper half of the bearing, in- stall a new, complete bearing with the same color ‘mark (select the color as shown in the next col- umn), and recheck the clearance. A\ caurion Do not file, shim, or scrape the bearings or the caps to adjust clearance. 10) If the plastigage shows the clearance is stil in- correct, ry the next larger or smaller bearing (the color listed above or below that one), and check clearance again Gore 1 he proper clearance cannot be obtained by using the appropriate argeror smaller boarings, replace the crankshaft and start over, Q) caurion If the marks are indecipherable because of an ac- cumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. CONNECTING ROD MARK LOCATION DISCRIMINATION OF CONNECTING ROD CLASS MARK INSIDE DIAMETER ° a ‘58,000 ~ 58.006mm (2.2834 ~ 2.2837in,) 1 > 58,006 ~ 58.012mm (2.2837 ~ 2.2839in.) 2 58,012 ~ 58.018mm © (2.2839 ~ 2.2842in,) CRANKSHAFT PIN MARK LOCATION DISCRIMINATION OF CRANKSHAFTEMA -58 ENGINE MECHANICAL SYSTEM DISCRIMINATION OF CRANKSHAFT 411) Selection CLASS Mark | OUTSIDE DIAMETER CONNECTING ROD OF PIN IDENTIFICATION MARK 1 A 54.966 ~ §4.972mm oa) 1(b) 2c) (2.1640 ~ 2,1642in,) h 54.960 ~ 54.966mm CRANK-| | (A) YEL- B c " | Sie Sesemm || epamee| haar | OE | cere | (voney 54,954 ~ 54.960mm INDEN- B c D m c : (2.1635 ~ 2.1638in.) TIGA’ | (8) | (GREEN) | (ONE) | (BLACK) MARK c D E PLACE OF IDENTIFICATION MARK (CONNECTING ey pLACE OF DEN (NONE) | (@LACK) | (BLUE) 3. Check the crankshaft bearing oll clearance. 41) To check main bearing-to journal oil clearance, remove the main bearing caps and bearing halves. 2). Clean each main journal and bearing half with a clean shop tower. 3) Place one strip of plastigage across each main journal. a 4) Reinstall the bearings and caps, then torque the DISCRIMINATION OF CONNECTING ROD BEARING bolts. Tightening torque 49.00Nm(5.0 kgf.m, 36.16Ibfft) + 90° 19.60 Nm(2.0 kgm, 14.46Ibf.t)+ 120° 29.40 ~ 31.36Nm(3.0 ~ 3.2 kgf.m, 21.70 ~ 23.14lbf ft) E sive | aosse -oose7iny D auack | Stl \Siamm c None | @rasoa-0.0596m) a | oncen | gee Semin a | vetow | S02 1805 Wore Do not tum the crankshaftENGINE BLOCK EMA -59 5) Remove the cap and bearing again, and measure the widest part of the plastigage. Standard oil clearance 0.022 ~ 0.040mm (0.0009 ~ 0.0016in.) 6) If the plastigage measures too wide or too nar- row, remove the upper half of the bearing, in- stall anew, complete bearing with the same color mark (select the color as shown in the next col- umn), and recheck the clearance. G caution Do not file, shim, or scrape the bearings or the caps to adjust clearance. 7) If the plastigage shows the clearance is stil in- correct, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again vore I the proper clearance cannot be obtained by using the appropiate largeror smaller bearings, replace the crankshaft and start over Ay caurion If the marks are indecipherable because of an ac- cumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. Crankshaft bore mark location Letters have been stamped on the block as a mark for the size of each of the § main journal bores, Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings. DISCRIMINATION OF CYLINDER BLOCK CLASS MARK | INSIDE DIAMETER A 73.500 ~ 73.606mm : (2.8937 ~ 2.8938in.) 73.508 ~ 73.512mm 5 8 (2.8939 ~ 2.8942in.) : c 73.512 ~ 73.518mm (2.8942 ~ 2.8944in.) CRANKSHAFT JOURNAL MARK LOCATION DISCRIMINATION OF CRANKSHAFT DISCRIMINATION OF CRANKSHAFT ‘OUTSIDE DIAMETER CLASS MARK OF JOURNAL A 68.954 ~ 68.960mm (2.7147 ~ 2.7150in.) 1 8 68.948 ~ 68.954mm (2.7145 ~ 2.7147in.) in c 68.942 ~ 68.948mm (2.7142 ~ 2.7145in.)EMA -60 ENGINE MECHANICAL SYSTEM PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING) DISCRIMINATION OF CRANKSHAFT BEARING 4, Check crankshaft end play. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard end play 0.10 ~ 0.28mm (0.0039 ~ 0.0110in.) THICKNESS OF roxoooie CLASS MARK BEARING : pue 22TT = 2.280mm If the end play is greater than maximum, replace the (0.0896 ~ 0.0897 in.) thrust bearings as a set 2.274 ~ 2.277mm ‘Thrust bearing thickness D BLACK (0.0895 ~ 0.0896in.) 2.41 ~ 2.45mm(0.0949 ~ 0.0964in.) 2.271 ~ 2.274mm c NONE 7 (0.0804 ~ 0.08965in.) 5. Inspect main journals and crank pins 2.268 ~ 2.271mm Using a micrometer, measure the diameter of each 5 GREEN (0.0893 ~ 0.0894in.) main journal and crank pin 2.265 ~ 2.268mm A YELLOW (9.9892 ~ 0.0893in,) Main journal diameter ; 68.942 ~ 68.960mm (2.7142 ~ 2.7148in.) SELECTION Crank pin diameter : 54.954 ~ 54.972mm CRANKSHAFT BORE IDENTIFICATION MARK a(A) b(B) ec) A 8 c CRANK! | (a) | (YEL- snare] | | {yy | (GREEN) | (one) IDEN- 8 c D TIFICA-| (8) Fon | (GREEN) | (NONE) | (BLACK) | MARK c D E NMG) | (ONE) | (BLACK) | (BLUE) (2.1635 ~ 2.1642in,)ENGINE BLOCK EMA CONNECTING RODS 4. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match, When anew connecting rod is installed, make ssure that the notches for holding the bearing in place are on the same side. 2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the ‘small end is apparent, the rod must be replaced as well 3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced ‘Allowable bend of connecting rod 0.05mm / 100mm (0.0020 in/3.94 in.) or less. Allowable twist of connecting rod 0.4mm | 100mm (0.0039 in,/3.94 in.) or less CYLINDER BLOCK 1. Remove gasket material. Using a gasket scraper, remove all the gasketmaterial from the top surface of the cylinder block. 2. Clean cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block. 3. Inspect top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Flatness of cylinder block gasket surface Standard : Less than 0.05mm(0,0020 in.),Less than 0.02mm(0.0008in.) / 150 x 150 4, Inspect cylinder bore diameter Visually check the cylinder for vertical scratchs. If deep scratches are present, replace the cylinder block.EMA -62 ENGINE MECHANICAL SYSTEM 5, Inspect cylinder bore diameter 7. Check the piston size code on the piston top face, Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial i- rections. Standard diameter 92,00 ~ 92.03mm (3.6220 ~ 3.6232in.) Class Size code _| Piston outer diameter 91.97-91.98mm A A (3.6209 ~ 3.6212in.) 91,98~91.99mm 8 None (3.6212 ~ 3.6216in.) 91,99-92.00mm S © (3.6216 ~ 3.6220in,) Frarssss 8. Select the piston related to cylinder bore class. 6. Check the cylinder bore size code on the cylinder block. Clearance : 0.02 ~ 0.04mm(0.0008 ~ 0.0016in.) I ce class | Size code | Ovlinder bore inne diameter ‘ & | cosea~Sb2zen) 2 & | sees anezany ° © | cove2s Siete)ENGINE BLOCK EMA -63 PISTON AND RINGS 4. Clean piston 1) Using a gasket scraper, remove the carbon from the piston top. 2) Using a groove cleaning tool or broken ring, clean the piston ring grooves. 3) Using solvent and a brush, thoroughly clean the piston, Gore Do not use a wir brush 2. The standard measurement of the piston outside di- ameter is taken 14 mm (0.5512 in.) from the bottom of the piston. Standard diameter 91.97 ~ 92.00mm (3.6209~ 3.6220in.) 3. Calculate the difference between the cylinder bore di- ameter and the piston diameter. Piston-to-cyiinder clearance 0.02 ~ 0.04mm(0.0008 ~ 0.0016in.) 4 Inspect the piston ring side clearance. Using afeeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Piston ring side clearance Standard No.1 : 0.04 ~ 0.078mm (0.0016 ~ 0.003tin.) No.2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.) il ring : 0,06 ~ 0.15mm (0.0024 ~ 0.0058in.) Limit No.1 : 0.1mm (0.004in.) No.2 : 0.1mm (0.004in.) Oil ring 0.2mm (0.008in.) Ifthe clearance is greater than maximum, replace the pistonEMA -64 ENGINE MECHANICAL SYSTEM 5, Inspect piston ring end gap. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter against the wear limits on page EMA - 62 Ifthe bore is over the service limit, the cylinder block must be replaced. (See page EMA - 62) Piston ring end gap Standard No.1 : 0.17 ~ 0.32mm (0.0067 ~ 0.0126in.) No.2 : 0.32 ~ 0.47m (0.0126 ~ 0.0185in.) Oil ring : 0,20 ~ 0,70mm (0.0079 ~ 0.0275in,) Limit No.1 : 0.6mm (0.0236in.) No.2 : 0.7mm (0.0275in.) 0.8mm (0.0318in.) Oil ring PISTON PINS 1 Measure the diameter of the piston pin. Piston pin diameter 23.001 ~ 23.006mm (0.9055 ~ 0.9057in.) 2, Measure the piston pin-to-piston clearance. Piston pin-to-piston clearance 0.01 ~ 0.02mm (0.0004 ~ 0.0008in.) 3 Check the difference between the piston pin diameter and the connecting rod small end diameter. Piston pin-to-connecting rod interference 0.016 ~ 0.032mm (0.00063 0.00126in.)ENGINE BLOCK EMA -65 REASSEMBLY tisv-cer 1) Align the bearing claw with the groove of the con- necting rod or connecting rod cap. NOTE 2) Install the bearings(A) in the connecting rod and + Thoroughly clean all parts to assembled. ‘connecting rod cap(B). + Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. + Replace all gaskets, O-rings and oil seals with new parts. 1. Assemble piston and connecting rod. 1) Use a hydraulic press for installation, 2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine. B 4, Install main bearings. nore Upper bearings have an oll groove of oil holes; Lower bearings do not. 1) Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings(A), 2. Install piston rings. 1) Install the oil ring spacer and 2 side rails by hand 2) Using a piston ring expander, install the 2 com- pression rings with the code mark facing upward. 3) Position the piston rings so that the ring ends are as shown, 2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lowerbear- ings. 3. Install connecting rod bearings.EMA -66 ENGINE MECHANICAL SYSTEM 5, Install thrust bearings. Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves fac- ing outward, nore + Always use new main bearing cap bolt. + if any of the bearing cap bolts in broken or de- formed, replace it. 6. Place crankshaft on the cylinder block. 7. Place main bearing caps on cylinder block. 8. Install main bearing cap bolts. 1) Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown. Tightening torque Main bearing cap bolt 49.00Nm(5.0 kgf.m, 36.16Ibfft) + 90° 19,60 Nm(2.0 kgf.m, 14.46Ibtt}+ 120° 29.40 ~ 31,36Nm(3.0 ~ 3.2 kgf.m, 21.70 ~ 23.14lbf.f) Use SST( 09221-44000 ), install main bearing cap bolts. (09221 - 4A000 2) Check that the crankshaft turns smoothly. 9. Check crankshaft end play. (See page EMA - 60) 10. Install piston and connecting rod assemblies. nore Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores. 1) Install the ring compressor, check that the bear- ing is securely in place, then position the piston in the cylinder, and tap it in using the wooden han- dle of a hammer.ENGINE BLOCK EMA -67 2) Stop after the ring compressor pops free, and check the connecting rod-to-check journal align- ment before pushing the piston into place. 3) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts. Tightening torque 19.6Nm (2.0kgf.m, 14.46lbf.f) + 90° Use SST( 09221-44000 }, install connecting rod bearing cap bolts, 09221 -4a000 Gore + Always use new connecting rod bearing cap bolt. + Maintain downward force on the ring compressor to prevent the rings from expanding before enter- ing the cylinder bore. 11. Check the connecting rod end play.(See page EMA - 56) 42. Install oil drain cover. Tightening torque 9.80 ~ 11.76Nm (1.0 ~ 1.2kgfim, 7.23 ~ 8.67Ibf-ft) NOTE + Make clean the sealing face before assembling two parts. + Remove harmful foreign matters on the sealing face before applying sealant Be assembling oil drain cover, the liquid sealant 7B1217H should be applied oil drain cover. The part must be assembled within § minutes after sealant was applied. Apply sealant fo the inner threads of the bolt holes.EMA -68 ENGINE MECHANICAL SYSTEM 13, Install rear oil seal cast Tightening torque nore * Mako clean the sealing face before assembling two pets + Remove harmful foreign matters on the sealing face before applying sealant + Be assembling rear oil seal case, the liquid sealant TB1217H should be applied rear oil seal case. + The part must be assembled within 5 minutes after sealant was applied. + Apply sealant to the inner threads of the bolt holes. 14, Using S$T(09231-3C200, 09231-H1100), install rear oil seal. 9231-30200 oazat-H1100 15, Install baffle plate. Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown. Tightening torque 9.80 ~ 11.76Nm (1.0 ~ 1.2kgim, 7.23 ~ 8.68Ibf.A) 16. Install upper oil pan. a. Using a gasket scraper, remove all the old pack- ing material from the gasket surfaces. b. Before assebling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan. ‘The part must be assembled within 5 minutes after the sealant was applied. Bead width : 2.5mm(0.tin,)ENGINE BLOCK EMA -69 NOTE + Make clean the sealing face before assem- bling two parts. + Remove harmful foreign matters on the seal- ing face before applying sealant + When applying sealant gasket, sealant must not be protruded into the inside of oil pan. + To prevent leakage of oll, apply sealant gas- ket ot the inner threads of the bolt holes. . Install oll pan. Uniformly tighten the bolts in several passes. Tightening torque 9,80 ~ 11,76Nm (1.0 ~ 1.2kgfim, 7.23 ~ 8.68Ibf.R) d. After assembly, wait at least 30 minutes before filing the engine with cil. 17. Install knock sensor. Tightening torque 15.68 ~ 23.52Nm (1.6 ~ 2.4kgtim, 11.57 ~ 17.961b6) 18, Install drive plate. Tightening torque 71.54 ~ 75.46Nm (7.3 ~ 7.7kgf.m, 62.80 ~ 55.691bf.ft) INSTALLATION | rciosces 41. Install power steering pump. 2. Install alternator. 3. Install air compressor 4, Install oil filter assembly.(See page EMA - 87) 5. Install oil pump.(See page EMA - 86) 6. Install cylinder head.(See page EMA - 48) 7. Install water temperature control assembly.(See page EMA - 77) 8, Install timing chain.(See page EMA - 30) 9. Install intake manifold.(See page EMA - 96) 10. Install exhaust manifold (See page EMA - 96)EMA -70 ENGINE MECHANICAL SYSTEM COOLING SYSTEM COMPONENT etcrrae 18.62 ~ 23.52 (1.9 ~ 2.4, 13.74 ~ 17.36) 9.8 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) 16.66 ~ 19.60 (1.7 ~ 2.0, 12.30 ~ 14.47) 7.84 ~9.80 (0.8 ~ 1.0, 5.78 ~7.23) 9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) TORQUE : N.m (kgf.m, Ibf-ft) 1. Water pump pulley 5. Water inlet pipe 2. Water pump 6. Gasket 3. Water pump gasket 7. O-ring 4, Thermostat 8. Air vent pipe 9. HoseCOOLING SYSTEM EMA ENGINE COOLANT REFILLING AND BLEEDING | -ow«00 @ warnine Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator. Q) caution When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint. If any coolant spills, rinse it off immediately. 1. Make sure the engine and radiator are cool to the touch. 2. Remove radiator cap. 3, Loosen the drain plug, and drain the coolant, 4, Tighten the radiator drain plug securely. 5. Remove, drain and reinstall the reservoir. Fill the tank halfway to the MAX mark with water, then up to the MAX mark with antifreeze, 6. Fill fluid mixture with coolant and water(4: 6) slowly through the radiator cap. Push the upperilower hoses of the radiator so as bleed air easily. OTE + Use only genuine antifreeze/coolant. + For best corrosion protection, the coolant con- centration must be maintained year-round at 50% ‘minimum. Coolant concentrations less than 50% may not provide sufficient protection against corrosion or freezing. + Coolant concentrations greater then 60% will im- pair cooling efficiency and are not recommended. Ay caurion * Do not mix diferent brands ttreezelcoolants «Do not use additional rust inhibitors or an- trust products; they may not be compatible withthe coolant of an- 10, "1 12, Start the engine and run coolant circulates. When the cooling fan operates and coolant circulates, refill coolant through the radiator cap. Repeat 7 until the cooling fan 3 ~ times and bleed air sufficiently out of the cooling system. Install the radiator cap and fill the reservoir tank to the "MAX" line with coolant. Run the vehicle under idle until the cooling fan oper- ales 2 ~ 3 times. Stop the engine and wait coolant gets cool Repeat 6 to 11 until the cootant level doesn't fall any more, bleed air out of the cooling system, Gaore As itis to bleed air out to the cooling system and refill coolant when coolant gets cool completely, recheck the coolant level in the reservoir tank for 2 ~ 3 days afler replacing coolant.EMA -72 ENGINE MECHANICAL SYSTEM CAP TESTING 1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester. 2. Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgt/om?, 14 ~ 19psi) 3. Check for a drop in pressure, 4, Ifthe pressure drops, replace the cap. TESTING Wait until engine is cool, then carefully remove the radiator cap and fil the radiator with engine coolant, then install it on the pressure tester. Apply a pressure tester to the radiator and apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/em? 14 ~18psi), Inspect for engine coolant leaks and a drop in pres- sure, Remove the tester and reinstall the radiator cap. Dore (Check for engine oil in the coolant and/or coolant in the engine oilCOOLING SYSTEM EMA -73 REMOVAL | éccasore 4, Remove the water pump(A) and gasket. WATER PUMP 4. Drain the engine coolant. @ warnine ‘Systemis under high pressure when th hot. To avoid danger of releasing scald coolant, remove the cap only when thi cool. 2. Remove drive belt(A). 3, Remove the 4 bolts and pump pulley(A).EMA -74 ENGINE MECHANICAL SYSTEM WATER TEMPERATURE CONTROL ASSEMBLY THERMOSTAT 1, Drain the engine coolant. Wore 2, Remove air cleaner assembly.(See page EMA - 16) Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficioncy. Do 3. Disconnect radiator upper and lower hose(A). not remove the thermostat, even if the engine tends to overheat. 1. Drain engine coolant so its level is below thermostat. 2. Remove water inlet(A) and thermostat(8). 4, Disconnect WTS connector.(See page EMA - 19) 5. Disconnect heater hose, water vent hose and water hose from water temperature control assembly. ones 6. Remove wiring protector. 7. Remove water temperature control assembly(A).COOLING SYSTEM EMA -75 RADIATOR 4. Drain the engine coolant. 2. Disconnect radiator upper and lower hoses(A). 3. Disconnect transaxle oil cooler hoses.(See TR group) 4, Remove radiator bracket. 5. Remove radiator assembly. INSPECTION WATER PUMP Check each part for cracks, damage or wear, and re- place the coolant pump assembly if necessary. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump as- sembly if necessary. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump as- sembly, (Gaore A small amount of 'weeping’ from the bleed hole is normal.EMA -76 ENGINE MECHANICAL SYSTEM ‘THERMOSTAT INSTALLATION crowercs 1, Immerse the thermostat in water and gradually © WATER PUMP. heatthe water. 1. Install the water pump(A) and a new gasket(B) with 12 bolts. Tightening torque 21.56 ~ 23.52Nm (2.2 ~ 2.4kgfim, 15.91 ~ 17.36)bf. ft) 9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68Ibf.ft) 2. Check the valve opening temperature. Valve opening temperature : 82°C (177°F) Full opening temperature : 95°C (205°F) If the valve opening temperature is not as specified, replace the thermostat. 3. Check the vaive tif. — Valve lift: Min, 10mm (0.4in.) at 95°C (205°F) Wore If the valve lif is not as specified, replace the thermo- ‘Mate clean the contact face before assombiy stat. 2. Install the 4 bolts and pump pulley(A). Tightening torque 7.84 ~ 9,80Nm (0.8 ~ 1.0kgfm, 5.78 ~ 7.23Ibf.ft)COOLING SYSTEM EMA -77 3. Install drive bett(A) WATER TEMPERATURE CONTROL ASSEMBLY (Ginore Make clean the contact face before assembly. 1. Install water temperature control assembly(A) and new gasket(B). Tightening torque 18,62 ~ 23.52Nm (1.9 ~ 2.4kghm, 13.74 ~ 17.361b6) 4, Fillwith engine coolant 5. Start engine and check for leaks, 6. Recheck engine coolant level, (Gore Use new O-rings(C) when reassembling. 2. Connect water hoses to the water temperature control assembly. 3. Install wiring protector. 4, Connect WTS connector. 5. Connect radiator upper and lower hose(A).ENGINE MECHANICAL SYSTEM EMA -78 6. Install air cleaner assembly. ‘THERMOSTAT 7. Fill with engine coolant, 1. Place thermostat in thermostat housing, 8. Start engine and check for leaks. 1) Install the thermostat with the jiggle valve up- 9. Recheck engine coolant level werd 2) Install a new thermostat(B) 2. Install water inlet(A). Tightening torque 16.66 ~ 19.60Nm (1.7 ~ 2.0kgiim, 12.30 ~ 14.47Ibt«t) 3. Fill with engine coolant. 4. Start engine and check for leaks.COOLING SYSTEM EMA -79 RADIATOR 4. Install radiator assembly. 2. Install radiator upper bracket. 3. Connect transaxle oil cooler hoses.(See TR group) 4, Connect radiator upper and lower hoses(A), 5. Fill with engine coolant. 6. Start engine and check for leaks, 7. Recheck engine coolant level.EMA -80 ENGINE MECHANICAL SYSTEM LUBRICATION SYSTEM COMPONENT exec: 9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) ~ 18.62 ~21.56 (1.9 ~ 2.2, 13.74 ~ 15.91) 19.60 ~ 23.52 (2.0 ~ 2.4, 14.47 ~ 17.36) 13 9.8 ~11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) 9.8-11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) TORQUE : N.m (kgf.m, Ibf.ft) il fiter cap 6. Gasket 14. Oil pump sprocket O-ring 7. O-ring 12. Oil pump chain cover Oil fiter element 8. Gasket 13. Lower oil paon Oil fiter body 8. Oil pump Oil fiter body cover 10. GasketLUBRICATION SYSTEM EMA -81 QIL AND FILTER ccsoosce 4, Replace oil fiter. a. Disconnect the ail filter cap from oil iter body. IN b. Remove the oi fiter element. “AUTION a caurio c. Check and clean the oil filter installation surface. + Prolonged and repeated contact with mineral 4. Check the part number of the new oil fiter is as ail will result in the removal of natural fats same as old one. from the skin, leading to dryness, irritation ©. Install new ol fiter element(A) and two and dermatitis. In addition, used engine oi! Oxrings(B) contains potentially harmful contaminants which may cause skin cancer. + Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. + Inorder to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites. 1. Wait for Sminutes after loosening the oil fiter cap by turning it counterclockwise to drain well the oil in the oil filter. f. Lightly screw the oil filter cap into place, and tighten it until the O-ring contacts the seat. Tightening torque 24,50Nm (2.5kgf:m, 18.08Ibf.") 5. Refill with engine ol a. Clean and install the oil drain plug with a new gasket. Tightening torque 34.3 ~ 44.1Nm (3.5 ~ 4.5kgim, 25.3 ~ 32.5Ibf.f) ccneosia b. Fill with fresh engine oll 2. Remove the ail filer cap. Capacity WIOIIfiter change : 6.4L(6.76U.S.qus,5.63Imp.ats) ‘WIO Oil filter change : 5.5L(5.81U.S.qus,4.84Imp.qts) il filter : 0.4L(0.42U.S.qus,0.36Imp.ats) Drain and refil : 5.2L(5.49U.S.qus.4.58imp.qts) 3. Remove the oil drain plug, and drain the oil into a container. cc. Install the oil fiter cap. 6. Start engine and check for oil leaks. 7. Recheck engine oil level.EMA -82 ENGINE MECHANICAL SYSTEM INSPECTION 1. Check engine oil quality. Check the oil for deterioration, entry of water, discol- coring or thinning, If the quality is visibly poor, replace the oil 2. Check engine oil level After warming up the engine and then 5 minutes after the engine stop, oil level should be between the * L’ and * F” marks on the dipstick. IF low, check for leakage and add oil up to the * F” mark. nore Do not fil with engine oil above the °F” mark.LUBRICATION SYSTEM EMA -83 SELECTION OF ENGINE OIL Hf SW-20 engine oil is not available, SW-30 or secondary recommanded engine oil for carrespanding temperature Recommended API classification : Above SJ or SL range can be used. Recommended SAE viscosity grades : SW-20 ‘Temperature range anticipated before Recommended SAE viscosity number next oil change 718°C -0.4°F For best performance and maximum protection of all types of operation, select only those lubricants which + Satisfy the requirement of the API classification. + Have proper SAE grade number for expected am- bient temperature range. Lubricants that do not have both an SAE grade num- ber and API service classification on the container should not be used.EMA -84 ENGINE MECHANICAL SYSTEM REMOVAL | ésoaser 4, Remove oil pump chain sprocket(A). ‘OL PUMP 1. Drain engine oil. 2. Using SST(09215-3C000) remove lower oil pan(A). A caurion Be careful not to damage the contact surfaces of upper oil pan and lower oil pan. 3. Remove cil pump chain cover(A),LUBRICATION SYSTEM EMA -85 OIL FILTER ASSEMBLY 4. Loosen the oii fiter cap by turning it counterclockwise to drain well the olin the oil iter, 2. Remove surge tank and intake manifold.(See page EMA - 92) 3, Disconnect oil pressure switch connector.(See page EMA - 18) 4, Drain the engine coolant, 5. Disconnect water hoses from ETC. 6. Remove water temperature control assembly (See page EMA - 74) 7. Disconnect water vent hose(A). 8, Remove oil filter body cover(B). 9. Remove ail filter body.(A). NOTE Be careful of the knock sensor connector. INSPECTION OIL PRESSURE SWITCH 4. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oll pressure switch, 2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is con- tinuity even when the fine wire is pushed, replace the ‘switch 3. Ifthere is no continuity when a SOkpa (7psi) vacuum is applied throgh the oil hole, the switch is operaing properly. Check for air leakage. If air leaks, the diaphragm is broken. Replace itEMA -86 ENGINE MECHANICAL SYSTEM INSTALLATION | rzcorse 3. Install oil pump chain cover(A). ‘OlL PUMP Tightening torque 4.76Nm (1 1. Install oi! pump(A). Tightening torque 19,60 ~ 23.52Nm (2.0 ~ 2.4kgf.m, 14.47 ~ 17.361bf.f) Wore Always use a new O-ring. 4, Install upper oil pan. a. Using a gasket scraper, remove all the old pack- ing material from the gasket surfaces. b. Before assembling the oil pan, the liquid sealant 7B1217H should be applied on upper cil pan. oer The part must be assembled within 5 minutes after the sealant was applied. 2. Install ol pump sprocket(A)and oil pump chain on the oil pump. Bead width : 2.5mm(0.tin.) Tightening torque 18.62 ~ 21.56Nm (1.9 ~ 2.2kgfm, 13.74 ~ 15.91Ibf-ft) A\ caution + Make clean the sealing face before as- sembling two parts. + Remove harmful foreign matters on the sealing face before applying sealant ‘+ When applying sealant gasket, sealant must not be protruded into the inside of oil pan. + To prevent leakage of oil, apply sealant gasket ot the inner threads of the bolt holes.LUBRICATION SYSTEM EMA -87 Install upper oil pan. OIL FILTER ASSEMBLY Uniformly tighten the bolts in several passes. 41. Install oil fter body(AA) and new O-rings. Tightening torque 9.80 ~ 11.76Nm (1.0 ~ 1.2kgfm, 7.23 ~ 8.68IbE.) Tightening torque eT A.duWa€ = 9.80 ~ 11.76Nm (1.0 ~ 1.2kgtm, .23 ~ 8.68IbE.f) d. After assembly, wait at least 30 minutes before filing the engine with oil, Kone NOTE + Allrubber gasket must be no damaged by assem bling parts. * Be careful of the knock sensor connector. + Always use a new O-ring 2. Install ol fiter body cover(A) and new gasket on the oil flter body, Tightening torque 9.80 ~ 11.76Nm (1.0 ~ 1.2kglm, 7.23 ~ 8.681bf.%)EMA -88 ENGINE MECHANICAL SYSTEM 3, Connect water vent hose(B) Tightening torque 9.80 ~ 11.76Nm (1.0 2kgf.m, 7.23 ~ 8.681b1.8) 4. Install water temperature control assembly (See page: EMA - 77) 5. Connect water hoses on the ETC. 6. Connect oil pressure switch connector (See page EMA - 18) 7. Install intake manifold and surge tank.(See page EMA = 96) 8. Fill with engine coolant. 9. Start engine and check for leaks. 10, Recheck engine coolant level.INTAKE AND EXHAUST SYSTEM INTAKE AND EXHAUST SYSTEM COMPONENT | ccosoass 9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68) 18.62 ~ 23.52 (1.9 ~ 2.4, 13.74 ~ 17.36) TORQUE : N.m (kgf.m, Ibf.ft) EMA -89 4. Surge tank 3. Intake manifold 2. Delivery pipeEMA -90 ENGINE MECHANICAL SYSTEM 16.66 ~ 21.56 (1.7 ~ 2.2, 12.29 ~ 15.91) TORQUE : N.m (kgf.m, Ibf.ft) 1. Gasket 3. Heat protector 2. Exhaust manifoldINTAKE AND EXHAUST SYSTEM EMA -91 39.2 ~ 58.8 (4.0 ~ 6.0, 28.92 ~ 43.37) TORQUE : N.m (kgf.m, Ibf.ft) 1. Catalytic converter 4, LH muffler 2. Center mutffier 5. Gasket 3. Main muffler 6. Rubber hangerEMA -92 REMOVAL | cssscrre INTAKE MANIFOLD 1 2, Disconnect AFS(A) and breather hose(8).. Remove air cleaner upper cover(D) and intake hose(C). ena 3. Disconnect RH oxygen sensor connector(A). a 4 ENGINE MECHANICAL SYSTEM Disconnect RH injector connector(A) and ignition coll connector(8). Disconnect ETC connector(A) and knock sensor con- nector(B), 6 Disconnect PCSV connector(A), MAP sensor connec- tor(8) and PCSV hose.INTAKE AND EXHAUST SYSTEM 7. Remove ETC bracket(A). 8. Disconnect water hoses(B) from ETC. 9. Disconnect PCV(C) hose. 10. Disconnect brake vacuum hose. 11, Remove surge tank bracket(A). i 12, Remove connector bracket(A) from surge tank. EMA -93 13. Remove surge tank(A). 15. Disconnect LH injector connector. 16, Remove delivery pipe(A)EMA -94 ENGINE MECHANICAL SYSTEM 17. Remove intake manifold(A) and gasket. EXHAUST MANIFOLD 1, Remove under cover(A). 2. Disconnect LHRH rear oxygen sensor connector from bracket. 3. Remove front mutfier(A).INTAKE AND EXHAUST SYSTEM EMA -95 4, Remove oil level gauge(A). 8. Disconnect RH front oxygen sensor connector from bracket, 5. Disconnect LH front oxygen sensor connector(B) from eee re a ea korrisax 9, Remove RH heat protector. 10. Remove RH exhaust manifold.EMA -96 ENGINE MECHANICAL SYSTEM INSTALLATION | cstscors INTAKE MANIFOLD 1. Install intake manifold and new gasket on the cylinder head Tightening torque 18.62 ~ 23.52Nm (1.9 ~ 2.4kgf.m, 13.74 ~ 17.26}bf.A) EXHAUST MANIFOLD 1. Install new gasket and exhaust manifold. Tightening torque 39.2 ~ 44.1Nm(4.0 ~ 4.5kgfm, 28.92 ~ 32.53ibf-t) 2. Install heat protector. nore Bo carota ofthe installation drcton 2. Install delivery pipe.(See FL group) 3. Connect LH injector connector. 4. Connect breather hose. Tightening torque 9.80 ~ 11.76Nm (1.0 ~ 1.2kgfm, 7.23 ~ 8.68Ibfft) 5. Install surge tank. Tightening torque 9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68Ibf.R) 6. Install connector bracket on the surge tank. Tightening torque 6.86 ~ 10.78Nm (0.7 ~ 1.1kgf.m, 5.06 ~ 7.96Ibf.t) 7. Install surge tank bracket Tightening torque 27.44 ~ 31.36Nm (2.8 ~ 3.2kgf.m, 20.25 ~ 23.14lbf.f) 8. Connect PCV hose. 9. Install ETC bracket. Tightening torque 15.68 ~ 25.48Nm (1.6 ~ 2.6kgf.m, 11.57 ~ 18.801bf.f) 10. Install air cleaner assembly. 11, Install engine cover. Tightening torque 16.66 ~ 21.56Nm(1.7 ~ 2.2kgf.m,12.30 ~ 15.91Ibf.N) 3. Install front muffler. Tightening torque 39.2 ~ 58.8N.m(4.0 ~ 6.0kghm, 28.92 ~ 43.37ibt.A) 4, Connect oxygen sensor connector. 5. Install under cover.