GENERAL ENGINE BLOCK

ENGINE AND TRANSAXLE ASSEMBLY COOLING SYSTEM

TIMING SYSTEM LUBRICATION SYSTEM

CYLINDER HEAD ASSEMBLY INTAKE AND EXHAUST SYSTEM

EM -2 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

GENERAL
SPECIFICATION E4EB72CB

Description Specifications Limit

General
Type V-type, DOHC
Number of cylinders 6
92mm (3.6220in)(3.3L)
Bore
96mm(3.7795in)(3.8L)
83.8mm (3.2992in)(3.3L)
Stroke
87.0mm(3.4252in)(3.8L)
3,342cc (203.94cu.in.)(3.3L)
Total displacement
3.778cc(230.55cu.in.)(3.8L)
Compression ratio 10.4
Firing order 1-2-3-4-5-6
Valve timing
Intake Opens(ATDC) 14˚ (3.3L) / 10 (3.8L)
Closes(ABDC) 62˚ (3.3L / 3.8L)
Exhaust Opens(BBDC) 42˚ (3.3L / 3.8L)
Closes(ATDC) 6˚ (3.3L / 3.8L)
Cylinder head
Flatness of gasket surface Less than 0.05mm (0.0019in.)
[Less than 0.02mm (0.0008in.) / 150x150]
Flatness of manifold Less than 0.1mm(0.0039in.)
Intake
mounting [Less than 0.03mm(0.001in)/110x110]
Less than 0.1mm(0.0039in.)
Exhaust
[Less than 0.03mm(0.001in)/110x110]
Camshaft
Cam height LH 46.3mm (1.8228in.)(3.3L)
Intake
Camshaft 46.8mm(1.8425in.)(3.8L)
Exhaust 45.8mm (1.8031in.)(3.3L / 3.8L)
RH 46.3mm (1.8228in.)(3.3L)
Intake
Camshaft 46.8mm(1.8425in.)(3.8L)
Exhaust 45.8mm (1.8031in.)(3.3L / 3.8L)
Journal outer LH ,RH 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.)
GENERAL EM -3

Description Specifications Limit

Bearing oil LH ,RH Intake No.1: 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 0.02 ~ 0.18mm (0.0008 ~ 0.0071in.)
Valve
Valve length Intake 105.27mm(4.1445in.)
Exhaust 105.50mm (4.1535in.)
Stem outer diameter Intake 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)
Exhaust 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)
Face angle 45.25 ~ 45.75
Thickness of Intake 1.56 ~ 1.86mm(0.06142 ~ 0.07323in.)
valvehead(margin)
Exhaust 1.73 ~ 2.03mm(0.06811 ~ 0.07992in.)
Valve stem to valve Intake 0.020 ~ 0.047mm (0.00078 ~ 0.00185in.) 0.07mm (0.00275in.)
guide clearance
Exhaust 0.030 ~ 0.054mm (0.00118 ~ 0.00212in.) 0.09mm (0.00354in.)
Valve guide
Inner diameter Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in.)
Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in.)
Length Intake 41.8 ~ 42.2mm (1.6457 ~ 1.6614in.)
Exhaust 41.8 ~ 42.2mm (1.6457 ~ 1.6614in.)
Valve seat
Width of seat Intake 1.15 ~ 1.45mm(0.05118 ~ 0.05709in.)
contact
Exhaust 1.35 ~ 1.65mm(0.05315 ~ 0.06496in.)
Seat angle Intake 44.75 ~ 45.20
Exhaust 44.75 ~ 45.20
Valve spring
Free length 43.86mm (1.7267in.)
Load 19.3±0.8kg/34.0mm (42.7±1.8 lb/1.3386in.)
42.3±1.3kg/24.2mm (93.3±2.9 lb/0.9527in.)
Out of squareness Less than 1.5
MLA
MLA outer diameter Intake 34.964 ~ 34.980mm (1.3765 ~ 1.3772in.)
Exhaust 34.964 ~ 34.980mm (1.3765 ~ 1.3772in.)
Cylinder head Intake 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.)
tappet bore inner
diameter Exhaust 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.)

MLA to tappet bore Intake 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) 0.07mm(0.0027in.)

clearance
Exhaust 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) 0.07mm(0.0027in.)
Valve clearance
EM -4 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

Description Specifications Limit

Intake 0.10 ~ 0.30mm
0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
(0.0039 ~ 0.0118in.)
Exhaust 0.20 ~ 0.40mm
0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)
(0.0078 ~ 0.0157in.)
Cylinder block
92.00 ~ 92.03mm (3.6220 ~ 3.6232in.)(3.3L)
Cylinder bore
96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)(3.8L)
Less than 0.05mm (0.0019in.)
Flatness of gasket surface
[Less than 0.02mm (0.0008in.) / 150x150]
Piston
91.96 ~ 91.99mm(3.6205 ~ 3.6216in.)(3.3L)
Piston outer diameter
95.96 ~ 95.99mm(3.7779 ~ 3.7791in.)(3.8L)
Piston to cylinder clearance 0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)
Ring groove width No. 1 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.) 1.26mm (0.0496in.)
No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.) 1.26mm (0.0496in.)
Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in.) 2.05mm (0.0807in.)
Piston ring
Side clearance No. 1 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.) 0.1mm (0.004in.)
No. 2 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.) 0.1mm (0.004in.)
Oil ring 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.) 0.2mm (0.008in.)
End gap No. 1 ring 0.17 ~ 0.32mm (0.0067 ~ 0.0126in.) 0.6mm (0.0236in.)
No. 2 ring 0.32 ~ 0.47mm (0.0126 ~ 0.0185in.) 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 ~ 23.021mm (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 -0.032 ~ -0.016mm (-0.0012 ~ 0.0006in.)
Connecting rod
Connecting rod big end innerdiameter 58.000 ~ 58.018mm(2.2834 ~2.2842in.)
Connecting rod bearing oil clearance 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 0.022 ~ 0.040mm (0.0008 ~ 0.0016in.)
End play 0.10 ~ 0.28mm (0.0039 ~ 0.0110in.)
Oil pump
450 ~ 550kPa
Relief valve opening pressure
(4.59 ~ 5.61kgf/cm²,65.28 ~ 79.79psi)
GENERAL EM -5

Description Specifications Limit

Engine oil
Oil quantity (Total) 6.4L(6.76U.S.qts,5.63lmp.qts)
Oil quantity (Oil pan) 5.5L(5.81U.S.qts,4.84lmp.qts)
Oil quantity (Oil filter) 0.4L(0.42U.S.qts,0.35lmp.qts)
Oil quantity (Drain and refill) 5.2L(5.49U.S.qts,4.58lmp.qts)
Oil quality Above SJ or SL
130kPa(1.32kgf/cm²,18.77psi)
Oil pressure
[at 1000rpm,110 C(230 F)]
Cooling system
Cooling method Forced circulation with electrical fan
Coolant quantity 8.6L(9.09U.S.qts,7.57lmp.qts)
Thermostat Type Wax pellet type
Opening temperature 82±2 C (179.6±35.6 F)
Fully openedtem-
95 C (203 F)
perature
Full lift 10mm (0.3937in.)
Radiator cap Main valve opening 93.16 ~ 122.58kpa
pressure (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)
Vacuum valve 0.98 ~ 4.90 kpa
opening pressure (0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi)
Water temperature sensor
Type Thermister type
Resistance 20 C (68 F) 2.31 ~ 2.59KΩ
80 C(176 F) 0.3222 KΩ
EM -6 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

TIGHTENING TORQUE

Quan-
Item Nm kgf.m lb-ft
tity
Crankshaft pulley bolt 1 284.2 ~ 303.8 29.0 ~ 31.0 209.76 ~ 224.22
Timing chain cover bolt B 17 18.62 ~ 21.56 1.9 ~ 2.2 13.74 ~ 15.91
Timing chain cover bolt C 4 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain cover bolt D 1 58.80 ~ 68.80 6.0 ~ 7.0 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 24.50 ~ 26.46 2.5 ~ 2.7 18.08 ~ 19.53
Timing chain cover bolt G 4 21.56 ~ 23.52 2.2 ~ 2.4 15.91 ~ 17.36
Timing chain cover bolt H 1 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain cover bolt I 1 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain cover bolt J 1 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Cam to cam guide bolt 4 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain auto tensioner bolt 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain auto tensioner nut 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain guide bolt 4 19.60 ~ 24.50 2.0 ~ 2.5 14.17 ~ 18.08
Oil pump chain cover bolt 3 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Oil pump chain tensioner bolt 1 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Oil pump chain guide bolt 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Oil pump chain sprocket bolt 1 18.62 ~ 21.56 1.9 ~ 2.2 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 9.8 ~ 10.2 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 bolt 1 53.90 ~ 57.82 5.5 ~ 5.9 39.78 ~ 42.67
OCV(oil control valve) bolt 2 9.80 ~ 11.76 1.0 ~ 1.2 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 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36

CVVT ＆ exhaust cam sprocket bolt 4 64.68 ~ 76.44 6.6 ~ 7.8 47.74 ~ 56.42
Camshaft bearing cap bolt 32 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Cylinder head cover bolt 38 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Connecting rod bearing bolt 12 19.60 + 90˚ 2.0 + 90˚ 14.46 + 90˚
Main bearing cap inner bolt(M11) 8 49.00 + 90˚ 5.0 + 90˚ 36.16 + 90˚
Main bearing cap outer bolt(M8) 8 19.60 + 120˚ 2.0 + 120˚ 14.46 + 120˚
Main bearing cap side bolt(M8) 6 29.40 ~ 31.36 3.0 ~ 3.2 21.70 ~ 23.14
Oil drain cover bolt 6 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Rear oil seal case bolt 6 9.80 ~ 11.76 1.0 ~ 1.2 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 1.0 ~ 1.2 7.23 ~ 8.68
GENERAL EM -7

Quan-
Item Nm kgf.m lb-ft
tity
Knock sensor bolt 2 15.68 ~ 23.52 1.6 ~ 2.4 11.57 ~ 17.36
Drive plate bolt 8 71.54 ~ 75.46 7.3 ~ 7.7 52.80 ~ 55.69
Oil filter cap 24.50 2.5 18.08
Oil drain bolt 1 34.30 ~ 44.10 3.5 ~ 4.5 25.31 ~ 32.55
Oil pump bolt 3 20.6 ~ 22.6 2.1 ~ 2.3 15.2 ~ 16.6
Oil filter body bolt 10 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Oil filter body cover bolt 11 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Water vent hose bolt 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Water pump bolt(Timing chain cover bolt L) 1 21.56 ~ 26.46 2.2 ~ 2.7 15.91 ~ 19.53
Water pump bolt(Timing chain cover bolt K) 4 9.80 ~ 11.76 1.0 ~ 1.2 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 4 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
Water temp. control bolt 2 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
Water inlet pipe bolt 3 16.66 ~ 19.60 1.7 ~ 2.0 12.30 ~ 14.47
Air vent pipe bolt 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Intake manifold bolt 6 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
Intake manifold nut 2 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
Surge tank bolt(3.3L) 5 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Surge tank nut(3.3L) 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Surge tank bolt (3.8L : M8 × 25) 3 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
Surge tank bolt (3.8L : M6 × 106) 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Surge tank nut (3.8L) 1 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
Breather pipe bolt 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Surge tank bracket bolt(3.3L) 2 27.44 ~ 31.36 2.8 ~ 3.2 20.25 ~ 23.14
Surge tank bracket bolt rear
2 27.44 ~ 31.36 2.8 ~ 3.2 20.25 ~ 23.14
(3.8L : M10 × 18 )
Surge tank bracket bolt front
2 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
(3.8L : M8 × 16)
ETC bracket bolt 2 15.68 ~ 25.48 1.6 ~ 2.6 11.57 ~ 18.80
Exhaust manifold nut 16 39.20 ~ 44.10 4.0 ~ 4.5 28.93 ~ 32.55
Heat protector bolt 8 16.66 ~ 21.56 1.7 ~ 2.2 12.30 ~ 15.91
Front muffler 2 39.20 ~ 58.80 4.0 ~ 6.0 28.93 ~ 43.40
EM -8 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

COMPRESSION 4) Repeat steps (a) through (c) for each cylinder.

NOTE NOTE
If the there is lack of power, excessive oil consump- This measurement must be done in as short a time as
tion or poor fuel economy, measure the compression possible.
pressure.
Compression pressure :
1. Warm up and stop engine. 1,225kPa (12.5kgf/cm², 177psi) - 200 ~ 250rpm
Allow the engine to warm up to normal operating tem- Minimum pressure :
perature. 1,078kPa (11.0kgf/cm², 156psi)
2. Remove the surge tank. (Refer to EM - 100)
5) If the cylinder compression in 1 or more cylinders
3. Remove the ignition coil connectors(A) and ignition is low, pour a small amount of engine oil into the
coils(B). cylinder through the spark plug hole and repeat
steps (1) through (3) for cylinders with low com-
pression.
• If adding oil helps the compression, it is likely
that the piston rings and/or 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.

A
6. Reinstall the spark plugs.

B 7. Install the ignition coil and ignition coil connectors.

8. Install the surge tank. (Refer to EM - 104)

KDRF158B

4. Remove the spark plugs.

Using a 16mm plug wrench, remove the 6 spark plugs.

5. Check cylinder compression pressure.

1) Insert a compression gauge into the spark plug

hole.

2) Fully open the throttle.

3) After 7 times of cranking the engine, measure the

compression pressure.

NOTE
Always use a fully charged battery to obtain engine
speed of 250 rpm or more.
GENERAL EM -9

VALVE CLEARANCE INSPECTION AND 5. Set No.1 cylinder to TDC/compression.

ADJUSTMENT
1) Turn the crankshaft pulley and align its groove
NOTE with the timing mark "T" of the lower timing chain
cover.
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.(Refer to EM - 17)

3. Remove the surge tank.(Refer to EM - 100)

4. Remove the cylinder head cover.

1) Disconnect the ignition coil connector and re-

move the ignition coil.

2) Disconnect the breather pipe assembly(A) from

the cylinder head cover.
KDRF108A

2) Check that the mark(A) of the camshaft timing

sprockets are in straight line on the cylinder head
surface as shown in the illustration.
A If not, turn the crankshaft one revolution (360 )

NOTE
Do not rotate engine counterclockwise

ECBF031A

3) Loosen the cylinder head cover bolts and then

remove the cover(A) and gasket.

A
KDRF113A

KDRF112A
EM -10 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

6. Inspect the valve clearance. Timing mark RH EXHAUST

1) Check only the valve indicated as shown. [No. 1

cylinder : TDC/Compression] measure the valve
clearance.

Timing mark RH EXHAUST

Timing mark INTAKE

INTAKE
LH EXHAUST

EDRF022A

7. Adjust the intake and exhaust valve clearance.

LH EXHAUST 1) Set the No.1 cylinder to the TDC/compression.

(Refer to EM - 9)
EDRF021A

Measurement method. 2) Remove the timing chain.(Refer to EM - 26)

• · Using a thickness gauge, measure the
clearance between the tappet and the base 3) Remove the camshaft bearing caps(A).
circle of camshaft.
· Record the out-of-specification valve clear-
A
ance measurements. They will be used later
to determine the required replacement ad-
justing 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 ~ 0.0157in.)

2) Turn the crankshaft pulley one revolution (360 )

and align the groove with timing mark "T" of the
KDRF196A
lower timing chain cover.
4) Remove the camshaft assembly(A).
NOTE
Do not rotate engine counterclockwise A

3) Check only valves indicated as shown. [NO. 4

cylinder : TDC/compression]. Measure the valve
clearance. (Refer to procedure step1))

KDRF197A
GENERAL EM -11

5) Remove MLAs. 13) Turn the crankshaft two turns in the operat-
ing direction(clockwise) and realign crankshaft
6) Measure the thickness of the removed tappet us- sprocket and camshaft sprocket timing marks(A).
ing a micrometer.

KDRF113A
EDKE889D

14) Recheck the valve clearance.

7) Calculate the thickness of a new tappet so that
the valve clearance comes within the specified Valve clearance (Engine coolant tempera-
value. ture: 20 C[68 F])
[Specification]
Valve clearance(Engine coolant tempera- Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
ture: 20 C[68 F]) Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)
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 (0.0118in.)]

8) Select a new tappet with a thickness as close as

possible to the calculated value.

NOTE
Shims are available in 41size increments of 0.015mm
(0.0006in.) from 3.00mm (0.118in.) to 3.600mm
(0.1417in.)

9) Place a new tappet on the cylinder head.

NOTE
Appling engine oil at the selected tappet on the pe-
riphery and top surface.

10) Install the intake and exhaust camshaft. (Refer

to EM - 55)

11) Install the bearing caps. (Refer to EM - 56)

12) Install the timing chain. (Refer to EM - 32)

EM -12 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

TROUBLESHOOTING EB9DDED8

Symptom Suspect area Remedy

Engine misfire with abnormal Worn crankshaft bearings. Replace the crankshaft and bearings
internal lower engine noises. Loose or improperly engine drive plate. as required.
Repair or replace the drive plate
as required.
Worn piston rings. Inspect the cylinder for a loss of
(Oil consumption may or may not cause compression.
the engine to misfire.) Repair or replace as required.
Replace the crankshaft and bearings
Worn crankshaft thrust bearings
as required.
Engine misfire with abnormal Stuck valves. Repair or replace as required.
valve train noise. (Carbon buildup on the valve stem)
Excessive worn or mis-aligned Replace the timing chain and
timing chain. sprocket as required.
Worn camshaft lobes. Replace the camshaft and valve lifters.
Engine misfire with coolant • Faulty cylinder head gasket and/or • Inspect the cylinder head and
consumption. cranking or other damage to the engine block for damage to
cylinder head and engine block the coolant passages and/or a
cooling system. faulty head gasket.
• Coolant consumption may or may not • Repair or replace as required.
cause the engine to overheat.
Engine misfire with excessive Worn valves, guides and/or valve Repair or replace as required.
oil consumption. stem oil seals.
Worn piston rings. • Inspect the cylinder for a loss
(Oil consumption may or may not cause of compression.
the engine to misfire) • Repair or replace as required.
Engine noise on start-up, but Incorrect oil viscosity. • Drain the oil.
only lasting a few seconds. • Install the correct viscosity oil.
Worn crankshaft thrust bearing. • Inspect the thrust bearing and
crankshaft.
• Repair or replace as required.
GENERAL EM -13

Symptom Suspect area Remedy

Upper engine noise,regard- Low oil pressure. Repair or replace as required.
less of engine speed.
Broken valve spring. Replace the valve spring.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain and/or Replace the timing chain and sprockets.
damaged sprocket teeth.
Worn timing chain tensioner, if applicable. Replace the timing chain tensioner
as required.
Worn camshaft lobes. • Inspect the camshaft lobes.
• Replace the timing camshaft and
valve lifters as required.
Worn valve guides or valve stems. Inspect the valves and valve guides,then
repair as required.
Stuck valves. (Carbon on the valve Inspect the valves and valve guides,
stem or valve seat may cause the then repair as required.
valve to stay open.
Worn drive belt, idler, tensioner Replace as required.
and bearing.
Lower engine noise,regard- Low oil pressure. Repair or required.
less of engine speed.
Loose or damaged drive plate. Repair or replace the drive plate.
Damaged oil pan, contacting the • Inspect the oil pan.
oil pump screen. • Inspect the oil pump screen.
• Repair or replace as required.
Oil pump screen loose, damaged • Inspect the oil pump screen.
or restricted. • Repair or replace as required.
Excessive piston-to-cylinder bore • Inspect the piston, piston pin
clearance. and cylinder bore.
• Repair as required.
Excessive piston pin-to-piston clearance. • Inspect the piston, piston pin and
the connecting rod.
• Repair or replace as required.
Excessive connecting rod bearing Inspect the following components
clearance 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 • Verify the piston pins and connecting
connecting rod installation rods are installed correctly.
• Repair as required.
EM -14 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

Symptom Suspect area Remedy

Engine noise under load. Low oil pressure Repair or replace as required.
Excessive connecting rod bearing Inspect the following components
clearance . andrepair as required :
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components,
andrepair as required.
• The crankshaft bearings.
• The crankshaft main journals.
• The cylinder block.
Engine will not Hydraulically locked cylinder. 1. Remove spark plugs and check
crank-crankshaft will • Coolant/antifreeze in cylinder. for fluid.
not rotate. • Oil in cylinder. 2. Inspect for broken head gasket.
• Fuel in cylinder. 3. Inspect for cracked engine block
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 1. Inspect crankshaft and connecting
rod bearings. rod bearing.
2. Repair as required.
Bent or broken connecting rod. 1. Inspect connecting rods.
2. Repair as required.
Broken crankshaft. 1. Inspect crankshaft.
2. Repair as required.
GENERAL EM -15

SPECIAL TOOLS E787872C

Tool (Number and name) Illustration Use

Crankshaft front oil seal installer Installation of the front oil seal
(09231-3C100)

KDRF233A

Flywheel stopper Removal and installation of the flywheel

(09231-3C300) and crankshaft pulley.

KCRF030D

Torque angle adapter Installation of bolts & nuts needing

(09221-4A000) an angular method

LCAC030A

Valve stem seal remover Remover of the valve stem seal

(09222-29000)

KDRF232A

Valve stem seal remover Installation of the valve stem seal

(09222-3C100)

LCAC030D
EM -16 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

Tool (Number and name) Illustration Use

Valve spring compressor Removal and installation of the intake
＆ holder A or exhaust valve
(09222-3K000) A : 09222-3K000
(09222-3C300) B : 09222-3C300 (holder)
A

ECRF003A

Crankshaft rear oil seal installer A Installation of the crankshaft rear oil seal
(09231-3C200) A : 09231-3C200
(09231-H1100) B B : 09231-H1100

ACRF003A

Oil pan remover Removal of oil pan

(09215-3C000)

KDRF219A

Oil filter wrench Removal and installation of the oil filter

(09263-3C100)

B6327000
ENGINE AND TRANSAXLE ASSEMBLY EM -17

ENGINE AND TRANSAXLE

ASSEMBLY D
C

REMOVAL E31DBAFC

CAUTION
• Use fender covers to avoid damaging paint-
edsurfaces.
• To avoid damage, unplug the wiring connec- A
tors carefully while holding the connector
portion.
B
KDRF173A
NOTE
• Mark all wiring and hoses to avoid misconnec- 5) Remove the air cleaner lower cover(A).
tion.

1. Remove the engine cover.

2. Remove the air duct(A).

A
A

ECBF016A

6. Remove front wheels.

7. Remove under cover(A).

KCBF143A

3. Disconnect the neagative terminal from the battery. A

4. Recovering refrigerant and remove the high ＆ low

pressure pipe. (Refer to HA group - air conditioner
compressor)

5. Remove the intake air hose and air cleaner assembly.

1) Disconnect the AFS connector(A).

2) Disconnect the breather hose(B) from air clean-

erhose.

3) Disconnect the ECM connector. (Refer to FL

group) KCBF101A

4) Remove the intake air hose(C) and air cleaner 8. Drain the engine coolant.
upper cover(D). Remove the radiator cap to speed draining.
EM -18 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

9. Remove the upper radiator hose and lower radiator 2) Disconnect RH oxygen sensor connector(A) and
hose(A). solenoid valve connector(B).

[3.8L]

A
A

KDRF148A

10. Remove transaxle oil cooler hose.

ECBF021A

11. Remove fuel hose(A) and PCSV(B) hose.

3) Disconnect power steering oil pressure sensor
connector(A).

KDRF149A

KDRF152A
12. Remove engine wiring.

1) Disconnect RH oxygen sensor connector(A). 4) Disconnect RH injector connector(A) and ignition

coil connector(B).
[3.3L]
[3.3L]

B
ECBF020A ECBF022A
ENGINE AND TRANSAXLE ASSEMBLY EM -19

[3.8L] 7) Disconnect alternator connector(A).

A
ECBF023A

KDRF157A
5) Disconnect OCV connector(A) and knock sensor
connector(B). 8) Disconnect LH ignition coil connector(A), injec-
tor connector(B), condenser connector(C) and
ground(D), and remove wiring harness protec-
A
tor(E).

D
B

C
KDRF155A

6) Disconnect LH front oxygen sensor connec- B

tor(A). KDRF158A

9) Disconnect LH CMPS(A) and oil pressure switch

connector(B).

KDRF156A

KDRF159A
EM -20 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

10) Disconnect PCSV connector(A) and MAP sensor 12) Disconnect ETC connector(A) and knock sensor
connector(B). connector(B).

[3.3L]

KDRF162A

ECBF024A
13) Disconnect WTS connector(A).
[3.8L]

A A

ECBF025A KDRF163A

11) Disconnect RH CMPS(A) and OTS connector(B). 14) Disconnect LH rear oxygen sensor connector(A)
and CPS connector(B).

B B

KDRF161A

KDRF164A
ENGINE AND TRANSAXLE ASSEMBLY EM -21

13. Disconnect the transaxle wire harness connector 17. Remove power steering pump hose(A).
and remove the transaxle control cable.(Refer to TR
group)

14. Disconnect EPS connector.

KDRF175A

18. Remove A/C compressor hose.

KCBF103A
19. Drain transaxle oil.
15. Remove heater hose(A).
20. Remove lower arm ball joint. (Refer to DS group)

21. Remove tie rod end ball joint. (Refer to DS group)

22. Remove stabilizer link. (Refer to SS group)

23. After removing a split pin and nut from the steering
A bar tie rod, disconnect it. (Refer to ST group)

24. Remove power steering return hose(A) and drain

power steering oil.

KDRF165A

16. Remove brake vacuum hose(A).

A
ECBF007A

25. Remove front roll stopper mounting bolt.

26. Remove rear roll stopper mounting bolt.

27. Remove steering u-joint mounting bolt. (Refer to ST

KDBF101A group)
EM -22 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

28. Remove front exhaust pipe(A). 32. Disconnet the ground cable(A) from the engine
mounting bracket.
A

KCBF102A
KDBF102A
29. Supporting the cross member(A) with a jack, remove
the stay with the mounting bolts. 33. Remove the engine mounting bracket(A).

Tightening torque :
137.3~156.9Nm (14.0~16.0kgf.m, 101.3~115.7lb-ft)

KDRF172A

34. Remove the transaxle mounting bracket(A).

KMRE009R

30. Remove drive shaft from transaxle.(Refer to DS

group)
B
31. Install jack for supporting engine and transaxle as-
sembly.

KMRE009T
ENGINE AND TRANSAXLE ASSEMBLY EM -23

35. Remove the engine and transaxle assembly by lifting INSTALLATION EAD5D6B1

vehicle.
Installation is in the reverse order of removal.
NOTE Perform the following :
• Adjust the shift cable.
When remove the engine and transaxle assembly, be
• Refill the engine with engine oil.
careful not to damage any surrounding parts or body
• Refill the transaxle with fluid.
components.
• Refill 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
for fuel leakage at any point in the fuel line.
EM -24 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

TIMING SYSTEM
COMPONENT EFFAFA9E

9.8 ~ 11.76
(1.0 ~ 1.2, 7.23 ~ 8.68)

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 ~ 2.2, 13.02 ~ 15.91)

9.8 ~ 11.76
(1.0 ~ 1.2, 7.23 ~ 8.68)
52.92 ~ 57.82
(5.4 ~ 5.9, 39.06 ~ 42.67)

96.04 ~ 99.96
(9.8 ~ 10.2, 70.85 ~ 73.74)

TORQUE : N.m (kgf.m, lb-ft)

1. Drive belt 5. Water pump pulley

2. Drive belt tensioner 6. Oil pan
3. Idler 7. Cylinder head cover
4. Damper pulley
ECBF008A
TIMING SYSTEM EM -25

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)

19.60 ~ 24.50
(2.0 ~ 2.5, 14.17 ~ 18.08)

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, lb-ft)

1. Timing chain cover 8. Timing chain 15. Timing chain guide
2. Oil pump chain cover 9. Cam to cam guide 16. Cam to cam guide
3. Oil pump sprocket 10. Timing chain guide 17. Tensioner adapter
4. Oil pump chain 11. Timing chain auto tensioner 18. Gasket
5. Crankshaft sprocket 12. Timing chain tensioner arm 19. Oil pump chain guide
6. Timing chain auto tensioner 13. Crankshaft sprocket 20. Oil pump temsioner assembly
7. Timing chain tensioner arm 14. Timing chain
ECBF009A
EM -26 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

REMOVAL EE688815 4. Remove the alternator(A).

Engine removal is required for this procedure.

1. Remove the drive belt(A).

KDRF104A

5. Remove drive belt idler(A).

KDRF101A

2. Remove the power steering pump(A).

A
A
KDRF105A

6. Remove drive belt auto tensioner(A).

KDRF102A

3. Remove the air compressor(A).

A KDRF106A

KDRF103A
TIMING SYSTEM EM -27

7. Remove water pump pulley(A). DISASSEMBLY ECE9DBD5

1. Remove cylinder head cover.

a. Remove connector bracket(A) from LH cylinder
head cover.

KDRF107A

8. Remove intake manifold.(Refer to EM - 100)

KDRF110A

b. Disconnect RH ignition coil connector(A),

condenser connector(B) and remove wiring
bracket(C)

B C

KDRF111A

c. Remove LH,RH ignition coil.

EM -28 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

d. Remove LH,RH cylinder head cover(A).

A

KDRF113A

KDRF112A NOTE
Do not rotate engine counterclockwise.
2. Set No.1 cylinder to TDC/compression.
3. Remove the lower oil pan(A).
1) Turn the crankshaft pulley and align its groove
Insert the blade of SST(09215-3C000) between the
with the timing mark "T" of the lower timing chain
upper oil pan and lower oil pan, and cut off applied
cover.
sealer and removed lower oil pan.
NOTE
Do not rotate engine counterclockwise.

09215
-3C000

ECRF060A

NOTE
KDRF108A
Be careful not to damage the contact surfaces of Up-
2) Check that the mark(A) of the camshaft timing per oil pan and lower oil pan.
sprockets are in straight line on the cylinder head
surface as shown in the illustration.
If not, turn the crankshaft one revolution (360 ).
TIMING SYSTEM EM -29

4. Remove the crankshaft damper pulley(A). 7. Remove RH cam-to-cam guide(A).

KDRF109A KDRF116A

5. Remove the timing chain cover(A). 8. Remove RH timing chain auto tensioner(A) and RH
timing chain tensioner arm(B).

A
A

KDRF115A
KDRF117A

NOTE
9. Remove RH timing chain.
Be careful not to damage the contact surfaces of cylin-
der block, cylinder head and timing chain cover. 10. Remove RH timing chain guide(A).

6. Install a set pin after compressing the timing chain

tensioner.

KDRF118A

KCRF105A
EM -30 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

11. Remove oil pump chain cover(A). 14. Remove oil pump chain sprocket(A) and oil pump
chain(B).

B
A

KDRF185A

KDRF121A
12. Remove oil pump chain tensioner assembly(A).
15. Remove crankshaft sprocket(A)(Oil pump ＆ RH
camshaft drive).

A A

KDRF119A

13. Remove oil pump chain guide(A). KDRF122A

16. Remove LH cam-to-cam guide(A).

KDRF120A

KDRF123A
TIMING SYSTEM EM -31

17. Remove LH timing chain auto tensioner(A) and LH 21. Remove tensioner adapter assembly(A).
timing chain tensioner arm(B).

KDRF127A

KDRF124A

18. Remove LH timing chain.

19. Remove LH timing chain guide(A).

KDRF125A

20. Remove crankshaft sprocket(A)(LH camshaft drive).

KDRF126A
EM -32 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

INSPECTION E33C7CDB REASSEMBLY E0BF1C9F

SPROCKETS, CHAIN TENSIONER, CHAIN 1. The key(A) of crankshaft should be aligned with the
GUIDE, CHAIN TENSIONER ARM timing mark(B) of timing chain cover. As a result of
this, the piston of No.1 cylinder is placed at the top
1. Check the camshaft sprocket and crankshaft sprocket
dead center on compression stroke.
for abnormal wear, cracks, or damage. Replace as
necessary.

2. Inspect the tensioner arm and chain guide for abnor-

mal wear, cracks, or damage. Replace as necessary.
B
3. Check that the tensioner piston moves smoothly when
the ratchet pawl is released with thin rod. A

BELT, IDLER, BELT TENSIONER, PULLEY

1. Check the belt for oil or dust deposits.

Replace, if necessary.
Small deposits should be wiped away with a dry cloth
or paper. Do not clean with solvent.

2. When the engine is overhauled or belt tension ad-

KDRF128A
justed, check the belt carefully. If any of the following
flaws are evident, replace the belt.
2. Install tensioner adapter assembly(A).
NOTE
• Do not bend, twist or turn the timing belt inside
out.
• Do not allow the timing belt to come into contact
with oil, water and steam.

3. Inspect the idler for easy and smooth rotation and

check for play or noise.
A

KDRF127A

3. Install crankshaft sprocket(A)(LH camshaft drive).

KDRF126A
TIMING SYSTEM EM -33

4. Install LH timing chain guide(A). 7. Install LH chain tensioner(A).

Tightening torque Tightening torque

19.60 ~ 24.50Nm(2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft) 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

KDRF125A KDRF124A

5. Install LH timing chain. 8. Install LH cam-to-cam guide(A).

To install the timing chain with no slack between each
shaft (cam, crank), follow the below procedure. Tightening torque
Crankshaft sprocket(A) → Timing chain guide(B) → 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
Exhaust camshaft sprocket(C) → Intake camshaft
sprocket(D).
The timing mark of each sprockets should be matched A
with timing mark (color link) of timing chain at installing
timing chain.

KDRF123A

KDRF123B

6. Install LH timing chain tensioner arm(B).

Tightening torque
18.62 ~ 21.56Nm(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)
EM -34 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

9. Install crankshaft sprocket(A)(Oil pump ＆ RH

camshaft drive).

KDRF118A

12. Install RH timing chain.

KDRF122A To install the timing chain with no slack between each
shaft (cam, crank), follow the below procedure.
10. Install oil pump chain(B) and oil pump sprocket(A). Crankshaft sprocket(A) → Intake camshaft
sprocket(B) → Exhaust camshaft sprocket(C).
Tightening torque The timing mark of each sprockets should be matched
18.62 ~ 21.56Nm(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft) with timing mark (color link) of timing chain at installing
timing chain.

KDRF121A
KDRF129A

11. Install RH timing chain guide(A).

Tightening torque
19.60 ~ 24.50Nm(2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft)

KDRF116B
TIMING SYSTEM EM -35

13. Install RH timing chain tensioner arm(B). 16. Install oil pump chain guide(A).

Tightening torque Tightening torque

18.62 ~ 21.56Nm(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft) 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

14. Install RH timing chain auto tensioner(A).

Tightening torque
9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

A
B

A
KDRF120A

17. Install oil pump chain tensioner assembly(A).

KDRF117A
Tightening torque
9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
15. Install RH cam-to-cam guide(A).

Tightening torque
9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

KDRF119A

18. Pull out the pins of hydraulic tensioners

KDRF116A (LH ＆ RH).
EM -36 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

19. Install oil pump chain cover(A). c. After applying liquid sealant TB1217H on timing
chain cover.
Tightening torque The part must be assembled within 5 minutes
9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) after sealant was applied.
Sealant should be applied without discontinuity.

Bead width : 2.5mm(0.1in.)

1 0.5mm

A * * *
* *
*
*
* * *
Sealant *
*
*
*
1 0.5mm *
KDRF185A

20. After rotating crankshaft 2 revolutions in regular direc- *

tion(clockwise viewed from front), confirm the timing
mark.
ECBF032A

NOTE d. Install the new gasket(A) to the timing chain

Always turn the crankshaft clockwise. cover.

21. Install timing chain cover. A

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 TB1217H 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(0.1in.)

KDRF220A

KDRF134A
TIMING SYSTEM EM -37

e. The dowel pins on the cylinder block and holes 22. Using SST(09231-3C100), install timing chain cover
on the timing chain cover should be used as a oil seal.
reference in order to assemble the timing chain
cover to be in exact position.
09231-3C100

Tightening torque
B(17): 18.62 ~ 21.56Nm(1.9 ~ 2.2kgf.m,
13.74 ~ 15.91lb-ft)
C(4): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
D(1): 58.80 ~ 68.80Nm(6.0 ~ 7.0kgf.m,
43.40 ~ 50.63lb-ft)
E(1): 58.80 ~ 68.80Nm(6.0 ~ 7.0kgf.m,
43.40 ~ 50.63lb-ft)
F(2): 24.50 ~ 26.46Nm(2.5 ~ 2.7kgf.m,
18.08 ~ 19.53lb-ft)
G(4): 21.56 ~ 23.52Nm(2.2 ~ 2.4kgf.m,
15.91 ~ 17.36lb-ft)
H(1): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) ECRF050A
I(1): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
J(1): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) 23. Install lower oil pan.
K(4): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) a. Using a gasket scraper, remove all the old pack-
L(1): 21.56 ~ 26.46Nm(2.2 ~ 2.7kgf.m, 15.91 ing material from the gasket surfaces.
~ 19.53lb-ft) - New bolt b. Before assebling the oil pan, the liquid sealant
TB1217H should be applied on oil pan.
The part must be assembled within 5 minutes
D E after the sealant was applied.
A
F G
G B
Bead width : 2.5mm(0.1in.). But marked
B
K area(*) to be 5.0mm(0.2in.)
B J G B
B B
G H B
B F L
I K B
B KKC
C B
B C B
B
B
B C B

ECBF033A

f. The firing and/or blow out test should not be per-

formed within 30 minutes after the timing chain
cover was assembled.

KDRF136A

CAUTION
• 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 oil, apply sealant gas-
ket ot the inner threads of the bolt holes.
• After assembly, wait at least 30 minutes be-
fore filling the engine with oil.
EM -38 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

f. Install oil pan(A).

Uniformly tighten the bolts in several passes.

Tightening torque
9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

09231-3C300

ECRF061A

25. Install cylinder head cover.

a. The hardening sealant located on the upper area
between timing chain cover and cylinder head
should be removed before assembling cylinder
KDRF114A head cover.
b. After applying sealant(TB1217H), it should
24. Using SST(09231-3C300) install crankshaft damper be assembled within 5 minutes.Bead width :
pulley(A). 2.5mm(0.1in.)

Tightening torque
284.2 ~ 303.8Nm(29.0 ~ 31.0kgf.m, 209.76
~ 224.22lb-ft)

KDRF231A

c. The firing and/or blow out test should not be per-

formed within 30 minutes after the cylinder head
KDRF109A cover was assembled.
TIMING SYSTEM EM -39

d. Install the cylinder head cover bolts as following g. Install connector bracket(A) from LH cylinder
method. head cover.

Tightening torque
9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

13
3 7 6
16
17
9 1 12
19 18
10 2 11 A
14
5 8 4
15
13 3 7 6
16
9 1 12
17
18 KDRF110A
10 2 11
19
14
15 5 8 4
KDRF139A

CAUTION
Do not reuse cylinder head cover gasket.

e. Install ignition coil

f. Connect RH ignition coil connector(A),
condenser connector(B) and install wiring
bracket(C).

B C

KDRF111A
EM -40 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

INSTALLATION E0ED79CB 4. Install drive belt idler(A).

1. Install intake manifold.(Refer to EM - 104) Tightening torque

52.92 ~ 57.82Nm(5.4 ~ 5.9kgf.m, 39.06 ~ 42.67lb-ft)
2. Install water pump pulley(A).

Tightening torque
7.84 ~ 9.80Nm(0.8 ~ 1.0kgf.m, 5.78 ~ 7.23lb-ft)

A
A
KDRF105A

5. Install alternator(A).

KDRF107A

3. Install drive belt auto tensioner(A).

Tightening torque
96.04 ~ 99.96Nm(9.8 ~ 10.2kgf.m, 70.85 ~ 73.74lb-ft)
17.64 ~ 21.56Nm(1.8 ~ 2.2kgf.m, 13.02 ~ 15.91lb-ft)

KDRF104A

6. Install air conditioner compressor(A).

KDRF106A

KDRF103A
TIMING SYSTEM EM -41

7. Install power steering pump(A).

KDRF102A

8. Install drive belt(A).

Crankshaft pulley → A/C pulley → idler pulley → alter-
nator pulley → water pump pulley → P/S pump pulley
→ tensioner pulley.
Rotate auto tensioner arm in the counter - clockwise
moving auto tensioner pulley bolt with wrench.
After putting belt on auto tensioner pulley, release the
auto tensioner pulley slowly.

KDRF101A
EM -42 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

CYLINDER HEAD
ASSEMBLY
COMPONENTS EEECCDC0

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, lb-ft)

1. RH cylinder head 4. LH cylinder head gasket
2. RH cylinder head gasket 5. Cylinder block
3. LH cylinder head
ECBF010A
CYLINDER HEAD ASSEMBLY EM -43

9.80 ~ 11.76
(1.0 ~ 1.2, 7.23 ~ 8.68)

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, lb-ft)

1. Camshaft bearing cap 6. MLA 11. Valve
2. Exhaust camshaft 7. Retainer lock 12. OCV
3. Intake camshaft 8. Retainer 13. Cylinder head
4. Exhaust camshaft sprocket 9. Valve spring
5. CVVT assembly 10. Valve stem seal
ECBF011A
EM -44 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

REMOVAL EC0F8ABA 6. Remove camshaft assembly(A).

CAUTION A

• Use fender covers to avoid damaging painted

surfaces.
• To avoid damaging the cylinder head, wait un-
til the engine coolant temperature drops be-
low normal temperature before removing it.
• When handling a metal gasket, take care not
to fold the gasket or damage the contact sur-
face of the gasket.
• To avoid damage, unplug the wiring connec-
tors carefully while holding the connector
portion.

NOTE KDRF197A

• Mark all wiring and hoses to avoid misconnec- 7. Remove cylinder head bolts, then remove cylinder
tion. head.
• Turn the crankshaft pulley so that the No. 1 piston
is at top dead center. (Refer to EM - 9) 1) Uniformly loosen and remove the 16 cylinder
head bolts, in several passes, in the sequence
Engine removal is required for this procedure. shown. Remove the 16 cylinder head bolts and
plate washers.
1. Remove exhaust manifold.(Refer to EM - 102)

2. Remove intake manifold.(Refer to EM - 100) 3 7 6 2

3. Remove timing chain.(Refer to EM - 26)

4. Remove water temperature control assembly. (Refer

4 8 5 1
to EM - 81)

5. Remove camshaft bearing cap(A).

1 5 8 4

A
2 6 7 3

KDRF199A

CAUTION
Head warpage or cracking could result from re-
moving bolts in an incorrect order.

2) Lift the cylinder head from the dowels on the

cylinder block and place the cylinder head on
KDRF196A
wooden blocks on a bench.

CAUTION
Be careful not to damage the contact surfaces of
the cylinder head and cylinder block.
CYLINDER HEAD ASSEMBLY EM -45

DISASSEMBLY EC0C0D1E 2) Remove the spring retainer.

NOTE 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

KDRF234A
KDRF200A

NOTE
2. Remove valves.
Do not reuse old valve stem seals.
1) Using SST(09222-3K000, 09222-3C300), com-
press the valve spring and remove retainer lock. 3. Remove OCV(A).

09222-3K000

09222-3C300

A
KDRF201A KDRF202A
EM -46 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

INSPECTION EA4BD93A VALVE AND VALVE SPRING

CYLINDER HEAD 1. Inspect valve stems and valve guides.

1. Inspect for flatness. 1) Using a caliper gauge, measure the inside diam-
Using a precision straight edge and feeler gauge, eter of the valve guide.
measure the surface the contacting the cylinder block
and the manifolds for warpage. Valve guide I.D.
Intake / Exhaust : 5.500 ~ 5.512mm (0.216 ~ 0.217in.)
Flatness of cylinder head gasket surface
Standard : Less than 0.05mm(0.002in.)[Less
than 0.02mm(0.0008in.)/150x150]
Flatness of manifold gasket surface
Standard : Less than 0.03mm(0.001in)/110x110

ECBF034A

2) Using a micrometer, measure the diameter of the

valve stem.

EDQF160A
Valve stem O.D.
Intake : 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)
2. Inspect for cracks. Exhaust : 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)
Check the combustion chamber, intake ports, exhaust
ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.

KCRF227A
CYLINDER HEAD ASSEMBLY EM -47

3) Subtract the valve stem diameter measurement 3. Inspect valve seats

from the valve guide inside diameter measure- Check the valve seat for evidence of overheating and
ment. improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
Valve stem-to-guide clearance Before reconditioning the seat, check the valve guide
[Standard] for wear. If the valve guide is worn, replace cylin-
Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0018in.) der head. Recondition the valve seat with a valve
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in.) seat grinder or cutter. The valve seat contact width
[Limit] should be within specifications and centered on the
Intake : 0.07mm (0.0027in.) valve face.
Exhaust : 0.09mm (0.0035in.)
4. Inspect valve springs.
2. Inspect valves. 1) Using a steel square, measure the out-of-square
of the valve spring.
1) Check the valve is ground to the correct valve
face angle. 2) Using a vernier calipers, measure the free length
of the valve spring.
2) Check that the surface of the valve for wear.
If the valve face is worn, replace the valve. Valve spring
[Standard]
3) Check the valve head margin thickness.
Free height : 43.86mm (1.7267in.)
If the margin thickness is less than minimum, re-
Out-of-square : 1.5˚
place the valve.

Margin
[Standard]
Intake : 1.56 ~ 1.86mm(0.06142 ~ 0.07323in.)
Exhaust : 1.73 ~ 2.03mm(0.06811 ~ 0.07992in.)

KCRF205A

Margin

ECKD221A

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.

If the valve stem tip is worn, replace the valve.
EM -48 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

MLA CAMSHAFT

1. Inspect MLA. 1. Inspect cam lobes.

Using a micrometer, measure the MLA outside diam- Using a micrometer, measure the cam lobe height.
eter.
Cam height
MLA O.D. [Standard value]
Intake/Exhaust : 34.964 ~ 34.980mm(1.3765 Intake : 46.3mm (1.8228in.)(3.3L)
~ 1.3771in.) Intake : 46.8mm (1.8425in.)(3.8L)
Exhaust : 45.8mm (1.8031in.)(3.3L / 3.8L)
2. Using a caliper gauge, measure MLA tappet bore in-
ner diameter of cylinder head.

Tappet bore I.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.)
KCRF206A

If the cam lobe height is less than standard, replace

the camshaft.

2. Inspect camshaft 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.

KCRF207A
CYLINDER HEAD ASSEMBLY EM -49

4) Install the bearing caps. (Refer to EM - 56) 3. Inspect camshaft end play.

1) Install the camshafts. (Refer to EM - 55)

CAUTION
Do not turn the camshaft. 2) Using a dial indicator, measure the end play while
moving the camshaft back and forth.
5) Remove the bearing caps.
Camshaft end play
6) Measure the plastigage at its widest point. [Standard value] : 0.02 ~ 0.18mm(0.0008 ~ 0.0071in.)

Bearing oil clearance

[Standard value]
Intake
No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.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.)

KDRF196B

If the end play is greater than maximum, replace

the camshaft. If necessary, replace cylinder
head.

3) Remove the camshafts.

KCRF208A

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.

EM -50 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

CVVT ASSEMBLY 4) Under the condition of (3), turn the CVVT assem-
bly to the advance angle side (the arrow marked
1. Inspect CVVT assembly. direction in the illustration) with your hand.
Depending on the air pressure, the CVVT assem-
1) Check that the CVVT assembly will not turn. bly will turn to the advance side without applying
force by hand. Also, under the condition that the
2) Apply vinyl tape to the retard hole except the one
pressure can be hardly applied because of the air
indicated by the arrow in the illustration.
leakage from the port, there may be the casethat
the lock pin could be hardly released.

A Retard
Retard

Advance
ECRF015A

ECRF016A
3) Wind tape around the tip of the air gun and apply
air of approx. 150kpa(1.5kgf/cm², 21psi) to the
5) Except the position where the lock pin meets at
port of the camshaft.
the maximum delay angle, let the CVVT assem-
(Perform this order to release the lock pin for the
bly turn back and forth and check the movable
maximum delay angle locking.)
range and that there is no disturbance.

NOTE Standard: Movable smoothly in the range about 22.5

When the oil splashes, wipe it off with a shop rag.
6) Turn the CVVT assembly with your hand and lock
it at the maximum delay angle position (counter
clockwise).
CYLINDER HEAD ASSEMBLY EM -51

REASSEMBLY ED39E8BC 3) Using the SST(09222 - 3K000, 09222-3C300),

compress the spring and install the retainer locks.
NOTE After installing the valves, ensure that the retainer
locks are correctly in place before releasing the
Thoroughly clean all parts to be assembled. valve spring compressor.
Before installing the parts, apply fresh engine oil to all
sliding and rotating surfaces. 09222-3K000
Replace oil seals with new ones.

1. Install valves.

1) Using SST(09222-3C100), push in a new oil seal.

NOTE
Do not reuse old valve stem seals.
09222-3C300
Incorrect installation of the seal could result in oil leak-
age past the valve guides.

09222-3C100
KDRF201A

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.

KCRF120B

2) Install the valve, valve spring and spring retainer. A

NOTE
Place valve springs so that the side coated with
enamel faces toward the valve spring retainer and
then installs the retainer.

KDRF200A

NOTE
MLA can be reinstalled in its original position.
EM -52 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

3. Install OCV(A). INSTALLATION E63A6A04

Tightening torque NOTE

9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
• 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 to bend it.
• Rotate the crankshaft, set theNo.1 piston at TDC.
(Refer to EM - 9)

1. Install the cylinder head.

a. The sealant locations on cylinder head and cylin-
der block must be free of engine oil and ETC.
b. Apply sealant on cylinder block top face before
assembling cylinder head gaskets.
The part must be assembled within 5 minutes
after sealant was applied.
A CYLNIDER CYLNIDER
BLOCK D 15mm BLOCK
15mm
KDRF202A B
TOP FACE TOP FACE
(LH BANK) (RH BANK)
NOTE
• To install OCV with gray colored connector into
RH bank.
• To install OCV with black colored connector into
LH bank.
A
CAUTION C
• Do not reuse the OCV when dropped.
• Keep clean the OCV. B
• Do not hold the OCV sleeve during servicing. C
RH LH
• When the OCV is installed on the engine, do BANK BANK
not move the engine with holding the OCV
yoke. D
A
Engine Front Face
ECBF017A
CYLINDER HEAD ASSEMBLY EM -53

NOTE NOTE
Refer to below illustration to apply the sealant. Be careful of the installation direction.

Bead width : 2.0~3.0 mm

Sealant locations : 1.0~1.5mm from block surface
Recommended sealant :Liquid sealant TB1217H
3 : 3.3L
8 : 3.8L

CYLINDER HEAD 3R
GASKET 2.0 ~ 3.0mm

SEALANT
R : RH
(TB1217H)
L : LH

1.0 ~ 1.5mm
KDRF203A

CYLINDER BLOCK
FRONT FACE d. Install the cylinder head.

ECBF018A
NOTE
Remove the extruded sealant after assembling cylin-
c. Apply sealant on cylinder head gaskets after as- der heads.
sembling cylinder head gaskets on cylinder block.
The part must be assembled within 5 minutes
after sealant was applied.

LH CYINDER RH CYINDER 15mm

15mm
HEAD GASKET D HEAD GASKET B

A
C
KDRF198A

B
RH C LH
BANK BANK

D
A
Engine Front Face
ECBF019A
EM -54 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

2. Place the cylinder head carefully in order not to dam- 09221 - 4A000
age the gasket with the bottom part of the end.

3. Install cylinder head bolts.

1) Do not 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, 28.93lb-ft)+ 120˚ + 90˚
18.62 ~ 23.52Nm(1.9 ~ 2.4kgf.m, 13.74 ~ 17.36lb-ft)(A)
KDRF223A

NOTE 4. Install the CVVT and camshaft sprocket.

Always use new cylinder head bolt.
Tightening torque
64.68 ~ 76.44Nm(6.6 ~ 7.8 kgf.m, 47.74 ~ 56.4lb-ft)
6 2 3 7

5 1 4 8

8 4 1 5

7 3 2 6

KDRF199B

KCRF122A

NOTE
A
• Install camshaft-inlet to dowel pin of CVVT as-
sembly .
At this time, attend not to be installed to oil hole
of camshaft-inlet.
• Hold the hexagonal head wrench portion of the
camshaft with a vise, and install the bolt and
CVVT assembly.
• Do not rotate CVVT assembly when camshaft is
installed to dowel pin of CVVT assembly.

ECBF035A
CYLINDER HEAD ASSEMBLY EM -55

5. Install camshafts(A). EXHAUST CAMSHAFT

NOTE
• Apply a light coat of engine oil on camshaft jour-
nals.
• Assemble the key groove of camshaft rear side A
to the same level of head top surface.
• Be careful the right, left bank, intake, exhaust
side before assembling.

KDRF227A

LH RH
3.3L / 3.8L A: 27mm(1.0630in.) A: 30mm(1.1811in.)

KDRF197A

INTAKE CAMSHAFT

KDRF226A

LH RH
A: 27mm(1.0630in.) A: 30mm(1.1811in.)
3.3L
B: 27mm(1.0630in.) B: 30mm(1.1811in.)
A: 30mm(1.1811in.) A: 27mm(1.0630in.)
3.8L
B: 27mm(1.0630in.) B: 30mm(1.1811in.)
EM -56 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

6. Install camshaft bearing caps. 7. Install water temperature control assembly.(Refer to

EM - 81)
Tightening torque
9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) 8. Install timing chain(Refer to EM - 32)

9. Check and adjust valve clearance. (Refer to EM - 9)

A 10. Install the exhaust manifold. (Refer to EM - 104)

11. Install the intake manifold. (Refer to EM - 104)

KDRF196A

NOTE
Be careful the right, left bank, intake, exhaust side,
front mark before assembling.

C
A

B
ECBF036A

A : L(LH),R(RH)
B : I(Intake),None(Exhaust)
C : Journal number
D : Front mark

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.
ENGINE BLOCK EM -57

ENGINE BLOCK
COMPONENTS EA1BE037

19.6 (2.0, 14.46) + 90

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, lb-ft)

1. Piston ring 6. Connecting rod lower bearing
2. Piston 7. Connecting rod bearing cap
3. Connecting rod 8. Baffle plate
4. Connecting rod upper bearing 9. Upper oil pan
5. Piston pin 10. Cylinder block
ECBF012A
EM -58 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

8.8 ~ 10.8
(0.9 ~ 1.1, 6.5 ~ 8.0)

71.54 ~ 75.46
(7.3 ~ 7.7, 52.80 ~ 55.69)

9.80 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68)

29.40 ~ 31.36 (3.0 ~ 3.2, 21.70 ~ 23.14)

49.00 (5.0, 36.16) +90

19.60 (2.0, 14.46) +120

TORQUE : N.m (kgf.m, lb-ft)

1. Oil drain 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 oil seal
ECBF001A
ENGINE BLOCK EM -59

REMOVAL E4DADBA3 9. Remove alternator(A) from engine.

CAUTION
• Use fender covers to avoid damaging painted
surfaces.
• To avoid damage, unplug the wiring connec-
tors carefully while holding the connector
portion.

NOTE
• Mark all wiring and hoses to avoid misconnec-
tion. A
• Inspection the timing belt before removing the
cylinder head.
• Turn the crankshaft pulley so that the No.1 piston
KDRF104A
is at top dead center. (Refer to EM - 9)
• Engine removal is required for this procedure. 10. Remove power steering pump(A) from engine.

1. Remove exhaust manifold.(Refer to EM - 102)

2. Remove intake manifold.(Refer to EM - 100)

3. Remove timing chain.(Refer to EM - 26)

4. Remove water temperature control assembly.(Refer

to EM - 81)

5. Remove cylinder head.(Refer to EM - 44)

A
6. Remove oil pump.(Refer to EM - 92)

7. Remove oil filter assembly.(Refer to EM - 93)

8. Remove A/C compressor(A) from engine.

KDRF102A

KDRF103A
EM -60 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

DISASSEMBLY EBCBF7FE 5. Remove rear oil seal case(A).

1. Remove drive plate.

2. Remove knock sensor(A).

KDRF208A

6. Remove oil drain cover(A).

KDRF205A

3. Remove upper oil pan(A).

A
A

KDRF209A

7. Check the connecting rod end play.(Refer to EM - 61)

KDRF206A

8. Check the connecting rod cap oil clearance.(Refer to

4. Remove baffle plate(A). EM - 62)

9. Remove piston and connecting rod assemblies.

A

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.

NOTE
• Keep the bearings, connecting rod and cap to-
gether.
• Arrange the piston and connecting rod assem-
KDRF207A blies in the correct order.
ENGINE BLOCK EM -61

10. Remove crankshaft main bearing cap and check oil INSPECTION EAA56C18

clearance.(Refer to EM - 64)
CONNECTING ROD AND CRANKSHAFT
11. Check the crankshaft end play.(Refer to EM - 65)
1. Check the connecting rod end play.
12. Lift the crankshaft(A) out of engine, being careful not Using a feeler gauge, measure the end play while
to damage journals. moving the connecting rod back and forth.

Standard end play : 0.1~ 0.25mm(0.004 ~ 0.010in.)

KDRF210A

NOTE
KDRF211A
Arrange the main bearings and thrust bearings in the
correct order. • If out-of-tolerance, install a new connecting rod.
• If still out-of-tolerance, replace the crankshaft.
13. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston 2. Check the connecting rod bearing oil clearance.
pin. If any movement is felt, replace piston and piston
pin as a set. 1) Check the matchmarks on the connecting rod
and cap are aligned to ensure correct reassem-
14. Remove piston rings. bly.

1) Using a piston ring expender, remove the 2 com- 2) Remove 2 connecting rod cap bolts.
pression rings.
3) Remove the connecting rod cap and bearing half.
2) Remove 2 side rails and the spacer by hand.
4) Clean the crank pin and bearing.
NOTE
5) Place plastigage across the crank pin.
Arrange the piston rings in the correct order only.
6) Reinstall the bearing half and cap, and torque the
15. Disconnect connecting rod from piston. bolts.
Using a press, remove the piston pin from piston.
(Press-in load : 800 ~ 1400kg (1764 ~ 3086lb) Tightening torque
19.6Nm (2.0kgf.m, 14.46lb-ft) + 90

NOTE
Do not turn the crankshaft.
EM -62 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

7) Remove 2 bolts, connecting rod cap and bearing- CONNECTING ROD MARK LOCATION
half.

8) Measure the plastigage at its widest point.

Standard oil clearance

0.030 ~ 0.048mm(0.0012 ~ 0.0019in.)

EDQF196A

DISCRIMINATION OF CONNECTING ROD

CLASS MARK INSIDE DIAMETER

58.000 ~ 58.006mm
0 a
(2.2834 ~ 2.2837in.)
KDRF212A
58.006 ~ 58.012mm
9) If the plastigage measures too wide or too nar- 1 b
(2.2837 ~ 2.2839in.)
row, remove the upper half of the bearing, in-
58.012 ~ 58.018mm
stall a new, complete bearing with the same color 2 c
(2.2839 ~ 2.2842in.)
mark (select the color as shown in the next col-
umn), and recheck the clearance.
CRANKSHAFT PIN MARK LOCATION
CAUTION DISCRIMINATION OF CRANKSHAFT
Do not file, shim, or scrape the bearings or the
caps to adjust clearance.

10) If the plastigage shows the clearance is still in-

correct, try the next larger or smaller bearing (the
color listed above or below that one), and check
clearance again.
P1
NOTE P2
P3
If the proper clearance cannot be obtained by using P4
P6 P5
the appropriate larger or smaller bearings, replace the
crankshaft and start over.

CAUTION
ECBF037A
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.
ENGINE BLOCK EM -63

DISCRIMINATION OF CRANKSHAFT 11) Selection

OUTSIDE DIAMETER CONNECTING ROD

CLASS MARK
OF PIN IDENTIFICATION MARK
54.966 ~ 54.972mm 0(a) 1(b) 2(c)
I A
(2.1640 ~ 2.1642in.)
A
54.960 ~ 54.966mm B C
II B CRANK- Ⅰ(A) (YEL-
(2.1638 ~ 2.1640in.) (GREEN) (BROWN)
SHAFT LOW)
54.954 ~ 54.960mm INDEN-
III C B C D
(2.1635 ~ 2.1638in.) TIFICA- Ⅱ(B) (GREEN) (BROWN) (BLACK)
TION
MARK C D E
PLACE OF IDENTIFICATION MARK (CONNECTING Ⅲ(C) (BROWN) (BLACK) (BLUE)
ROD BEARING)

3. Check the crankshaft bearing oil clearance.

1) 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.

4) Reinstall the bearings and caps, then torque the

Color
bolts.

ECRF021A
Tightening torque
DISCRIMINATION OF CONNECTING ROD BEARING 49.00Nm(5.0 kgf.m, 36.16lb-ft) + 90
19.60 Nm(2.0 kgf.m, 14.46lb-ft)+ 120
THICKNESS OF 29.40 ~ 31.36Nm(3.0 ~ 3.2 kgf.m, 21.70 ~ 23.14lb-ft)
CLASS MARK
BEARING
1.514 ~ 1.517mm NOTE
E BLUE
(0.0596 ~ 0.0597in.) Do not turn the crankshaft.
1.511 ~ 1.514mm
D BLACK
(0.0595 ~ 0.0596in.)
1.508 ~ 1.511mm
C BROWN
(0.0594 ~ 0.0595in.)
1.505 ~ 1.508mm
B GREEN
(0.0593 ~ 0.0594in.)
1.502 ~ 1.505mm
A YELLOW
(0.0591 ~ 0.0593in)
EM -64 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

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.)
1
2 BB
3 BB B
4 CB B
B B

ECBF038A

DISCRIMINATION OF CYLINDER BLOCK

CLASS MARK INSIDE DIAMETER

73.500 ~ 73.506mm
a A
(2.8937 ~ 2.8939in.)
KCRF170A
73.506 ~ 73.512mm
b B
(2.8939 ~ 2.8942in.)
6) If the plastigage measures too wide or too nar-
row, remove the upper half of the bearing, in- 73.512 ~ 73.518mm
c C
stall a new, complete bearing with the same color (2.8942 ~ 2.8944in.)
mark (select the color as shown in the next col-
umn), and recheck the clearance.
CRANKSHAFT JOURNAL MARK LOCATION

CAUTION DISCRIMINATION OF CRANKSHAFT

Do not file, shim, or scrape the bearings or the

caps to adjust clearance.

7) If the plastigage shows the clearance is still in-

correct, try the next larger or smaller bearing (the J1J2
J3
color listed above or below that one), and check J4
clearance again.

NOTE
If the proper clearance cannot be obtained by using
the appropriate larger or smaller bearings, replace the
crankshaft and start over.

CAUTION ECBF039A

If the marks are indecipherable because of an ac- DISCRIMINATION OF CRANKSHAFT

cumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with OUTSIDE DIAMETER
solvent or detergent. CLASS MARK
OF JOURNAL

Crankshaft bore mark location 68.954 ~ 68.960mm

I A
Letters have been stamped on the block as a (2.7147 ~ 2.7150in.)
mark for the size of each of the 5 main journal 68.948 ~ 68.954mm
bores. II B
(2.7145 ~ 2.7147in.)
Use them, and the numbers or bar stamped on
68.942 ~ 68.948mm
the crank (marks for main journal size), to choose III C
(2.7142 ~ 2.7145in.)
the correct bearings.
ENGINE BLOCK EM -65

PLACE OF IDENTIFICATION MARK (CRANKSHAFT 4. Check crankshaft end play.

BEARING) Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
screwdriver.

Standard end play

Color
0.10 ~ 0.28mm (0.0039 ~ 0.0110in.)

ECRF022A

DISCRIMINATION OF CRANKSHAFT BEARING

ECKD001B
THICKNESS OF
CLASS MARK
BEARING
If the end play is greater than maximum, replace the
2.277 ~ 2.280mm thrust bearings as a set.
E BLUE
(0.0896 ~ 0.0897in.)
2.274 ~ 2.277mm Thrust bearing thickness
D BLACK 2.41 ~ 2.45mm(0.0949 ~ 0.0964in.)
(0.0895 ~ 0.0896in.)
2.271 ~ 2.274mm
C BROWN 5. Inspect main journals and crank pins
(0.0894 ~ 0.0895in.)
Using a micrometer, measure the diameter of each
2.268 ~ 2.271mm main journal and crank pin.
B GREEN
(0.0893 ~ 0.0894in.)
2.265 ~ 2.268mm Main journal diameter : 68.942 ~ 68.960mm
A YELLOW (2.7142 ~ 2.7149in.)
(0.0892 ~ 0.0893in.)
Crank pin diameter : 54.954 ~ 54.972mm
SELECTION (2.1635 ~ 2.1642in.)

CRANKSHAFT BORE
IDENTIFICATION MARK
a(A) b(B) c(C)
A
B C
CRANK- Ⅰ(A) (YEL-
(GREEN) (BROWN)
SHAFT LOW)
IDEN-
B C D
TIFICA- Ⅱ(B) (GREEN) (BROWN) (BLACK)
TION
MARK C D E
Ⅲ(C) (BROWN) (BLACK) (BLUE)

ECKD001E
EM -66 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

CONNECTING RODS CYLINDER BLOCK

1. When reinstalling, make sure that cylinder numbers 1. Remove gasket material.
put on the connecting rod and cap at disassembly Using a gasket scraper, remove all the gasketmaterial
match. When a new connecting rod is installed, make from the top surface of the cylinder block.
sure that the notches for holding the bearing in place
are on the same side. 2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the
2. Replace the connecting rod if it is damaged on the cylinder block.
thrust faces at either end. Also if step wear or a
severely rough surface of the inside diameter of the 3. Inspect top surface of cylinder block for flatness.
small end is apparent, the rod must be replaced as Using a precision straight edge and feeler gauge,
well. measure the surface contacting the cylinder head
gasket for warpage.
3. Using a connecting rod aligning tool, check the rod for
bend and twist. If the measured value is close to the Flatness of cylinder block gasket surface
repair limit, correct the rod by a press. Any connecting Standard : Less than 0.05mm(0.0020 in.),Less
rod that has been severely bent or distorted should be than 0.02mm(0.0008in.) / 150 x 150
replaced.

Allowable bend of connecting rod :

0.05mm / 100mm (0.0020 in./3.94 in.) or less
Allowable twist of connecting rod :
0.1mm / 100mm (0.0039 in./3.94 in.) or less

EDQF154A

4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder
block.
ENGINE BLOCK EM -67

5. Inspect cylinder bore diameter [3.3L]

Using a cylinder bore gauge, measure the cylinder
bore diameter at position in the thrust and axial di- Cylinder bore inner
Class Size code
rections. diameter
92.00~92.01mm
Standard diameter A A
(3.6220 ~ 3.6224in.)
92.00 ~ 92.03mm (3.6220 ~ 3.6232in.)(3.3L)
96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)(3.8L) 92.01~92.02mm
B B
(3.6224 ~ 3.6228in.)
92.02~92.03mm
C C
(3.6228 ~ 3.6232in.)

[3.8L]

Cylinder bore inner

Class Size code
diameter
96.00~96.01mm
A A A
(3.7795 ~ 3.7799in.)
B
C 96.01~96.02mm
B B
(3.7799 ~ 3.7803in.)
96.02~96.03mm
C C
(3.7803 ~ 3.7807in.)

EDQF153A

6. Check the cylinder bore size code on the cylinder

block.

RH
Bank
LH
Bank
1
3 BB
5 BB B
CB B 2
B B 4
6

ECBF002A
EM -68 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

7. Check the piston size code on the piston top face. PISTON AND RINGS

1. 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.
A
3) Using solvent and a brush, thoroughly clean the
piston.

NOTE
Do not use a wire brush.
KDRF215A
2. The standard measurement of the piston outside di-
[3.3L] ameter is taken 14 mm (0.5512 in.) from the bottom
of the piston.
Class Size code Piston outer diameter
91.96~91.97mm Standard diameter
A A
(3.6205 ~ 3.6209in.) 91.96 ~ 91.99mm (3.6205~ 3.6216in.)(3.3L)
95.96 ~ 95.99mm (3.7779~ 3.7791in.)(3.8L)
91.97~91.98mm
B B
(3.6209 ~ 3.6213in.)
91.98~91.99mm
C C
(3.6213 ~ 3.6219in.)

[3.8L]

Class Size code Piston outer diameter

95.96~95.97mm
A A
(3.7779 ~ 3.7783in.)
95.97~95.98mm
B B
(3.7783 ~ 3.7787in.)
95.98~95.99mmm
C C ECKD001D
(3.7787 ~ 3.7791in.)
3. Calculate the difference between the cylinder bore di-
8. Select the piston related to cylinder bore class. ameter and the piston diameter.

Clearance : Piston-to-cylinder clearance

0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)(3.3L / 3.8L) 0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)(3.3L / 3.8L)
ENGINE BLOCK EM -69

4. Inspect the piston ring side clearance. 5. Inspect piston ring end gap.
Using a feeler gauge, measure the clearance between To measure the piston ring end gap, insert a piston
new piston ring and the wall of the ring groove. ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down
Piston ring side clearance(3.3L / 3.8L) with a piston. Measure the gap with a feeler gauge. If
Standard the gap exceeds the service limit, replace the piston
No.1 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.) ring. If the gap is too large, recheck the cylinder bore
No.2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.) diameter against the wear limits on page EM - 67 If
Oil ring : 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.) the bore is over the service limit, the cylinder block
Limit must be replaced. (Refer to EM - 67)
No.1 : 0.1mm (0.004in.)
No.2 : 0.1mm (0.004in.) Piston ring end gap(3.3L / 3.8L)
Oil ring : 0.2mm (0.008in.) 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.)
Oil ring : 0.8mm (0.0315in.)

ECKD001G

If the clearance is greater than maximum, replace the

piston.

ECKD001K
EM -70 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

PISTON PINS

1. Measure the diameter of the piston pin.

Piston pin diameter

23.002 ~ 23.006mm (0.9056 ~ 0.9057in.)

ECKD001Z

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

-0.032 ~ -0.016mm (-0.00126 ~ -0.00063in.)
ENGINE BLOCK EM -71

REASSEMBLY E2B1FCB7 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.
A
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

KCRF118B

4. Install main bearings.

A NOTE
Upper bearings have an oil 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).

KCRF168A

2. Install piston rings.

1) Install the oil ring spacer and 2 side rails by hand.

A
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.

KDRF216A

2) Align the bearing claw with the claw groove of the

main bearing cap, and push in the 4 lowerbear-
ings.

ECKD321A

3. Install connecting rod bearings.

EM -72 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

5. Install thrust bearings. NOTE

Install the 2 thrust bearings(A) under the No.3 journal
position of the cylinder block with the oil grooves fac- • Always use new main bearing cap bolt.
ing outward. • If any of the bearing cap bolts in broken or de-
formed, replace it.

18 17 19
A

16 12 9 13
8 4 1 5

7 3 2 6
15 11 10 14

21 20 22

KDRF140A

Use SST( 09221-4A000 ), install main bearing

ECKD324A cap bolts.

6. Place crankshaft on the cylinder block.

09221 - 4A000

KDRF224A

KDRF210A 2) Check that the crankshaft turns smoothly.

7. Place main bearing caps on cylinder block. 9. Check crankshaft end play. (Refer to EM - 65)
8. Install main bearing cap bolts.
10. Install piston and connecting rod assemblies.
1) Install and uniformly tighten the bearing cap
bolts, in several passes, in the sequence shown. NOTE
Before installing the pistons, apply a coat of engine oil
Tightening torque
to the ring grooves and cylinder bores.
Main bearing cap bolt
49.00Nm(5.0 kgf.m, 36.16lb-ft) + 90 (1 ~ 8)
1) Install the ring compressor, check that the bear-
19.60 Nm(2.0 kgf.m, 14.46lb-ft)+ 120 (9 ~ 16)
ing is securely in place, then position the piston in
29.40 ~ 31.36Nm(3.0 ~ 3.2 kgf.m, 21.70 ~
the cylinder, and tap it in using the wooden han-
23.14lb-ft) (17 ~ 22)
dle of a hammer.
ENGINE BLOCK EM -73

2) Stop after the ring compressor pops free, and 11. Check the connecting rod end play.(Refer to EM - 61)
check the connecting rod-to-check journal align-
ment before pushing the piston into place. 12. Install oil drain cover.

3) Apply engine oil to the bolt threads. Install the Tightening torque
rod caps with bearings, and torque the bolts. 8.8 ~ 10.8Nm (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0lb-ft)

Tightening torque
19.6Nm (2.0kgf.m, 14.46lb-ft) + 90

Use SST(09221-4A000), install connecting rod

bearing cap bolts.

09221 - 4A000 A

KDRF209A

NOTE
• Make clean the sealing face before assembling
two parts.
• Remove harmful foreign matters on the sealing
KDRF225A
face before applying sealant
• Be assembling oil drain cover, the liquid sealant
NOTE TB1217H should be applied oil drain cover.
• Always use new connecting rod bearing cap bolt. • The part must be assembled within 5 minutes
• Maintain downward force on the ring compressor after sealant was applied.
to prevent the rings from expanding before enter- • Apply sealant to the inner threads of the bolt
ing the cylinder bore. holes.

ECBF003A

ECKD001F
EM -74 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

13. Install rear oil seal case.

Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.67lb-ft) 09231-3C200

09231-H1100

KDRF237A

15. Install baffle plate.

Install and uniformly tighten the baffle plate bolts, in
several passes, in the sequence shown.
A

Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
KDRF208A

NOTE
• Make clean the sealing face before assembling
two parts. 1 6 11 10 7 2
• 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 4 5 12 9 8 3
after sealant was applied.
• Apply sealant to the inner threads of the bolt
holes. KDRF135A

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(0.1in.)

KDRF218A

14. Using SST(09231-3C200, 09231-H1100), install rear

oil seal.

KDRF130A
ENGINE BLOCK EM -75

NOTE INSTALLATION EC9DBCE3

• Make clean the sealing face before assembling 1. Install power steering pump.
two parts.
• Remove harmful foreign matters on the sealing 2. Install alternator.
face before applying sealant
• When applying sealant gasket, sealant must not 3. Install air conditioner compressor
be protruded into the inside of oil pan.
• To prevent leakage of oil, apply sealant gasket ot 4. Install oil filter assembly.(Refer to EM - 95)
the inner threads of the bolt holes.
5. Install oil pump.(Refer to EM - 94)
e. Install upper oil pan. 6. Install cylinder head.(Refer to EM - 52)
Uniformly tighten the bolts in several passes.
7. Install water temperature control assembly.(Refer to
Tightening torque EM - 81)
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
8. Install timing chain.(Refer to EM - 32)

9. Install intake manifold.(Refer to EM - 104)

2
3 6 11 15 14 10 1
10. Install exhaust manifold.(Refer to EM - 104)

4 5 12 16 13 9 8
7

KDRF131A

17. Install knock sensor.

Tightening torque
15.68 ~ 23.52Nm (1.6 ~ 2.4kgf.m, 11.57 ~ 17.36lb-ft)

KDRF205A

18. Install drive plate.

Tightening torque
71.54 ~ 75.46Nm (7.3 ~ 7.7kgf.m, 52.80 ~ 55.69lb-ft)
EM -76 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

COOLING SYSTEM
COMPONENT E6DF76AB

18.62 ~ 23.52 (1.9 ~ 2.4, 13.74 ~ 17.36)

9.8 ~ 11.76 (1.0 ~ 1.2, 7.23 ~ 8.68)

21.56 ~ 23.52 (2.2 ~ 2.4, 15.91 ~ 17.36)

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, lb-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
ECBF013A
COOLING SYSTEM EM -77

4.9 ~ 7.8
(0.5 ~ 0.8, 3.6 ~ 5.8)

TORQUE : N.m (kgf.m, lb-ft)

1. Radiator
2. Radiator fan
ECBF004A
EM -78 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

ENGINE COOLANT REFILLING AND 7. Start the engine and run coolant circulates.
When the cooling fan operates and coolant circulates,
BLEEDING ED42148D
refill coolant through the radiator cap.
WARNING 8. Repeat 7 until the cooling fan 3 ~ 5times and bleed air
Never remove the radiator cap when the engine is sufficiently out of the cooling system.
hot. Serious scalding could be caused by hot fluid
under high pressure escaping from the radiator. 9. Install the radiator cap and fill the reservoir tank to the
"MAX" line with coolant.

CAUTION 10. Run the vehicle under idle until the cooling fan oper-
When pouring engine coolant, be sure to shut the ates 2 ~ 3 times.
relay box lid and not to let coolant spill on the
11. Stop the engine and wait coolant gets cool.
electrical parts or the paint. If any coolant spills,
rinse it off immediately. 12. Repeat 6 to 11 until the coolant level doesn’t fall any
more, bleed air out of the cooling system.
1. Make sure the engine and radiator are cool to the
touch.
NOTE
2. Remove radiator cap. As it is to bleed air out to the cooling system and refill
coolant when coolant gets cool completely, recheck
3. Loosen the drain plug, and drain the coolant.
the coolant level in the reservoir tank for 2 ~ 3 days
4. Tighten the radiator drain plug securely. after replacing coolant.

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 upper/lower hoses
of the radiator so as bleed air easily.

NOTE
• 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.

CAUTION
• Do not mix different brands of an-
tifreeze/coolants.
• Do not use additional rust inhibitors or an-
tirust products; they may not be compatible
with the coolant.
COOLING SYSTEM EM -79

CAP TESTING TESTING

1. Remove the radiator cap, wet its seal with engine 1. Wait until engine is cool, then carefully remove the
coolant, then install it no pressure tester. radiator cap and fill the radiator with engine coolant,
then install it on the pressure tester.

KCRF184A

2. Apply a pressure tester to the radiator and apply

a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm² 14
ECKD501X
~18psi).
2. Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm²,
14 ~ 19psi) 3. Inspect for engine coolant leaks and a drop in pres-
sure.
3. Check for a drop in pressure.
4. Remove the tester and reinstall the radiator cap.
4. If the pressure drops, replace the cap.
NOTE
Check for engine oil in the coolant and/or coolant in
the engine oil.
EM -80 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

REMOVAL EECA3D1E 4. Remove the water pump(A) and gasket.

WATER PUMP

1. Drain the engine coolant.

A
WARNING
System is under high pressure when the engine is
hot. To avoid danger of releasing scalding engine
coolant, remove the cap only when the engine is
cool.

2. Remove drive belt(A).

KDRF221A

KDRF101A

3. Remove the 4 bolts and pump pulley(A).

KDRF107A
COOLING SYSTEM EM -81

WATER TEMPERATURE CONTROL ASSEMBLY THERMOSTAT

1. Drain the engine coolant. NOTE

2. Remove air cleaner assembly.(Refer to EM - 17) Removal of the thermostat would have an adverse
effect, causing a lowering of cooling efficiency. 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(B).

A

KDRF148A

4. Disconnect WTS connector.(Refer to EM - 20)

5. Disconnect heater hose, water vent hose and water

hose from water temperature control assembly.
KDRF195A
6. Remove wiring protector.

7. Remove water temperature control assembly(A).

KDRF194A
EM -82 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

RADIATOR

1. Drain the engine coolant. 6. Remove the radiator bracket(A).

2. Remove the air duct(A).

A
A

KCBF142A

KCBF143A 7. Remove the radiator(A).

3. Disconnect radiator upper and lower hoses(A). A

KCBF142B

KDRF148A
8. Remove the radiator fan(A).
4. Disconnect transaxle oil cooler hoses.(Refer to TR
group)

5. Disconnect the radiator fan connector(A).

A
A

KCBF142C

KCBF159A
COOLING SYSTEM EM -83

INSPECTION EEE5DC80 THERMOSTAT

WATER PUMP 1. Immerse the thermostat in water and gradually

heatthe water.
1. Check each part for cracks, damage or wear, and re-
place the coolant pump assembly if necessary.

2. Check the bearing for damage, abnormal noise and

sluggish rotation, and replace the coolant pump as-
sembly if necessary.

3. Check for coolant leakage. If coolant leaks from hole,

the seal is defective. Replace the coolant pump as-
sembly.

NOTE
A small amount of "weeping" from the bleed hole is
normal.
ECKD503B

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 valve lift.

Valve lift : Min. 10mm (0.4in.) at 95 C (205 F)
If the valve lift is not as specified, replace the thermo-
stat.
EM -84 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

INSTALLATION EFD4FFC4 3. Install drive belt(A).

WATER PUMP

1. Install the water pump(A) and a new gasket(B) with

12 bolts.

Tightening torque A
21.56 ~ 23.52Nm (2.2 ~ 2.4kgf.m, 15.91 ~ 17.36lb-ft)
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

KDRF101A

4. Fill with engine coolant.

5. Start engine and check for leaks.

6. Recheck engine coolant level.

A

KDRF221B

NOTE
Make clean the contact face before assembly.

2. Install the 4 bolts and pump pulley(A).

Tightening torque
7.84 ~ 9.80Nm (0.8 ~ 1.0kgf.m, 5.78 ~ 7.23lb-ft)

KDRF107A
COOLING SYSTEM EM -85

WATER TEMPERATURE CONTROL ASSEMBLY 6. Install air cleaner assembly.

NOTE 7. Fill with engine coolant.

Make clean the contact face before assembly. 8. Start engine and check for leaks.

1. Install water temperature control assembly(B) and 9. Recheck engine coolant level.
new gasket(A).

Tightening torque
18.62 ~ 23.52Nm (1.9 ~ 2.4kgf.m, 13.74 ~ 17.36lb-ft)

KDRF194B

NOTE
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).

KDRF148A
EM -86 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

THERMOSTAT RADIATOR

1. Place thermostat in thermostat housing. 1. Install the radiator fan(A) to the radiator.

1) Install the thermostat with the jiggle valve up-

ward.

2) Install a new thermostat(B).

A
A

KCBF142C

2. Install the radiator(A).

A
KDRF195A

2. Install water inlet(A).

Tightening torque
16.66 ~ 19.60Nm (1.7 ~ 2.0kgf.m, 12.30 ~ 14.47lb-ft)

3. Fill with engine coolant.

4. Start engine and check for leaks.

KCBF142B

3. Install the radiator bracket(A).

KCBF142A
COOLING SYSTEM EM -87

4. Reconnect the radiator fan connector(A). 8. Fill with engine coolant.

9. Start engine and check for leaks.

10. Recheck engine coolant level.

KCBF159A

5. Connect transaxle oil cooler hoses.(Refer to TR

group)

6. Connect radiator upper and lower hoses(A).

KDRF148A

7. Install the air duct(A).

KCBF143A
EM -88 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

LUBRICATION SYSTEM
COMPONENT E35BD1AA

9.80 ~ 11.76
(1.0 ~ 1.2, 7.23 ~ 8.68)

18.62 ~21.56
(1.9 ~ 2.2, 13.74 ~ 15.91)

20.6 ~ 22.6 (2.1 ~ 2.3, 15.2 ~ 16.6)

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, lb-ft)

1. Oil filter cap 6. Gasket 11. Oil pump sprocket

2. O - ring 7. O - ring 12. Oil pump chain cover
3. Oil filter element 8. Gasket 13. Lower oil paon
4. Oil filter body 9. Oil pump
5. Oil filter body cover 10. Gasket
ECBF005A
LUBRICATION SYSTEM EM -89

OIL AND FILTER EEB0D5C9 e. Install new oil filter element(A) and two new
O-rings(B).
CAUTION
• Prolonged and repeated contact with mineral
oil will result in the removal of natural fats
from the skin, leading to dryness, irritation B
and dermatitis. In addition, used engine oil
contains potentially harmful contaminants
which may cause skin cancer. A
• 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 water-less hand cleaner,
to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
• In order to preserve the environment, used oil KDRF188A
and used oil filter must be disposed of only at
designated disposal sites. f. Apply clean engine oil to the new O-rings.
Lightly screw the oil filter cap into place, and
1. Park the car on level ground. tighten it until the O-ring contacts the seat.
Start the engine and let it warm up. g. Finally tighten it again by specified tightening
torque.
2. Turn the engine off and open the hood.
Remove the engine cover. Tightening torque
24.50Nm (2.5kgf.m, 18.08lb-ft)
3. Wait for 5minutes after loosening the oil filter cap by
turning it counterclockwise with SST(09263-3C100)
to drain well the oil in the oil filter. 6. Refill with engine oil.
a. Install the oil drain plug with a new gasket.

09263-3C100 Tightening torque

34.3 ~ 44.1Nm (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)

b. Fill with fresh engine oil, after remove the engine

oil level gauge.

Capacity
Total : 6.4L(6.76U.S.qts,5.63lmp.qts)
Oil pan : 5.5L(5.81U.S.qts,4.84lmp.qts)
Oil filter : 0.4L(0.42U.S.qts,0.35lmp.qts)
Drain and refill : 5.2L(5.49U.S.qts,4.58lmp.qts)

ECRF051A c. Install the oil filler cap and oil level gauge.

4. Drain the engine oil. 7. Start the engine and check to be sure no oil is leaking
a. Remove the oil filler cap. from the drain plug or oil filter.
b. After lifting the car, remove the oil drain plug and
drain the oil into a container. 8. Recheck engine oil level.

5. Replace oil filter.

a. Disconnect the oil filter cap from oil filter body.
b. Remove the oil filter element.
c. Check and clean the oil filter installation surface.
d. Check the part number of the new oil filter is as
same as old one.
EM -90 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

INSPECTION

1. Check engine oil quality.

Check the oil for deterioration, entry of water, discol-
oring 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.

NOTE
Do not fill with engine oil above the "F" mark.
LUBRICATION SYSTEM EM -91

SELECTION OF ENGINE OIL If 5W-20 engine oil is not available, 5W-30 or secondary
recommanded engine oil for carrespanding temperature
Recommended API classification : Above SJ or SL range can be used.
Recommended SAE viscosity grades : 5W-20

Temperature range
anticipated before Recommended SAE viscosity number
next oil change

10W

- 30

5W

- 20

- 30

EDRF020A

NOTE
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.
EM -92 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

REMOVAL EEB453AF 4. Remove oil pump chain sprocket(A).

OIL PUMP

1. Drain engine oil.

2. Using SST(09215-3C000) remove lower oil pan(A).

09215 KDRF189A
-3C000
5. Remove oil pump(A).

ECRF060A

CAUTION
Be careful not to damage the contact surfaces of
upper oil pan and lower oil pan. A

3. Remove oil pump chain cover(A).

KDRF190A

KDRF185A
LUBRICATION SYSTEM EM -93

OIL FILTER ASSEMBLY INSPECTION E9C606A4

1. Loosen the oil filter cap by turning it counterclockwise OIL PRESSURE SWITCH
to drain well the oil in the oil filter.
1. Check the continuity between the terminal and the
2. Remove surge tank and intake manifold.(Refer to EM body with an ohmmeter.
- 100) If there is no continuity, replace the oil pressure
switch.
3. Disconnect oil pressure switch connector.(Refer to
EM - 19)

4. Drain the engine coolant.

5. Disconnect water hoses from ETC.

6. Remove water temperature control assembly.(Refer

to EM - 81)

7. Disconnect water vent hose(A).

8. Remove oil filter body cover(B).

ECKD001W

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
A switch.

B 3. If there is no continuity when a 50kpa (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.
KDRF191A

9. Remove oil filter body.(A).

ECKD001Y

KDRF192A

NOTE
Be careful of the knock sensor connector.
EM -94 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

INSTALLATION EF2EDF0E 3. Install oil pump chain cover(A).

OIL PUMP Tightening torque

9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
1. Install oil pump(A).

Tightening torque
20.6 ~ 22.6Nm (2.1 ~ 2.3kgf.m, 15.2 ~ 16.6lb-ft)

NOTE
Always use a new O-ring(B).

KDRF185A

B
4. Install lower oil pan.
a. Using a gasket scraper, remove all the old pack-
A ing material from the gasket surfaces.
b. Before assembling the oil pan, the liquid sealant
TB1217H should be applied on upper oil pan.
The part must be assembled within 5 minutes
KDRF222A
after the sealant was applied.
2. Install oil pump sprocket(A)and oil pump chain on the
oil pump. Bead width : 2.5mm(0.1in.)
But marked area(＊) to be 5.0mm(0.2in.)
Tightening torque
18.62 ~ 21.56Nm (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)

KDRF136A

KDRF189A CAUTION
• 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 oil, apply sealant gas-
ket ot the inner threads of the bolt holes.
LUBRICATION SYSTEM EM -95

e. Install lower oil pan. OIL FILTER ASSEMBLY

Uniformly tighten the bolts in several passes.
1. Install oil filter body(A) and new O-rings.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

KDRF114A
KDRF192A

f. After assembly, wait at least 30 minutes before

filling the engine with oil. NOTE
• All rubber gasket must be no damaged by assem-
bling parts.
• Be careful of the knock sensor connector.
• Always use a new O-ring

2. Install oil filter body cover(B) and new gasket on the

oil filter body.

Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

KDRF191A
EM -96 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

3. Connect water vent hose(A)

Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

4. Install water temperature control assembly.(Refer to

EM - 81)

5. Connect water hoses on the ETC.

6. Connect oil pressure switch connector.(Refer to EM -

19)

7. Install intake manifold and surge tank.(Refer to EM -

104)

8. Fill with engine coolant.

9. Start engine and check for leaks.

10. Recheck engine coolant level.

INTAKE AND EXHAUST SYSTEM EM -97

INTAKE AND EXHAUST

SYSTEM
COMPONENT ECD3DA39

[3.3L] [3.8L]
9.80 ~ 11.76
(1.0 ~ 1.2, 7.23 ~ 8.68)

18.62 ~ 23.52
(1.9 ~ 2.4,
13.74 ~ 17.36)

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, lb-ft)

1. Surge tank 4. Intake manifold

2. Surge tank gasket 5. Intake manifold gasket
3. Delivery pipe
ECBF026A
EM -98 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

39.2 ~ 44.1
(4.0 ~ 4.5, 28.92 ~ 32.53)

16.66 ~ 21.56
(1.7 ~ 2.2, 12.29 ~ 15.91)

TORQUE : N.m (kgf.m, lb-ft)

1. Gasket 3. Heat protector

2. Exhaust manifold
ECBF014A
INTAKE AND EXHAUST SYSTEM EM -99

39.2 ~ 58.8 (4.0 ~ 6.0, 28.92 ~ 43.37)

39.2 ~ 58.8 (4.0 ~ 6.0, 28.92 ~ 43.37)

TORQUE : N.m (kgf.m, lb-ft)

1. Catalytic converter 4. LH muffler

2. Center muffler 5. Gasket
3. Main muffler 6. Rubber hanger
ECBF015A
EM -100 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

REMOVAL E689CFFB 4. Disconnect RH injector connector(A) and ignition coil

connector(B).
INTAKE MANIFOLD

1. Disconnect AFS(A) and breather hose(B).

2. Remove air cleaner upper cover(D) and intake

hose(C).

D
C

B
KDRF153A

A
5. Disconnect PCSV connector(A), MAP sensor connec-
tor(B) and PCSV hose.

B
KDRF173A

3. Disconnect RH oxygen sensor connector(A).

A
A

KDRF160A

6. Disconnect ETC connector(A) and knock sensor con-

nector(B).

KDRF151A

KDRF162A
INTAKE AND EXHAUST SYSTEM EM -101

7. Remove ETC bracket(A). 12. Remove connector bracket(A) from surge tank.

8. Disconnect water hoses(B) from ETC.

9. Disconnect PCV(C) hose.

B A
KDRF178A

13. Remove surge tank(A).

KDRF176A [3.3L]
A
10. Disconnect brake vacuum hose.

11. Remove surge tank stay(A).

[3.3L]

A ECBF029A

[3.8L]

ECBF027A

[3.8L] B

A ECBF030A

ECBF028A
EM -102 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

14. Disconnect breather pipe assembly(A). EXHAUST MANIFOLD

1. Remove under cover(A).

A
A

ECBF031A

15. Disconnect LH injector connector. KCBF101A

16. Remove delivery pipe(A). 2. Disconnect LH,RH rear oxygen sensor connector
from bracket.

3. Remove front muffler(A).

A
A

KDRF181A

17. Remove intake manifold(A) and gasket.

KCBF102A

KDRF182A
INTAKE AND EXHAUST SYSTEM EM -103

4. Remove oil level gauge(A). 8. Disconnect RH front oxygen sensor connector from
bracket.
5. Disconnect LH front oxygen sensor connector(B) from
bracket.

A A

KDRF177B

KDRF183A 9. Remove RH heat protector.

6. Remove LH heat protector(A). 10. Remove RH exhaust manifold.

KDRF184A KDRF187A

7. Remove LH exhaust manifold.

EM -104 ENGINE (G6DB/G6DA - GSL 3.3/3.8)

INSTALLATION E5F3CD1A

INTAKE MANIFOLD
7. Install surge tank stay.
1. Install intake manifold and new gasket on the cylin-
der head. Pre-tighten all bolts by 3.9 ~ 5.9Nm (0.4 ~ Tightening torque
0.6kgf.m, 2.9 ~ 4.3lb-ft) and then tighten by the spec- 27.44 ~ 31.36Nm (2.8 ~ 3.2kgf.m, 20.25 ~ 23.14lb-ft)
ified torque.

Tightening torque 8. Connect brake vacuum hose.

18.62 ~ 23.52Nm (1.9 ~ 2.4kgf.m, 13.74 ~ 17.36lb-ft)
9. Connect PCV hose.

NOTE 10. Connect water hoses to ETC.

Be careful of the installation direction.
11. Install ETC bracket.

Tightening torque
15.68 ~ 25.48Nm (1.6 ~ 2.6kgf.m, 11.57 ~ 18.80lb-ft)

12. Connect ETC connector and knock sensor connector.

7 3 2 5 13. Connect PCSV connector, MAP sensor connector

and PCSV hose.

14. Connect RH injector connector and ignition coil con-

nector.
6 1 4 8
15. Connect RH oxygen sensor connector.

16. Install air cleaner upper cover and intake hose.

17. Connect AFS(A) and breather hose.

EXHAUST MANIFOLD
EDQF164A
1. Install new gasket and exhaust manifold.
2. Install delivery pipe.(Refer to FL group)
Tightening torque
3. Connect LH injector connector. 39.2 ~ 44.1Nm(4.0 ~ 4.5kgf.m, 28.92 ~ 32.53lb-ft)

4. Connect breather pipe assembly.

2. Install heat protector.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) Tightening torque
16.66 ~ 21.56Nm(1.7 ~ 2.2kgf.m, 12.30 ~ 15.91lb-ft)
5. Install surge tank.
3. Install front muffler.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) Tightening torque
39.2 ~ 58.8N.m(4.0 ~ 6.0kgf.m, 28.92 ~ 43.37lb-ft)
6. Install connector bracket on the surge tank.
4. Connect oxygen sensor connector.
Tightening torque
6.86 ~ 10.78Nm (0.7 ~ 1.1kgf.m, 5.06 ~ 7.96lb-ft)
5. Install under cover.