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Manual de taller Hyunda santa fe 3.5
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50% found this document useful (2 votes)
892 views85 pagesSanta Fe Engine 3.5
Manual de taller Hyunda santa fe 3.5
Uploaded by
JoseCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
/ 85
GENERAL
‘SPECIFICATIONS
TIGHTENING TORQUE
CHECKING ENGINE OIL
‘SELECTION OF ENGINE OIL.
CHANGE OF OIL.
REPLACEMENT OIL FILTER.
CHECKING COOLANT LEAK
RADIATOR CAP PRESSURE TEST.
COOLANT SPECIFIC GRAVITY TEST.
CHECKING COMPRESSION PRESSURE
ADJUSTING DRIVE BELT AND
TENSIONER,
SPECIAL SERVICE TOOL.
TROUBLESHOOTING.
TIMING SYSTEM
TIMING BELT
‘COMPONENTS.
REMOVAL
INSPECTION.
INSTALLATION
CYLINDER HEAD ASSEMBLY
CYLINDER HEAD
COMPONENTS.
DISASSEMBLY
INSPECTION.
REASSEMBLY
MAIN MOVING SYSTEM
CAM SHAFT
‘COMPONENTS.
DISASSEMBLY
INSPECTION.
HLA (HYDRAULIC LASH ADJUSTTER)
REASSEMBLY
CONNECTING ROD
COMPONENTS.
REMOVAL
DISASSEMBLY
INSPECTION.
REASSEMBLY
INSTALLATION
CRANK SHAFT
‘COMPONENTS.
DISASSEMBLY
INSPECTION.
REASSEMBLY
EM-24
EM-26
EM27
EM-28
EM31
EM-32
EM-33
EM-36
EM-38
EM39
EM-40
EM-41
EM-42
EM-45
EM-46
EM-46
EM-46
EM-47
EM49
EM-50
EM-51
EM51
EM-53
Engine
(G6CU — GSL 3.5)
COOLING SYSTEM
‘SCHEMATIC DIAGRAM
ENGINE COOLANT HOSE/PIPES
COMPONENTS
REASSEMBLY
COOLANT TEMPERATURE SENSOR,
ENGINE COOLANT PUMP
COMPONENTS
REMOVAL
INSPECTION.
INSTALLATION
RADIATOR
COMPONENTS,
REMOVAL
INSPECTION
INSTALLATION
RADIATOR CAP,
COMPONENTS.
INSPECTION
THERMOSTAT
COMPONENTS.
REMOVAL.
INSPECTION
REASSEMBLY
LUBRICATION SYSTEM
‘OlL PUMP
COMPONENTS.
DISASSEMBLY
INSPECTION
REASSEMBLY
INTAKE AND EXHAUST SYSTEM
EXHAUST MANIFOLD.
COMPONENTS.
REMOVAL.
INSPECTION
INSTALLATION
INTAKE MANIFOLD
COMPONENTS.
REMOVAL.
INSPECTION
INSTALLATION
MUFFLER,
COMPONENTS.
REMOVAL.
INSPECTION
INSTALLATION
EM-55
EMS7
EM-58
EM58
EMS9
EM-60
EM-60
EM-60
EM61
EM-62
EM62
EM-62
EM-63
EM63
EM64
EM-64
EM65
EM-65
EM-66
EM-67
EM67
EM-68
EM71
EM-72
EM72
EM-73
EM74
EM-75
EM75
EM-76
EMI7
EM-78
EM-79
EM-79 AIR CLEANER (ACL)
COMPONENTS.
REMOVAL,
INSPECTION
INSTALLATION
ENGINE BLOCK
CYLINDER BLOCK
REMOVAL,
INSPECTION
INSTALLATION
ENGINE MOUNTS.
COMPONENTS
REMOVAL.
EM-80
EM-80
EM81
EM81
EM-82
EM-82
EM-83
EM-84
EM-85 GENERAL
GENERAL
SPECIFICATIONS | csosrcer
Description ‘Specific Limit
General
Type V = type, DOH
Number of cylinders 6
Bore 93.0 mm (3.661 in)
Stroke 85.8 mm (3.9779 in.)
Total displacement 3497 ce
Compression ratio 10.0
Firing order 1-2-3-4-5-6
Valve timing
Intake valve
Opens (BTDC) 165°
Closes (ABDC) 555°
Exhaust valve
Opens (BBDC) 435°
Closes (ATDC) 185°
Valve overlap 32°
Intake valve duration 282
Exhaust valve duration 244
Camshaft
Drive mechanism Cogged type belt
Cam height intake 35,098 ~ 35.298 mm (1.3818 ~ 1.3897 in.)
Cam height exhaust ‘34,81 ~ 35,01 mm (1.3705 ~ 1.3783 in.)
Journal diameter 25,951 ~ 25.970 mm (1.0220 ~ 1.0224 in.)
Bearing oil clearance (0,05 ~ 0.09 mm (0.0007 ~ 0.0024 in.)
End play 0.1 ~ 0.15 mm (0.0039 ~ 0.0089 in.)
Cylinder head
Flatness of gasket surface Max. 0.03 mm (0.0012 in.) 0.05 mm
Flatness of maunting surface
Intake Max. 0.10 mm (0.0039 in.)
Exhaust Max. 0.18 mm (0.0089 in.) 0.10 mm
Valve guide hole diameter 045 mm
0.05mm (0.002in.) OS.
0.25mm (0.010in.) OS.
0.50mm (0.020in.) OS.
Intake valve seat ring hole diameter
0.3mm (0.012in) O.S.
Q.6mm (0.024in) O.S.
Exhaust valve seat ring hole diameter
0.3mm (0.012in) O.S.
0.6mm (0.024in,) O.S.
12.05 ~ 12.068 mm (0.474 ~ 0.475 in.)
12.25 ~ 12.268 mm (0.482 ~ 0.483 in.)
12.50 ~ 12.518 mm (0.492 ~ 0.493 in.)
36,30 ~ 36,325 mm (1.429 ~ 1.430 in.)
36.60 ~ 36.625 mm (1.441 ~ 1.442 in.)
33.30 ~ 33.325 mm (1.311 ~ 1.312 in.)
33.60 ~ 33.625 mm (1.323 ~ 1.324 in.) EM-4 ENGINE(G6CU-GSL 3.5)
Description Specification Limit
valve
Overall length
Intake 106.28 mm (4.184 in.) 105.78 mm (4.164 in.)
Exhaust 105.4 mm (4.180 in.) 4104.9 mm (4.130 in.)
Stem diameter
Intake 6.565 ~ 6.580 mm (0.258 ~ 0.259 in.)
Exhaust 6.530 ~ 6.550 mm (0.257 ~ 0.258 in.)
Face angle 45° ~ 455°
Margin
Intake 4.0 mm (0.0394 in.) 0.5 mm (0.0197 in.)
Exhaust 4.5 mm (0.089 in.) 4.0 mm (0.039 in.)
Clearance (stem-to - guide)
Intake 0.02 ~ 0.05 mm (0.0009 ~ 0.0020 in.) (0.4. mm (0.0039 in.)
Exhaust 0.05 ~ 0.085 mm (0.0020 ~ 0.0033 in.) 0.15 mm (0.0059 in.)
Valve spring
Free height 46.4 mm (1.8268 in.) 45.4 mm (1.787 in.)
Load 24.0 kg / 37.9 mm (63 Ib | 1.492 in.)
Out of squareness Max 2° 4
Valve guide
Length
Intake 45.5 mm (1.7913 in.)
Exhaust 50.5 mm (1.9882 in.)
Service oversize 0.05, 0.25, 0.50
Valve seat contact width
Intake 0.9 ~ 1.3 mm (0.036 ~ 0.051 in.)
Exhaust 0.9 ~ 1.3 mm (0.035 ~ 0.051 in.)
Service oversize 0.30, 0.60
Seat angle
Intake 435° ~ 44°
Exhaust 43.5° ~ 44°
Piston
Diameter (Standard) 92.96 ~ 92.99 mm (3.659 ~ 3.661 in.)
Clearance (Piston-to-cylinder) 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in.)
Ring groove width
No. 1 41,503 ~ 1.505 mm (0.0592 ~ 0.05928 in.)
No. 2 4.501 ~ 1.503 mm (0.0591 ~ 0.0592 in.)
oil 3.010 ~ 3.030 mm (0.1185 ~ 0.1193 in.)
Piston for service 0.25 mm (0.010 in.), 0.50 mm ( 0.020 in.)
Oversize
Piston ring
Number of rings per piston 3
Compression ring type
Oil ring 1
Compression ring type
No 1 Barrel type, steel
No. 2 ‘Taper type, special cast iron
Oil ring type 3 = piece type
Ring end gap
No. 1 0.20 ~ 0.30 mm (0.0078 ~ 0.0118 in.)
No. 2 0.40 ~ 0.55 mm (0.0187 ~ 0.0216 in.)
Oil ring side rail 0.2 ~ 0.7 mm (0.0079 ~ 0.0276 in.)
Ring side clearance
No. 1 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.)
No. 2 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in.)
Ring for service 0.25mm (0.010 in.), 0.50 mm (0.020 in.) GENERAL
Out - of - roundness of journal and pin
‘Taper of journal and pin
End play
Main bearing
Oil clearance
Max. 0.03 mm (0.0012 in.)
Max. 0.005 mm (0.0002 in.)
0.05 ~ 0.25 mm (0.002 ~ 0.0088 in.)
0.022 ~ 0.040 mm (0.00086 ~ 0.00157 in.)
Description Specification Limit
Connecting rod
Side clearance (Big end) (0.10 ~ 0.25 mm (0.0039 ~ 0.0098 in.)
Bend 0.05 mm or less / 100 mm
(0.0020 in. or less / 3.997 in.)
Twist 0.1 mm or less / 100 mm
(0.0039 in. or less / 3.937 in.)
Bearing
Oil clearance 0.026 ~ 0.044 mm (0.001 ~ 0.0017 in.) 0.4 mm (0.004 in.)
Pin diameter 22.001 ~ 22.004 mm (0.8661 ~ 0.8663 in.)
Crankshaft
Journal 0.0. 63,982 ~ 64.00 mm (2.519 ~ 2.5197 in.)
Pin 0.0. 54,982 ~ 55.00 mm (2.165 ~ 2.1653 in.)
0.3 mm (0.012 in.)
Cylinder block
Cylinder bore
Flatness of gasket surface
Out - of - roundness and taper
93 mm (3.661 in.)
Max. 0.05 mm (0.002 in.)
Max. 0.02 mm (0.0008 in.)
0.05 mm (0.002 in.)
‘il pump
Body clearance
Side clearance
Tip clearance
0.100 ~ 0.181 mm (0.0039 ~ 0.0071 in.)
0.040 ~ 0.085 mm (0.0016 ~ 0.0037 in.)
0.06 ~ 0.018 mm (0.0024 ~ 0.0071 in.)
Relief spring
Free length 46.3 mm (1.823 in.)
Load 6.9 kg / 39-1 mm (15.18 Ib. J 1.54 in.)
Oil filter
‘Type Cartridge, full flow
Engine oil pressure
80 kPa (11.4 psi) or more @700rpm
[Conditions : Oil temperature is 85 to
95°C (185 to 203°F)]
Cooling method
Engine coolant cooling, forced circulation
with electric fan
Cooling system
Normal opening temperature
Opening temperature range
Wide open temperature
Quantity 82 lit (8.61 USats., 7.2 Imp.ats)
Thermostat
‘Type Wax pellet type with jiggle valve
82°C (179.6F)
80°C ~ 84°C (176 ~ 183.2°F)
98°C (203°)
Radiator cap
Main valve opening pressure
Main valve closing pressure
Vacuum valve opening pressure
86.1 ~ 124.5 kPa
(0.98 ~ 1.27 kglomk, 13.94 ~ 18.06 psi)
83.4 kPa (0.85 kglomk, 12.1 psi)
= 6.86 kPa (- 0.07 kglem*, - 1.00 psi) ENGINE(G6CU-GSL 3.5)
Description Specification Limit
‘Air cleaner
‘Type Dry type
Element Unwoven clath type
Exhaust pipe
Muffler
Suspension system
Expansion resonance type
Rubber hangers
SERVICE STANDARD
Stanard value
Coolant concentration
Tropical area : 40%
Other area : 50%
LUBRICANT
Engine coolant : Ethylene glycol base for aluminum
SEALANT
radiator
Engine coolant temperature sensor
“Three bond No.2310 or equivalent
LOCTITE 9627 or equivalent GENERAL EM-7
TIGHTENING TORQUE
Nm Kg.em bt
Crankshaft bolt 180 ~ 190 1,800 ~ 1,900 130 ~ 138)
Timing belt tensioner 43 ~ 55 430 ~ 550 32~41
Camshaft sprocket bolt 80 ~ 100 1800 ~ 1000 60 ~ 74
Cylinder head cover bolts 8-10 80 ~ 100 6-74
Main bearing cap bolts 70 ~ 80 700 ~ 800 52 ~ 59
Connecting rod nuts 34 + 90 340 + 90” 26 + 207
Cylinder head bolts
Cold engine 105 ~ 115 1080 ~ 1150 75 ~ 82
Oil pan drain plug 35 ~ 45 350 ~ 450 26 ~ 32
Lower oil pan bolt 10~ 12 100 ~ 120 72~8
Upper oil pan bolt
[10 x 38 mm (1.4961 in.)] 30 ~ 42 300 ~ 420 22 ~ 30
{6 * 18 mm (0.7087 in,}} 5-7 50 ~ 70 37-5
(6 161.5 mm (6.358 in.)] 5-7 50 ~ 70 37-5
[6 * 152.5 mm (6.004 in)} 5-7 50 ~ 70 37-5
Oil screen bolt 15 ~22 180 ~ 220 1-18
Oil pump case bolts 16 ~ 20 180 ~ 200 11~14
Oil relief valve plug 40 ~ 50 400 ~ 500 29 ~ 36
il pump cover screw a~12 80 ~ 120, 58-87
Oil pressure switch a~15 80 ~ 150 58~ 11
Oil iter 12~16 120 ~ 160, a7~ 116
Drive plate and adaptor plate bolt 73~77 730 ~ 770 53 ~ 55
Air cleaner body installation bolt a~12 80 ~ 120 6-9
Surge tank stay 15 ~ 20 150 ~ 200 1-14
Air intake surge tank to intake manifold (bolt) 16 ~ 20 160 ~ 200 1-14
Ar intake surge tank to intake manifold (nut) 16 ~ 20 180 ~ 200, 114
Intake manifold to engine 20 ~ 23 200 ~ 230 14 ~16
Heat protector to exhaust manifold 12~15 120 ~ 150 14
Exhaust manifold to engine 40 ~ 45 400 ~ 450 29 ~33
Oil level gauge guide to engine 12~15 120 ~ 150 9-11
Water outlet fitting bolt 17 ~20 170 ~ 200 12.3~145
Power steering oil pump bracket to front 17 ~26 170 ~ 260, 12~19
cylinder head assembly
Power steering oll pump to bracket 17 ~ 26 170 ~ 260 12-19
Crank position sensor whee! screw 1-12 110 ~ 120 8-87
Engine mounting insulator bolt 90 ~ 110 ‘900 ~ 1,100 65 ~ 80
[12 x 115 mm (0.4724 * 0.5806 in.)
Engine mounting bracket nut 60 ~ 80 600 ~ 800 43 ~ 58
Engine mounting bracket bolt 60 ~ 80 600 ~ 800 43 ~ 58
[12 x 60 mm (0.4724 x 2.3622 in.)]
Front roll stopper bracket to sub frame bolts 60 ~ 80 600 ~ 800 43 ~ 58
Front roll stopper insulator bolt and nut 50 ~ 65 500 ~ 650 36 ~ 47
[10 x 85 mm (0.3937 x 3.3469 in.)]
Front roll stopper bracket to transaxle bolts 60 ~ 80 600 ~ 800 43 ~ 58
Rear roll stopper bracket to sub frome bolts 60 ~ 80 600 ~ 800 43 ~ 58
Rear roll stopper insulator nolt and nut 50 ~ 65, 500 ~ 650 36 ~ 47
Rear roll stopper bracket to transaxle bolts 50 ~ 65 500 ~ 650 36 ~ 47
Transaxle mounting sub bracket nut 60 ~ 80 600 ~ 800 43 ~ 58
‘Transaxle mounting bracket bolts 60 ~ 80 600 ~ 800 43 ~ 58
Transaxle mounting insulator bolt 90 ~ 110 900 ~ 1100 65 ~ 80
[12 x 115 mm (0.4724 x 0.5906 in.)]
Starter to engine bolt 27 ~ 34 270 ~ 340 20 ~ 25
Generator inlet pipe to front cylinder head assembly 12-15 120 ~ 150 9-11
Fuel hose clamp to rear cylinder head assembly 12-15 120 ~ 150 9-11
‘Transaxle mounting plate 10~12 100 ~ 120 Tt ENGINE(G6CU-GSL 3.5)
Nm Kg.em bt
Rear plate 10~ 12 100 ~ 120 73-86
Oil seal case 10 ~ 12 100 ~ 120 73~86
Crankshaft pulley bolt 180 ~ 190 1,800 ~ 1,900 130 ~ 138
Timing belt cover bolt (MB) 10 ~ 12 100 ~ 120 7-9
Timing belt cover bolt (MB) 20~27 200 ~ 270 14~20
Engine hanger bracket to engine 27 ~ 38 270 ~ 380 20~27
Generator mount bracket to engine 20 ~ 30 200 ~ 300 14 ~22
Generator mount nut (Engine front case side) 20 ~ 30 200 ~ 300 14 ~22
Generator mount bolt (Generator mount 20 ~ 30 200 ~ 300 14~22
Startor to engine (Nut) 20 ~ 30 200 ~ 300 14 ~ 22
Drive belt pulley bolt 35 ~ 55 350 ~ 550 26 ~ 40
Drive belt tensioner bolt 45 ~ 50 480 ~ 500 33 ~ 36
Engine cootant pump to cylinder block bolt head mark
(a) 15 ~ 22 150 ~ 200 11> 15
(M10) 33 ~ 50 330 ~600 24 ~ 36
Engine coolant temperature sensor 20 ~ 40 200 ~ 400 14~29
Engine coolant init fiting attaching bolt 17 ~ 20 170 ~ 200 12~14
Air cleaner mounting bolts 8-12 80 ~ 120 6-9
Intake manifold to cylinder head nuts 20 ~ 23 200 ~ 230 14-16
‘Throttle body to surge tank bolts 25 ~ 30 250 ~ 300 18 ~ 22
Exhaust manfold to cylinder head nuts 40 ~ 45 400 ~ 450 29 ~ 33
Exhaust manifld heat protector to exhaust manifold bolts 12~15 120 ~ 150 9-11
Oxygen sensor to exhaust manifold 40 ~ 50 400 ~ 500 29~ 36
Front exhaust pipe to exhaust manifold nuts 30 ~ 40 300 ~ 400 22~29
Front exhaust pipe to catalytic converter bolts 40 ~ 60 400 ~ 600 29 ~ 43
Catalytic converter to center exhaust pipe nuts 30 ~ 40 300 ~ 400 22 ~ 29
Center exhaust pipe to main muller nuts 30 ~ 40 300 ~ 400 22~29
Main muffler hanger support bracket bolts 10 ~ 15 100 ~ 150 7= 11
Delivery puipe installation bolts 10 ~ 15 100 ~ 150 711
Timing belt tensioner pulley bolt 43 ~ 55 430 ~ 550 31 ~ 40
Timing belt idler pulley bolt 50 ~ 60 500 ~ 600 36 ~ 43,
Timing belt tensioner arm FIXED BOLT 35 ~ 55 350 ~ 650 26 ~ 40
Auto tensioner fixed bolt 20~27 200 ~ 270 14~20
Startor to engine (Bolt) 27 ~ 34 270 ~ 340 20 ~ 25
Camshaft bearing cap
Outer 19~21 190 ~ 210 14-15
Inner 10 ~ 12 110 ~ 120 7-9 GENERAL
EM-9
CHECKING ENGINE OIL
1. Position a vehicle on a level surface.
2. Tum off the engine.
Gore
In the case of a vehicle that has not been used for a
prolonged period, run the engine for several minutes.
Turn off the engine and wait for 5 minutes at least,
then check the oil level.
3. Check that the engine cil level is within the level range
indicated on the oil dipstick. Ifthe oil level is found to
fallen to the lower limit the °L* mark), refill to the
mark,
NOTE
When refling, use the proper grade of engine oll
4, Check that the oil is not dity or mixed with coolant or
gasoline, and that it has the proper viscosity. EM -10 ENGINE(G6CU-GSL 3.5)
SELECTION OF ENGINE OIL
Recommended ILSAC classification: GF-3 OR ABOVE
Recommended API classification : SL(SJ) OR ABOVE
Recommended SAE viscosity grades:
Temperature range
anticipated before Recommended SAE viscosity number
next oil change
XK /\) /\, JN
2ow| 15w | tow sw!
+50 | -40 | -30 | -20
20
10
“1 : Recommended regardless of environment
If not available, refer to the recommended SAE viscosity numbers.
For best performance and maximum protection of all
types of operation, select only those lubricants which:
1. Satisfy the requirements of the API classification
2. Have the proper SAE grade number for expected
ambient temperature range.
3. Lubricants which do not have both an SAE grade
number and an API service classification on the
container should not be used. GENERAL
CHANGE ENGINE OIL,
1. Run the engine until ifreaches normal operating tem-
perature,
2. Tun off the engine.
3. Remove the oil filer cap and oil iter and then drain
plug.
Drain the engine oil
4, Tighten the drain plug to the specified torque.
Tightening torque
ll pan drain plug
35 ~ 45 Nm (350 ~ 450 kg.om, 25 ~ 33 Ib.)
NOTE
Whenever tightening the oil drain plug, use a new
drain plug gasket.
5. Fill the new engine oil through the oil filler cap.
Drain and refill
Ol quantity : 4.3 lit (4.5 U.S. qus., 3.8 Imp. ats.)
NOTE
Do not over fil This will cause oll aeration and loss
of oil pressure,
6. Install the oil filer cap,
7. Start and run the engine.
8 Tum off the engine and then check the oil level. Add
oil it necessary,
REPLACEMENT OIL FILTER
FILTER SELECTION
‘All Hyundai Motor Company engines are equipped with
a high quality, disposable oil fiter. This filer is recom-
mended as a replacement fier for all vehicles. The quality
of after market replacement fiters is various considerably.
High quality of replacement fiters should be used to as-
sure the most efficient service. Make sure that the rubber
gasket from the old ol fiter is completely removed from
the contact surface on the engine block before installing a
new fitter.
PROCEDURE FOR REPLACING OIL FILTER
4. Use a filter wrench to remove the oil fiter.
2. Before installing a new oll fiter on the engine, apply
clean engine oil to the surface of the rubber gasket.
3, Tighten the oil fiter of the specified torque.
Tightening torque
Oilfter : 42~ 16 Nm (120 ~ 160 kg.om, 8.7 ~ 11.6 1b.)
4, Start and run the engine and check engine oil leaks. EM-12 ENGINE(G6CU-GSL 3.5)
5. Alter stopping the engine, check the oil level and add
oll as necessary,
‘Awol enaine oi
CHECKING COOLANT LEAK CHECK
4. Loosen the radiator cap,
2, Confirm that the coolant level is up to the filer neck,
3. Install a radiator cap tester to the radiator filler neck
‘and apply 150 KPa (21psi, 1.53 kglom?) pressure,
Hold for two minutes, then check for leakage from the
radiator, hoses or connections.
CAUTION
Radiator coolant may be extremely hot. Do
not open the system while hot, or scalding
engine coolant could gush out, causing per-
sonal injury. Allow the vehicle to cool before
servicing this system.
2. When the tester is removed, be careful not to
spill any coolant from it.
3. Besure to clean away completely any coolant
from the area.
4. Be careful, when installing and removing the
tester and when testing, not to deform the
filler neck of the radiator.
4, If there is leakage, repair or replace with the apropri-
ate part
RADIATOR CAP PRESSURE TEST
4. Use an adapter to attach the cap to the tester,
2, Increase the pressure until the indicator of the gauge
‘stops moving,
‘Main valve opening pressure
107.94 14.7 kPa (1.1 + 0.15 kg/em?, 15.64 + 2.13 psi)
Main valve closing pressure
83.4 kPa (0.85 kgicm’, 12.1 psi)
3. Check that the pressure level is maintained at or
above the limit
4, Replace the radiator cap if the reading does not re-
main at or above the limit,
NOTE
Be sure that the cap is clean before testing, since rust
or other foreign material on the cap seal will cause an
incorrect reading GENERAL
SPECIFIC GRAVITY TEST
1
Measure the specific gravity of the coolant with a hy-
drometer.
Measure the coolant temperature and calculate the
concentration from the relation between the specific
gravity and temperature, Use the following table for
reference,
7 a
RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY
Coolant temperature °C (°F) and specific gravity Freezing | Safe operating | __ coolant
temperature | temperature | Concentration
10 (50) | 20(68) | 30 (86) | 40 (104) | 50 (122) | "°C (°F) ee (er) (Specie
1054 [1.050 [1045 [1042 | 1.036 | -16 (32) “11 (12.2) 30% |
t063_[ tose [10544 | toas | 1.048 20-4) 15 (5) 35%
sori | 1067 [1062 | to57 | 052 [25 (13) 20 (4) 40%
tora | tore | 1069 | 1068 | 1058 | -30(22) 25 (13) 45%
1087 | 1082 | 1076 [| toro | 1064 | -36(328) “31 (23.8) 50%
1095 [1.090 | 1084 [1077 | 4.070 [42 (44) 37 (35) 55%
1103 [ 1098 [1082 | toast. | 1076 [ -50 (58) “45 (49) 60%
EXAMPLE + Ifthe concentration is above 60%, the engine
The safe operating temperature is -15°C (6°F) when
the measured specific gravity is 1.058 at coolant tem-
perature of 20°C (68°F)
}\, CAUTION
+ If the concentration of the coolant is below
30%, its anti-corrosion property will be ad-
versely affected.
RECOMMENDED COOLAN
cooling property will decrease, affecting the
engine adversely. For these reasons, be sure
to maintain the concentration level within the
‘specified range.
+ Do not mix types of anti - freeze.
‘Antifreeze
ETHYLENE GLYCOL BASE FOR ALUMINUM
Mixture ratio of antifreeze in coolant
50% [Except tropical areas)
40% [Tropical areas] EM -14 ENGINE(G6CU-GSL 3.5)
CHECKING COMPRESSION PRESSURE
4, Before checking the engine compression, check the
engine oil level. Also check that the starter motor and
battery are all in normal operating condition.
2. Start the engine and wait until the engine coolant tem-
perature reaches 80-95°C (176~205°F).
3. Stop the engine and disconnect the spark plug cables.
4, Remove the spark plugs.
5. Crank the engine to remove any foreign material in
the cylinders.
6. Insert the compression gauge into the spark plug
hole.
7. Depress the accelerator pedal to open the throttle
fully.
8. Crank the engine and read the gauge.
Standard value = 1,200kpa(12.2 kg/cm , 170psi)
Limit : 1,050kpa(10.7kglom? , 149psi)
9. Repeat steps 6 to 8 forall cylinders, making sure that
the prossure difference for each of the cylinders is
within the specified limit
Limit
Max. 100kpa (1.0 kglem, 14psi) between cylinders
10. Ifa cylinder's compression or pressure differential is
‘outside the specification, add a small amount of oil
through the spark plug hole, and repeat steps 6 to 9.
1) Ifthe addition of oil causes the compression to
rise, itis possible that the piston ring is worn.
2) If the compression remains the same, valve
‘seizure, poor valve seating or a compression
leak in the cylinder head gasket are all possible
Tightening torque
Spark plug : 20 ~ 30 Nm (200 ~ 300 kg.om, 14 ~ 22 Ib.)
TIGHTENING CYLINDER HEAD BOLTS
41. First loosen slightly and then tighten to the specified
torque.
Tightening torque
Cylinder head bolts cold (Engine temperature
approximately 20°C (68°F)
4105 ~ 115 Nm (1050 ~ 1150 kg.om, 75 ~ 82 Ib ft.)
2, Be sure to follow the specific torque sequence as
shown in the illustration
NOTE
Run the engine to normal operating temperature and
Jo it cool, then re-torque the bolts to specifications.
<
Timing bot sido
ADJUSTING VALVE CLEARANCE
‘As the intake and exhaust valves are equipped with hy-
draulic lash adjusters, there is no need to adjust the valve
clearance. The proper function of the hydraulic lash mech-
anism may be determined by checking for tappet noise.
When there is a tappet noise or any unusual naise, chock
the hydraulic lash adjusterby removing and bleeding or re-
placing it GENERAL EM «15
ADJUSTING DRIVE BELT AND TENSIONER Tahiening togue
rae oF ot
1. Hang boon he puley othe tensinorandinan —EMONEE HBEEMBD DAL
the tensioner.
(lfthe tensioner is already installed, loosen its mount-
ing bol to allow belt installation.)
‘Tension pully Tensioner assembly bot Generator
Power steonng puly Crankshaft pully Tension pully Airconditioner pully ler pully
2. Install power steering belt 3, Install drive belt EM-16 ENGINE(G6CU-GSL 3.5)
4. Adjust the power steering belt tension to specification ENGINE AND TRANSAXLE ASSEMBLY
by turing the adjusting bolt (Q) clockwise or counter
clockwise. REMOVAL
1, Remove the battery and engine cover.
2. Remove the battery stay.
3, Delach the air cleaner.
4, Disconnect the connectors from the engine harness.
5. Adjust the drive belt tension to specification by turing
the adjusting bolt (Q) clockwise or counter clockwise,
980 (10 ka)
6. When installing the belt on the pulley, make sure itis
centered on the pulley.
1. Alternator, starter
2. Power steering switch connector, oll pressure
gauge connector, air conditioner switch
3. Injector sonnectors
4. Back up lamp switch connector
5. AIT solenoid, inhibitor switch connector
Wrong v-nivbod ott wrong GENERAL
EM-17
6. Coolant temperature
8. Disconnect the brake booster vacuum hose.
7. Ignition coils, power TR connector
8. Idle speed control valve (ISC) connector
8. AFS and ATS connectors
10. Oxygen sensor connector etc.
5. Disconnect the transaxle oil cooler hoses (AMT).
Grote
Vien deconnecting hoses, make denitaon marks
fo avoid moling ony mistoke whon isang trom
oan
Gy cauTion
Be careful not to spill any of the oil or fluid from
the hoses. Plug the openings to prevent the entry
of foreign material.
6. Disconnect the radiator upper and lower hoses on the
engine side
Disconnect the engine ground and transaxle ground.
9. Disconnect the heater hoses (inlet and outlet) on the
engine side,
10. Remove the main fuel line (supply and return) at the
delivery pipe.
a
11. Disconnect the
transaxle.
speedometer cable from the
42. Disconnect the control cable from the transaxle. i ENGINE(G6CU-GSL 3.5)
18. Remove the power steering hose from the engine 17. Loosen the strut lower bolt and separate from the
‘mount bracket. knuckle.
14, Detach the steering dust cover in the engine compart. 18. Remove the wheel speed sensor from the knuckle.
‘ment and then disconnect the gear box universal joint
\
‘Make sure to make identification marks between the \
universal joint and the gear box for reassembly. 7
15. Raise the vehicle and then remove the front tre.
18. Remove the caliper assemply from knuckle and hold
the upper side. GENERAL
19. Remove the front muffler bots
20. Put the special fixture on the T/M jack and then adjust
itto the sub - frame.
(wore
CCheok that all the cables, harness connector and
hoses are disconnected from the ‘engine. and
transaxle assembly.
24. Remove the engine mount bolts,
EM-19
22, Remove the bolts and nuts that fasten the engine
‘mount bracket to the body.
23. Remove the transaxle mounting bracket bolts
24, Remove the left mount insulator bolt.
25. Remove the cross member fixing borts.
28. While directing the transaxle side downward, lift the
engine and transaxle assembly up and out of the ve~
hice.
INSTALLATION,
Installation is the reverse order of removal. EM -20 ENGINE(G6CU-GSL 3.5)
SPECIAL TOOLS
‘Tool (Number and name)
Mlustration
Use
Crankshaft front oll seal installer
(09214-33000)
Installation of the crankshaft
front oil seal
Camshaft oll seal installer
(09221-21000)
Installation of the camshaft oll seal
Valve guide installer
(09221-3F000 AB)
Removal and installation of the
valve guide
Valve stem oil seal installer
(09222-28200)
Installation of the valve stem oll seal
Valve spring compressor
(09222-28000)
Removal and installation of the
intake or exhaust valve GENERAL
EM 21
Tool (Number and name)
Mlustration
Use
Valve stem oil seal remover
(03222-29000)
Removal of the valve stem oil seal
Crankshaft rear oll seal installer
(09231 - 33000)
LO
Installation of the crankshaft rear oll seal
Crankshaft wrench
(09231-33100)
Used if the crankshaft needs to be
rotated to attach the timing belt, ete.
Socket wrench
09244-28100
Timing belt tension adjustment EM -22 ENGINE(G6CU-GSL 3.5)
TROUBLESHOOTING
Worn piston pin
Wom piston in cylinder
Broken piston ring
‘Symptom Probable cause Remedy
Knocking of crankshaft | Worn main bearing Replace
and bearing Seized bearing Replace
Bent crankshaft Replace
Excessive crankshaft end play Replace thrust bearing
Piston and connecting | Worn bearing Replace
rod knock Seized bearing Replace
Replace piston and pin or
connecting rod
Recondition cylinder
Repair or replace
Improper connecting rod alignment Replace
Noisy valves Faully auto-lash adjuster Replace
Thin or diluted engine oil (low oll pressure) | Change
Wom or damaged valve stem or valve guide _| Replace
Excessively worn oylinder
and piston
‘Shortage of engine oil
Dirty engine oil
Poor quality of engine oil
Improperly assembled piston and
connecting rod
Improper piston ring end clearance
Dirty air cleaner
‘Add or replace
Check oil level on daily basis
Replace
Use proper oil
Repair or replace
Replace
Clean air cleaner assembly and
replace the air fiter
Connecting rod and main
beaing noise
Insufficient oll supply
Thin or diluted engine oil
Excessive bearing clearance
‘Check engine oil level
Change and determine cause
Replace
Damaged crankshaft
bearing
‘Shortage of engine oil
Low oil pressure
Poor quality of engine oil
Worn or outof -round of crankshaft journal
Restricted oll passage in crankshaft
Worn bearing
‘Add oF replace
Check oil level on daily basis
Adjust or repair
Use proper engine oil
Replace
Clean
Replace bearing and check engine
oll and lubrication system
Bearing improperiy installed Replace
Non-concentric crankshaft or bearing Replace
Timing belt noise Incorrect belt tension Replace
Low compression
Blown cylinder head gasket
Wom or damaged piston rings
Worn piston or cylinder
Wor or damaged valve seat
Replace gasket
Replace rings
Repair or replace piston andlor
cylinder block
Repair or replace valve andlor seat ring
Oil pressure drop
Low engine oll level
‘Check engine oil level
Faulty oll pressure switch Replace
Clogged oil filter Replace
Wom oil pump gears or cover Replace
Thin or diluted engine oil Change and determine cause
Ol relief valve stuck (open) Repair
Excessive bearing clearance Replace
High oll pressure Oil relief valve stuck (closed) Repair GENERAL
‘Symptom Probable cause Remedy
Excessive engine roling | Loose engine roll stopper (front, rear) Re-tighten
and vibration Loose transaxle mount bracket Re-tighten
Loose engine mount bracket Rectighten
Loose center member Re-tighten
Broken transaxle mount insulator Replace
Broken engine mount insulator Replace
Broken engine roll stopper insulator Replace
Low coolant level Leakage of coolant
Damaged radiator core joint Replace
Corroded or cracked hoses Replace
(Radiator hose, heater hose, etc)
Faulty radiator cap valve or setting of spring | Replace
Faulty thermostat Replace
Faulty engine coolant pump Replace
Clogged radiator Foreign material in coolant Replace
‘Abnormally high coolant | Faulty thermostat Replace paris
temperature Faulty radiator cap Replace
Restriction of low in cooling system Replace
Loose or missing drive belt Adjust or replace
Faulty engine coolant pump Replace
Faulty temperature gauge or wiring
Faulty electric fan
Repair or replace
Repair or replace
Faulty thermo-sensor on radiator Replace
Insufficient coolant Refi coolant
‘Abnormally low coolant | Faulty thermostat Replace
temperature Faulty temperature gauge or wiring Repair or replace
Leakage from oil cooling | Loose hose and pipe connection Replace
system
Blocked or collapsed hose and pipe
Repair or replace
Tnoperative electrical
cooling fan
Damaged
Replace or repair
Exhaust gas leakage
Loose connections
Broken pipe or muffler
Re-tighten
Repair or replace
‘Abnormal noise
Detached baffle plate in muffler
Broken rubber hanger
Pipe or muffler contacting vehicle body
Broken pipe or muffler
Replace
Replace
Correct
Repair or replace EM -24 ENGINE(G6CU-GSL 3.5)
TIMING SYSTEM
TIMING BELT
COMPONENTS | excones
Camshaft sprocket
Timing bot
{80 ~ 100 (800 ~ 1000, 60 ~ 74)
35-55
(@50 ~ 850, 26 - 40)
Auto tensioner
Vee
20-27 by Sensing blade
te Tare-29
ES
4B
(0 9,01 -29 Ae of ari
(- ier rankshatt \
Crankshat pulley sprocket
S
P
— support
SY curate
50-19 (80-0191)
50 ~ 60 (500 ~ 550, 31 - 29) Timing bet lower cover
TORQUE : Nm (kg.cm, Ib.ft) TIMING SYSTEM EM -25
‘Water pump pulley
Timing mark
~ cam Position Sensor(CPS)
Camshatt sprocket
Idler pulley
Tensioner arm —__
Tensioner pulley
-
¢
Auto tensioner ——
CCrankshatt sprocket EM -26 ENGINE(G6CU-GSL 3.5)
REMOVAL cccscor
1. Remove the wheel of passenger side.
2. Remove the side cover.
3. Remove the engine cover.
4, Disconnect the powersteering hose fixing on the en-
gine mounting bracket.
Ly)
5. Remove the engine mounting bracket.
Ay caumion
Before removing the engine mounting bracket
‘support the engine oil pan with a jack or equiva-
ent so as not to do down the engine.
6. Disconnect the connectors from the timing belt upper
cover and remove the upper cover
7. Remove the drive belt and loosen the 2 alternator
‘mounting nuts (14 mm) and 2 bolts (12 mm) connect-
ing the engine support bracket.
8. Loosen the 5 engine support bracket bolts
Qy caurion
Te loosen th bolt shown inthe forward of engine,
frst scone te atornator
Remove the engine support bracket bolt by moving
the engine up and down slightly and remove the
bracket upward. TIMING SYSTEM EM 27
10.
"
Remove the auto tensioner. INSPECTION | tec:
41. Inspect the belt closely. If the following problems are
evident, replace the belt with anew one.
41) Hardened back surface of rubber
Back surface is glossn, non-elastic and so hard
that when the nail of your finger is pressed into it,
no mark is produced,
NOTE
Rotate the crankshaft clockwise and align the timing
‘mark to set the No.1 cylinder's pistan to TDC (com-
pression stroke)
Atthis time, the timing marks of the camshaft sprocket
and cylinder head cover should coincide with each
LUnbot the tensioner to remove the timing be. cows
(nore 3) Side of bet is badly worn
it you plan to uso to timing bel again, mark tho rot
ton drection onthe bolt so you reinstall corecty, O)nore
A belt in good condition should have clear-cut sides
as if it wore cut with a sharp knife.
Separator roundeu vet
Abnormal wear
(Fity canvas foer) EM -28 ENGINE(G6CU-GSL 3.5)
4) Teeth are badly worn out INSTALLATION | evssscu
Initial stage : Canvas on load side of the tooth The methed of installing timing belt and auto tensioner.
flank worn (flufy canvas fibers, rubber gone,
color changed to white, and unclear canvas 1. Install idler pulley to engine support lower bracket.
texture)
Last stage : Canvas on the load side of the tooth
flank worn down and rubber exposed (tooth width
reduced}.
5) Missing tooth
Re
Flank worn
(On oad see
g
Tooth missing and
canvas ber exposes 2. Install tensioner arm, shaft and plane washer to cylin-
OO der block.
35 ~55 Nm (350 ~ 550 kg.cm)
we B
and idler pulley. Warner
0 pump case —f TIMING SYSTEM
EM -29
3. Install crankshaft sprocket and align the timing mark
CCrankshat sprocket
A caution
Be careful notto bend crankshaft sensing ede
Sensing bade
4, Install camshaft sprocket and adjust inital installation
state as illustration,
8.7 pitch Coin cidence
Install auto tensioner to oil pump case.
(Gore
If the auto fensioner rod is in its fully extended posi-
tion, reset itas follows.
toto
1. Clamp it in a vise equipped with soft jaws, in a
level position. Use a plain washer if there is a
ppulg at the buttom of the auto tensioner.
2. Compress the rod slowly with the vase until the
of hole in the rod is aligned with set hole in the
cylinder.
3. Insert a set pin through the auto tensioner body
and rod.
Ay caution
Leave the se pin installed in the auto fensione. EM -30
ENGINE(G6CU-GSL 3.5)
Alighen the timing marks of each sprocket and install
the timing belt in this order.
Crankshaft sprocket —> Idler pulley > Exhaust
camshaft sprocket (LH) —* Intake camshaft sprocket
(RH) —> Exhaust camshaft sprocket (RH) — Ten-
sioner pulley
nore
+ Inthis step, No. 1 isin TDC (Compression stroke)
+ Do not insert fingers.
7. After instalating the timing belt, reconfirm the timing
mark.
8, Timing belt tension adjustment
41) Setting tension (under Non-operation of auto ten-
sioner : set pin installed)
1. Alter turning the crankshaft 1/4 revolution
counter clockwise, turn it clockwise to fitit in
the position counter clockwise, turn it clock-
wise to fit itn the position of No. 1 TDC.
Release the center bolt, and apply the ton-
sion to the belt using tensioner pulley socket
‘and torque wrench as. shown illustration
and then tighten the center bolt by specified
torque.
Tension torque : 5Nm (50kg.cm, 3.71ib.f)
(nore
Be care not to turn the tensioner ply with the
center bot when tightening the center bolt
Tightening torque
Tensioner bolt
43 ~ 55Nm (430 ~ 550kg.cm, 31 ~ 391b.f)
2. Pullout the set pin of auto tensioner
2) Tension checking (under operation of auto ten-
sioner : set pin removed)
1. Rotate the crankshaft 2 rotation clockwise
and measure the projected load of auto ten-
sioner in the TOC (#1 compression stroke)
after 5 minutes.
2. Check the projected length is 3.8 ~ 4.5 mm.
3. Check again if the timing marks of each
sprocket is with in specified position,
9. Install the engine support bracket.
10. Install the timing belt cover.
411, Install the alternator and drive belt
412, Install the engine mounting bracket.
43, Install the side cover.
14, Install the wheel of passenger side. CYLINDER HEAD ASSEMBLY. EM -31
CYLINDER HEAD
ASSEMBLY
CYLINDER HEAD
COMPONENTS | crcorse
Sa _ Rocker arm
Valve spring
Retainer lock
Valve spring retainer
Vawe stem seal— ——— Spring shoot
Valve guide
Cylinder head bott s
105 «115 (1050 -
2+ oyinderneed FH) yin nea)
eae A
55 Exhaust valve seat ring a .
Se s
Z
Exhaust viave
a
TORQUE : Nm (kg.cm, Ib.ft) EM -32 ENGINE(G6CU-GSL 3.5)
DISASSEMBLY
1
10.
Remove the engine, For additional information, refer
to engine and transaxle assembly in this section,
For additional information, refer to intake manifold in
this section.
Remove the cables from the spark plugs. The cables
should be removed by holding the boot portion
Remove the ignition coil
Remove the upper and lower timing belt cover.
Remove the timing belt and camshaft sprockets.
For additional information, refer to timing belt in this,
section,
Remove the heat protector and exhaust manifold as-
sembly.
Remove the coolant pump pulley and head cover.
Remove the intake and exhaust camshaft
For additional information, refer to camshaft in this
section
Remove the cylinder head assembly, The cylinder
hhead bolts should be removed using the 12 mm
socket, in two or three steps.
411, Clean the gasket pieces from the cylinder block top
surface and cylinder head bottom surface.
NOTE
Make sure that fragments from the gasket do not fall
in the engine.
RETAINER LOCK
1. Compress the valve spring using special tool, (09222
= 28000, 09222 - 28100)
2, Remove the retainer lock.
3. Remove the valve spring, valve spring retainer valve
spring sheet and valve, CYLINDER HEAD ASSEMBLY.
INSPECTION
CYLINDER HEAD
1, Remove scale, sealing compound and carbon
deposits. After cleaning oll passages, apply com-
pressed air to make certain that the passages are
not clogged.
2. Visually check the cylinder head for cracks, damage
or water leakage.
3. Check the cylinder head surface for flainess with a
straight edge and feeler gauge as shown in the ilus-
tration,
Cylinder head flatness
Standard dimensions : Max. 0.03 mm (0.0059 in.)
0.05 mm (0.0020 in.)
Service limit
VALVE GUIDES
Check the valve stem-to-guide clearance. Ifthe clearance
‘exceeds the service limit, replace the valve guide with a
new oversize guide.
Valve stem-to-guide clearance
Standard value
Intake : 0.02 ~ 0.05 mm (0.0009 ~ 0.0020 in.)
Exhaust : 0.050 ~ 0.085 mm (0.0020 ~ 0.0033 in.)
‘Stem ciameter
Guide insae ameter
EM -33,
VALVE
4. Replace the valve if its stem is bent, wom or dam-
aged, Also replace itif the stem end (the surface con-
tacting the hydraulic-lash adjuster) is hollowed out.
2. Check the valve face contact area, and recondition or
replace as necessary.
3. Replace the valve if the width of the margin thickness
of the valve head) is less than the minimum specified
Valve margin
Standard value
Intake : 1.0mm(0.0394 in.)
Exhaust : 1.3mm(0.0512 in.)
(test be athe
ante of he face EM -34 ENGINE(G6CU-GSL 3.5)
VALVE SPRING
4. Checkthe free height of each valve spring and replace
if necessary.
2. Using a square, test the squareness of each valve
spring. Ifthe spring is excessively out-f-square, re~
place it
Valve spring
Standard value
Free height : 46.4 mm (1.8268 in.)
Load : 24 kg / 37.9 mm (53 Ib / 1.492 in.)
Out - of - square : Max. 2°
Service limit
Free height
Out - of - square
45.4. mm (1.787 in.)
Max. 4°
Outotsquare
}
REPLACING VALVE GUIDE
4. Using the special tool (09221-3F000 A/B), withdraw
the old valve guide out the bottom of the cylinder head,
2. Recondition the valve guide hole so that itcan receive
the newly press-fited oversize valve guide.
VALVE GUIDE OVERSIZES
() (]
0921-000,
00221-3F 0008,
Valve gude Valve
y guide
/
RY o>
3. Using the special too! (09221-3F000 A/B) press-fit the
valve guide. The valve guide must be press-fitted from
the upper side ofthe cylinder head. Keep in mind that
the intake and exhaust valve guides are different in
length,
4. After the valve guide is press-fited, insert a new valve
‘and check for proper clearance.
5. Alter the valve guide is replaced, check that the valve
is fully seated. Recondition the valve seats as neces-
sary.
(Gore
Do not installa valve guide unless itis oversize.
t |
(1.5350) (4.653 in
Oversize valve
guide hole size
mm (in.)
12.08 ~ 12.068
(0.474 ~ 0.475)
1225 ~ 12.268
(0.482 ~ 0.483)
1250 ~ 12518
(0.492 ~ 0.493)
Size mm (i Size Mark
0.05 (0.002) 0s. 5
0.25 (0.010) OS. 25
0.80 (0.020) Os. 80
41 CYLINDER HEAD ASSEMBLY.
REPLACING VALVE SEAT RING
0.5-1.0mm (0.020-0.039 in)
Md,
ZZ
VALVE SEAT RING OVERSIZES
(0.020-0.039 in)
EM -35
2. Enlarge the diameter of the valve seat so that it
‘matches the specified hole diameter of the new valve
1. Cut away the inner face of the valve seat to reduce seat ring
the wall thickness.
Height of |
KE
Size ‘Oversize hole diameter
Description | Size mm(in.) | jury | Seat ring helght H mm (in.) LD mm (ind
Intake valve | 0.3 (0.012)0.8. | 30 7.9~8.1(0.311~0.319) | 36,300 ~ 36.925 (1.429 ~ 1.430)
seatring | 06(0.024)0.8. | 60 82~8.4(0.323~0.331) | 36,600 ~ 36.625 (1.441 ~ 1.442)
Exhaust valve | 0.3(0.012)08. | 30 79~8.1(0311~0.319) | 33.900~ 93.325 (1.311 ~ 1.312)
seatring | 0.6 (0.024) 0.8. | 60 82~8.4(0323~0331) | 33.600 ~ 33.625 (1.323 ~ 1.324)
3. Heat the cylinder head to about 250°C (480°F) and
press-fit an oversize seat ring for the bore in the cylin-
der head,
4. Using lapping compound, lap the valve to the new
seat.
Valve seat contact width
Intake : 0.9 ~ 1.3 mm (0.035 ~ 0.051 in.)
Exhaust : 0.9 ~ 1.3 mm (0.035 ~ 0.051 in.) EM -36 ENGINE(G6CU-GSL 3.5)
REASSEMBLY wes
4. Install the spring seats.
2. Using special tool (09222-28200), lightly tap the seal
in position,
(Gore
+ De fot route old wah stan soats,
+ incomedt installation ofthe sea could result in oll
leakage of rom the vale guides.
\Vave stem seal
09222-28200
3, Apply engine oll to each valve. Insert the valve into
their guides. Avoid pushing the valve into the seal by
force. After instaling the valve,check that it moves
smoothly.
4, Place valve springs so that the
5
fe coated with
‘enamel faces toward the valve spring retainer.
Spring Retainer
name
coated
‘ring
‘tom seal
——— Spring sheet
Using the special tool (09222 - 28000, 09222 -
28100), 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.
(wore
When the spring is compressed, check that the valve
stem seal is not pressed against the bottom of the
retainer.
Clean both gasket surfaces of the cylinder head and
cylinder block.
Verify the identification marks on the cylinder head
gasket CYLINDER HEAD ASSEMBLY. EM -37
8. Install the gasket so that the surface with the identif-
cation mark faces toward the cylinder head,
9. Tighten the cylinder head bolts in the sequence
shown in the illustration with a torque wrench.
10. Tighten the cylinder head bolts. Starting at top center,
tighton all cylinder head bolts in sequence as shown
in the illustration, using the 12 mm socket.
Tightening procedure
Cylinder head bolt :
4105 ~ 115 Nm (1050 ~ 1150 kg.om, 75 ~ 82 Ib.) EM -38 ENGINE(G6CU-GSL 3.5)
MAIN MOVING SYSTEM
CAMSHAFT
COMPONENTS | exccairs
Cylinder head cover bot
8 ~ 10 (80 ~ 100,6 ~ 7.4)
eA 7 casket oittiter cap
EDS 19 ~21 (190 ~ 210, 14-15)
YE 8
_— Bearing cap (Feat)
Bearing eap (Front) an 2
Ls ae Sg Octet any
© * Ss
Cylinder head (RH)
Camshatt (EX)
Cylinder head (LH)
{80 - 100 (800 ~1000, 60 - 74)
Camshatt sprocket
TORQUE : Nm (kg.cm, Ib.ft) MAIN MOVING SYSTEM
DISASSEMBLY
1. Remove the engine cover and intake manifold.
For additional information, refer to the intake manifold
section,
2. Disconnect the breather hose and the engine har-
For additional information, refer to the engine and
transaxle assembly section,
3. Remove the timing bet.
For additional information, refer to the timing belt sec-
tion,
4, Remove the spark plug cables.
5. Loosen the cylinderhead cover bolts and then remove
it
6
7.
8
EM -39
Remove the camshaft sprockets
Remove the camshaft bearing caps.
Front beatngeap — Beningcap Rear beanng cap
Remove the camshafts.
camsnat ————
Recker am
Lash agus EM -40
INSPECTION vsti
CAMSHAFTS
4. Check the camshaft journals for wear. Ifthe journals
are badly worn out, replace the camshaft
2. Check the cam lobes for damage. I the lobe is dam-
aged or excessively worn out, replace the camshaft.
Cam height
Standard
Intake : 35.098 ~ 35.298 mm (1.9818 ~ 1.9897 in.)
Exhaust : 34.81 ~ 35.01 mm (1.3705 ~ 1.3783 in.)
3, Check the cam surface for abnormal wear or damage,
and replace if necessary.
4, Check each bearing for damage. If the bearing
surface is excessively damaged, replace the cylinder
head assembly or camshaft bearing cap, as neces-
sary.
‘Camshaft end play
0.4 ~ 0.15 mm (0.0039 ~ 0.0059 in.)
ENGINE(G6CU-GSL 3.5)
OIL SEAL (CAMSHAFT FRONT)
4. Check the lips for wear. If lip threads are worn out,
replace the oil seal with new one.
2. Check a contact surface of oil seal lip on camshaft. If
there stratified wear, replace the camshaft MAIN MOVING SYSTEM
HLA (HYDRAULIC LASH ADJUSTER)
With the HLA filed with engine oll, hold A and press B by
hand. If 8 moves, replace the HLA
EM -41
ce
- Se
Problem
Possible cause
‘Action
1. Temporary noise when starting
a cold engine
Normal
This noise will disappear atfer the oil in
the engine reaches the normal pressure,
2. Continuous noise when the
engine is started after parking
more than 48 hours,
Oil leakage of the high pressure
‘chamber on the HLA, allowing
air to get in.
'3. Continuous noise when the engine
is first started after rebuilding
oylinder head,
Insufficient oll in cylinder
head oil gallery,
4. Continuous noise when the engine
is started after excessiviy craking the
engine by the starter motor or band.
'5. Continuous noise when the engine
is running after changing the HLA.
il leakage of the high -
pressure chamber in the HLA,
allowing air to get in.
Insufficient oil in the HLA.
Noise will disappear within 15 minutes
when engine runs at 2000 - 3000 rpm.
If it doesn't disappear, refer to
step 7 below.
Ay caution
Do not run engine at a speed
higher than 3000 rpm, as this
may damage the HLA.
%. Contiunous noise during idle
after high engine speed.
Engine oil level too high or too low.
Check oil level
Drain or add oil as necessary
Excessive amount of air in the
oil at high engine speed,
Check oil supply system.
Deteriorated oil
Check oil quailty
If deteriorated, replace with
specitied type.
7. Noise continues for more than
16 minutes.
Low oil pressure.
Check oil pressure and oll supply
system of each part of engien.
Faulty HLA
Remove the eylinder head cover and
press HLA down by hand.
Itit moves, replace the HLA, EM -42
ENGINE(G6CU-GSL 3.5)
AUTOLASH ADJUSTER
1
2
Check autolash adjusters for free play by inserting a
‘small wire through the air bleed hole in the rocker arm
and push the autolash adjuster check ball down very
lightly.
While lightly holding the check ball down move the
rocker arm up and down to check for free play. Ifthere
isno play replace the autolash adjuster.
REASSEMBLY
CAMSHAFT AND BEARING CAP
4, Rotate the crankshaft and No. 1 cylinder is in TDC.
(Compression stroke)
2. Check the position of the rocker arm whether itis ex-
actly installed on the lash adjuster and valve or not,
3. Install the camshaft dowel pin as illustration
oyinder nea (RH)
ovine hes)
| MAIN MOVING SYSTEM
4. The left and right banks of the camshafts are different
and you shouid be careful not to confuse them.
Identification signal
Left bank
Intake (IN) : 1
Exhaust (Ex) :
Right bank
Intake (IN) : J
Exhaust (Ex) : H
6
Tighten the bearing cap by 2 or 3 steps
Tightening Torque
Outer (*) 16 EA
19 ~ 20Nm (190 ~ 210kg.cm, 14 ~ 15ib ft)
Inner 24 EA
10 ~ 12Nm (100 ~ 120kg.cm, 7.4 ~ 8.8ib.t)
Conon
Conoco
5. Confirm the identification mark and the number.
Bearing caps of No.3, No.4, and No.5 have the front
mark and arrange the front mark upon the cylinder
head while installing the bearing caps.
Identification mark
Intake = 1
Exhaust
©
EM -43, EM -44 ENGINE(G6CU-GSL 3.5)
7. Install the cylinder head cover
41) Install the gasket to the cylinder head cover cor-
rectly.
2) Clean sealing surface on camshaft cap.
Clean sealing surface with use plastic scraper, fo pre-
vent oi leak:
3) Apply sealant to the sealing surface on cylinder
head cover and camshaft cap,
Sealant type: LT 6800
(@4i) (inp
Gore
Be careful of gasket escapement when installing the
coylinder head cover. You must use the washer when
installing the cylinder head cover bolts
Front Rear
@ ® ® ] MAIN MOVING SYSTEM
CONNECTING ROD
COMPONENTS | ccxaxs
EM ~45,
No.1 Pistionrign
Piston rign
oiring
Piston ——&)
Piston pin ry
oe —- connecting ro bo
¢ ~
VP connecting rod bearng
Connecting rod
Piston and connecting rod assembly
Connecting tod upper bearing
‘Connecting od lower bearing
3 connecting oa ap
<< 4+ 90" (340 + 907,26 + 80°)
TORQUE : Nm (kg.cm, Ib-ft) EM -46 ENGINE(G6CU-GSL 3.5)
REMOVAL eure
4. Remove the timing belt.
For additional information, refer to timing belt in this,
section.
2. Remove the cylinder head.
For additional information, refer to cylinder head in the
section,
3, Remove the oil pan
4, Remove the oil screen,
DISASSEMBLY | eri:
CONNECTING ROD CAP
{\ CAUTION
Keep the bearings in order with thelr correspond-
ing connecting rods (according to cylinder num-
bers) for proper reassembly.
4. Remove the connecting rod cap bolts, then remove
the caps and the big end lower bearing mark for re-
assembly.
2. Push each piston connecting rod assembly toward the
top of the cylinder.
Cylinder number
INSPECTION
PISTONS AND PISTON PINS
Check each piston for scuffing, scoring, wear and
‘other defects. Replace any piston that is defective.
2. Check each piston ring for breakage, damage and
‘abnormal wear. Replace the defective rings. When
the piston requires replacement, its rings should also
be replaced.
3. Check that the piston pin fits in the piston pin hole,
Replace any piston and pin assembly thats defective.
‘The piston pin must be pressed smoothly by hand into
the pin hole (at room temperature)
PISTON RINGS.
1. Measure the piston ring side clearance. If the mea-
‘sured value exceeds the service limit, insert a new
ring in the ring groove to measure the side clearance.
Ifthe clearance still exceeds the service limit, replace
the piston and rings together. Ifits less than the ser-
vice limit, replace only the piston rings.
Piston ring side clearance
No. 1 ; 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.)
No. 2 : 0.02 ~ 0.08 mm (0.0008 ~ 0.0024 in.)
Oil ring side ral : 0.2 ~ 0.7 mm (0.0079 ~ 0.0276 in.)
2. 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.
PISTON RING END GAP
‘Standard dimensions
No. 1: 0.2 ~ 0.3 mm (0.0078 ~ 0.0118 in.)
No. 2: 0.40~ 0.55mm (0.0157 ~ 0.0216 in.)
Oil ring side ral : 0.2 ~ 0.7 mm (0.0079 ~ 0.0276 in.)
When replacing the ring without correcting the oylin-
der bore, check the gap with the ring situated at the
lower part of cylinder that is less worn out MAIN MOVING SYSTEM
PISTON RING SERVICE SIZE AND MARK
‘Standard None
(0.25 mm (0.010 in.) OS 25
0.60 mm (0.020 in.) 0.8 50
NOTE
The mark can be found on the upper side of the ring
next to the end.
CONNECTING RODS
1. When the connecting rod cap is installed, make sure
that the cylinder numbers, marked on rod end cap
at disassembly, match. When a new connecting rod
is installed, make sure that the notches holding the
bearing in placeare on the same side.
2. Replace the connecting rod if itis damaged at either
tend of the thrust faces. Ifit has a stratified wear, or if
the surface of the inside diameter of the small end is
severely rough, replace the rod.
EM -47
REASSEMBLY
4, Install the spacer.
ie a
Spacer
Upper se ait Lower seal
>> Gy tet
cap poston
Tension bearing <8 in
2
\
OY EM -60 ENGINE(G6CU-GSL 3.5)
REMOVAL esos
1
2
3
Using the drain plug, drain the coolant,
Remove the drive belt.
Remove the timing belt cover, the auto tensioner and
idler pulley.
For additional information, refer to timing belt in this
section,
Remove the engine coolant pump mounting bolts.
Remove the engine coolant pump assembly from the
cylinder block.
INSPECTION | cxx2ce
4. Check the engine coolant pump for cracks, damage or
wear, and replace the pump assembly if necessary
2. Check the bearing for damage, abnormal noise and
sluggish rotation and replace the pump assembly if
necessary,
3. Check the seal for leaks and replace the pump as-
sembly if necessary,
INSTALLATION | ears
4. Clean the gasket surfaces of the engine coolant pump
body and the cylinder block.
2. Install the new engine coolant pump gasket and pump
assembly. Tighten the bolts to the specified torque.
Tightening torque
Engine coolant pump bolt
Head mark
(MB) : 15 ~ 22 Nm (150 ~ 220 kg.om, 11 ~ 16 Ib.t)
(M10) : 33 ~ 50 Nm (830~ 500 kg.cm, 24 ~ 36 Ib.t)
3, Install the auto tensioner and timing belt. Adjust the
timing belt tension, then install the timing belt cover.
4, Install the drive belt and then adjust the auto ten-
5. Refll the coolant,
6. Run the engine and check for leaks. COOLING SYSTEM EM 61
RADIATOR
COMPONENTS | cxcrace: EM -62 ENGINE(G6CU-GSL 3.5)
REMOVAL
1
Disconnect the ground cable from the battery termi-
ral,
2. Disconnect the fan motor connector.
2. Loosen the radiator lower hose to drain the coolant
4. Disconnect the upper and lower hoses and overtow
tube after marking the radiator hose and tho hose
clamp the ease assem
5. Forvehicleswth automatic ransares, disconnect the
Sil cool hoses forthe automate waneate
3) caution
Cover or plug the hose and inlets of the radiator
So that dust and other foreign material ete. can
notenter after the hose fs disconnected from the
radiator,
6. Remove the head am.
For adational information refer tothe BE
7. Remove the front bumper.
For adational information refer tothe BD
8. Remove the radiator fan motor fom the radiator
INSPECTION | cassia
1. Check or foreign material between the radiator fins
2. Check the ralator fs for damage and straighten i
necessary,
3. Chock the radiator for corrosion, damage, rust or
scale,
4. Check he radiator hoses foreracs, damage or dote-
roraton
5. Chock th reservoir tank or damage
6. Check the automatic transaxle ll cooler hoses fr
cracking, damage or deterioration (only A/T).
INSTALLATION ex
1
Fill the radiator and reservoir tank with a clean coolant
mixture.
Run the engine until the coolant warms up enough so
that the thermostat valve opens and then tur off the
engine.
Remove the radiator cap and pour the coolant up to
the filer neck of the radiator. Fill the reservoir tank to
the upper level
Check that there are no leaks from the radiator, hoses
‘or connections. COOLING SYSTEM
RADIATOR CAP
COMPONENTS,
EM 63
Radiator cap
Spring
High pressure valve
Pressure : 107.9214.7 (1.120.15, 15.6422.13)
PRESSURE : Kpa (kg/cm?, psi)
Bentvalve Vacuum spring
Pressure : 83.4 (0.85, 12.1)
INSPECTION
1. Check the radiator cap for damage, cracks or weak~
ening,
Weakening
Wieakesing
2. Connect the tester to the radiator cap.
3, Increase the pressure until the indicator of the gauge
stops moving
4, Replace the radiator cap ifthe reading does not hold
steady for about 10 seconds. EM -64 ENGINE(G6CU-GSL 3.5)
THERMOSTAT
COMPONENTS | exssccen
Water outet iting
17-20 (170 -200,128 - 145) —“@y
17-20 (170 ~ 200, 128 ~ 14.5)
Thermostat Water inlet iting
&
Gasket
TORQUE : Nm (kg.cm, Ib.ft)
REMOVAL couse
41, Drain the coolant to thermostat level or below.
2, Remove the inlet fiting and gasket.
3. Remove the thermostat. COOLING SYSTEM
INSPECTION csuno
1. Heat the thermostat as shown in the illustration.
2. Check that the valve operates property,
3. Verify the temperature at which the valve begins to
open.
Valve opening temperature : 80 ~ 84°C (176 ~ 183.2°F)
Full opening temperature : 95°C (203°F)
990000
EM 65
INSTALLATION
4. Check that the flange of the thermostat is correctly
placed in the socket of the thermostat housing,
2, Install the inlet fitting,
Tightening torque
Engine coolant inlet fiting bolt
17 ~ 20 Nm (170 ~ 200 kg.cm, 12
14 ot)
3. Refill the coolant. EM -66 ENGINE(G6CU-GSL 3.5)
LUBRICATION SYSTEM
OIL PUMP
COMPONENTS | eso
© oy on ‘switch
&, fiter
_— a
Ret
er at ve sping
alt valve plug R3
Crankshatt sprocket Lower baffle
“ par 10 ~ 12 (100 ~ 120, 7 ~9)
TORQUE : Nm (kg.cm, Ib.ft) LUBRICATION SYSTEM
DISASSEMBLY
1. Remove the oil pressure switch, using 24 mm deep
socket
iS
(Gy) nore
‘Since a sealant is used on the threaded area, be care~
ful not to damage the oil pressure switch.
2. Remove the oil fer and the oil pan
3, Remove the oil screen and gasket.
4, Remove the three bracket securing bolts and remove
the oil fiter bracket and gasket.
5. Remove the oil relief valve plug from the oil pump
6. Remove the oil pump case.
EM -67
INSPECTION
lL PUMP
41. Visually check the parts of the oll pump case for
cracks and damage,
2. Assemble the rotor on the oll pump and then check
the clearance with a thickness gauge.
il pump side clearance
‘Standard value
Body clearance
(0.100 ~ 0.181 mm (0.0039 ~ 0.0071 in.)
Side clearance
0.040 ~ 0.095 mm (0.0016 ~ 0.0037 in.)
il pump Tip clearance :
0.06 ~ 0.18 mm (0.0024 ~ 0.0071 in.)
J— Sige clearance
RELIEF PLUNGER AND SPRING
1. Check the reli plunger for smooth operation
2. Check the relief spring for deformation or breaks
OL FILTER BRACKET
1. Make sure that there is no damage on the surface that
‘mates with the oil filter,
2, Check the oil fter bracket for oll leaks or cracks, EM -68
ENGINE(G6CU-GSL 3.5)
OIL PRESSURE SWITCH
4. Check the continuity between the terminal and the
body with an ohmmeter.
If there is no continuity, replace the oil pressure
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 50 kpa (7 psi) vacuum
is applied through the oil hole, the switch is operating
properiy.
Check for air leakage. If air leaks, the diaphragm is
broken Replace it
A
Fine wire
Operation Pressure
Oil pressure switch
£80 kpa (0.8 kg / cm*, 11.4 psi) or more @ 700 rpm
REASSEMBLY
41. Install the oil pump case with the gasket
Tightening torque
Oil pump case bolt
415 ~ 20 Nm (150 ~ 200 kg.cm, 11 ~ 14 Ib.t)
il pump cover screw
8 ~ 12 Nm (80 ~ 120 kg.cm, 6 ~ 9 Ib.t)
Front view>
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