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ENGINE MECHANICAL SECTION EM

1. GI Tool name Description Spark plug wrench Removing and installing spark plug MA NT047 Pulley holder Holding camshaft pulley while tightening or LG loosening camshaft bolt EG NT035 Valve seat cutter set Finishing valve seat dimensions FE CL NT048 Piston ring expander Removing and installing piston ring MT AT NT030 Valve guide drift Removing and installing valve guide TF Diameter mm in T Braus PD a 10 5 0 413 b 6 6 0 260 NTO15 P Valve guide reamer Reaming valve guide or hole for over size valve guide 2 BA Intake d 7 0 mm 0 276 in dia E d 11 2 mm 0 441 in dia BR Exhaust d 8 0 mm 0 315 in dia NTO16 d 12 2 mm 0 480 in dia ST Camshaft oil seal drift Installing camshaft oil seal RS a j a 60 mm 2 36 in dia BT c b 44 5 mm 1 752 in dia NT613 c 75 mm 2 95 in Front oil seal drift Installing front oil seal HA X a a 52 mm 2 05 in dia NT049 b 44 mm 1 73 in dia DX Tool name Rear oil seal drift PREPARATION Commercial Service Tools Cont d Description Installing rear oil seal Q Hp tl dh a 46 mm 1 81 in e b 110 mm 4 33 in c 84 mm 3 31 in WEM152 d 96 mm 3 78 in EM 6 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING Noise Vibration and Harshness NVH Tappet noise AN o Chain tensioner 3 i Camshaft V
2. Go to SUP6 1st Rev Vol ENGINE MECHANICAL SECTION E M zm G a MODIFICATION NOTICE e VG33E engine has been introduced for Australia EC e A T models with QD32 engine have been introduced for Latin America For information not included here refer to information for QD32 engine in D22 series Supplement Il Service Manual Pub No SM9E D22BG0 i GL MT VG33E Removal mm mrrrmmmmserevvvvvvsvsssssvevever 29 PRECAUTIONS Ludde 2 edle ET A Paris Bisa liing Angular Tightehlhig re cn 2 Rasa p p Liquid Gasket Applicallon Procedure ce 2 ly EE qe PREPARATION 3 InstallatiOn icri rettet enten 41 KEN p cs du E ENGINE REMOVAL 46 Special Service Tools 3 Removal 47 ER Semics De 5 REMOVAI ns PD NOISE VIBRATION AND HARSHNESS NVH ner pa TROUBLESHOOTING eese 7 inspection ix I ME 49 Noise Vibration and Harshness NVE asocia 7 ie Bi FA OUTER COMPONENT PARTS TT 9 Ves COMPRESSION PRESSURE 13 BA Measurement of Compression Pressure 13 QD32 OPNE 14 ENGINE REMOVAL ss 60 R MOVAL teet he E 14 CYLINDER BLOCK ess 61 BR INSAIANON a coiere tete ertet tee 16 ASer 62 TIMING BELT eee nn nrnnnnnnnnnnnnnnnnen 18 RemMOVAI iii 19 4 v se 1 ST aor reri o om
3. EM 63 SERVICE DATA AND SPECIFICATIONS SDS VALVE T Margin thickness Inspection and Adjustment Cont d Hydraulic valve lifter Unit mm in Lifter outside diameter Lifter guide inside diameter Unit mm in 15 947 15 957 0 6278 0 6282 16 000 16 013 0 6299 0 6304 Clearance between lifter and lifter guide Valve guide 0 043 0 066 0 0017 0 0026 Standard Unit mm in Service SEM188 Valve guide f 11 023 11 034 11 223 11 234 Valve h AD RARE Der Intake 0 4340 0 4344 0 4418 0 4423 Intake 41 95 42 25 1 6516 1 6634 diameter ru TT EET Exhaust 34 95 35 25 1 3760 1 3878 0 4733 0 4738 0 4812 0 4817 Valve length L Valve guide Intake 124 15 124 45 Inner Intake 7 000 7 018 0 2756 0 2763 4 8878 4 8996 diameter Finished Exhaust 122 85 123 15 size Exhaust 8 000 8 018 0 3150 0 3157 4 8366 4 8484 TS insita 10 975 10 996 11 175 11 196 Valve stem diameter d Cylinder head 0 4321 0 4329 0 4400 0 4408 valve guide hole Intake 6 965 6 980 0 2742 0 2748 aac ey 11 975 11 996 12 175 12 196 Exhaust 7 962 7 970 0 3135 0 3138 0 4715 0 4723 0 4793 0 4802 Valve seat angle a i Intake ar een ko 0 027 0 059 0 0011 0 0023 Intake valve guide Exhaust 45 15 45 45 Exhaust Standard Max tolerance Valve margin T Intake
4. Fuel feed hose M 9 Remove intake manifold from engine loosen the bolts in numerical order as shown Refer to OUTER COMPO NENT PARTS The following parts should be disconnected to remove intake manifold a Engine coolant temperature switch harness connector b Thermal transmitter harness connector c Water hose from thermostat housing Loosen bolts in numerical order 10 Remove both of the camshaft sprockets 11 Remove rear timing belt cover 12 Remove distributor and ignition wires After removing distributor from cylinder head do not rotate distributor rotor 13 Remove harness clamp from RH rocker cover 14 Remove front exhaust tube from exhaust manifold Refer to EXHAUST SYSTEM in SEM819C EM 30 CYLINDER HEAD Removal Cont d 15 Remove A C compressor and alternator Refer to HA and Eu Cylinder block o 21 6 29 4 sections bed n 16 Remove A C compressor and alternator bracket GI MA A C compressor and alternator N LC EG FE compressor 43 2 57 8 L 4 4 5 8 O 21 6 29 4 7 43 2 57 8 CL 32 42 2 2 2 9 4 4 5 8 16 21 32 42 E MT CaA SEMO83H 17 Remove power steering oil pump Refer to ST section ir Power steering x ard 18 Remove power steering oil pump bracket oil pump 12 15 NC A en TE amp ER in 9 15 7 20 6 NX a a Power steering FA 1 6 2 1 v P
5. c i A S Insulator1 9 AX O AX 19 2 9 3 8 4 0 30 0 39 26 0 33 9 e Fuel pressure regulator Injector fuel tube assembly 1 Ignition wire AG Insulator e pu i7 J 1 4 1 7 10 12 hg 6 3 8 3 Spark plug 0 65 0 84 56 73 C 19 6 29 4 2 00 3 00 Distributor support 14 46 21 69 1 Refer to Injector in EC section 2 Do not disassemble 8 Be sure not to contact adjacent parts Always replace after every disassembly Apply genuine liquid 9 1 6 2 1 12 15 Fan pulley Ig 5 9 9 8 0 6 1 0 52 86 Fan coupling Cooling fan gasket or equivalent lel 5 9 9 8 Nem kg m in Ib 0 6 1 0 52 86 Nem kg m ft Ib SEM136H EM 10 OUTER COMPONENT PARTS MA Rear heater return pipe j 8 4 10 7 0 86 1 1 75 95 ES T 9 8 4 10 7 J 0 86 1 1 75 95 TU i EC le Front heater return pipe GL MT AT Oil filter stud TF 0 29 4 39 2 di 3 0 3 9 22 28 d PD 9 15 7 20 6 FA 1 6 2 1 12 15 P d E D v ab Power steering oil pump adjusting bar BR Oil filter OJ 15 21 1 6 2 1 11 15 Refer to Changing Oil Filter in MA section Power steering oil pump bracket ST 9 15 7 20 6 RS 1 6 2 1 12 15 Apply genuine liquid gasket or equivalent BT e Always replace after every disassembly Ie Nem kg m
6. 0 0722 0 0723 SERVICE DATA AND SPECIFICATIONS SDS No 4 main bearing Inspection and Adjustment Cont d Grade Thickness T Identification number mm in color 1 817 1 821 0 0 0715 0 0717 Black 1 821 1 825 Brow 0 0717 0 0719 1 825 1 829 0 0719 0 0720 Green 1 829 1 833 3 0 0720 0 0722 Yellow 4 1 833 1 837 Blue 0 0722 0 0723 Main bearing 0 25 mm 0 0098 in undersize Unit mm in No 1 main bearin 1 990 1 302 g 0 0770 0 0772 Thickness T No 2 3 and No 4 main 1 948 1 956 bearings 0 0767 0 0770 AVAILABLE CONNECTING ROD BEARING Connecting rod bearing undersize Standard 1 502 1 506 0 0591 0 0593 Bearing clearance Main bearing clearance No 1 bearing Standard Limit No 2 3 and No 4 bearings Standard Limit Unit mm in 0 030 0 048 0 0012 0 0019 0 060 0 0024 0 038 0 065 0 0015 0 0026 0 080 0 0031 Connecting rod bearing clearance Standard Limit 0 014 0 054 0 0006 0 0021 0 090 0 0035 Unit mm in Crank pin journal diameter Dp 49 961 49 974 1 9670 1 9675 Undersize 0 08 0 0031 0 12 0 0047 0 25 0 0098 1 542 1 546 0 0607 0 0609 1 562 1 566 0 0615 0 0617 1 627 1 631 0 0641 0 0642 MISCELLANEOUS COMPONENTS Flywheel Drive plate Runout TIR Unit mm in Less than 0 15 0 0059 Camshaft sprocket Runout TIR Les
7. 1 8504 1 8514 l 416 418 Inner diameter of 42 500 42 525 ss UNI 1 646 dia camshaft bearing 1 6732 1 6742 Unit mm in SEM755A 48 000 48 025 u 1 8898 1 8907 AT 46 920 46 940 _ Exhaust valve seat CRE RON Outer diameter of 42 420 42 440 m TE camshaft journal 1 6701 1 6709 Standard 47 920 47 940 1 8866 1 8874 PD Camshaft runout Less than 1 0 004 1 7 0 067 TIR 0 04 0 0016 WT 10 004 Camshaft end pla GS 0108 FA per 0 0012 0 0024 RA 2 32 5 32 7 s 1 280 1 287 dia 34 4 34 6 BR 1 354 1 362 dia A Oversize 0 5 0 0201 RO 3 0 5 ST 0 012 0 020 37 500 37 516 1 4764 1 4770 dia Cylinder head EM671 RS Cam height A Intake 39 242 39 432 1 5450 1 5524 BT Exhaust 38 943 39 133 1 5332 1 5407 Wear limit of cam height 0 15 0 0059 HA Total indicator reading 34 4 34 6 1 354 1 362 dia EL Unit mm in SEM756A DX EM 65 SERVICE DATA AND SPECIFICATIONS SDS Inspection and Adjustment Cont d CYLINDER BLOCK CONNECTING ROD Unit mm in Unit mm in Center distance Bend torsion per 100 3 94 154 1 154 2 6 067 6 071 Limit Bend 0 15 0 0059 Torsion 0 30 0 0118 Piston pin bushing inner f 20 982 20 994 0 8261 0 8265 diameter Connecting rod big end 53 000 53 013 2 0866 2 0871 inner diameter Side
8. Install intake manifold Install all parts which were removed in step 9 under CYLIN DER HEAD Removal e If only intake manifold is removed and to be used again install it using the following procedure 1 Tighten all bolts and nuts to 4 N m 0 4 kg m 35 in lb 2 Tighten all bolts and nuts to 9 N m 0 9 kg m 80 in lb 3 Tighten all bolts and nuts to 8 to 10 N m 0 8 to 1 0 kg m 71 to 88 in lb CAUTION If replacing intake manifold with a new one cylinder head gasket must also be replaced with a new one Refer to Step 4 15 Install injector fuel tube assembly Refer to Injector in section 16 Connect all injector harness connectors 17 Install fuel feed and fuel return hoses to injector fuel tube assembly 18 Install intake manifold collector Install all parts which were removed in step 5 under CYLIN DER HEAD Removal 19 Install accelerator control wire Refer to Adjusting Accelerator Wire in 20 Check hydraulic valve lifter a Push plunger forcefully with your finger e Be sure to check it with rocker arm in its free position not on the lobe b If valve lifter moves more than 1 mm 0 04 in air may be inside it c Bleed air off by running engine at 1 000 rpm under no load for about 10 minutes d If hydraulic valve lifters are still noisy replace them and bleed air off again in the same manner as in step 20 c 21 Install remaining parts in reverse order of re
9. PD F ST RS EL DX Sealing point e PP SEM894BB Tube presser SEM310F Cut here 7 mm 0 28 in Liquid gasket Bolt hole SEM015E Groove Inner side AEM080 OIL PAN Installation 1 D Before installing oil pan remove all traces of liquid gasket from mating surface using a scraper Also remove traces of liquid gasket from mating surface of cyl inder block Apply liquid gasket to oil pan gasket and rear oil seal retainer gasket Use Genuine Liquid Gasket or equivalent Apply a continuous bead of liquid gasket to mating surface of oil pan using tube presser SST WS39930000 Use Genuine Liquid Gasket or equivalent Be sure liquid gasket is 3 5 to 4 5 mm 0 138 to 0 177 in wide Apply liquid gasket to inner sealing surface as shown in figure EM 16 OIL PAN Installation Cont d 5 Install the oil pan o Tighten the oil pan bolts to specification in numerical order as GI gt shown in the figure e Attaching should be done within 5 minutes after coating Wait at least 30 minutes before refilling engine oil MA Install remaining parts in reverse order of removal oe LG EG TF PD F EM 17 TIMING BELT CAUTION a Do not bend or twist timing belt b After removing timing belt do not turn crankshaft and camshaft separately because valves will strike p
10. ROCKER SHAFT AND ROCKER ARM AT 1 Check rocker shafts for scratches damage and wear 2 Check outer diameter of rocker shaft Diameter TE 17 979 18 000 mm 0 7078 0 7087 in PD F SEM761A 3 Check inner diameter of rocker arm BA Diameter 18 007 18 028 mm 0 7089 0 7098 in 4 Calculate rocker arm to shaft clearance by outer diameter of BR rocker shaft and inner diameter of rocker arm Rocker arm to shaft clearance 0 007 0 040 mm 0 0003 0 0016 in ST CAUTION Keep rocker arm with hydraulic valve lifter standing to prevent air from entering hydraulic valve lifter when checking RS SEM762A 3 HYDRAULIC VALVE LIFTER BT 1 Check contact and sliding surfaces for wear or scratches 2 Check the outer diameter of valve lifter H Outer diameter 15 947 15 957 mm 0 6278 0 6282 in SEM243E EM 39 Wide pitch Narrow pitch V Cylinder head side SEM638B Knock pin SEM834B SEM280A Rocker shaft direction Exhaust TE LT fal 19 RH cylinder head front LH cylinder E head front QI To fol Te Tol lie Intake SEM835BA CYLINDER HEAD Inspection Cont d 3 Check valve lifter guide inner diameter Valve lifter guide inner diameter 16 000 16 013 mm 0 6299 0 6304 in 4 Calculate clearance between valve lifter and valve lifter gu
11. 0 9 kg m 80 in Ib 14 Tighten intake manifold bolts and nuts to 8 to 10 N m 0 8 to 1 0 kg m 71 to 88 in Ib EM 42 CYLINDER HEAD Installation Cont d If only intake manifold is removed and to be used again install it using the following procedure GI 1 Tighten all bolts and nuts to 4 N m 0 4 kg m 35 in lb 2 Tighten all bolts and nuts to 9 N m 0 9 kg m 80 in lb 3 Tighten all bolts and nuts to 8 to 10 N m 0 8 to 1 0 kg m MA 71 to 88 in Ib CAUTION If replacing intake manifold with a new one cylinder head gasket must also be replaced Refer to step 4 Tighten bolts in Le numerical order SEM825C 6 Install both rocker covers in numerical order as shown Rocker cover bolt EG W 1 3 Nm 0 1 0 3 kg m 9 26 in Ib Right bank B Engine front a Left bank GL DOES MT SEM317FA 7 Install A C compressor and alternator bracket AT Cylinder block 0 21 6 29 4 g Install alternator and A C compressor Refer tolELland HA sec 2 2 2 9 16 21 tions TE D A C compressor PD and alternator O 15 7 17 7 1 6 1 8 P 12 13 M od RA D adjusting ARS bar f 9 14 0 17 0 1 5 1 7 BR 11 12 compressor 0 43 2 57 8 m SU 4 4 5 8 0 21 6 29 4 4 43 2 57 8 32 42 2 2 2 9 4 4 5 8 16 21 32 42 RS Nem kg m ft lb r2 Tem SEMO83H BY HA EL DX EM 43 CYLINDER HEAD Installation Cont
12. 9 i EGR control 9 I ns N valve EX Ecrc 8PT E V ci A R B Ww valve 1 i Purge connectors aS Throttle D 39 2 54 8 Q opener Fa 9 4 0 5 5 i Gasket oio 29 40 A ne AAC i l 35 45 EGR guide assembly W 6 4 6 26 tube 21 27 3 6 4 6 26 33 MT 2 1 2 8 s 20 re 2028 70 86 To heater 105805 0 99 70 286 AT f To water pipe Gasket e 1 0 1 1 i 6 5 8 0 7 8 0 7 0 8 61 69 2nd 18 22 E os Liquid gasket L pr Heater pipe 3 Refer to Installation of PD To radiator CYLINDER HEAD Thermal transmitter Intake manifold 3 19 20 Gasket C3 FA 1 5120 TESTEM 0 20 29 2 0 3 0 14 22 16 21 1 6 2 1 12 15 i o Engine coolant RA temperature sensor O Refer to Installation Le of CYLINDER HEAD To LH Copper washer 3 BR To RH rocker cover RA rocker cover ST RS BT HA e Always replace after every disassembly Apply genuine liquid gasket or equivalent EL ll Nem kg m in Ib 9 Nem kg m ft lb DX SEM082H EM 9 OUTER COMPONENT PARTS SEC 164210221 19 8 4 10 8 0 9 1 1 75 95 7 ist 4 9 6 0 Fuel feed hose assembly 0 50 0 61 3 7 4 4 2 9 3 8 2nd ne ats 0 30 0 39 26 0 33 9 ii Fuel return hose Fuel injector cap 1 m el 5 1 6 4 ne end eA Y 0 52 0 65 45 1 56 4 G Q xD O ring Fuel injector 1 Q
13. Attach tags to valve lifters so as not to mix them up Removal 1 Release fuel pressure Refer to Releasing Fuel Pressure in 2 Remove timing belt Refer to Removal 3 Drain the engine coolant by removing drain plugs from both sides of cylinder block EM 29 Gi MA TF PD F U RA ST RS EL DX CYLINDER HEAD Removal Cont d 4 Separate accelerator control wire from intake manifold collec tor Refer to 5 Remove intake manifold collector from engine Refer to EM 9 OUTER COMPONENT PARTS The following parts should be disconnected to remove intake manifold collector a Harness connectors for IACV AAC valve Throttle position sensor Throttle position switch Distributor and EGRC solenoid valve Water hoses from collector Heater hoses PCV hose from RH rocker cover Vacuum hoses for EVAP canister Master brake cylinder and Pressure regulator Purge hose from EVAP canister EGR tube Earth harnesses Air duct hose EGRC solenoid valve N 9205 gear Water hose EGR solenoid valve EGR tube SEM339FA 6 Remove fuel feed and fuel return hoses from injector fuel tube IE ESN assembly EG e Ce pee ee Disconnect all injector harness connectors TR 109 L gt Remove injector fuel tube assembly Refer to Injector in EC E ON 4 Up 9 2 Injector harness connector Fuel return NG SEM817C
14. as necessary Installation 1 Confirm that the No 1 piston is set at TDC on the compression stroke 2 Install the tensioner and tensioner spring e Once the stud is removed apply a locking sealant to the threads of the stud on cylinder block side before installing 3 Turn the tensioner fully outward with a hexagon wrench and temporarily tighten the lock nut 4 Setthe timing belt when the engine is cold 1 Point the arrow on timing belt toward the front of the belt cover 2 Align the white lines on the timing belt with the punch marks on the camshaft sprockets and crankshaft sprocket EM 21 Gi MA LG 2j TF PD F U RA ST RS EL DX AEM440 98 N W iio kg 22 1b Co O Camshaft Camshaft sprocket sprocket LH RH Tensioner pulley Timing belt Crankshaft sprocket SEM744DA SEM886B TIMING BELT Installation Cont d Number of timing belt teeth for installation reference Total number of timing belt teeth 133 Between LH and RH camshaft sprockets 40 Between LH camshaft sprocket and crankshaft timing 43 sprocket 5 Install the remaining parts in the reverse order of removal Number of teeth between timing marks Tension Adjustment AFTER BELT REPLACEMENT NOTE If the timing belt was replaced or to adjust tension on a used belt follow this procedure 1 Loosen the tensioner
15. clearance Standard 0 20 0 35 0 0079 0 0138 Limit 0 40 0 0157 SEM321A After installing in connecting rod Surface flatness Limit 0 10 0 0039 Cylinder bore Inner diameter Standard No 1 No 2 and No 6 cylinders Grade No 1 91 500 91 510 3 6024 3 6027 Grade No 2 91 510 91 520 3 6027 3 6031 Grade No 3 91 520 91 530 3 6031 3 6035 Standard No 3 and No 4 cylinders Grade No 1 91 500 91 505 3 6024 3 6026 Grade No 2 91 505 91 510 3 6026 3 6027 Grade No 3 91 510 91 515 3 6027 3 6029 Grade No 4 91 515 91 520 3 6029 3 6031 Grade No 5 91 520 91 525 3 6031 3 6033 Grade No 6 91 525 91 530 3 6033 3 6035 Standard No 5 cylinder Grade No 1 91 515 91 520 3 6029 3 6031 Grade No 2 91 520 91 525 3 6031 3 6033 Grade No 3 91 525 91 530 3 6033 3 6035 Grade No 4 91 530 91 535 3 6035 3 6037 Grade No 5 91 535 91 540 3 6037 3 6039 Grade No 6 91 540 91 545 3 6039 3 6041 Wear limit 0 20 0 0079 Out of round difference between X and Y Less than 0 015 0 0006 Taper difference between A Less than 0 015 0 0006 and C Main journal inner diam eter No 1 main journal Grade No 3 66 645 66 651 2 6238 2 6240 Grade No 4 66 651 66 657 2 6240 2 6243 Grade No 5 66 657 66 663 2 6243 2 6245 Grade No 6 66 663 66 669 2 6245 2 6248 No 2 3 and 4 main journals Grade No 0 66 645 66 654
16. differential carrier bleeder hose Refer to PD sec tion in original Service Manual Remove differential front mounting bolts RH amp LH Refer to PD section in original Service Manual Remove front differential carrier Refer to PD section in original Service Manual Remove front differential carrier mounting bracket Refer to PD section in original Service Manual Remove idler arm Refer to ST section in original Service Manual Remove starter motor Refer to EL section in original Service Manual Hoist engine with engine slingers and support transmission with transmission jack Refer to EM 48 ENGINE REMOVAL and Remove transmission i d engine mounting bracket nuts RH amp LH Refer to ENGINE REMOVAL Remove engine mounting bolts or nuts RH amp LH Refer to ENGINE REMOVAL Remove engine gussets Refer to EM 48 ENGINE REMOVAL Lift up engine Refer to EM 46 ENGINE REMOVAL If necessary disconnect exhaust tube Refer to Exhaust Sys tem in FE section Loosen oil pan bolts in numerical order as shown in the figure Remove oil pan Insert seal cutter SST between cylinder block and oil pan Do not drive seal cutter into oil pump or rear oil seal retainer portion or aluminum mating face will be damaged Do not insert screwdriver or oil pan flange will be deformed Slide Tool by tapping its side with a hammer and remove oil pan EM 15 MA LG EG TF
17. grade number SEM508A No 4 journal No 3 grade number 2 SEM167B CYLINDER BLOCK Inspection Cont d 4 Measure outer diameter Dm of each crankshaft main journal as shown 5 Calculate main bearing clearance No 1 main bearing clearance A Dm Standard 0 030 0 048 mm 0 0012 0 0019 in Limit 0 060 mm 0 0024 in No 2 3 and No 4 main bearing clearance A Dm Standard 0 038 0 065 mm 0 0015 0 0026 in Limit 0 080 mm 0 0031 in 6 If it exceeds the limit replace bearing 7 f clearance cannot be adjusted within the standard of any bearing grind crankshaft journal and use undersized bearing a When grinding crankshaft journal confirm that L dimension in fillet roll is more than the specified limit L 0 1 mm 0 004 in b As necessary grind the crankshaft journals to specification or replace with an available service part Refer to EM 57 CRANKSHAFT 8 If crankshaft is reused measure main bearing clearances and select thickness of main bearings If crankshaft is replaced with a new one it is necessary to select thickness of main bearings as follows a Grade number of each cylinder block main journal is punched on the respective cylinder block These numbers are punched in either Arabic or Roman numerals b Grade number of each crankshaft main journal is punched on the respective crankshaft These numbers a
18. in Ib HA 9 Nem kg m ft lb EL DX SEM147H EM 11 OUTER COMPONENT PARTS VG33E SEC 140 fy 5 1 6 5 0 52 0 66 45 1 57 3 9 5 1 6 5 0 52 0 66 45 1 57 3 0 39 49 4 0 5 0 29 36 RH exhaust manifold cover RH exhaust manifold 7 re DS EGR tube ic I Ny f i Gasket e 9l 5 1 6 5 z 0 52 0 66 45 1 57 3 Stud bolt 74 9 13 17 1 3 1 7 9 12 C2 28 33 2 9 3 4 21 25 A G 2 oun ha 0 52 0 66 45 1 57 3 LH exhaust manifold Stud bolt 9 13 17 1 3 1 7 9 12 0 28 a3 2 9 3 4 21 25 LH exhaust manifold cover Stud bolt mn 10 Cylinder head side D e Always replace after every disassembly i Nem kg m in lb W Nem kg m ft lb SEM307FA EM 12 COMPRESSION PRESSURE 20 mm 0 79 in dia Use compressor tester whose end rubber portion is less than 20 mm 0 79 in dia Otherwise it may be caught by cylinder head during removal SEM387C Measurement of Compression Pressure 1 2 3 pe 10 11 Warm up engine Turn ignition switch off Release fuel pressure Refer to procedure without CONSULT II of Releasing Fuel Pressure in ectio Remove fuel pump fuse until the end of step 10 Remove all spark plugs Clean the area around plug with compressed air before remov ing the spark plug Disconnect the camshaft position sens
19. is applied to the knock sensor replace it with new one After installing knock sensor connect sub harness and lay it out to rear of engine REPLACING PILOT BUSHING L 2 Remove pilot bushing using SST or suitable tool as shown Install pilot bushing as shown using suitable drift EM 59 MA TF PD F ENGINE REMOVAL SEC 112 310 320 4WD models 9 ke 42 51 Insulator 4 2 5 3 31 38 9 31 42 3 2 4 3 23 31 Engine mounting bracket Rear engine 3 31 42 mounting member 3 2 4 3 23 31 9 42 51 Insulator a 4 2 5 3 31 38 p 31 42 3 2 4 3 23 31 O Nem kg m ft Ib SEM150H EM 60 CYLINDER BLOCK SEC 110 120 130 135 150 313 16 21 Gil U 1 6 2 1 12 15 Rear plate M T models Engine revolution Rear oil seal retainer assembly A e Rear plate Upper MA sensor 2 3 A T models Gasket 4 Gasket e O ring e 8 89 5 6 8 4 Cylinder block d 0 57 0 85 use gt 2040 2 6 3 6 19 26 Gasket 3 C 4 Oil j Over Idler gear i il pump EI ol alas oS Idler gear shaft FY NS e v mJ KYAT fy SOSH 2 p S 0 54 0 74 47 64 Front plate Camshaft Gasket e bushing lal Oil jet F4 6 CR so 6 2 1952 Rear plate 4 Lower Washer Dy 3 A T model
20. lock nut then turn tensioner clockwise and counterclockwise with a hexagon wrench at least two times 2 Tighten the tensioner lock nut 3 Turn the crankshaft clockwise a full rotation at least two times then slowly set the No 1 piston at TDC on the compression stroke 4 Measure the deflection of the timing belt midway between the camshaft sprockets while pushing with the specified force as shown Belt deflection when engine is cold reference value 13 15 mm 0 51 0 59 in at 98 N 10 kg 22 Ib force 5 Ifthe belt deflection is not within specification return to step 1 and repeat the procedure AFTER ENGINE OVERHAUL OR ENGINE REASSEMBLY WITH ROCKER COVERS REMOVED NOTE If the engine was overhauled or previously disassembled i e intake manifold or cylinder head were removed follow this timing belt tension adjustment procedure 1 Loosen the rocker shaft bolts to relieve the belt tension caused by the camshafts 2 Loosen the tensioner lock nut keeping the tensioner steady with a hexagon wrench EM 22 TIMING BELT Tension Adjustment Cont d 3 Turn the tensioner 70 to 80 degrees clockwise with a hexa gon wrench to release the belt tension and temporarily tighten GI the lock nut 4 Turn the crankshaft clockwise at least twice then slowly set the No 1 piston at TDC on the compression stroke MA LG 5 Push the middle of the timing belt between RH camshaft sprocket and tensioner pulley with
21. or equivalent SEM861CB Left side m 2 pu d zc pus Apply genuine liquid gasket or equivalent Drain plug SEM862CB RH exhaust Q manifold LH exhaust NO 9 i manifold E s Tighten in numerical order SEM318FB Cylinder head bolt washer Cylinder head side SEM877A CYLINDER HEAD Installation Set No 1 piston at TDC on its compression stroke as follows Align crankshaft sprocket aligning mark with mark on oil pump 1 a b body Confirm that knock pin on camshaft is set at the top Install both drain plugs Apply sealant to drain plug threads Apply genuine liquid gas ket or equivalent Drain plug 34 44 Nm 3 5 4 4 kg m 25 32 ft Ib Install exh manifolds to cylinder head Refer to OUTER COMPONENT PARTS for tightening torque Install cylinder head with new gasket Be sure to install washers between bolts and cylinder head with the beveled side up as shown Do not rotate crankshaft and camshaft separately or valves will hit piston heads EM 41 Gi MA LG TF PD F ST RS EL DX Cylinder head bolt L Le E Cera 1 FIT SEM348F TIGHTENING METHOD o Nem EE Q 22 Ze 32 5 S29 S5 GE E 9 5 SEM143H KV101 12100 EMM0603D CYLINDER HEAD Installatio
22. or piston ring assembly Piston PISTON RING END GAP Presa With the piston ring on top of the piston insert the piston and ring into the cylinder bore as shown Measure the piston ring gap End gap Top ring 0 21 0 40 mm 0 0083 0 0157 in 2nd ring 0 50 0 69 mm 0 0197 0 0272 in Oil ring 0 20 0 69 mm 0 0079 0 0272 in Max limit of ring gap Top ring 0 54 mm 0 0213 in 2nd ring 0 80 mm 0 0315 in Oil ring 0 95 mm 0 0374 in a If out of specification replace piston ring If gap still exceeds the limit even with a new ring rebor linder and use oversized pis ton and piston rings Refer to Piston ring CAUTION When replacing the piston check the cylinder block surface for scratches or seizure If scratches or seizure is found hone or replace the cylinder block Bend CONNECTING ROD BEND AND TORSION Feeler gauge Bend r Limit 0 15 mm 0 0059 in per 100 mm 3 94 in length Torsion Limit 0 30 mm 0 0118 in per 100 mm 3 94 in length If it exceeds the limit replace connecting rod assembly SEM038F EM 50 CYLINDER BLOCK Inspection Cont d Torsion Feeler gauge MA SEMOOSF LG CYLINDER BLOCK DISTORTION AND WEAR 1 Clean upper face of cylinder block and measure the distortion EG Limit 0 10 mm 0 0039 in FE GL MT SEM394E 2 If out of specification resurface the cylinder block sealing sur AT face The resurf
23. replace after every disassembly SEMO086H EM 48 SEM326F N P aid heater kr OY nM M al order p Loosen in numeric SEM551E SEM684E CYLINDER BLOCK CAUTION When installing sliding parts such as bearings and pistons be sure to apply engine oil on the sliding surfaces Place removed parts such as bearings and bearing caps in their proper order and direction When installing connecting rod bolts and main bearing cap bolts apply new engine oil to threads and seating sur faces Disassembly PISTON AND CRANKSHAFT 1 2 3 4 oo Place engine on a work stand SST Drain engine coolant and engine oil Refer to Changing Engine Oil and Changing Engine Coolant in Remove oil pan and oil pump Refer to Removal Remove timing belt Refer to Checking Drive Belts in section Remove water pump Refer to Water Pump in ILC section Remove cylinder head Refer to EM 29 Removal Remove pistons with connecting rods When disassembling piston and connecting rod remove snap ring first then heat piston to 60 to 70 C 140 to 158 F or use piston pin press stand at room temperature CAUTION 8 When piston rings are not replaced make sure that piston rings are mounted in their original position and direction When replacing piston rings install them with the punch mark facing u
24. the specified force 98 N 10 EG kg 22 Ib to apply tension on part A and part B of the tim ing belt as shown Camshaft Camshaft 6 Loosen the tensioner lock nut keeping the tensioner steady FE sprocket sprocket with a hex n wrench ei au e th a hexago enc 10 kg 22 Ib GL Tensioner pulley Timing belt Crankshaft MT sprocket AEM446 7 Position a feeler gauge size 0 5 mm 0 0206 in thick and 12 7 AT Crankshaft mm 0 500 in wide under the tensioner pulley as shown sprocket TF Timing Tensioner belt PD pulley Feeler lt a gauge FA SEM240E 8 Turn the crankshaft clockwise until the feeler gauge is posi R tioned between the tensioner pulley and the timing belt as shown e The timing belt will move about 2 5 teeth BR 9 Tighten the tensioner lock nut keeping the tensioner steady with a hexagon wrench 10 Turn the crankshaft clockwise or counterclockwise to remove ST the feeler gauge 11 Turn the crankshaft clockwise at least two full rotations then slowly set the No 1 piston at TDC on the compression stroke RS NG NG OK Feeler gauge sprocket SEM889BA 98 N 12 Measure the deflection of the timing belt midway between the BT 10 kg 22 w camshaft sprockets while pushing with a force of 98 N 10 kg 22 lb as shown Belt deflection when engine is cold Reference value FA 13 15 mm 0 51 0 59 in at 98 N 10 kg 22 Ib Camshaft force sproc
25. 0 020 0 053 Valve to valve 0 0008 0 0021 Intake 1 15 1 45 0 0453 0 0571 0 10 0 0039 guide clearance 0 030 0 049 Exhaust Exhaust 1 35 1 65 0 0531 0 0650 Valve margin T limit More than 0 5 0 020 Valve stem end surface grinding limit Less than 0 2 0 008 Valve clearance Intake Exhaust Valve spring Free height mm in 50 47 1 9870 Pressure N kg Ib at height Installation 349 380 35 6 38 8 78 5 85 4 at 40 0 1 575 mm in Out of square Valve open 770 837 78 5 85 4 173 1 188 2 at 30 0 1 181 mm in 2 0 0 079 Valve deflection limit 0 0012 0 0019 E 0 20 0 0079 Rocker shaft and rocker arm Rocker shaft Outer diameter Rocker arm Inner diameter Clearance between rocker arm and rocker shaft EM 64 Unit mm in 17 979 18 000 0 7078 0 7087 18 007 18 028 0 7089 0 7098 0 007 0 040 0 0003 0 0016 SERVICE DATA AND SPECIFICATIONS SDS Inspection and Adjustment Cont d Intake valve seat CAMSHAFT AND CAMSHAFT BEARING Unit mm in Standard l MA 41 6 41 8 1 638 1 646 dia LG Oversize 0 5 0 020 3 0 5 bo 0 020 44 500 44 516 1 7520 1 7526 dia EG SEM893BA 1 75 0 0689 Standard Max tolerance FE Camshaft journal to bear 0 060 0 105 ing clearance 0 0024 0 0041 QT 9 0099 47 000 47 025 GL
26. 2 6238 2 6242 Grade No 1 66 654 66 663 2 6242 2 6245 Grade No 2 66 663 66 672 2 6245 2 6249 Difference in inner diam eter between cylinders Standard Less than 0 05 0 0020 EM 66 SERVICE DATA AND SPECIFICATIONS SDS Inspection and Adjustment Cont d PISTON PISTON RING AND PISTON PIN Piston ring Available piston oy Gl Unit mm in Standard Limit Side clearance MA d 0 024 0 076 Top 0 0009 0 0030 0 11 0 0043 0 030 0 070 L 2nd 0012 0 0028 0 1 0 004 a Oil 0 015 0 190 u 0 0006 0 0075 LG Ring gap 0 21 0 40 T 0 0083 0 0157 0 54 0 0213 EC 0 50 0 69 2nd 0 0197 0 0272 0 80 0 0315 z m kn 0 20 0 69 Piston skirt diameter A i irt di Oil rail ring 0 0079 0 0272 0 95 0 0374 Standard No 1 No 2 G and No 6 cylinders i m Piston pin Grade No 1 91 465 91 475 3 6010 3 6014 ve Unit mm in Grade No 2 91 475 91 485 3 6014 3 6018 MT Piston pin outer diameter pe Grade No 3 91 485 91 495 3 6018 3 6022 0 8256 0 8261 Standard No 3 4 and Interference fit of piston pin to pis 0 0 004 0 0 0002 A 5 cylinders ton Grade No 2 1 91 480 91 485 3 6016 3 6018 Piston pin to connecting rod bush i l Grade No 3 2 91 485 91 490 3 6018 3 6020 A een TF Grade No 3 3 91 490 91 495 3 60
27. 20 3 6022 Standard ed ade No 290 91 495 3 6020 3 6022 0 0002 0 0007 a D Grade No 4 4 91 495 91 500 3 6022 3 6024 Limit 0 023 0 0009 PD Grade No 4 5 91 500 91 505 3 6024 3 6026 Values measured at ambient temperature of 20 C 68 F Grade No 5 6 91 505 91 510 3 6026 3 6027 FA 0 29 0 0098 91 715 91 745 3 6108 3 6120 oversize Service D 030 0 01 37 91 965 91 995 3 6207 3 6218 RA oversize Service a dimension 49 0 1 929 BR Grade No 0 Piston pin hole diameter d 20 969 20 975 0 8255 0 8258 Grade No 1 20 975 20 981 0 8258 0 8260 ST Piston to cylinder bore clearance RS Standard No 1 No 2 0 025 0 045 0 0010 0 0018 and No 6 cylinders i Standard No 3 and 4 i i BY cylinders 0 015 0 025 0 0006 0 0010 Standard No 5 cylin 0 030 0 040 0 0012 0 0016 der HA EM 67 SERVICE DATA AND SPECIFICATIONS SDS Inspection and Adjustment Cont d AVAILABLE MAIN BEARING CRANKSHAFT Unit mm in Main journal dia Dm No 1 main journal Grade No 3 62 969 62 975 2 4791 2 4793 Grade No 4 62 963 62 969 2 4789 2 4791 Grade No 5 62 957 62 963 2 4786 2 4789 Grade No 6 62 951 62 957 2 4784 2 4786 No 2 3 and 4 main journals Grade No 0 62 967 62 975 2 4790 2 4793 Grade No 1 62 959 62 967 2 4787 2 4790 Grade No 2 62 951 62 959 2 4784 2 4787 Pin jour
28. 20 naboer 21 SERVICE DATA AND SPECIFICATIONS SDS 63 RS Tension AdjuSMEN traces 22 General Specifications 63 OIL SEAL REPLACEMENT 25 Inspection and Adjustment ici scans 63 CYLINDER HEAD LL 28 BT FA EL DX EM 1 Groove Bolt hole SEM371C Inner side AEM080 PRECAUTIONS Parts Requiring Angular Tightening Use an angle wrench for the final tightening of the following engine parts 1 Cylinder head bolts 2 Connecting rod cap nuts Do not use a torque value for final tightening The torque value for these parts are for a preliminary step Ensure thread and seat surfaces are clean and coated with engine oil Liquid Gasket Application Procedure a Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves Also completely clean any oil stains from these portions Apply a continuous bead of liquid gasket to mating sur faces Use Genuine Liquid Gasket or equivalent e Be sure liquid gasket is 3 5 to 4 5 mm 0 138 to 0 177 in dia for oil pan e Be sure liquid gasket is 2 0 to 3 0 mm 0 079 to 0 118 in dia in areas except oil pan Apply liquid gasket to inner surface around hole perimeter area unless otherwise specified Assembly should be done within 5 minutes after coating Wait at least 30 minutes before refilling engine oil and engine coolant EM 2 Tool number Tool name ST0501S000 PREPARAT
29. 59 gear hole 5 5 6 0 40 43 DX SEM151H EM 61 Drive plate Engine front a Reinforcement plate Adapter drive plate Crankshaft R Rounded Pilot converter SEM149H CYLINDER BLOCK Assembly Drive plate assembly A T models Install drive plate as follows Install reinforcement plate so that the peripheral area R faces drive plate side Fix crankshaft with a ring gear stopper SST Tighten mounting bolts diagonally in several steps EM 62 SERVICE DATA AND SPECIFICATIONS SDS General Specifications Unit kPa bar kg cm psi 300 rpm GI Cylinder arrangement V 6 Compression pressure Displacement cm cu in 3 275 199 84 Standard 1 196 11 96 12 2 173 MA Bore and stroke mm in 91 5 x 83 3 602 x 3 27 Minimum 883 8 83 9 0 128 Valve arrangement OHC o Differential limit between cylinders 98 0 98 1 0 14 Firing order 1 2 3 4 5 6 a Number of piston rings Compression 2 Valve timing LG Oil 1 Number of main bearings 4 EC Compression ratio 8 9 gt amp FE Cylinder number g S Hr Le Yo GL Ea py pot gt Ate Q gt MT EM120 Unit degree a b c d e f d 240 244 4 60 9 51 SEM713A TF PD F Inspection and Adjustment RA CYLINDER HEAD Unit mm in BR Standard Limit NES Less than ST Head surface distortion 0 03 0 0012 0 1 0 004 RS BT Height j Height nominal HA 106 8 107 2 4 205 4 220 SEM082B EL DX
30. ION Special Service Tools Description Disassembling and assembling Engine stand assembly D ST05011000 Engine stand ST05012000 Base NT042 KV10106500 Engine stand shaft NTO28 KV10110001 Engine sub attachment irs g E NT032 i ST10120000 Loosening and tightening cylinder head bolt Oylinder head bolt wrench a 13 0 51 dia b 12 0 47 c 10 0 39 NT583 Unit mm in KV10112100 Tightening bearing cap cylinder head bolts Angle wrench etc NTO14 KV10110600 Disassembling and assembling valve compo Valve spring compressor EN nents S NT033 g KV10107501 Installing valve oil seal Valve oil seal drift NT025 EM 3 MA LG EG TF PD F EL DX Tool number Tool name KV10110300 Piston pin press stand assembly KV10110310 Cap KV10110330 Spacer ST13030020 Press stand ST13030030 Spring 8 KV10110340 Drift 8 KV10110320 Center shaft PREPARATION Special Service Tools Cont d Description Disassembling and assembling piston with connecting rod NT036 EM03470000 Piston ring compressor ST16610001 Pilot bushing puller KV10111100 Seal cutter Installing piston assembly into cylinder bore NT044 Removing crankshaft pilot bushing NT045 Removing oil pan NT046 WS39930000 Tube presser Pressing the tube of liquid gasket NT052 EM 4 PREPARATION Commercial Service Tools
31. Refer to EM 53 BEARING CLEARANCE S No 1 PD No 2 No 3 Lower main bearing FA No 4 SEM208E 2 Install crankshaft and main bearing caps and tighten bolts to R the specified torque e Prior to tightening bearing cap bolts place bearing cap in its proper position by shifting crankshaft in the axial direc BB tion e Tighten bearing cap bolts gradually in two or three stages Start with center bearing and move outward sequentially ST e After securing bearing cap bolts make sure crankshaft turns smoothly by hand e Lubricate threads and seat surfaces of the bolts with new RS engine oil 3 Measure crankshaft end play BT Crankshaft end play Standard 0 050 0 170 mm 0 0020 0 0067 in FA Limit 0 30 mm 0 0118 in If beyond the limit replace No 4 bearing with a new one EL DX EM 57 SEM159B EM03470000 or suitable TA PBIC0921E SEM338F CYLINDER BLOCK Assembly Cont d 4 Install connecting rod bearings in connecting rods and connect ing rod caps e Confirm that correct bearings are used Refer to Connecting rod bearing Big end e Install bearings so that oil hole in connecting rod aligns with oil hole of bearing as shown 5 Install pistons with connecting rods using SST or suitable tool as shown a Install them into corresponding cylinders with SST o
32. U JA QI eg bearing noise LG Timing chain F and chain p tensioner noise A m A lt EG YT dI NEM E GL MT AT TF Water pump noise PD FA D Drive belt RA noise slipping BR A C compressor Idler pulley pulley Water pump pulley Connecting AS Piston slap A rod bearing noise noise BT Power steering HA oil pump pulley Alternator pulley EL Crank pulley DX Main bearing noise SEM141H EM 7 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING Noise Vibration and Harshness NVH Cont d NVH TROUBLESHOOTING CHART ENGINE NOISE Use the chart below to help you find the cause of the symptom 1 Locate the area where noise occurs 2 Confirm the type of noise 3 Specify the operating condition of engine 4 Check specified noise source If necessary repair or replace these parts Operating condition of engine o E S 2 2 Ref 5 2 ci guion si Type of noise amp E 2 5 S Source of noise Check item ens noise z 5 5 amp page ol Flelele oa o O O o o a E x E E m lt Top of engine Ee Tappet noise Hydraulic valve lifter EM agl Rocker cover Cylinder head Rattle Camshaft bearing Camshaft journal clearance EM 35 noise Camshaft runout EM 34l Piston and piston pin clearance Enea Slap or knock Piston pin noise Connecting rod bushing clear EM 56 ance Small end Piston to bore clearance EM 51l Crankshaft pul NS Piston slap noise PiSton ri
33. acing limit is determined by cylinder head resurfac ing required TE Amount of cylinder head resurfacing is A Amount of cylinder block resurfacing is B The maximum limit is as follows PD A B 0 2 mm 0 008 in Nominal cylinder block height from crankshaft center F 227 60 227 70 mm 8 9606 8 9645 in 3 If necessary replace cylinder block PISTON TO BORE CLEARANCE RA 1 Using a bore gauge measure cylinder bore for wear out of round and taper Out of round difference between X and Y standard BY 0 015 mm 0 0006 in Taper difference between A and C standard 0 015 mm 0 0006 in FA If it exceeds the limit rebore all cylinders Replace cylinder block if necessary Refer to CYLINDER BLOCK 2 Check for scratches and seizure If seizure is found hone it EL Unit mm in SEM321AA EM 51 Piston grade number and ring set SEM557A Front mark Piston grade No SEM399F SEM258C CYLINDER BLOCK Inspection Cont d e f both cylinder block and piston are replaced with new ones select piston of the same grade number punched on cylinder block upper surface Refer to EM 67 Available piston Combination grade number for cylinder bore and piston Except for No 1 2 For No 3 4 and 5 oylinders and 6 cylinders Oylinder bore grade No Piston grade No 3 Measure piston skirt diameter Pis
34. al rubber 3 fe 5 9 7 9 0 61 0 80 53 69 S ee Oil pump cover Front oil seal TK EF e DEN S Gasket e Gasket e AE 8 Regulator valve F1 a y TT Spring 0 16 17 Oil strainer Outer rotor al Oil pump body cet 9 shim 1 6 1 7 11 6 12 3 A 9 83 93 8 5 9 5 61 69 9 6 3 8 3 8 Regulator plug 19 6 4 7 5 0 66 0 76 57 66 0 64 0 85 0 39 69 s s 8 3 Flywheel 0 22 29 55 6 73 8 4 7 29 51 0 64 0 85 55 6 73 8 2 2 3 0 16 22 9 21 26 2 1 2 7 15 20 4 Rear oil seal retainer Rear oil seal Rear plate cover en Oil level Pilot bushing gauge guide KE Main bearing E Snap ring 2 Select proper thickness GAL te e 954 72 q Piston pin Ki 0 55 0 73 47 7 63 4 l 9 5 4 7 2 Connecting rod E 0 55 0 73 Connecting rod bearing al GB Bit 200 Crankshaft FY Main bearing cap Connecting rod cap Engien rear rubber Oil pan Fal d EE 20 100 9 2 10 2 67 74 Tighten or loosen in two or three stages ra Refer to Assembly 1 3 0 4 0 22 29 Oil pan side gasket e Chamfer j Engien rear rubber Piston pin Apply genuine liquid E iude gasket or equivalent Oil pan i Nem kg m in Ib gasket 2 Q O Nem kg m ftlb fy 6 3 8 3 Nem kg m ft Ib Drain plug 0 64 0 85 A Lubricate with new engine oil 29 39 55 6 73 8 Always
35. d 9 Install power steering oil pump bracket and power steering oil Power steering r2 ve Me pump Refer to BT section oil pump 12 15 10 Install exhaust front tube to exhaust manifold Refer to un EXHAUST SYSTEM in i 1 6 2 1 amp f y Power steering 12 15 oil pump bracket p E v P il Power steering d 2 oil pump adjusting bar 11 Install rear belt cover and camshaft sprocket Refer to EM 18 TIMING BELT e RH camshaft sprocket and LH camshaft sprocket are dif ferent parts Be sure to install them in the correct location Identification mark e ENGINE RH camshaft sprocket R3 0 53 FRONT LH camshaft sprocket L3 3 27 12 Install timing belt and adjust belt tension Refer to EM 21 SEM303A Installation 13 Install distributor 1 Align mark on shaft with protruding mark on housing Distributor drive gear Mark on shaft Mark on housing protruding Mark on housing indented SEM837B 2 After installing confirm that distributor rotor head is set as shown in figure Vi Rotor head position No 1 cylinder at TD o SEM337F EM 44 Tighten bolts in numerical order SEM825C Ne ENKE PE ar D 999 000 D p em S S y Fuel feed hose SEM817C Injector harness connector SEM531A CYLINDER HEAD Installation Cont d 14
36. d to 150 to 160 C 302 to 320 F by soaking in heated oil 4 Press fit valve seat until it seats on the bottom of the valve seat bore WARNING Cylinder head contains heat When working wear protective equipment to avoid getting burned 5 Cut or grind valve seat using suitabl at the specified dimensions as shown in SDS Refer to EMA VALVE 6 After cutting lap valve seat with abrasive compound 7 Check valve seating condition Intake Exhaust Seat face angle a degree 45 45 Contacting width W mm in 1 75 0 0689 1 7 0 067 VALVE DIMENSIONS Check dimensions in each valve Refer to EM 64 VALVE When valve head has been worn down to 0 5 mm 0 020 in in margin thickness replace valve Grinding allowance for valve stem tip is 0 2 mm 0 008 in or less EM 38 CYLINDER HEAD Inspection Cont d VALVE SPRING s Squareness GI 1 Measure S dimension of the valve spring against a right angle tool for out of square as shown MA Out of square e Less than 2 0 mm 0 079 in RU 2 If it exceeds the limit replace spring ew SEM207E LG Pressure 1 Check valve spring pressure EG Pressure Installation 349 380 N 35 6 38 8 kg 78 5 85 4 Ib at E height 40 0 mm 1 575 in Valve open G 770 837 N 78 5 85 4 kg 173 1 188 2 Ib at gt height 30 0 mm 1 181 in 2 If not within specification replace the valve spring MT EM113
37. e Valve spring o y of CYLINDER HEAD s Evano oil seal Valve guide O O seat 3 Valve spring seat Exhaust valve FA ko 6 3 8 3 0 65 0 84 56 73 Cylinder head rear cover Rear cover gasket e 0 78 88 8 0 9 0 58 65 Camshaft locate plate LH cylinder head Gasket 2 e mm Cylinder head E Washer 1 i Cylinder block 2 Cylinder head gasket identification for VG33E cor LH camshaft Camshaft front oil seal KG 3 Be sure to align cut portion to cylinder head bolt N m kg m in ib 9 Nem kg m ft lb lal Lubricate with new engine oil Always replace after every disassembly SEM139H EM 28 SEM870BA Apply genuine liquid gasket or equivalent sma207Cc Left side D 1 W PA Apply genuine liquid gasket or equivalent Drain plug SMA208CB CYLINDER HEAD CAUTION e When installing sliding parts such as rocker arms cam shaft and oil seal be sure to apply new engine oil on their sliding surfaces e When tightening cylinder head bolts and rocker shaft bolts apply new engine oil to thread portions and seat surfaces of bolts e If hydraulic valve lifter is kept on its side there is a risk of air entering it After removal always set hydraulic valve lifter straight up or when laying it on its side have it soak in new engine oil e Do not disassemble hydraulic valve lifter e
38. earing clearance C Dp Standard FA 0 014 0 054 mm 0 0006 0 0021 in Limit 0 090 mm 0 0035 in EL 6 If it exceeds the limit replace the connecting rod bearing 7 f clearance cannot be adjusted within the standard of any DX bearing grind crankshaft journal and use undersized bearing m Refer to EM 53 Main bearing EM 55 SEM673E SEM062A AEM100 CYLINDER BLOCK Inspection Cont d Method B Using plastigage CAUTION e Do not turn crankshaft or connecting rod while plastigage is being inserted e When bearing clearance exceeds the specified limit ensure that the proper bearing has been installed Then if excessive bearing clearance exists use a thicker main bearing or undersized bearing so that the specified bear ing clearance is obtained CONNECTING ROD BUSHING CLEARANCE Small end 1 Measure inner diameter C of the connecting rod small end 2 Measure outer diameter Dp of piston pin bushing 3 Calculate connecting rod bushing clearance Connecting rod bushing clearance C Dp Standard 0 005 0 017 mm 0 0002 0 0007 in Limit 0 023 mm 0 0009 in If it exceeds the limit replace connecting rod assembly or connect ing rod bushing and or piston set with pin REPLACEMENT OF CONNECTING ROD BUSHING Small end 1 Drive in small end bushing into the rod until it is flush with end surface of rod CAUTION Be sure to ali
39. gn the oil holes 2 After driving in small end bushing ream the bushing so that clearance between connecting rod bushing and piston pin is the specified value Clearance between connecting rod bushing and pis ton pin 0 005 0 017 mm 0 0002 0 0007 in FLYWHEEL DRIVE PLATE RUNOUT Runout Total indicator reading Flywheel Less than 0 15 mm 0 0059 in CAUTION Do not surface flywheel Replace as necessary EM 56 CYLINDER BLOCK Assembly PISTON GI 1 Install new snap ring on one side of piston pin hole 2 Heat piston to 60 to 70 C 140 to 158 F and assemble piston MA piston pin connecting rod and new snap ring e Align the direction of piston and connecting rod e Numbers stamped on connecting rod and cap correspond to each cylinder e After assembly make sure connecting rod swings KS Front mark ET Engine front Oil hole Cylinder number Me smoothly LG Stamped mark 3 Set piston rings as shown Oil ring expander go e Install the second ring with the stamped surface facing upward EG mamng DE Standard mark 2 N second ring Top ring mating Oil ring upper FE rail mating 90 CL Oil ring lower ring mating 90 rail mating MT SEM148H Upper main bearing No 1 With oil groove CRANKSHAFT AT No 2 1 Set main bearings in their proper positions on cylinder block No 3 FRONT and main bearing cap No 4 e Confirm that correct main bearings are used TE
40. ide by outer diameter of valve lifter and valve lifter guide inner diameter Standard clearance between valve lifter and valve lifter guide 0 043 0 066 mm 0 0017 0 0026 in Assembly 1 Install valve component parts Always use new valve oil seal Refer to EM 25 OIL SEAL REPLACEMENT Install valve spring uneven pitch type with its narrow pitch side toward cylinder head side After installing valve component parts use plastic hammer to lightly tap valve stem tip to assure a proper fit Install camshafts locate plates and cylinder head rear covers Position the knock pin of camshaft at the top as shown Install valve lifters and valve lifter guide Assemble valve lifters to their original position and hold all valve lifters with wire to prevent lifters from falling out of the guide After installing remove the wire Install rocker shafts with rocker arms Tighten bolts gradually in two or three stages to specifica tion in the following camshaft positions Before tightening be sure to set camshaft the lobe at the position where lobe is not lifted Set No 1 piston at TDC on its compression stroke and tighten rocker shaft bolts for No 2 No 4 and No 6 cylinders Set No 4 piston at TDC on its compression stroke and tighten rocker shaft bolts for No 1 No 3 and No 5 cylinders Install exhaust manifold to cylinder head in reverse order of removal EM 40 Apply genuine liquid gasket
41. iston heads c Make sure that timing belt camshaft sprocket crankshaft sprocket and belt tensioner are clean and free from oil and water d Installation should be carried out when engine is cold SEC 120 130 135 Rear belt cover Cylinder block RH camshaft sprocket K1 7 78 88 8 0 9 0 58 65 Conical washer Belt tensioner nut 9 43 58 4 4 5 9 32 43 Front upper belt cover Stud LH camshaft Apply locking sealant to sprocket threads on cylinder F1 78 88 block side 8 0 9 0 58 65 N Tensioner spring Belt tensioner Timing belt plate Crankshaft sprocket Front lower belt cover Crank pulley plate Crankshaft pulley V 7 191 211 19 5 21 5 141 156 o Nem kg m in Ib O Nem kg m ft lb l ai Lubricate with new engine oil SEM311FB EM 18 TIMING BELT Removal 1 Remove engine under cover Gil 2 Drain engine coolant from radiator Refer to Changing Engine Coolant in Be careful not to spill engine coolant on drive belts MA 3 Remove radiator Refer to Radiator in 4 Remove Sk cooling fan and water pump pulley Refer to Cooling Fan n LG section 5 Remove the lon belts Refer to Checking Drive Belts in e Power steering pump drive belt LG e Compressor drive belt e Alternator drive belt 6 Remove all spark plugs EC 7 Remove distributor protector 8 Remove compressor d
42. itable EG tool e When removing exhaust side valve oil seal pull it out with suit able tool B CL MT SEM285A 5 Apply engine oil to new valve oil seal and install it to specifica AT tion as shown e When installing intake side valve oil seal use SST as shown T e When installing exhaust side valve oil seal set it by hand TE valve side ER ee PD ia eg Dy DS FA RA Valve oil seal BR Eo Ea dT ST TN o e RS SEM142H CAMSHAFT OIL SEAL BT 1 Remove timing belt Refer to EM 19 Removal 2 Remove camshaft sprocket Refer to EM 18 TIMING BELT HA 3 Remove camshaft Refer to EM 28 CYLINDER HEAD 4 Remove camshaft oil seal Be careful not to scratch cylinder head EL 5 Apply engine oil to new camshaft oil seal EM 25 OIL SEAL REPLACEMENT Engine I Engine inside outside Oil seal lip Dust seal lip SEM715A SEM284A ce Ey Ye z SEM241E Engine a Engine inside outside Oil seal lip Dust seal lip SEM715A 6 Position the oil seal in the specified direction as shown 7 Install the oil seal using suitable drift 8 Install the remaining parts in the reverse order of removal FRONT OIL SEAL 1 Remove timing belt and crankshaft sprocket Refer to EM 19 Removal 2 Remove oil pump assembly Refer to Oil Pump in LC sectionl 3 Remove front oil seal from oil pump body 4 Apply engine oil to new oil seal 5 Position the oil
43. ket 13 If the belt deflection is not within specification return to step 1 EL LH and repeat procedure Camshaft sprocket RH Tensioner pulley Timing belt a Crankshaft sprocket SEM744DA EM 23 TIMING BELT Tension Adjustment Cont d 14 Install the lower and upper belt covers Front upper belt cover Water inlet 68 DL ale 9 KA vp w X JA Rear belt PTS ol Compressor bracket No Tightened parts No Tightened parts Bolt t Bolt AV pg Rubber washer Ca 8 Front lower belt cover 1 v Front upper belt cover pes H pe e Welded nut ul Hexagon bolt with washer Ta Bolt dal pr Rubber washer Rear belt cover 4 1 Q pos 8 uH Front lower belt cover as Bolt Rubber washer 4 a Bolt 1 4 pes 3 Front lower belt cover pe Front lower belt cover Lock spring washer SEM313F 15 Install the remaining components in the reverse order of removal EM 24 OIL SEAL REPLACEMENT VALVE OIL SEAL 1 Remove rocker cover 2 Remove rocker shaft assembly and valve lifters with valve lifter guide 3 Remove valve springs using SST as shown MA e Piston concerned should be set at TDC to prevent valve from falling into the cylinder bore LG 4 Remove valve oil seals e When removing intake side valve oil seal use Tool or su
44. main bearing x With oil groove No 1 No 2 No 3 No 4 FRONT No 3 Lower main bearing SEM208E No 4 SEM505A CYLINDER BLOCK Inspection Cont d CRANKSHAFT 1 Check crankshaft main and pin journals for score wear or cracks 2 With a micrometer measure journals for taper and out of round MA Out of round difference between X and Y Less than 0 005 mm 0 0002 in Taper difference between A and B Less than 0 005 mm 0 0002 in LG 3 Measure crankshaft runout e Place a V block on a precise flat table to support the journals EG on the both end of the crankshaft e Place a dial gauge straight up on the No 3 journal e While rotating the crankshaft read the movement of the pointer FE on the dial gauge Total indicator reading Runout Total indicator reading Less than 0 10 mm 0 0039 in GL MT BEARING CLEARANCE AT NOTE Either of the following two methods may be used however method A gives more reliable results and is preferable TE Method A Using bore gauge amp micrometer Main bearing PD 1 Set main bearings in their proper positions on cylinder block and main bearing cap 2 Install main bearing cap to cylinder block FA Tighten all bolts in correct order in two or three stages Refer to EM 57 CRANKSHAFT RA BR ST RS 3 Measure inner diameter A of each main bearing as shown BT HA EL DX EM 53 No 1 journal
45. moval EM 45 Gi MA LG EG ST RS EL DX ENGINE REMOVAL Front engine slinger Rear engine slinger upper CA C 20 6 26 5 2 1 2 7 16 19 No tm 9 Engine L r mounting put 0 35 3 45 1 bracket 3 6 4 6 26 33 Insulator Engine mounting bracket Heat insulator MV mounting CA bracket v 0 31 42 cup PAS Insulator b 0 31 42 C 41 52 3 2 4 3 23 30 4 2 5 3 30 38 0 31 42 3 2 4 3 23 30 Rear engine slinger upper Rear engine slinger lower 9 31 42 3 2 4 3 23 30 Engine mounting bracket 0 41 52 4 2 5 3 30 38 9 35 3 45 1 3 6 4 6 PE 33 LH cylinder head amp 43 1 54 9 4 4 5 5 32 40 Insulator 0 68 87 7 0 8 8 51 64 Rear engine mounting member 0 41 52 4 2 5 3 30 O Nem kg m ft Ib SEM085H EM 46 SEM828C ENGINE REMOVAL WARNING Situate vehicle on a flat and solid surface Place chocks at front and back of rear wheels Do not remove engine until exhaust system has completely cooled off Otherwise you may burn yourself and or fire may break out in fuel line For safety during subsequent steps the tension of wires should be slackened against the engine Before disconnecting fuel hose release fuel pressure from fuel line Refer to Fuel Pre
46. move exhaust manifolds from cylinder head EM 32 CYLINDER HEAD Disassembly Cont d 2 Remove rocker shafts with rocker arms e Bolts should be loosened in two or three steps GI 3 Remove hydraulic valve lifters and lifter guide e Hold hydraulic valve lifters with wire so that they will not drop from lifter guide MA SEM304A LG 4 Remove oil seal and camshaft e Before removing camshaft measure camshaft end play EG Refer to EM 35 CAMSHAFT END PLAY Engine front SEM259A 5 Remove valve components using SST as shown TF PD F 6 Remove valve oil seals using suitable tool RA SEM285A EM 33 VEST Straightedge EE i E PEU e d oou II SEM868A WBIA0235E SEM549A CYLINDER HEAD Inspection CYLINDER HEAD DISTORTION 1 Measure the cylinder head surface using a straightedge and a feeler gauge as shown If the surface flatness is beyond the specified limit resurface it or replace it as necessary Head surface flatness Less than 0 1 mm 0 004 in Resurfacing limit The resurfacing limit of cylinder head is determined by the cylinder block resurfacing in an engine Amount of cylinder head resurfacing is A Amount of cylinder block resurfacing is B The maximum limit is as follows A B 0 2 mm 0 008 in 2 After resurfacing cylinder head check that camshaft
47. n e Canvas on tooth face is worn down e Canvas on tooth is fluffy rubber layer is worn down and faded white or weft is worn down and invisible Belt is contaminated by engine oil engine coolant or water SEM395A Rotating direction SEM397A EM 20 e Camshaft jamming e Distributor jamming e Damaged camshaft crankshaft oil seal e Tensioner jamming e Overheated engine e Interference with belt cover e Improper installation of belt e Malfunctioning crankshaft pulley plate timing belt plate e Poor belt cover sealing e Engine coolant leakage at water pump e Camshaft not functioning properly e Distributor not functioning properly e Excessive belt tension e Poor oil sealing of each oil seal e Engine coolant leakage at water pump e Poor belt cover sealing Camshaft o Camshaft sprocket sprocket LH RH o 1 cylinder at TDC in f compression Aligning stroke marks SEM510EA Hook tensioner spring ra C gt ME Arrow A pz SEM243A Camshaft sprocket lt X_ LH sprocket S 7 timing belt RH No 1 oylinder at TDC in compression stroke Aligning marks Crankshaft timing sprocket SEM511EA TIMING BELT Inspection Cont d BELT TENSIONER AND TENSIONER SPRING 1 Check belt tensioner for smooth turning 2 Check condition of tensioner spring 3 Replace belt tensioner and tensioner spring
48. n Cont d 5 Tighten cylinder head bolts in numerical order as shown using angle wrench ST10120000 J24239 01 Apply engine oil to threads and seating surfaces of cylinder head bolts before installing them e Cylinder head bolts for D 9 and 2 are longer than the others L 127 mm 5 00 in for D 9 and 2 L5 106 mm 4 17 in for others e Install intake manifold and cylinder head at the same time using the following procedure kg m 22 ft Ib Tighten cylinder head bolts to 29 N m 3 6 0 kg m 43 ft lb 1 0 2 Tighten cylinder head bolts to 59 N m 6 0 3 Loosen cylinder head bolts completely 4 Tighten cylinder head bolts to 10 N m 1 0 kg m 7 ft lb b Tighten intake manifold bolts and nuts to 4 N m 0 4 kg m 35 in Ib 6 Tighten intake manifold bolts and nuts to 18 N m 1 8 kg m 13 ft lb 7 Tighten intake manifold bolts and nuts to 16 to 20 N m 1 6 to 2 0 kg m 12 to 14 ft lb 8 Loosen intake manifold bolts and nuts completely 9 Tighten cylinder head to 29 N m 3 0 kg m 22 ft lb 10 Turn cylinder head bolts to 60 to 65 degrees clockwise If an angle wrench is not available tighten cylinder head bolts to 54 to 64 N m 5 5 to 6 5 kg m 40 to 47 ft lb 11 Tighten cylinder head sub bolts to 9 0 to 11 8 N m 0 92 to 1 20 kg m 80 to 104 in Ib 12 Tighten intake manifold bolts and nuts to 4 N m 0 4 kg m 35 in Ib 13 Tighten intake manifold bolts and nuts to 9 N m
49. nal dia Dp 49 955 49 974 1 9667 1 9675 Center distance r 41 5 1 634 Out of round difference between X and Y Upper main bearing With oil groove With oil groove No 1 x e AN a KO S Lower main bearing Without oil groove Standard Less than 0 005 0 0002 Taper difference between A and B Standard Less than 0 005 0 0002 Runout TIR Standard Less than 0 025 0 0010 Limit Less than 0 10 0 0039 Free end play Standard 0 050 0 170 0 0020 0 0067 Limit 0 30 0 0118 SEM645 Out of round Difference between amp and Taper Difference between and B SHI SEM715 A SEM327A No 1 main bearing Grade Thickness T Width W Identification number mm in mm in color mark 1 822 1 825 0 0 0717 0 0719 Black A 1 825 1 828 1 0 0719 0 0720 Brown B 1 828 1 831 2 0 0720 0 0721 Green C 1 831 1 834 22 4 22 6 3 0 0721 0 0722 0 882 0 890 Yellow D 1 834 1 837 7 0 0722 0 0723 Blue E 1 837 1 840 0 0723 0 0724 Pink F 1 840 1 843 6 0 0724 0 0726 Purple G No 2 and 3 main bearing Grade Thickness T Width W Identification number mm in mm in color 1 817 1 821 0 0 0715 0 0717 Black 1 821 1 825 0 0717 0 0719 1 825 1 829 18 9 19 1 0 0719 0 0720 0 744 0 752 1 829 1 833 3 0 0720 0 0722 T l 1 833 1 837 Bie EM 68
50. ncern SEM208BB WARNING e Place vehicle on a flat and solid surface e Place chocks at front and rear of rear wheels e You should not remove oil pan until exhaust system and cooling system have completely cooled off Otherwise you may burn yourself and or fire may break out in the fuel line e When remove front and or rear engine mounting bolts or nuts lift up slightly engine for safety work CAUTION e In lifting engine be careful not to hit against adjacent parts especially against accelerator wire casing end brake tube and brake master cylinder For tightening torque refer to specified sections Remove undercover Drain engine oil Refer to Changing Engine Oil in Remove stabilizer bar Refer to FA section in original Service Manual Remove front propeller shaft from front differential carrier Refer to PD section in original Service Manual 5 Remove front drive shaft fixing bolts RH amp LH Refer to FA section in original Service Manual 6 Support front differential carrier and remove front differential carrier member bolts RH amp LH Refer to PD section in origi nal Service Manual 7 Remove front differential carrier fixing bolts Refer to PD sec tion in original Service Manual De EM 14 OG G co KV10111100 SEM112EA OIL PAN Removal Cont d 8 9 10 11 12 13 14 15 16 17 18 19 Remove front
51. ng side clearance EM 50dl ley P P P Piston ring end gap EM 50l nee block Connecting rod bend and torsion EM 50 ide o a Connecting rod bushing clear Oil pan Knock Connecting rod ance Small end EM 56 bearing noise Connecting rod bearing clear EM 55 ance Big end Knock Main bearing Main bearing oil clearance EM 53l noise Crankshaft runout EM 53l Whine or hiss Timing belt noise imi in too tight imi Timing belt g Loose timing belt EM2d cover Timing belt noise Belt contacting case too loose Other drive belts squealing B Sticking or slip Drive belts deflection MA section fizzing Checking ping Other drive belt si i er arive pelts 5 Belts Front of engine Creaking Slipping Idler pulley bearing operation Squall Creak Water pump noise Water pump operation Water Pump A Closely related B Related C Sometimes related Not related EM 8 OUTER COMPONENT PARTS SEC 140 147 148 163 GI 9 5 10 6 37 Air relief plug 0 52 0 64 46 56 9 8 4 10 8 9 16 21 0 86 1 1 74 6 95 5 1 7 2 1 12 15 QQ 8 43 10 8 0 86 1 1 74 6 95 6 MA 9 34 3 44 1 A07 EGRC solenoid o 2 94 3 82 9 8 4 10 8 Earth 8 valve 0 29 0 38 0 86 1 1 74 6 95 5 9 i PCV valve 26 33 l 18 22 7 3 5 4 4 DRE de 1 8 2 2 13 16 lel SN 26 32 C er 7 T 77 e Le I P u LU Go j v ee TS galley EG Gasket
52. or harness connector at the distributor Attach a compression tester to No 1 cylinder Depress accelerator pedal fully to keep throttle valve wide open Crank engine and record highest gauge indication Repeat the measurement on each cylinder as shown above Always use a fully charged battery to obtain specified engine speed Compression pressure kPa bar kg cm psi 300 rpm Standard 1 196 11 96 12 2 173 Minimum 883 8 83 9 0 128 Difference limit between cylinders 98 0 98 1 0 14 If cylinder compression in one or more cylinders is low pour a small amount of engine oil into cylinders through spark plug holes and retest compression If adding oil improves cylinder compression piston rings may be worn or damaged If so replace piston rings after checking piston If pressure stays low a valve may be sticking or seating improperly Inspect and repair valve and valve seat Refer to SDS If valve or valve seat is damaged excessively replace them If compression in any two adjacent cylinders is low and if adding oil does not improve compression there is leakage past the head gasket surface If so replace cylinder head gasket Install removed parts in reverse order of removal EM 13 Gi MA LG EG TF PD F ST RS EL DX OIL PAN Removal Numbers in this illustration indicate step Nos of the removal procedures below For tightening torque refer to sections in co
53. ower steering PD 12 15 oil pump bracket B E d a A E oil pump adjusting bar 30 e Ag BR ST RS SEM084H 19 Loosen and remove the bolts from both rocker covers in BI numerical order as shown Remove both rocker covers HA ron G EL Left bank A DX D B stwst7F EM 31 Right bank Vehicle SEM870BA RH exhaust manifold LH exhaust manifold a Q Loosen in reverse order Tighten in numerical order SEM318FA CYLINDER HEAD Removal Cont d 20 Remove cylinder head with exhaust manifold loosen the bolts in the numerical order as shown e A warped or cracked cylinder head could result from not removing the cylinder head bolts in the specified numeri cal order e Cylinder head bolts should be loosened in two or three steps Disassembly CAUTION e When installing sliding parts such as rocker arms cam shaft and oil seal be sure to apply new engine oil on their sliding surfaces e When tightening cylinder head bolts and rocker shaft bolts apply new engine oil to thread portions and seat surfaces of bolts e If hydraulic valve lifter is kept on its side there is a risk of air entering it After removal always set hydraulic valve lifter straight up or when laying it on its side have it soak in new engine oil e Do not disassemble hydraulic valve lifter e Attach tags to valve lifters so as not to mix them up 1 Re
54. p If there is no punchmark install with either side up Remove bearing cap and crankshaft Before removing bearing cap measure crankshaft end play Refer to EM 57 CRANKSHAFT CAUTION The bearing cap bolts should be loosened in two or three steps in numerical order as shown 9 Remove knock sensor CAUTION Handle the sensor carefully and avoid impact to it Inspection PISTON AND PISTON PIN CLEARANCE 1 Measure inner diameter of piston pin hole dp as shown Standard diameter dp 20 969 20 981 mm 0 8255 0 8260 in EM 49 MA LG EG TF PD F CYLINDER BLOCK Inspection Cont d 2 Measure outer diameter of piston pin Dp as shown Standard diameter Dp 20 971 20 983 mm 0 8256 0 8261 in 3 Calculate piston pin clearance dp Dp 0 0 004 mm 0 0 0002 in If the clearance is out of specification replace piston assembly with pin Micrometer AEMO24 PISTON RING SIDE CLEARANCE Ne N Measure the piston ring to piston side clearance as shown Side clearance Top ring 0 024 0 076 mm 0 0009 0 0030 in 2nd ring 0 030 0 070 mm 0 0012 0 0028 in Oil ring 0 015 0 190 mm 0 0006 0 0075 in Max limit of side clearance Top ring 0 11 mm 0 0043 in Feeler gauge OK e J Feeler gauge 2nd ring 0 10 mm 0 0039 in Ring seMo2aaA f out of specification replace piston and
55. r suitable tool e Be careful not to scratch cylinder wall by connecting rod e Arrange so that front mark on piston head faces toward front of engine b Install connecting rod bearing caps e Lubricate threads and seat surfaces with new engine oil Tighten connecting rod bearing cap nuts to the specified torque Connecting rod bearing nut 1 Tighten to 14 to 16 N m 1 4 to 1 6 kg m 10 to 12 ft Ib 2 Turn nuts 60 to 65 degrees clockwise If an angle wrench is not available tighten nuts to 38 to 44 N m 3 9 to 4 5 kg m 28 to 33 ft Ib 6 Measure connecting rod side clearance Connecting rod side clearance Standard 0 20 0 35 mm 0 0079 0 0138 in Limit 0 40 mm 0 0157 in If beyond the limit replace connecting rod and or crankshaft 7 Install rear oil seal retainer e Install new rear oil seal before installing rear oil seal retainer EM 58 E Engine front Knock sensor G SEM027H ST16610001 or suitable tool SEM087H CYLINDER BLOCK Assembly Cont d KNOCK SENSOR 1 Install knock sensor e Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor e Install knock sensor so that connector faces rear of engine e Do not tighten the mounting bolts while holding the connector e Make sure that the knock sensor does not interfere with other parts CAUTION If any impact by dropping
56. re punched in either Arabic or Roman numerals c Select main bearing with suitable thickness according to the following example or table EM 54 CYLINDER BLOCK Inspection Cont d Main bearing grade number No 1 main bearing GI Identification color Crankshaft Cylinder block main journal grade number main journal MA grade number 3 4 5 6 3 0 Black 1 Brown 2 Green 3 Yellow 4 1 Brown 2 Green 3 Yellow 4 Blue 5 2 Green 3 Yellow 4 Blue 5 Pink C 6 3 Yellow 4 Blue 5 Pink 6 Purple 8 No 2 3 and No 4 main bearings EG Identification color Main journal grade number E 0 1 2 Crankshaft 0 0 Black 1 Brown 2 Green CL journal grade 1 1 Brown 2 Green 3 Yellow number 2 2 Green 3 Yellow 4 Blue MT For example Main journal grade number 1 Crankshaft journal grade number 2 AT Main bearing grade number 1 2 3 Yellow TF PD F Connecting rod bearing Big end RA Inside micrometer 1 Install connecting rod bearing to connecting rod big end and cap 2 Install connecting rod cap to connecting rod Tighten bolts to BR the specified torque Refer to CRANKSHAFT 3 Measure inner diameter C of each bearing installed in the connecting rod big end T RS AEM027 4 Measure outer diameter Dp of each crankshaft pin journal BT 5 Calculate connecting rod bearing clearance Connecting rod b
57. rive belt idler bracket FE 9 Disconnect fresh air intake tube for rocker cover 10 Disconnect water hose for thermostat housing GL MT Fiti 11 Set No 1 piston at TDC on its compression stroke by rotating AT V buc M crankshaft M 12 Remove crankshaft pulley bolt 13 Remove crankshaft pulley with a suitable puller TE 14 Remove front upper and lower belt covers PD 0 10 20 10 20 LE Crankshaft pulley BTDC P SEM347F 15 Align the camshaft and crankshaft sprockets to the timing RA marks on the rear belt cover and oil pump body e Align punchmark on LH camshaft sprocket with punch mark on timing belt rear upper cover BR e Align punchmark on crankshaft sprocket with the align ment mark on oil pump housing e Temporarily install crank pulley bolt on crankshaft so that ST crankshaft can be rotated U lt EX Timing belt rear V upper cover Y Punchmark RS EL Crankshaft DX sprocket Alignment mark SEM394CA EM 19 TIMING BELT Removal Cont d SEM240A Symptom Inspection Visually check the condition of timing belt Replace if any abnormality is found Problem 16 Loosen timing belt tensioner nut turn tensioner then remove timing belt Cause Tooth is broken tooth root is cracked Back surface is cracked worn e Side surface is worn e Belt corners are worn and round e Wicks are frayed and coming out e Teeth are wor
58. rotates freely by hand If resistance is felt cylinder head must be replaced Nominal cylinder head height 106 8 107 2 mm 4 205 4 220 in CAMSHAFT VISUAL CHECK Check camshaft for scratches seizure and wear Replace as nec essary CAMSHAFT RUNOUT 1 Support the camshaft at the No 2 and No 4 camshaft journals 2 Measure camshaft runout at the No 3 journal as shown Runout Total indicator reading Limit 0 1 mm 0 004 in 3 If it exceeds the limit replace camshaft CAMSHAFT CAM HEIGHT 1 Measure camshaft cam height as shown Standard cam height Intake 39 242 39 432 mm 1 5450 1 5524 in Exhaust 38 943 39 133 mm 1 5332 1 5407 in Cam wear limit 0 15 mm 0 0059 in 2 If wear is beyond the limit replace camshaft EM 34 Inspection Cont d SEM879A la End play ng Locate plate Dial gauge SEM392E Unit mm in 0 03 0 06 0 02 0 0012 0 0024 0 0008 Engine rear side Identifi No cation identification Punched identification mark C mark mark SEM393E CAMSHAFT JOURNAL CLEARANCE 1 Measure outer diameter of camshaft journal Standard outer diameter A 46 920 46 940 mm 1 8472 1 8480 in B 42 420 42 440 mm 1 6701 1 6709 in C 47 920 47 940 mm 1 8866 1 8874 in 2 Measure inner diameter of camshaft bearing for the corre 3 sponding camshaft journal positions measured in
59. s MT 35 52 Idler gear Camshaft i i gear F Piston ring A 9 16 19 9 57 66 er a e 1 6 1 9 12 14 A 5 8 6 7 Piston pin 9 Flywheel M T models U 16 21 42 48 p 0 167 186 2 S i 17 19 1 6 2 1 12 15 gt ring 3 TF Timing gear case Connecting rod SNAM bushin Mating surface to timing Ad pP 9 147 167 Connecting 15 0 17 0 PD gear case and front plate 15 0 rod bearing E 109 123 3 16 21 1 6 2 1 12 15 Connecting rod y bearing cap Reinforcement plate Spacer Ph D Grommet cover 9 29 39 gil a ys Adapter drive plate FA Crankshaft Timing gear case cover 3 0 4 0 22 29 P a AT models i9 7 9 0 7 0 9 61 78 9 7s 83 BA 8 0 8 5 58 61 e Always replace after every disassembly Crankshaft pulley BB I N m kg m in ib rankshaft O Nem kg m ft lb d Lubricate with F i 9 Drive plate T E Lubricate with engine oil AIT models S Apply recommended sealant Main bearing E Pilot converter Nissan genuine part o 373 402 A T models KP610 00250 or equivalent 38 41 275 296 RS 1 Keep in correct order 2 Do not damage the sensor edges Main bearing cap Thrust bearing FA 3 Models with tachometer 5 4 Models without tachometer Oil pan KO 167 177 BT gasket e 17 0 18 0 5 6 123 130 Oil pan side Oil pan inner Idler gear HA Oil pan S T 7 9 Gasket 5 0 7 0 9 61 78 e EL Crankshaft Align oil 9 54
60. s than 0 1 0 004 EM 69 Grind so that bearing clearance is the specified value Gi MA LG EG TF PD F ST RS EL DX
61. seal with the correct orientation as shown EM 26 OIL SEAL REPLACEMENT Engine a Engine inside outside Oil seal lip Dust seal lip SEM715A 6 d Install the new oil seal using a suitable tool as shown Install the remaining parts in the reverse order of removal REAR OIL SEAL 1 Remove flywheel Refer to CL section 2 Remove rear oil seal retainer 3 Remove rear oil seal from rear oil seal retainer CAUTION Be careful not to scratch the rear oil seal retainer 4 Apply engine oil to new oil seal 5 Position the new oil seal as shown 6 Install the new oil seal using a suitable tool 7 Install rear oil seal retainer with a new gasket to cylinder block CAUTION Always use a new oil seal retainer gasket 8 Install the remaining parts in the reverse order of removal EM 27 Gi MA LG EG TF PD F ST RS EL DX CYLINDER HEAD SEC 102 111 130 Exhaust oF 9 Tok LIT Ta D RH cylinder LH cylinder head front head front LH rocker cover Gasket e Rocker armi fy 1 3 0 1 0 3 9 26 GIERF Tol on Ti lie Intake al 918 22 gt 1 8 2 2 13 16 RH rocker cover Hydraulic 9 1 3 0 1 0 3 9 26 valve lifter M6 with washer valve lifter guide Valve collect Cylinder head bolt d M spring retainer VS Oil filler cap Refer to Installation S
62. ssure Release in EC section Before removing front axle from transmission place safety stands under designated front supporting points Refer to for lifting points and tow truck towing Be sure to hoist engine and transmission in a safe manner For engines not equipped with engine slingers attach proper slingers and bolts described in PARTS CATALOG CAUTION When lifting engine be careful not to strike adjacent parts especially accelerator wire casing brake lines and brake master cylinder In hoisting the engine always use engine slingers in a safe manner Removal 1 2 3 4 oo 0 11 Remove engine undercover and hood Refer to BT section TE ea coolant Refer to Changing Engine Coolant in Disconnect vacuum hoses a n harnesses and connectors and so on Refer to Remove radiator with shr n oling fan Refer to Radia tor and Cooling Fan in Remove drive belts Refer to Remove power steering oil pump and air conditioner compres sor Refer tolSTland Ha sections Remove front exhaust tube Refer to EXHAUST SYSTEM in FE section Remove transmission from vehicle Refer to MT section Install engine slingers Hoist engine with engine slingers and remove engine mounting bolts from both sides Remove engine from vehicle EM 47 MA LG EG TF PD F ST RS EL DX CYLINDER BLOCK SEC 110 120 150 313 Inner rotor EP so Se
63. step 1 Standard inner diameter A 47 000 47 025 mm 1 8504 1 8514 in B 42 500 42 525 mm 1 6732 1 6742 in C 48 000 48 025 mm 1 8898 1 8907 in If clearance exceeds the limit replace camshaft and or cylinder head Camshaft journal clearance limit 0 15 mm 0 0059 in CAMSHAFT END PLAY 1 2 3 Install camshaft and locate plate in cylinder head Measure camshaft end play Camshaft end play Standard 0 03 0 06 mm 0 0012 0 0024 in If it is out of the specified range select thickness of camshaft locate plate to obtain standard specified end play Example When camshaft end play is 0 08 mm 0 0031 in with camshaft locate plate replace camshaft locate plate 2 with camshaft locate plate 3 to set the end play at 0 05 mm 0 0020 in EM 35 MA LG EG 3 TF PD F Cu LS i 9 eK S 6 Valve guide Valve Top SEM800A Center Bottom SEM751A SEM008A CYLINDER HEAD VG33E Inspection Cont d CAMSHAFT SPROCKET RUNOUT 1 Support the camshaft at the No 2 and No 4 camshaft journals 2 Install sprocket on camshaft 3 Measure camshaft sprocket runout Runout Total indicator reading Limit 0 1 mm 0 004 in 4 If it exceeds the limit replace camshaft sprocket VALVE GUIDE CLEARANCE 1 Measure valve deflection in a right angled direction with cam shaft Valve and valve guide mos
64. tly wear in this direction Valve deflection limit Dial gauge reading 0 20 mm 0 0079 in 2 If it exceeds the limit check valve to valve guide clearance a Measure valve stem diameter and valve guide inner diameter b Check that clearance is within specification Valve to valve guide clearance Intake 0 020 0 053 mm 0 0008 0 0021 in Exhaust 0 030 0 049 mm 0 0012 0 0019 in Limit 0 10 mm 0 0039 in c If it exceeds the limit replace valve or valve guide VALVE GUIDE REPLACEMENT 1 To remove valve guide heat cylinder head to 150 to 160 C 302 to 320 F by soaking in heated oil EM 36 CYLINDER HEAD Inspection Cont d 2 Drive out valve guide with a press under a 20 kN 2 ton 2 2 US ton 2 0 Imp ton pressure or hammer and suitable tool WARNING GI Cylinder head contains heat When working wear protective equipment to avoid getting burned MA SEM264A LG 3 Ream cylinder head valve guide hole to specification for the service valve guide part as shown EG Valve guide hole diameter for service parts Intake FE 11 175 11 196 mm 0 4400 0 4408 in Exhaust 12 175 12 196 mm 0 4793 0 4802 in CL MT 4 Heat cylinder head to 150 to 160 C 302 to 320 and press AT service valve guide onto cylinder head to the specified height as shown WARNING TE Cylinder head contains heat When working wear protective equipment to avoid ge
65. ton diameter A Refer to Available piston Measuring point a Distance from the top 49 0 mm 1 929 in 4 Make sure piston to bore clearance is within specification Piston to cylinder bore clearance B Standard No 1 2 and 6 cylinders 0 025 0 045 mm 0 0010 0 0018 in No 3 and 4 cylinders 0 015 0 025 mm 0 0006 0 0010 in No 5 cylinder 0 030 0 040 mm 0 0012 0 0016 in 5 Determine piston oversize according to amount of oylinder wear Oversize pistons are available for service Refer to Available piston 6 Oylinder bore size is determined by adding piston to bore clear ance to piston diameter A Rebored size calculation D A B C where D Bored diameter A Piston diameter as measured B Piston to bore clearance C Honing allowance 0 02 mm 0 0008 in 7 Install main bearing caps and tighten to the specified torque to prevent distortion of cylinder bores in final assembly 8 Cut cylinder bores e When any cylinder needs boring all other cylinders must also be bored e Do not cut too much out of cylinder bore at a time Cut only 0 05 mm 0 0020 in or so in diameter at a time 9 Hone cylinders to obtain specified piston to bore clearance 10 Measure finished cylinder bore for out of round and taper e Measurement should be done after cylinder bore cools down EM 52 Taper Difference between A and B Out of round Difference between X and Y SEM316AA SEM434 Upper
66. tting burned Height L PD 13 2 13 4 mm 0 520 0 528 in Intake side Exhaust side 5 Ream out the new service valve guide in the cylinder head to the specified diameter F Valve guide finished inner diameter SEMO089C Intake 7 000 7 018 mm 0 2756 0 2763 in BA Exhaust 8 000 8 018 mm 0 3150 0 3157 in BR ST RS VALVE SEATS BY Check valve seats for any evidence of pitting at valve contact surface and re surface or replace the valve seat if it has worn out HA e Before repairing valve seats check valve and valve guide for wear If they have worn replace them Then correct valve seat Refer to EM 64 VALVE EL e Use both hands to cut uniformly SEMO90C EM 37 Recess SEM795A SEM008A SEM892B T Margin thickness Q i SEM188A CYLINDER HEAD Inspection Cont d REPLACING VALVE SEAT FOR SERVICE PARTS 1 Bore out old seat until it collapses The machine depth stop should be set so that boring cannot continue beyond the bot tom face of the seat recess in cylinder head 2 Ream cylinder head recess CAUTION Reaming should be done in circles concentric to the valve guide center so that valve seat will have the correct fit Reaming bore for service valve seat Oversize 0 5 mm 0 020 in Intake 44 500 44 516 mm 1 7520 1 7526 in Exhaust 37 500 37 516 mm 1 4764 1 4770 in 3 Heat cylinder hea

ENGINE MECHANICAL SECTION EM

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