TUCSON(JM) > 2008 > G 2.

7 DOHC > Engine Mechanical System

Engine Mechanical System > General Information > General Information

SPECIFICATIONS

Description Specifications Limit

General

Type V-type, DOHC

Number of cylinder 6

Bore 86.7mm (3.4133in.)

Stroke 75mm (2.9528in.)

Total displacement 2,656cc

Compression ratio 10 : 1

Firing order 1-2-3-4-5-6

Valve timing

Intake valve

Opens (BTDC) 6°

Closes (ABDC) 46°

Exhaust valve

Opens (BBDC) 44°

Closes (ATDC) 8

Camshaft

Drive mechanism Cogged type belt

Cam height

Intake 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.) 43.45mm (1.7106in.)

Exhaust 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.) 43.45mm (1.7106in.)

25.964 ~ 25.980mm (1.0222 ~

Journal diameter 25.914mm (1.0202in.)
1.0228in.)

Bearing oil clearance 0.02 ~ 0.061mm (0.0007 ~ 0.0024in.) 0.1mm (0.0039in.)

End play 0.1 ~ 0.15mm (0.0039 ~ 0.0059in.)

Cylinder head

Flatness of cylinder head surface Max. 0.03mm (0.0012in.) 0.05mm (0.0020in.)

Flatness of manifold mounting
surface

Intake Max. 0.15mm (0.0059in.) 0.15mm (0.0059in.)

Exhaust Max. 0.15mm (0.0059in.) 0.15mm (0.0059in.)

Valve guides hole diameter

0.05 (0.002) O.S. 11.05 ~ 11.068mm (0.435 ~ 0.436in.)

0.25 (0.010) O.S. 11.25 ~ 11.268mm (0.443 ~ 0.444in.)

0.50 (0.020) O.S. 11.50 ~ 11.518mm (0.453 ~ 0.453in.)

Intake valve seat ring hole

diameter

0.3 (0.012) O.S. 33.300 ~ 33.325mm (1.311 ~ 1.312in.)

Exhaust valve seat ring hole

diameter

0.3 (0.012) O.S. 28.600 ~ 28.621mm (1.126 ~ 1.127in.)

Valve

Overall length

Intake 96.1mm (3.783in.)

Exhaust 97.15mm (3.825in.)

Stem diameter

Intake 5.965 ~ 5.98mm (0.235 ~ 0.2354in.)

Exhaust 5.95 ~ 5.965mm (0.234 ~ 0.235in.)

Face angle 45° ~ 45.5°

Margin

Intake 1.0mm (0.0394in.) 0.5mm (0.0197in.)

Exhaust 1.3mm (0.0512in.) 0.8mm (0.0315in.)

Clearance (Stem-to-guide)

Intake 0.02 ~ 0.05mm (0.008 ~ 0.0020in.) 0.10mm (0.0039in.)

Exhaust 0.030 ~ 0.065mm (0.0012 ~ 0.0026in.) 0.13mm (0.0051in.)

Valve spring

Free length 42.5mm (1.6732in.) 41.5mm (1.6339in.)

21.9kg/34mm
Load 21kg/35mm (48.4lb/1.3780in.)
(48.4lb/1.3386in.)
Out of squareness Max. 1.5° Max. 3°

Piston

Diameter (Standard) 86.68 ~ 86.71mm (3.413 ~ 3.414in.)

Clearance (Piston-to-cylinder) 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)

Ring groove width

No.1 1.230 ~ 1.250mm (0.0484 ~ 0.0492in.)

No.2 1.220 ~ 1.250mm (0.0480 ~ 0.0488in.)

Oil 2.515 ~ 2.535mm (0.0990 ~ 0.0998in.)

Piston for service 0.25mm (0.010in.), 0.50mm (0.020in.)

Piston ring

Number of rings per piston 3

Compression ring 2

Oil ring 1

Compression ring type

No.1 Inner bevel type

No.2 Taper type

Oil ring type 3-piece type

Ring end gap

No.1 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.) 0.8mm (0.031in.)

No.2 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.) 0.8mm (0.031in.)

Oil ring side rail 0.2 ~ 0.7mm (0.0079 ~ 0.0276in.) 1.0mm (0.039in.)

Ring side clearance

No.1 0.04 ~ 0.08mm (0.0016 ~ 0.0031in.) 0.1mm (0.004in.)

No.2 0.03 ~ 0.07mm (0.0012 ~ 0.0028in.) 0.1mm (0.004in.)

Rings for service 0.25mm (0.010in.), 0.50mm (0.020in.)

Connecting rod

2,450 ~ 12,225N
Piston pin installation force 0.4mm (0.016in.)
(250 ~ 1,250kg, 551 ~ 2,755lb)

Side clearance (big end) 0.10 ~ 0.25mm (0.0039 ~ 0.0098in.)

005mm or less/100mm
Bend
(0.0020in. or less/3.937in.)
Bearing oil clearance 0.018 ~ 0.036mm (0.0007 ~ 0.0014in.) 0.1mm (0.004in.)

Crankshaft

61.982 ~ 62.000mm (2.4402 ~

Journal O.D.
2.4409in.)

47.982 ~ 48.000mm (1.8891 ~

Pin O.D.
1.8898in.)

Out-of-round, taper of journal and

Max. 0.003mm (0.0012in.)
pin

Taper of journal and pin Max. 0.005mm (0.00020in.)

End play 0.070 ~ 0.250mm (0.0028 ~ 0.0098in.) 0.4mm (0.016in.)

Main bearing of clearance 0.004 ~ 0.022mm (0.0002 ~ 0.0009in.) 0.1mm (0.004in.)

Cylinder block

Cylinder bore 86.7mm (3.4134in.)

Flatness of gasket surface Max. 0.03mm (0.0012in.) 0.05mm (0.002in.)

Out-of-round of cylinder bore Max. 0.02mm (0.0008in.)

When replacing a short

Oil quantity(Total) 4.8L(5.07US qt, 4.22lmp qt) engine or a block
assembly

When replacing an oil

Oil quantity(Oil pan) 4.2L(4.44US qt, 3.70lmp qt)
pan only

Oil quantity
4.5L(4.76US qt, 3.96lmp qt)
(Drain and refill including oil filter)

Oil quality Above API SJ/SL or SAE 5W-20

Oil pump

Body clearance 0.100 ~ 0.181mm (0.0039 ~ 0.0071in.)

Side clearance 0.040 ~ 0.095mm (0.0016 ~ 0.0037in.)

Relief spring

Free height 43.8mm (1.724in.)

Load 4.6kg/39.3mm (10lb/1.548in.)

Oil filter

Type Cartridge, full flow

50kPa (7.3psi) or more

Engine oil pressure [Conditions : Oil temperature is 75 to
90°C (167 to 194°F)]
 Engine coolant cooling, forced
Cooling method
circulation with electric fan

Cooling system quantity 7.0lit (7.4U.S.qts., 6.1lmp.qts)

Theromstat

Type Wax pellet type with jiggle valve

Normal opening temperature 82 ± 2.0°C (179.6 ± 3.6°F)

Opening temperature range 80 ~ 84°C (176 ~ 183.2°F)

Wide open temperature 95°C (203°F)

Radiator cap

107.9 ± 14.7kPa (1.1 ± 0.15kg/cm²,

Main valve opening pressure
15.65 ± 2.13psi)

Main valve closing pressure 83.4kPa (0.85kg/cm², 12.1psi)

Vacuum valve opening pressure -6.86kPa (-0.07kg/cm², -1.00psi)

Air cleaner

Type Dry

Element Paper type

Exhaust pipe

Muffler Expansion reaonance type

Suspend system Rubber hangers

SERVICE STANDRDS
Standard value

Coolant concentration

Tropical areas 40%

Other areas 50%

COOLANT

Engine coolant Ethlylen glycol base for aluminum radiator

SEALANT

LOCTITE 262 or equivalent, Three bond No.1324

Engine coolant temperature sensor
or equivalent.

Oil pressure switch 3M ATD No.8660 or Three bond No.1141E

PCV valve LOCTITE 242 or equivalent

TIGHTENING TORQUE
Item Nm kgf.m lb-ft

Camshaft sprocket bolt 90 ~ 110 9.0 ~ 11.0 65 ~ 85

Cylinder head cover bolt 8 ~ 10 0.8 ~ 1.0 5.8 ~ 7.2

Main bearing cap bolt 2.7~3.3 +

19.5~24 +
M10 27~33 + (90°~94°) (90°~95°)
(90°~94°)
M8 13~19 + (90°~94°) 1.3~1.9 +
10~14 + (90°~94°)
(90°~95°)

1.6~2.0 +
Connecting rod bolt 16~20 + (90°~94°) 12~15 + (90°~94°)
(90°~94°)

2.3~2.7 +
23~27 + (58°~62°) 17~20 + (58°~62°)
Cylinder head bolt(Cold engine) (58°~62°) +
+ (43°~47°) + (43°~47°)
(43°~47°)

Oil pan drain plug 35 ~ 45 3.5 ~ 4.5 25 ~ 33

Lower oil pan bolt 10 ~ 12 1.0 ~ 1.2 7~9

Upper oil pan bolt

[10 × 38mm (0.937 × 1.4961in.)] 30 ~ 42 3.0 ~ 4.2 22 ~ 30
[8 × 22mm (0.3150 × 0.8661in.)] 19 ~ 28 1.9 ~ 2.8 14 ~ 20
[161.5mm (6.3582in.)] 5~7 0.5 ~ 0.7 4~5
[152.5mm (6.0039in.)] 5~7 0.5 ~ 0.7 4~5

Oil screen bolt 15 ~ 22 1.5 ~ 2.2 11 ~ 16

Oil pump case bolt 12 ~ 15 1.2 ~ 1.5 9 ~ 11

Oil relief valve plug 40 ~ 50 4.0 ~ 5.0 29 ~ 36

Oil pressure switch 15 ~ 22 1.5 ~ 2.2 11 ~ 16

Oil pressure cover screw 8 ~ 12 0.8 ~ 1.2 6~9

Oil filter 12 ~ 16 1.2 ~ 1.6 9 ~ 12

Drive plate and adapte 73 ~ 77 7.3 ~ 7.7 53 ~ 56

Air cleaner body installation bolt 8 ~ 12 0.8 ~ 1.2 6~9

Surge tank stay 15 ~ 20 1.5 ~ 2.0 11 ~ 14

Air intake surge tank to intake

15 ~ 20 1.5 ~ 2.0 11 ~ 14
manifold(bolt)

Air intake surge tank to intake

15 ~ 20 1.5 ~ 2.0 11 ~ 14
manifold(nut)

Intake manifold to cylinder head 19 ~ 21 1.9 ~ 2.1 14 ~ 15

Heat protector exhaust manifold 17 ~ 22 1.7 ~ 2.2 12 ~ 16

Exhaust manifold to cylinder head

30 ~ 35 3.0 ~ 3.5 22 ~ 26
(Self-locking nut)

Oil level gauge guide to engine 12 ~ 15 1.2 ~ 1.5 9 ~ 11

Water outlet fitting bolt 17 ~ 20 1.7 ~ 2.0 12 ~ 14

Power steering oil pump bracket to

17 ~ 26 1.7 ~ 2.6 12 ~ 19
cylinder head

Crank position sensor wheel screw 5~6 0.5 ~ 0.6 3.6 ~ 4.3

Engine mounting insulator bolt 50 ~ 65 5.0 ~ 6.5 36 ~ 47

Engine mounting bracket nut 60 ~ 80 6.0 ~ 8.0 43 ~ 58

Engine mounting bracket bolt 60 ~ 80 6.0 ~ 8.0 43 ~ 58

Engine support bracket bolt 60 ~ 70 6.0 ~ 7.0 43 ~ 51

Front roll stopper bracket sub frame bolt 50 ~ 65 5.0 ~ 6.5 36 ~ 47

Front roll stopper insulator bolt and nut 50 ~ 65 5.0 ~ 6.5 36 ~ 47

Rear roll stopper bracket to sub frame 50 ~ 65 5.0 ~ 6.5 36 ~ 47

Rear roll stopper insulator bolt and nut 50 ~ 65 5.0 ~ 6.5 36 ~ 47

Transaxle mounting bracket bolt 50 ~ 65 5.0 ~ 6.5 36 ~ 47

Transaxle mounting insulator bolt 90 ~ 110 9.0 ~ 11.0 65 ~ 80

Fuel hose clamp to rear cylinder head

12 ~ 15 1.2 ~ 1.5 9 ~ 11
assembly

Transaxle mounting plate 10 ~ 12 1.0 ~ 1.2 7~9

Rear plate 10 ~ 12 1.0 ~ 1.2 7~9

Oil seal case 10 ~ 12 1.0 ~ 1.2 7~9

Crankshaft pulley bolt 180 ~ 190 18 ~ 19 130 ~ 138

Timing belt cover bolt 10 ~ 12 10.0 ~ 12 7~9

Engine hanger bracket to engine 20 ~ 27 2.0 ~ 2.7 14 ~ 20

Alternator mounting bracket to engine 20 ~ 30 2.0 ~ 3.0 14 ~ 22

Alternator mounting nut (Engine front

20 ~ 30 2.0 ~ 3.0 14 ~ 22
case side)

Alternator mounting bolt (Alternator

20 ~ 30 2.0 ~ 3.0 14 ~ 22
mounting bracket side)

Starter to transmission(nut) 20 ~ 30 2.0 ~ 3.0 14 ~ 22

Starter to transmission(bolt) 27 ~ 34 2.7 ~ 3.4 20 ~ 25

Drive belt pulley bolt 35 ~ 55 3.5 ~ 5.5 25 ~ 40

Drive belt tensioner bolt 20 ~ 27 2.0 ~ 2.7 14 ~ 20

Engine coolant pump to cylinder block

15 ~ 22 1.5 ~ 2.2 11 ~ 16
bolt (Head mark "7" mark)

Engine coolant temperature sensor 20 ~ 40 2.0 ~ 4.0 14 ~ 29

Engine coolant inlet fitting attaching bolt 17 ~ 20 1.7 ~ 2.0 12 ~ 14

Throttle body to surge tank bolt 15 ~ 20 1.5 ~ 2.0 11 ~ 14

Oxygen sensor to exhaust manifold 40 ~ 50 4.0 ~ 5.0 29 ~ 36

Front exhaust pipe to exhaust manifold

30 ~ 40 3.0 ~ 4.0 22 ~ 29
nut

Front exhaust pipe to catalytic converter

40 ~ 60 4.0 ~ 6.0 29 ~ 43
bolt

Catalytic converter to center exhaust

40 ~ 60 4.0 ~ 6.0 29 ~ 43
pipe nut

Center exhaust pipe to main muffler nut 40 ~ 60 4.0 ~ 6.0 29 ~ 43

Main muffler hanger support bracket

10 ~ 15 1.0 ~ 1.5 7 ~ 11
bolt

Delivery pipe installation bolt 10 ~ 15 1.0 ~ 1.5 7 ~ 11

Timing belt tensioner pulley bolt 43 ~ 55 4.3 ~ 5.5 31 ~ 40

Timing belt idler puley bolt 50 ~ 60 5.0 ~ 6.0 36 ~ 43

Timing blelt tensioner arm fixed bolt 35 ~ 55 3.5 ~ 5.5 25 ~ 40

Auto tensioner fixed bolt 20 ~ 27 2.0 ~ 2.7 14 ~ 20

Accelerator cable bracket 4~6 0.4 ~ 0.6 3~4

Spark plug 20 ~ 30 2.0 ~ 3.0 14 ~ 22

COMPRESSION PRESSURE

If the there is lack of power, excessive oil consumption or poor fuel economy, measure the
compression pressure.

1. Warm up and stop engine

Allow the engine to warm up to normal operating temperature.
2. Remove ignition coils. (Refer to Ignition system in EE Group)
3. Remove spark plugs.
Using a 16mm plug wrench, remove the 6 spark plugs.
4 Check cylinder compression pressure
. A. Insert a compression gauge into the spark plug hole.

B. While cranking the engine, measure the compression pressure.

Always use a fully charged battery to obtain engine speed of 250 rpm or more.

C Repeat steps (a) through (b) for each cylinder.

.

This measurement must be done in as short a time as possible.

Compression pressure :
1,420kPa (14.5kgf/cm², 206psi)
Minimum pressure :
1,270kPa (13kgf/cm², 184psi)
Difference between each cylinder :
100kPa (1.0kgf/cm², 15psi) or less

D. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into
the cylinder through the spark plug hole and repeat steps (a) through (b) for cylinders with low
compression.
• 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 sticking or seating is improper, or there may be leakage
past the gasket.
5. Reinstall spark plugs. (Refer to Ignition system in EE Group)
6. Install ignition coils. (Refer to Ignition system in EE Group)

Engine Mechanical System > General Information > Special Service Tools

SPECIAL SERVICE TOOLS

Tool (Number and

Illustration Use
name)
Crankshaft front oil seal Installation of the front oil seal
installer
(09214-33000)

Camshaft oil seal Installation of the camshaft oil seal

installer
(09214-21000)

Valve guide installer Remove and installation of the valve

(09221-3F100 A/B) guide

Valve stem oil seal Installation of the valve stem oil seal
installer
(09222-22001)

Valve spring Removal and installation of the intake

compressor & adaptor or exhaust valve
(09222-28000, 09222-
28100)

Crankshaft rear oil seal 1. Installation of the engine rear oil

installer seal
(09231-33000) 2. Installation of the crankshaft rear oil
seal

Torque angle adapter Installation of bolts & nunts needing an

(09221-4A000) angular method.
Engine Mechanical System > General Information > Troubleshooting

TROUBLESHOOTING

Symption Suspect area Remedy

Engine misfire with Loose or improperly installed engine Repair or replace the flywheel as
abnormal internal flywheel. required.
lower engine
noises. Worn piston rings Inspect the cylinder for a loss of
(Oil cousumption may or may not cause compression.
the engine to misfire.) Repair or replace as required.

Worn crankshaft thrust bearings Replace the crankshaft and bearings as

required

Engine misfire with Stuck valves. Repair or replace as required

abnormal valve (Carbon buidup on the valve stem)
train noise.
Excessive worn or mis-aligned timing Replace the timing chain and sprocket
chain as required.

Worn camshaft lobes. Replace the camshaft and valve lifters.

Engine misfire with • Faulty cylinder head gasket and/or • Inspect the cylinder head and
coolant cranking or other damage to the engine block for damage to the
consumption cylinder head and engine block coolant passages and/or a faulty
cooling system. head gasket.
• Coolant consumprion may or may • Repair or replace as required.
not cause the engine to overheat.

Engine misfire with Worn valves, guides and/or valve stem Repair or replace as required.
excessive oil oil seals.
consumption
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.

Engine noise on Incorrect oil viscosity • Drain the oil.

start-up, but only • Install the correct viscosity oil.
lasting a few
Worn crankshaft thrust bearing. • Inspect the thrust bearing and
seconds.
crankshaft.
• Repair or replace as required.

Upper engine Low oil pressure Repair or replace as required.

noise, regardless
of engine speed. Broken valve spring. Replace the valve spring.

Worn or dirty valve lifters. Replace the valve lifters.

Stetched or broken timing chain and/or

Replace the timing chain and sprockets.
damaged sprocket teeth.

Worn timing chain tensioner, if Replace the timing chain tensioner as

applicable. 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 valve
then repair as required.
to stay open.

Lower engine Low oil pressure. Repair or required.

noise, regardless
of engine speed Loose or damaged flywheel. Repair or replace the flywheel.

Damaged oil pan, contacting the oil • Inspect the oil pan.
pump screen. • Inspect the oil pump screen.
• Repair or replace as required.

Oil pump screen loose, damaged or • Inspect the oil pump screen.
restircted. • Repair or replace as required.

Excessive piston-to-cylinder bore • Inspect the piston, piston pin and

clearance. cylinder bore.
• Repair as required.

Excessive piston pin-to-connecting rod • Inspect the piston, piston pin and
clearance the connecting rod.
• Repair or replace as required.

Excessive connecting rod bearing Inspect the following components and

clearance repair as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
• The crankshaft journal.

Excessive crankshaft bearing clearance Inspect the following components, and

repair as required.
• The crankshaft bearing.
• The crankshaft journals.

Incorrect piston, piston pin and • Verify the piston pins and
connecting rod installation connecting rods are installed
correctly.
• Repair as required.

Engine noise under Low oil pressure Repair or replace as required.

load
Excessive connecting rod bearing Inspect the following components and
clearance repair as required :
• The connecting rod bearings.
• The connecting rods.
• The crankshaft

Excessive crankshaft bearing clearance Inspect the following components, and

 repair as required.
• The crankshaft bearings.
• The crankshaft journals.
• The cylinder block crankshaft

Engine will not Hydraulically locked cylinder 1. Remove spark plugs and check for
crank-crankshaft • Coolant/antifreeze in cylinder. fluid.
will 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.
gears. 2. Repair as required.

Material in cylinder 1. Inspect cylinder for damaged

• Broken valve components and/or foreign
materials.
• Piston material
2. Repair or replace as required.
• Foreign material

Seized crankshaft or connecting rod 1. Inspect crankshaft and connecting

bearings. rod bearing.
2. Repair as required.

Bend or broken connecting rod. 1. Inspect connecing rods.

2. Repair as required.

Broken crankshaft 1. Inspect crankshaft.

2. Repair as required.

Engine Mechanical System > Timing System > Timing Belt > Components and
Components Location

COMPONENTS
Engine Mechanical System > Timing System > Timing Belt > Repair
procedures
REMOVAL
Engine removal is not required for this procedure.
1. Remove the engine cover.
2. Remove RH front wheel.
3. Remove 2bolts(B) and RH side cover(A).

4. Turn the crankshaft pulley, and align its groove with timing mark “T”of the timing belt cover.

Always turn the crankshaft clockwise.

5. Remove drive belt(A) and belt tensioner(B).

6. Remove the engine mount bracket.

 (1) Set the jack to the engine oil pan.

Place wooden block between the jack and engine oil pan.

(2) Remove the 2bolts, 2nuts and engine mount bracket(A).

7. Remove the power steering pump. (Refer to Power steering pump in ST Group)
8. Remove the 7bolts(B) and timing belt upper cover(A).

9. Remove the crankshaft pulley bolt and crankshaft pulley(A).

10. Remove the drive belt idler pulley(A).

11. Remove the 4bolts(B) and timing belt lower cover(A).

12. Remove the engine support bracket(A).

13. Check that timing marks of the camshaft timing pulleys and cylinder head covers are aligned.
If not, turn the crankshaft 1revolution(360°).
14. Remove timing belt tensioner.
Alternately loosen the 2bolts, and remove the tensioner(A).

15. Remove the timing belt(A).

If the timing belt is reused, make an arrow indicating the turning direction to make sure that
the belt is reinstalled in the same direction as before.

16. Remove the tensioner pulley(A) and timing belt idler pulley(B).
17. Remove the crankshaft sprocket.
18. Remove camshaft sprockets.
Hold the hexagonal head wrench portion of the camshaft with a wrench and remove the bolt and
camshaft sprocket.

Be careful not to damage the cylinder head and valve lifter with the wrench.

INSTALLATION
1. Install the crankshaft sprocket.
Align the pulley set key with the key groove the crankshaft sprocket and slide on the crankshaft
sprocket.
2 Install the camshaft sprockets and tighten the bolts to the specified torque.
. (1) Temporarily install the camshaft sprocket bolts.
(2 Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the
) camshaft sprocket bolts.

Tightening torque
Camshaft sprocket bolt
90 ~ 110Nm (9.0 ~ 11.0kgf.m, 65 ~ 80lb-ft)

3 Install the idler pulley(B) and the tensioner pulley(A).

.
Tightening torque
Idler pulley bolt
50 ~ 60Nm (5.0 ~ 6.0kgf.m, 36 ~ 43lb-ft)
Tensioner arm fixed bolt
35 ~ 55Nm (3.5 ~ 5.5kgf.m, 25 ~ 40lb-ft)
 Insert and install the idler pulley to the roll pin that is pressed in the water pump boss.

4. Align the timing marks of the camshaft sprocket and crankshaft sprocket with the No.1 piston
placed at top dead center and its compression stroke.

5. Set timing belt tensioner.

(1) Using a press, slowly press in the push rod.
(2) Align the holes of the push rod and housing pass a set pin through the holes to keep the setting
position of the push rod.
(3) Release the press.

6 Install the timing belt tensioner.

. (1) Temporarily install the tensioner with the 2bolts.
(2 Alternately tighten the 2bolts.
)
 Tightening torque
20 ~ 27Nm (2.0 ~ 2.7kgf.m, 14 ~ 20lb-ft)

7. Install the timing belt.

(1) Remove any oil or water on the sprockets, and keep them clean.
(2) Install the tming belt in this order.
Crankshaft sprocket(A) → Idler pulley(B) → Camshaft sprocket LH side(C) → Water pump
pulley(D) → Camshaft sprocket RH side(E) → Tensioner pulley(F).

8. Remove the set pin(A) from the tensioner.

9. Timing belt tensioner checking.

(1) Rotate the crankshaft 2turns clockwise and measure the projected length of the auto tensioner
 at TDC(#1 compression stroke) after 5 minutes.
(2) The projected length should be 7 ~ 9mm (0.27 ~ 0.31in.)

10 Install the engine support bracket(A).

.
Tightening torque
B : 60 ~ 70Nm (6.0 ~ 7.0kgf.m, 43 ~ 51lb-ft)
C : 15 ~ 22Nm (1.5 ~ 2.2kgf.m, 11 ~ 16lb-ft)

11 Install the timing belt lower cover(A) with 4bolts(B).

.
Tightening torque
Timing belt cover bolt
10 ~ 12Nm (1.0 ~1.2kgf.m, 7 ~ 9lb-ft)
12 Install the drive belt idler pulley(A).
.
Tightening torque
Idler pulley bolt
35 ~ 55Nm (3.5 ~ 5.5kgf.m, 25 ~ 40lb-ft)

13 Install the crankshaft pulley(A).

. Make sure that crankshaft sprocket pin fits the small hole in the pulley.

Tightening torque
Crankshaft pulley bolt
180 ~ 190Nm (18.0 ~ 19.0kgf.m, 130 ~ 138lb-ft)

14. Install the timing belt upper cover(A) with 7bolts(B).

15. Install the power steering pump. (Refer to Power steering pump in ST Group)
16. Install the drive belt tensioner(B) and drive belt(A).

17 Install the engine mount bracket.

. Install engine mount bracket with 2nuts and 2bolt.

Tightening torque
60 ~ 80Nm (6.0 ~ 8.0kgf.m, 44 ~ 59lb-ft)

18. Install RH side cover(A) with 2bolts(B).

19. Install RH front wheel.

20. Install engine cover.
INSPECTION

SPOCKETS, TENSIONER, IDLER

1. Check the camshaft sproket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal
wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or
noise.
Replace as necessary.

3. Replace the pulley if there is a grease leak from its bearing.

TIMING BELT
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 adjusted, check the belt carefully. If any of the
following flaws are evident, replace the belt.

• 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.

Engine Mechanical System > Cylinder Head Assembly > Components and
Components Location

COMPONENTS
Engine Mechanical System > Cylinder Head Assembly > Repair procedures

REMOVAL
 • Use fender covers to avoid damaging painted surfaces.
• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below
normal temperature before removing it.
• When handling a metal gasket, take care not to fold the gasket or damage the contact surface
of the gasket.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring and hoses to avoid misconnection.

• Inspect the timing belt before removing the cylinder head.
• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Remove the air duct(A).

2. Disconnect the negative terminal from the battery.

3. Drain the engine coolant.

Remove the radiator cap to speed draining.
4. Remove the engine cover.
5. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the AFS connector(A).
(2) Disconnect the breather hose(B) from air cleaner hose.
(3) Remove the intake air hose and air cleaner assembly(C).
6. Remove the upper radiator hose(A) and lower radiator hose(B).

7. Remove the heater hoses(A).

8. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and
the intake manifold.
(1) TPS(Throttle Position Sensor) connector(A).
(2) ISA(Idle Speed Actuator) connector(B).
(3) PCSV(Purge Control Solenoid Valve) connector(C).
(4) VIS actuator connector(D).
(5) Injector connector(E).
(6) Knock sensor connectors(F).
(7) CMP(Camshaft Position Sensor) connector(G).
(8) ECT(Engine Coolant Temperature) sensor connector(A).
(9) Ignition coil connector(B).
(10) Crankshaft position sensor connector(C).
(11) Oxygen sensor connector(D).

(12) Three fuel injector connectors(A).

(13) Disconnect ground cable(A) from the cowl panel.

 (14) IAT(Intake Air Temperature) sensor connector(A).
(15) VIS actuator connector(B).

9. Remove the fuel inlet hose(A) from delivery pipe.

10. Remove the PCSV hose.

11. Remove the brake booster vacuum hose(A).
12. Remove the accelerator cable by loosening the locknut, then slip the cable end out of the throttle
linkage.

13. Remove the PCV hose(A).

14. Remove the intake manifold.

15. Remove the power steering pump. (Refer to Power steering pump in ST Group).
16. Remove the exhaust manifold.
17. Remove the timing belt.
18. Remove the spark plug cable. (Refer to Ignition system in EE Group)
19. Remove the cylinder head covers(A).
20. Remove the camshaft sprocket.
21. Remove the camshaft bearing caps(A).

22. Remove the camshafts(A).

23. Remove the timing belt rear cover(A).

24. Remove the water temperature control assembly(A) and water pipe.
25. Remove the cylinder head bolts, then remove the cylinder heads.
(1) Uniformly loosen and remove the 8 cylinder head bolts on each cylinder head in several
passes and in the sequence shown, then repeat for the other side, as shown. Remove the 16
cylinder head bolts and plate washer.

Head warpage or cracking could result from removing bolts in an incorrect order.

(2) Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on
wooden blocks on a bench.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

REPLACEMENT

VALVE GUIDE
1. Using the SST(09221-3F100A), withdraw the old valve guide toward the bottom of cylinder head.
2. Recondition the valve guide hole so that it can match the newly press-fitted oversize valve guide.
3 Using the SST(09221-3F100A/B), press-fit the valve guide. The valve guide must be press-fitted
. from the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guides are
different in length.
Over size mm(in.) Size mark Oversize valve guide hole size mm(in.)

11.05 ~ 11.068
0.05 (0.002) 5
(0.4350 ~ 0.4357)

11.25 ~ 11.268
0.25 (0.010) 25
(0.4429 ~ 0.4436)

11.50 ~ 11.518
0.50 (0.020) 50
(0.4528 ~ 0.4535)

Valve guide length

Intake : 39mm (1.535in.)
Exhaust : 43mm (1.693in.)

4. After the valve guide is press-fitted, insert a new valve and check for proper stem -to-guide
clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve
seats as necessary.

INSTALLATION

• 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 the No.1 piston at TDC.
1. Install the cylinder head gaskets on the cylinder block.
 Be careful of the installation direction.

2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3 Install cylinder head bolts.
.
Tightening torque
23~27Nm (2.3~2.7kgf.m, 17~20lb-ft) + (58°~62°) + (43°~47°)

(1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.
(3 Install and uniformly tighten the cylinder head bolts on each cylinder head in several passes and
) in the sequence shown, then repeat for the other side, as shown.

If only one of the cylinder head bolts dose not meet the torque specification, replace the cylinder
head bolt.

Torque : 23~27Nm (2.3~2.7kgf.m, 17~20lb-ft) + (58°~62°) + (43°~47°)

 (4) Retighten the cylinder head bolts by 60° in the numerical order shown.
(5) Retighten the cylinder head bolts by 45° in the numerical order shown.

4 Install the water pipe and water temperature control assembly(A).

.
Tightening torque
Water temperature control
15 ~ 20Nm (1.5 ~ 2.0kgf.m, 11 ~ 14lb-ft)

5 Install the timing belt rear cover(A).

.
Tightening torque
Timing belt rear cover
10 ~ 12Nm (1.0 ~ 1.2kgf.m, 7 ~ 9lb-ft)
6 Install the camshafts.
. (1) Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain
sprocket as shown.

(2) Install the camshaft(A).

(3 Install the camshaft bearing caps(A).

)
Tightening torque
M6(38mm) : 10 ~ 12Nm (1.0 ~ 1.2kgf.m, 7 ~ 9lb-ft)
M6(50mm) : 14 ~ 16Nm (1.4 ~ 1.6kgf.m, 10 ~ 12lb-ft)
 • Apply new engine oil to the thrust portion and journal of the camshafts.
• Apply a light coat of engine oil on the threads and under the heads of the bearing cap
bolts.

7. Using the SST (09214-21000), install the camshaft bearing oil seal.

8 Install the camshaft sprocket.

. (1) Temporarily install the camshaft sprocket bolts.
(2 Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the
) camshaft sprocket bolts.

Tightening torque
Camshaft sprocket bolt
90 ~ 110Nm (9.0 ~ 11.0kgf.m, 65 ~80lb-ft)

9. Install semi-circular packing.

10 Install the cylinder head cover.
. (1) Install the cylinder head cover gasket(A) in the groove of the cylinder head cover(B).
 • Before installing the head cover gasket, thoroughly clean the head cover gasket and
the groove.
• When installing, make sure the head cover gasket is seated securely in the corners of
the recesses with no gap.

(2) Apply liquid gasket to the head cover gasket at the corners of the recess.

• Use liquid gasket, loctite No.5699.

• Check that the mating surfaces are clean and dry before applying liquid gasket.
• After assembly, wait at least 30 minutes before filling the engine with oil.

(3 Install the cylinder head covers(A) with the 16bolts. Uniformly tighten the bolts in several
) passes.

Tightening torque
8 ~ 10Nm (0.8 ~ 1.0kgf.m, 6 ~ 7.4lb-ft)
11. Install the spark plug cable. (Refer to Ignition system in EE Group)
12. Install the timing belt.
13. Install the exhaust manifold.
14. Install the power steering pump. (Refer to Power steering pump in ST Group)
15. Install the intake manifold.
16. Install the PCV hose(A).

17. Install the accelerator cable.

18. Install the brake booster vacuum hose(A).

19. Install the PCSV hose.

20. Install the fuel inlet hose(A).

21. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the
intake manifold.
(1) VIS actuator connector(B).
(2) IAT(Intake Air Temperature) sensor connector(A).

(3) Connect the ground cable(A) to the cowl panel.

(4) Three fuel injector connectors(A).

(5) Oxygen sensor connector(D).

(6) Crankshaft position sensor connector(C).
(7) Ignition coil connector(B).
(8) ECT sensor connector(A).

(9) CMP(Camshaft position sensor) connector(G).

(10) Knock sensor connector(F).
(11) Injector connector(E).
(12) VIS actuator connector(D).
(13) PCSV(Purge Control Solenoid Valve) connector(C).
(14) ISA connector(B).
 (15) TPS connector(A).

22. Install the heater hoses(A).

23. Install the upper radiator hose(A) and lower radiator hose(B).

24. Install the intake air hose and air cleaner assembly.
(1) Install the intake air hose and air cleaner assembly(C).
(2) Connect the breather hose(B) from air cleaner hose.
(3) Connect the AFS connector(A).
25. Install the engine cover.
26. Connect the negative terminal to the battery.

27. Install the air duct(A).

28. Filll with engine coolant.

29. Start the engine and check for leaks.
30. Recheck engine coolant level and oil level.

DISASSEMBLY

Identify HLA(Hydraulic Lash Adjuster), valves, valve springs as they are removed so that each item
 can be reinstalled in its original position.

1. Remove HLAs(A).

2. Remove valves.
(1) Using SST(09222-28000, 09222-28100), compress the valve spring and remove retainer lock.

(2) Remove the spring retainer.

(3) Remove the valve spring.
(4) Remove the valve.
(5) Using needle-nose pliers, remove the oil seal.
(6) Using a magnetic finger, remove the spring seat.

INSPECTION

Cleaning
1. Clean top surfaces of pistons and cylinder block.
(1) Turn the crankshaft, and bring each piston to top dead center(TDC).
Using a gasket scraper, remove all the carbon from the piston top surface.
(2) Using a gasket scraper, remove all the gasket material from the cylinder block surface.
(3) Using compressed air, blow carbon and oil from the bolt holes.

2. Remove gasket material.

Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.
 Be careful not to scratch the cylinder block contact surface.

3. Clean combustion cambers.

Using a wire brush, remove all the carbon from the combustion cambers.

Be careful not to scratch the cylinder block contact surface.

4. Clean cylinder heads.

Using a soft brush and solvent. throrghly clean the cylinder head.
5. Clean valves.
(1) Using a gasket scraper, chip off any carbon from the valve head.
(2) Using a wire brush throroghly clean the valve.

CYLINDER HEAD
1 Inspect for flatness.
. Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder
block for warpage.

Flatness of cylinder head gasket surface

Standard : Less than 0.03mm(0.0012 in.)
Limit : 0.05 mm ( 0.0020 in.)

2. Inspect for cracks.

Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If
cracked, replace the cylinder head.

VALVE AND VALVE SPRING

1 Inspect valve stems and valve guides.
. (1) Using a caliper gauge, measure the inside diameter or the valve guide.
Valve guide inside.
 (2) Using a micrometer, measure the diameter of the valve stem.

(3 Subtract the valve stem diameter measurement from the valve guide inside diameter
) measurement.
Valve stem-to-guide clearance

[Standard]
Intake : 0.02 ~ 0.05mm (0.0008 ~ 0.0020in.)
Exhaust : 0.030 ~ 0.065mm (0.0012 ~ 0.0026in.)
[Limit]
Intake : 0.1mm (0.0040in.)
Exhaust : 0.13mm (0.0051in.)

If the clearance is greater than maximum, replace the valve and valve guide.

2 Inspect valves.
. (1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
(3 Check the valve head margin thickness.
) If the margin thickness is less than minimum, replace the valve.

Margin
[Standard]
Intake : 1.0mm (0.0394in.)
Exhaust : 1.3mm (0.0512in.)
[Limit]
Intake : 0.5mm (0.0197in.)
 Exhaust : 0.8mm (0.0315in.)

(4) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.

3. Inspect valve seats

Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it,
then recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve
seat contact width should be within specifications and centered on the valve face.
4 Inspect valve springs.
. (1) Using a steel square, measure the out-of-square of the valve spring.
(2 Using a vernier calipers, measure the free length of the valve spring.
)
Valve spring
[Standard]
Free height : 42.5mm (1.6732in.)
Load : 21kg/35mm (48.4kg/1.378mm)
[Limit]
Free height : -1.0mm ( -0.0394 in.)
Out-of-square : 3°

If the free length is not as specified, replace the valve spring.

CAMSHAFT
1 Inspect cam lobes.
. Using a micrometer, measure the cam lobe height.

Cam height
[Standard value]
Intake : 43.95 ~44.15mm (1.7303 ~ 1.7382in.)
Exhaust : 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)

If the cam lobe height is less than minimum, replace the camshaft.
2 Inspect cam journals.
. Using a micrometer, measure the journal diameter.

Journal diameter
Standard value
25.964 ~ 25.980mm (1.0222 ~ 1.0228in.)

If the journal diameter is not as specified, check the oil clearance.

3. Inspect camshaft bearings.
Check that bearing for flaking and scoring. If the bearings are damaged, replace the bearing caps
and cylinder head as a set.
4 Inspect camshaft journal oil 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.

(4) Install the bearing caps.

 Do not turn the camshaft.

(5) Remove the bearing caps.

(6 Measure the plastigage at its widest point.
)
Bearing oil clearance
Standard value : 0.02 ~ 0.061mm (0.0008 ~ 0.0024in.)
Limit : 0.1mm (0.0039in.)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the
bearing caps and cylinder head as a set.
(7) Completely remove the plastigage.
(8) Remove the camshafts.

5 Inspect camshaft end play.

. (1) Install the camshafts.
(2 Using a dial indicator, measure the end play while moving the camshaft back and forth.
)
Camshaft end play
Standard value : 0.1 ~ 0.15mm (0.004 ~ 0.0059in.)

If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.
(3) Remove the camshafts.
REASSEMBLY

Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.

1. Install valves.
(1) Install the spring seats.
(2) Using SST(09222-22001), push in a new oil seal.

Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage past the valve guides.

(3) Install the valve, valve spring and spring retainer.

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

(4) Using the SST(09222-28000, 09222-28100), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing
the valve spring compressor.
 (5) 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 HLAs.
Check that the HLA rotates smoothly by hand.

Engine Mechanical System > Engine And Transaxle Assembly > Repair
procedures

REMOVAL

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
 • Mark all wiring and hoses to avoid misconnection.
• Inspection the timing belt before removing the cylinder head.
• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Remove the air duct(A).

2. Disconnect the negative terminal from the battery.

3. Drain the engine coolant.

Remove the radiator cap to speed draining.

4. Remove the engine cover.

5. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the AFS connector(A).
(2) Disconnect the breather hose(B) from air cleaner hose.
 (3) Remove the intake air hose and air cleaner assembly(C).

6. Remove the upper radiator hose(A) and lower radiator hose(B).

7. Remove the heater hoses(A).

8. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and
the intake manifold.
(1) TPS(Throttle Position Sensor) connector(A).
(2) ISA(Idle Speed Actuator) connector(B).
(3) PCSV(Purge Control Solenoid Valve) connector(C).
(4) VIS actuator connector(D).
(5) Injector connector(E).
(6) Knock sensor connector(F).
(7) CMP(Camshaft Position Sensor) connector(G).
(8) ECT(Engine Coolant Temperature) sensor(A) connector.
(9) Ignition coil connector(B).
(10) Crankshaft position sensor connector(C).
(11) Rear oxygen sensor connector(D).

(12) Three fuel injector connectors(A).

(13) Disconnect ground cable(A) from the cowl panel.

 (14) Intake air temperature sensor connector(A).
(15) VIS actuator connector(B).

9. Disconnect front heated oxygen sensor(LH) connector(A), air compressor switch connector(B) and
oil pressure sensor connector(C).

10. Disconnect rear heated oxygen sensor(RH) connector.

11. Remove the fuel inlet from delivery pipe(A).
12. Remove the PCSV hose.
13. Remove the brake booster vacuum hose(A).

14. Remove the accelerator cable by loosening the locknut, then slip the cable end out of the throttle
linkage.

15. Remove the power steering pump hose(A).

16. Remove the battery body bracket.

17. Disconnect the transaxle wire harness connector.

A. Disconnect the inhibitor switch connector(A).
 B. Disconnect the transaxle range connector(B).
C. Disconnect the input shaft speed connector(C).

D. Disconnect the output shaft speed connector(A).

E. Disconnect the vehicle speed sensor connector(B).

18. Remove the control cable(A) transaxle range switch.

19. Remove the transaxle oil cooler hoses(A/T)(A).

20. Remove the under cover(A).

21. Remove the front exhaust pipe(A).

22. Remove the front tires.

23. Disconnect the stabilizer bar link and remove the mounting bolts from the lower arm the front
axles.
24. Remove the steering u-joint mounting bolt(A). (Refer to Steering system in ST Group)
25. Install the jack for supporting engine and transaxle assembly.
26. Remove the engine mounting bracket(A).

27. Remove the transaxle mounting bracket(A).

28 Remove the sub frame mounting bolts and nuts.

.
Tightening torque
A : 160 ~ 180Nm (16.0 ~ 18.0kgf.m, 118 ~ 133lb-ft)
B : 70 ~ 90Nm (7.0 ~ 9.0kgf.m, 52 ~ 66lb-ft)
29. Jack up the vehicle.

INSTALLATION
Perform the following :
• Adjust the shift cable.
• Adjust the throttle cable.
• Refill the engine with engine oil.
• Refill the transaxle with fluid.
• 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 pressureizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

Engine Mechanical System > Cylinder Block > Components and Components
Location

COMPONENT
Engine Mechanical System > Cylinder Block > Repair procedures
DISASSEMBLY
1. A/T : remove drive plate.
2. Install engine to engine stand for disassembly(A).
3. Remove timing belt.
4. Remove cylinder head.
5. Remove oil level gauge assembly.
6. Remove the alternator. (Refer to in EE Group).
7. Remove the air conditioner compressor. (Refer to in HA Group)
8. Remove the power steering pump bracket(A).

9. Remove water pump.

10. Remove knock sensors(A).

11. Remove the lower oil pan(A).

12. Remove oil screen.
Remove the 2bolts(B), oil screen(A) and gasket.

13. Remove the upper oil pan(A).

14. Check the connecting rod end play.

15. Remove the connecting rod caps and check oil clearance.
16. Remove piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
 (2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder
block.

• Keep the bearings, connecting rod and cap together.

• Arrange the piston and connecting rod assemblies in the correct order.

17. Remove front case.

18. Remove oil seal case.
Remove the 3bolts(B) and oil seal case(A).

19. Check the crankshaft end play.

20. Remove crankshaft bearing cap and check oil clearance.

21. Lift the crankshaft(A) out of the engine, being careful not to damage journals.

Arrange the main bearings and trust washers in the correct order.
22. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston
and pin as a set.
23. Remove piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove the 2side rails and oil ring by hand.

Arrange the piston rings in the correct order only.

24. Disconnect connecting rod from piston.

DISASSEMBLY
1. A/T : remove drive plate.
2. Install engine to engine stand for disassembly(A).
3. Remove timing belt.
4. Remove cylinder head.
5. Remove oil level gauge assembly.
6. Remove the alternator. (Refer to in EE Group).
7. Remove the air conditioner compressor. (Refer to in HA Group)
8. Remove the power steering pump bracket(A).
9. Remove water pump.
10. Remove knock sensors(A).

11. Remove the lower oil pan(A).

12. Remove oil screen.

Remove the 2bolts(B), oil screen(A) and gasket.

13. Remove the upper oil pan(A).

14. Check the connecting rod end play.
15. Remove the connecting rod caps and check oil clearance.
16. Remove piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder
block.

• Keep the bearings, connecting rod and cap together.

• Arrange the piston and connecting rod assemblies in the correct order.

17. Remove front case.

18. Remove oil seal case.
Remove the 3bolts(B) and oil seal case(A).

19. Check the crankshaft end play.

20. Remove crankshaft bearing cap and check oil clearance.
21. Lift the crankshaft(A) out of the engine, being careful not to damage journals.

Arrange the main bearings and trust washers in the correct order.

22. Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston
and pin as a set.
23. Remove piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove the 2side rails and oil ring by hand.

Arrange the piston rings in the correct order only.

24. Disconnect connecting rod from piston.

INSPECTION

CONNECTING ROD AND CRANKSHAFT

1 Check the connecting rod end play.
. Using a dial indicator, measure the end play while moving the connecting rod back and forth.

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

Maximum end play : 0.4mm(0.016in.)

A. If out-of-tolerance, replace the connecting rod assembly.

B. If still out-of-tolerance, replace the crankshaft.
2 Check the connecting road bearing oil clearance.
. (1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct
reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and bearing half.
(4) Clean the crank pin and bearing.
(5) Place plastigage across the crank pin.
(6 Reinstall the bearing half and cap, and torque the bolts.
)
Tightening torque
16 ~ 20Nm (1.6 ~ 2.0kgf.m, 12 ~ 15lb-ft) + 90°

Do not turn the crankshaft.

(7) Remove the 2bolts, connecting rod cap and bearing half.
(8 Measure the plastigage at its widest point.
)
Standard oil clearance
0.018 ~ 0.036mm(0.0007 ~ 0.0014in.)
(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install
a new, complete bearing with the same color mark (select the color as shown in the next
column), and recheck the clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing
(the color listed above or below that one), and check clearance again.

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

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub
them with a wire brush or scraper. Clean them only with solvent or detergent.

Connecting rod mark location

Discrimination of connecting rod

CLASS MARK INSIDE DIAMETER

51.000 ~ 51.006mm
0 A
(2.0079 ~ 2.0081in.)
 51.006 ~ 51.012mm
1 B
(2.0081 ~ 2.0083in.)

51.012 ~ 51.018mm
2 C
(2.0083 ~ 2.0086in.)

Crankshaft pin mark location

Discrimination of crankshaft
CLSASS MARK OUTSIDE DIAMETER OF PIN

47.994 ~ 48.000mm
I A
(1.8895 ~ 1.8898in.)

47.988 ~ 47.994mm
II B
(1.8893 ~ 1.8895in.)

47.982 ~ 47.988mm
III C
(1.8890 ~ 1.8893in.)

Place of identification mark (Connecting rod bearing)

Discrimination of connecting rod bearing

CLASS MARK THICKNESS OF BEARING

1.500 ~ 1.503mm
A BLUE
(0.0590 ~ 0.0591in.)

B BLACK 1.497 ~ 1.500mm

 (0.0589 ~ 0.0590in.)

1.494 ~ 1.497mm
C NONE
(0.0588 ~ 0.0589in.)

1.491 ~ 1.494mm
D GREEN
(0.0587 ~ 0.0588in.)

1.488 ~ 1.491mm
E YELLOW
(0.0586 ~ 0.0587in.)

(11) Selection
ASSEMBING
CRANKSHAFT INDENTIFICATION CONNECTING ROD
CLASSIFICATION OF
MARK IDENTIFICATION MARK
BEARING

0 (A) E (YELLOW)

I (A) 1 (B) D (GREEN)

2 (C) C (NONE)

0 (A) D (GREEN)

II (B) 1 (B) C (NONE)

2 (C) B (BLACK)

0 (A) C (NONE)

III (C) 1 (B) B (BLACK)

2 (C) A (BLUE)

3 Check the crankshaft bearing oil clearance.

. (1) To check main bearing-to-journal oil clearance, remove the main 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 bolts.
)
Tightening torque
M8
13 ~ 19Nm (1.3 ~ 1.9kgf.m, 10 ~ 14lb-ft) + (90°~95°)
M10
27 ~ 33Nm (2.7 ~ 3.3kgf.m, 19.5 ~ 24lb-ft) + (90°~95°)

Do not turn the crankshaft.

(5 Remove the cap and bearing again, and measure the widest part of the plastigage.
)
Standard oil clearance
0.004 ~ 0.022mm (0.00016 ~ 0.00087in.)
 (6) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install
a new, complete bearing with the same color mark (select the color as shown in the next
column), and recheck the clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.

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

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub
them with a wire brush or scraper. Clean them only with solvent or detergent.

Connecting rods
1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at
disassembly match. When a new connecting rod is installed, make sure that the notches for holding
the bearing in place are on the same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a
severely rough surface of the inside diameter of the small end is apparent, the rod must be
replaced as well.
3 Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is
. close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent
or distorted should be replaced.

Allowable bend of connecting rod

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

Letters have been stamped on the end of the block as a mark for the size of each of the 4 main
journal bores.

Discrimination of cylinder block

CALSS MARK INSIDE DIAMETER

66.000 ~ 66.006mm
a A
(2.5984 ~ 2.5986in.)

66.006 ~ 66.012mm
b B
(2.5986 ~ 2.5989in.)

66.012 ~ 66.018mm
c C
(2.5989 ~ 2.5991in.)

Crankshaft journal mark location

Discrimination of crankshaft
CLASS MARK OUTSIDE DIAMETER OF JOURNAL

61.994 ~ 62.000mm
I A
(2.4407 ~ 2.4409in.)

61.988 ~ 61.994mm
II B
(2.4405 ~ 2.4407in.)

61.982 ~ 61.988mm
III C
(2.4402 ~ 2.4405in.)

Place of identification mark (Crankshaft bearing)

 Discrimination of crankshaft bearing
CLASS MARK THICKNESS OF BEARING

2.007 ~ 2.010mm
A BLUE
(0.0790 ~ 0.0791in.)

2.004 ~ 2.007mm
B BLACK
(0.0789 ~ 0.0790in.)

2.001 ~ 2.004mm
C NONE
(0.0788 ~ 0.0789in.)

1.998 ~ 2.001mm
D GREEN
(0.0787 ~ 0.788in.)

1.995 ~ 1.998mm
E YELLOW
(0.0785 ~ 0.0787in.)

Selection
ASSEMBLING
CRANKSHAFT IDENTIFICATION CRANKSHAFT BORE
CLASSIFICATION OF
MARK IDENTIFICATION MARK
BEARING

a (A) E (YELLOW)

I (A) b (B) D (GREEN)

c (C) C (NONE)

a (A) D (GREEN)

II (B) b (B) C (NONE)

c (C) B (BLACK)

a (A) C (NONE)

III (C) b (B) B (BLACK)

c (C) A (BLUE)

4 Check crankshaft end play.

. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with
a screwdriver.
 Standard end play
0.07 ~ 0.25mm (0.0027 ~ 0.0098in.)
Limit : 0.30mm (0.0118in.)

If the end play is greater than maximum, replace the thrust bearings as a set.

Thrust bearing thickness

1.925 ~ 1.965mm (0.076 ~ 0.077in.)

5 Inspect main journals and crank pins

. Using a micrometer, measure the diameter of each main journal and crank pin.

Main journal diameter

61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)
Crank pin diameter
47.982 ~ 48.000mm (1.8890 ~ 1.8898in.)

CYLINDER BLOCK
1. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3 Inspect top surface of cylinder block for flatness.
. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head
gasket for warpage.

Flatness of cylinder block gasket surface

Standard : Less than 0.03mm(0.0012 in.)
Limit : 0.05 mm ( 0.0020 in.)

4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder liner.
5 Inspect cylinder bore diameter
. Using a cylinder bore gauge, measure the cylinder bore diameter at position A, B and C in the
thrust and axial directions.

Standard diameter
86.70 ~ 86.73mm (3.4134 ~ 3.4145in.)

6. Check the cylinder bore size code(A) on the cylinder block bottom face.
 Size
Class Cylinder bore inner diameter
code

A 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) A

B 86.71 ~ 86.72mm (3.4137 ~ 3.4141in.) B

C 86.72 ~ 86.73mm (3.4141 ~ 3.4145in.) C

7. Check the piston size code(A) on the piston top face.

Stamp the grade mark of basic diameter with rubber stamp.

Size
Class Piston diameter
code

A 86.68 ~ 86.69mm (3.4126 ~ 3.4130in.) A

B 86.69 ~ 86.70mm (3.4130 ~ 3.4133in.) None

C 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) C

8 Select the piston related to cylinder bore class.

.
Clearance : 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)

Boring Cylinder
1. Oversize pistons should be selected according to the largest bore cylinder.
Identification Mark Size

0.25 0.25mm (0.010in.)

0.50 0.50mm (0.0250in.)

The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.

3 According to the measured O.D., calculate the new bore size.
.
New bore size = Piston O.D + 0.01 to 0.03mm
(0.0004 to 0.0012 in.) (clearance between piston and
cylinder) - 0.01 mm (0.0004 in.) (honing margin.)

4. Bore each of the cylinders to the calculated size.

To prevent distortion that may result from temperature rise during honing, bore the cylinder
holes in the firing order.

5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with
cylinder).
6 Check the clearance between the piston and cylinder.
.
Standard : 0.01 ~ 0.03mm (0.0004 ~ 0.0012 in.)

When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one
cylinder to the oversize.

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

Do not use a wire brush.

2 The standard measurement of the piston outside diameter is taken 38.5mm (1.516in.) from the top
. land of the piston.
 Standard diameter
86.68 ~ 86.71mm (3.4126 ~ 3.4138in.)

3 Calculate the difference between the cylinder bore diameter and the piston diameter.
.
Piston-to-cylinder clearance
0.01 ~ 0.03mm(0.0004 ~ 0.0012in.)

4 Inspect the piston ring side clearance.

. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring
groove.

Piston ring side clearance

No. 1 : 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.)
No. 2 : 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)
Limit
No. 1 : 0.1mm (0.004in.)
No. 2 : 0.1mm (0.004in.)

If the clearance is greater than maximum, replace the piston.

5 Inspect piston ring end gap.
. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at
right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a
feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large,
recheck the cylinder bore diameter against the wear limits. If the bore is over the service limit, the
cylinder block must be rebored.

Piston ring end gap

 Standard
No.1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)
No.2 : 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)
Limit
Oil ring : 0.2 ~ 0.7mm (0.0079 ~ 0.0276in.)

PISTON PINS
1 Measure the diameter of the piston pin.
.
Piston pin diameter
21.001 ~ 21.007mm (0.8268 ~ 0.8270in.)

2 Measure the piston pin-to-piston clearance.

.
Piston pin-to-piston clearance
0.011 ~ 0.018mm (0.00043 ~ 0.00071in.)

3 Check the difference between the piston pin diameter and the connecting rod small end diameter.
.
Piston pin-to-connecting rod interference
0.016 ~ 0.033mm (0.00063 ~ 0.00130in.)

OIP PRESSURE SWITCH

1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.

2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is
continuity even when the fine wire is pushed, replace the switch.
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 diahragm is broken. Replace it.

INSPECTION

CONNECTING ROD AND CRANKSHAFT

1 Check the connecting rod end play.
. Using a dial indicator, measure the end play while moving the connecting rod back and forth.

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

Maximum end play : 0.4mm(0.016in.)
 A. If out-of-tolerance, replace the connecting rod assembly.
B. If still out-of-tolerance, replace the crankshaft.
2 Check the connecting road bearing oil clearance.
. (1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct
reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and bearing half.
(4) Clean the crank pin and bearing.
(5) Place plastigage across the crank pin.
(6 Reinstall the bearing half and cap, and torque the bolts.
)
Tightening torque
16 ~ 20Nm (1.6 ~ 2.0kgf.m, 12 ~ 15lb-ft) + 90°

Do not turn the crankshaft.

(7) Remove the 2bolts, connecting rod cap and bearing half.
(8 Measure the plastigage at its widest point.
)
Standard oil clearance
0.018 ~ 0.036mm(0.0007 ~ 0.0014in.)
(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install
a new, complete bearing with the same color mark (select the color as shown in the next
column), and recheck the clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing
(the color listed above or below that one), and check clearance again.

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

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub
them with a wire brush or scraper. Clean them only with solvent or detergent.

Connecting rod mark location

Discrimination of connecting rod

CLASS MARK INSIDE DIAMETER

51.000 ~ 51.006mm
0 A
(2.0079 ~ 2.0081in.)

51.006 ~ 51.012mm
1 B
(2.0081 ~ 2.0083in.)

51.012 ~ 51.018mm
2 C
(2.0083 ~ 2.0086in.)

Crankshaft pin mark location

Discrimination of crankshaft
CLSASS MARK OUTSIDE DIAMETER OF PIN

47.994 ~ 48.000mm
I A
(1.8895 ~ 1.8898in.)

47.988 ~ 47.994mm
II B
(1.8893 ~ 1.8895in.)

47.982 ~ 47.988mm
III C
(1.8890 ~ 1.8893in.)

Place of identification mark (Connecting rod bearing)

Discrimination of connecting rod bearing

CLASS MARK THICKNESS OF BEARING

1.500 ~ 1.503mm
A BLUE
(0.0590 ~ 0.0591in.)

1.497 ~ 1.500mm
B BLACK
(0.0589 ~ 0.0590in.)

1.494 ~ 1.497mm
C NONE
(0.0588 ~ 0.0589in.)

1.491 ~ 1.494mm
D GREEN
(0.0587 ~ 0.0588in.)

E YELLOW 1.488 ~ 1.491mm

 (0.0586 ~ 0.0587in.)

(11) Selection
ASSEMBING
CRANKSHAFT INDENTIFICATION CONNECTING ROD
CLASSIFICATION OF
MARK IDENTIFICATION MARK
BEARING

0 (A) E (YELLOW)

I (A) 1 (B) D (GREEN)

2 (C) C (NONE)

0 (A) D (GREEN)

II (B) 1 (B) C (NONE)

2 (C) B (BLACK)

0 (A) C (NONE)

III (C) 1 (B) B (BLACK)

2 (C) A (BLUE)

3 Check the crankshaft bearing oil clearance.

. (1) To check main bearing-to-journal oil clearance, remove the main 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 bolts.
)
Tightening torque
M8
13 ~ 19Nm (1.3 ~ 1.9kgf.m, 10 ~ 14lb-ft) + (90°~95°)
M10
27 ~ 33Nm (2.7 ~ 3.3kgf.m, 19.5 ~ 24lb-ft) + (90°~95°)

Do not turn the crankshaft.

(5 Remove the cap and bearing again, and measure the widest part of the plastigage.
)
Standard oil clearance
0.004 ~ 0.022mm (0.00016 ~ 0.00087in.)
 (6) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install
a new, complete bearing with the same color mark (select the color as shown in the next
column), and recheck the clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.

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

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub
them with a wire brush or scraper. Clean them only with solvent or detergent.

Connecting rods
1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at
disassembly match. When a new connecting rod is installed, make sure that the notches for holding
the bearing in place are on the same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a
severely rough surface of the inside diameter of the small end is apparent, the rod must be
replaced as well.
3 Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is
. close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent
or distorted should be replaced.

Allowable bend of connecting rod

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

Letters have been stamped on the end of the block as a mark for the size of each of the 4 main
journal bores.
Discrimination of cylinder block
CALSS MARK INSIDE DIAMETER

66.000 ~ 66.006mm
a A
(2.5984 ~ 2.5986in.)

66.006 ~ 66.012mm
b B
(2.5986 ~ 2.5989in.)

66.012 ~ 66.018mm
c C
(2.5989 ~ 2.5991in.)

Crankshaft journal mark location

Discrimination of crankshaft
CLASS MARK OUTSIDE DIAMETER OF JOURNAL

61.994 ~ 62.000mm
I A
(2.4407 ~ 2.4409in.)

61.988 ~ 61.994mm
II B
(2.4405 ~ 2.4407in.)

61.982 ~ 61.988mm
III C
(2.4402 ~ 2.4405in.)

Place of identification mark (Crankshaft bearing)

 Discrimination of crankshaft bearing
CLASS MARK THICKNESS OF BEARING

2.007 ~ 2.010mm
A BLUE
(0.0790 ~ 0.0791in.)

2.004 ~ 2.007mm
B BLACK
(0.0789 ~ 0.0790in.)

2.001 ~ 2.004mm
C NONE
(0.0788 ~ 0.0789in.)

1.998 ~ 2.001mm
D GREEN
(0.0787 ~ 0.788in.)

1.995 ~ 1.998mm
E YELLOW
(0.0785 ~ 0.0787in.)

Selection
ASSEMBLING
CRANKSHAFT IDENTIFICATION CRANKSHAFT BORE
CLASSIFICATION OF
MARK IDENTIFICATION MARK
BEARING

a (A) E (YELLOW)

I (A) b (B) D (GREEN)

c (C) C (NONE)

a (A) D (GREEN)

II (B) b (B) C (NONE)

c (C) B (BLACK)

a (A) C (NONE)

III (C) b (B) B (BLACK)

c (C) A (BLUE)

4 Check crankshaft end play.

. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with
a screwdriver.
 Standard end play
0.07 ~ 0.25mm (0.0027 ~ 0.0098in.)
Limit : 0.30mm (0.0118in.)

If the end play is greater than maximum, replace the thrust bearings as a set.

Thrust bearing thickness

1.925 ~ 1.965mm (0.076 ~ 0.077in.)

5 Inspect main journals and crank pins

. Using a micrometer, measure the diameter of each main journal and crank pin.

Main journal diameter

61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)
Crank pin diameter
47.982 ~ 48.000mm (1.8890 ~ 1.8898in.)

CYLINDER BLOCK
1. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3 Inspect top surface of cylinder block for flatness.
. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head
gasket for warpage.

Flatness of cylinder block gasket surface

Standard : Less than 0.03mm(0.0012 in.)
Limit : 0.05 mm ( 0.0020 in.)

4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder liner.
5 Inspect cylinder bore diameter
. Using a cylinder bore gauge, measure the cylinder bore diameter at position A, B and C in the
thrust and axial directions.

Standard diameter
86.70 ~ 86.73mm (3.4134 ~ 3.4145in.)

6. Check the cylinder bore size code(A) on the cylinder block bottom face.
 Size
Class Cylinder bore inner diameter
code

A 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) A

B 86.71 ~ 86.72mm (3.4137 ~ 3.4141in.) B

C 86.72 ~ 86.73mm (3.4141 ~ 3.4145in.) C

7. Check the piston size code(A) on the piston top face.

Stamp the grade mark of basic diameter with rubber stamp.

Size
Class Piston diameter
code

A 86.68 ~ 86.69mm (3.4126 ~ 3.4130in.) A

B 86.69 ~ 86.70mm (3.4130 ~ 3.4133in.) None

C 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) C

8 Select the piston related to cylinder bore class.

.
Clearance : 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)

Boring Cylinder
1. Oversize pistons should be selected according to the largest bore cylinder.
Identification Mark Size

0.25 0.25mm (0.010in.)

0.50 0.50mm (0.0250in.)

The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.

3 According to the measured O.D., calculate the new bore size.
.
New bore size = Piston O.D + 0.01 to 0.03mm
(0.0004 to 0.0012 in.) (clearance between piston and
cylinder) - 0.01 mm (0.0004 in.) (honing margin.)

4. Bore each of the cylinders to the calculated size.

To prevent distortion that may result from temperature rise during honing, bore the cylinder
holes in the firing order.

5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with
cylinder).
6 Check the clearance between the piston and cylinder.
.
Standard : 0.01 ~ 0.03mm (0.0004 ~ 0.0012 in.)

When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one
cylinder to the oversize.

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

Do not use a wire brush.

2 The standard measurement of the piston outside diameter is taken 38.5mm (1.516in.) from the top
. land of the piston.
 Standard diameter
86.68 ~ 86.71mm (3.4126 ~ 3.4138in.)

3 Calculate the difference between the cylinder bore diameter and the piston diameter.
.
Piston-to-cylinder clearance
0.01 ~ 0.03mm(0.0004 ~ 0.0012in.)

4 Inspect the piston ring side clearance.

. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring
groove.

Piston ring side clearance

No. 1 : 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.)
No. 2 : 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)
Limit
No. 1 : 0.1mm (0.004in.)
No. 2 : 0.1mm (0.004in.)

If the clearance is greater than maximum, replace the piston.

5 Inspect piston ring end gap.
. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at
right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a
feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large,
recheck the cylinder bore diameter against the wear limits. If the bore is over the service limit, the
cylinder block must be rebored.

Piston ring end gap

 Standard
No.1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)
No.2 : 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)
Limit
Oil ring : 0.2 ~ 0.7mm (0.0079 ~ 0.0276in.)

PISTON PINS
1 Measure the diameter of the piston pin.
.
Piston pin diameter
21.001 ~ 21.007mm (0.8268 ~ 0.8270in.)

2 Measure the piston pin-to-piston clearance.

.
Piston pin-to-piston clearance
0.011 ~ 0.018mm (0.00043 ~ 0.00071in.)

3 Check the difference between the piston pin diameter and the connecting rod small end diameter.
.
Piston pin-to-connecting rod interference
0.016 ~ 0.033mm (0.00063 ~ 0.00130in.)

OIP PRESSURE SWITCH

1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.

2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is
continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50kpa (7psi) is applied throgh the oil hole, the switch is operaing
properly.
Check for air leakage. If air leaks, the diahragm is broken. Replace it.

REASSEMBLY

• Thoroughly clean all parts to assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble piston and connecting rod.
(1) Use a hydraulic press for installation.
(2) The piston front mark(A) and the connecting rod front mark(B) must face the timing belt side of
the engine.
2. Install piston rings.
(1) Install the oil ring expander and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.

3. Install connecting rod bearings.

(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings in the connecting rod and connecting rod cap.

4. Install main bearings.

Upper 1, 2, 3, 4 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 4upper
bearings(A).

(2) Align the bearing claw with the claw groove of the main bearing cap(A), and push in the 4lower
bearings(B).

5. Install thrust bearings.

Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil
grooves facing outward.

6. Place crankshaft(A) on the cylinder block.

7. Place main bearing caps on cylinder block.
8 Install main bearing cap bolts.
.

• The main bearing cap bolts are tightened in 2 progressive steps.

• If any of the bearing cap bolts in broken or deformed, replace it.

Tightening torque
Main bearing cap bolt
M8
13 ~ 19Nm (1.3 ~ 1.9kgf.m, 10 ~ 14lb-ft) + (90°~ 95°)
M10
27 ~ 33Nm (2.7 ~ 3.3kgf.m, 19.5 ~ 24lb-ft) + (90°~ 95°)

(1) Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2 Install and uniformly tighten the 16bearing cap bolts, in several passes, in the sequence shown.
)
Tightening torque
M8(A) : 13 ~ 19Nm (1.3 ~ 1.9kgf.m, 10 ~ 14lb-ft)
M10(B) : 27 ~ 33Nm (2.7 ~ 3.3kgf.m, 19.5 ~ 24lb-ft)

(3) Retighten the bearing cap bolts by 90° ~ 94° in the numerical order shown.
 (4) Check that the crankshaft turns smoothly.

9. Check crankshaft end play.

10 Install piston and connecting rod assemblies.
.

Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.

(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded
ends of the connecting rod bolts.
(2) Install the ring compressor, check that the bearing is securely in place, then position the piston
in the cylinder, and tap it in using the wooden handle of a hammer.
(3) Stop after the ring compressor pops free, and check the connecting rod-to-check journal
alignment before pushing the piston into place.
(4 Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
)
Tightening torque
16 ~ 20Nm (1.6 ~ 2.0kgf.m, 12 ~ 15lb-ft) + 90° ~ 94°

Maintain downward force on the ring compressor to prevent the rings from expanding
before entering the cylinder bore.

11 Apply liquid gasket to the oil seal case and install the oil seal case(A).
.
 Tightening torque
10 ~ 12Nm (1.0 ~ 1.2kgf.m, 7.3 ~ 8.8lb-ft)

• Use liquid gasket MS721-40A or equivalent

• Check that the mating surfaces are clean and dry.

12. Install rear oil seal.

(1) Apply engine oil to a new oil seal lip.
(2) Using SST(09231-33000) and a hammer, tap in the oil seal until its surface is flush with the
rear oil seal retainer edge.

13. Install front case.

14 Install the upper oil pan.
. (1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket
surfaces.

Check that the mating surfaces are clean and dry before applying liquid gasket.

(2 Install the oil pan(A) with the 17bolts.

) Uniformly tighten the bolts in several passes.

Tightening torque
19 ~ 28Nm (1.9 ~ 2.8kgf.m, 14 ~ 20lb-ft) : (1 ~ 15)
5 ~ 7Nm (0.5 ~ 0.7kgf.m, 4 ~ 5lb-ft) : (16,17)
 • To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
• Do not install the parts if five minutes or more have elapsed since applying the liquid
gasket. Instead, reapply liquid gasket after removing the residue.
• After assembly, wait at least 30 minutes before filling the engine with oil.

15 Install oil screen.

. Install a new gasket and oil screen(A) with 2bolts(B).

Tightening torque
15 ~ 22Nm (1.5 ~ 2.2kgf.m, 11 ~ 16lb-ft)
16 Install the lower oil pan.
. (1) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Use liquid gasket MS 721-40A or equivalent.

• To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
• Do not install the parts if five minutes or more have elapsed since applying the liquid
gasket. Instead, reapply liquid gasket after removing the residue.
• After assembly, wait at least 30 minutes before filling the engine with oil.

(2 Install the lower oil pan 10bolts.

) Uniformly tighten the bolts serveral passes

Tightening torque
10 ~12Nm (1.0 ~ 1.2kgf.m, 7.3 ~ 8.8lb-ft)

17 Install oil pressure sensor.

. (1) Apply adhesive to 2 or 3 threads.
Adhesive : THREE BOND TB2403 or equivalent.
(2 Install the oil pressure sensor(A).
)
Tightening torque
15 ~ 22Nm (1.5 ~ 2.2kgf.m, 11 ~ 16lb-ft)
18 Install knock sensor(A).
.
Tightening torque
17 ~ 26Nm (1.7 ~ 2.6kgf.m, 12.5 ~ 19lb-ft)

19. Install water pump.

20 Install the power steering pump bracket(A).
.
Tightening torque
35 ~ 55Nm (3.5 ~ 5.5kgf.m, 25.8 ~ 40.6lb-ft)

21. Install the air conditioner compressor. (Refer to HA Group)

22. Install the alternator. (Refer to EE Group)
23 Install oil level gauge assembly.
. (1) Install a new O-ring on the oil level gauge.
(2) Apply engine oil on the O-ring.
(3 Install the oil level gauge assembly (A) with the bolt.
)
Tightening torque
12 ~ 15Nm (1.2 ~ 1.5kgf.m, 9 ~ 11lb-ft)

24. Install cylinder head.

25. Install timing belt.
26. Remove engine stand.
27 Install drive plate.
.
Tightening torque
73 ~ 77Nm (7.3 ~ 7.7kgf.m, 53 ~ 56lb-ft)

REASSEMBLY

• Thoroughly clean all parts to assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble piston and connecting rod.
(1) Use a hydraulic press for installation.
(2) The piston front mark(A) and the connecting rod front mark(B) must face the timing belt side of
the engine.

2. Install piston rings.

(1) Install the oil ring expander and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.
3. Install connecting rod bearings.
(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings in the connecting rod and connecting rod cap.

4. Install main bearings.

Upper 1, 2, 3, 4 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 4upper
bearings(A).

(2) Align the bearing claw with the claw groove of the main bearing cap(A), and push in the 4lower
bearings(B).
5. Install thrust bearings.
Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil
grooves facing outward.

6. Place crankshaft(A) on the cylinder block.

7. Place main bearing caps on cylinder block.

8 Install main bearing cap bolts.
.

• The main bearing cap bolts are tightened in 2 progressive steps.

• If any of the bearing cap bolts in broken or deformed, replace it.

Tightening torque
 Main bearing cap bolt
M8
13 ~ 19Nm (1.3 ~ 1.9kgf.m, 10 ~ 14lb-ft) + (90°~ 95°)
M10
27 ~ 33Nm (2.7 ~ 3.3kgf.m, 19.5 ~ 24lb-ft) + (90°~ 95°)

(1) Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2 Install and uniformly tighten the 16bearing cap bolts, in several passes, in the sequence shown.
)
Tightening torque
M8(A) : 13 ~ 19Nm (1.3 ~ 1.9kgf.m, 10 ~ 14lb-ft)
M10(B) : 27 ~ 33Nm (2.7 ~ 3.3kgf.m, 19.5 ~ 24lb-ft)

(3) Retighten the bearing cap bolts by 90° ~ 94° in the numerical order shown.

(4) Check that the crankshaft turns smoothly.

9. Check crankshaft end play.

10 Install piston and connecting rod assemblies.
.

Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.

(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded
ends of the connecting rod bolts.
 (2) Install the ring compressor, check that the bearing is securely in place, then position the piston
in the cylinder, and tap it in using the wooden handle of a hammer.
(3) Stop after the ring compressor pops free, and check the connecting rod-to-check journal
alignment before pushing the piston into place.
(4 Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
)
Tightening torque
16 ~ 20Nm (1.6 ~ 2.0kgf.m, 12 ~ 15lb-ft) + 90° ~ 94°

Maintain downward force on the ring compressor to prevent the rings from expanding
before entering the cylinder bore.

11 Apply liquid gasket to the oil seal case and install the oil seal case(A).
.
Tightening torque
10 ~ 12Nm (1.0 ~ 1.2kgf.m, 7.3 ~ 8.8lb-ft)

• Use liquid gasket MS721-40A or equivalent

• Check that the mating surfaces are clean and dry.

12. Install rear oil seal.

(1) Apply engine oil to a new oil seal lip.
 (2) Using SST(09231-33000) and a hammer, tap in the oil seal until its surface is flush with the
rear oil seal retainer edge.

13. Install front case.

14 Install the upper oil pan.
. (1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket
surfaces.

Check that the mating surfaces are clean and dry before applying liquid gasket.

(2 Install the oil pan(A) with the 17bolts.

) Uniformly tighten the bolts in several passes.

Tightening torque
19 ~ 28Nm (1.9 ~ 2.8kgf.m, 14 ~ 20lb-ft) : (1 ~ 15)
5 ~ 7Nm (0.5 ~ 0.7kgf.m, 4 ~ 5lb-ft) : (16,17)
 • To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
• Do not install the parts if five minutes or more have elapsed since applying the liquid
gasket. Instead, reapply liquid gasket after removing the residue.
• After assembly, wait at least 30 minutes before filling the engine with oil.

15 Install oil screen.

. Install a new gasket and oil screen(A) with 2bolts(B).

Tightening torque
15 ~ 22Nm (1.5 ~ 2.2kgf.m, 11 ~ 16lb-ft)

16 Install the lower oil pan.

. (1) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Use liquid gasket MS 721-40A or equivalent.

• To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
• Do not install the parts if five minutes or more have elapsed since applying the liquid
gasket. Instead, reapply liquid gasket after removing the residue.
• After assembly, wait at least 30 minutes before filling the engine with oil.

(2 Install the lower oil pan 10bolts.

) Uniformly tighten the bolts serveral passes

Tightening torque
 10 ~12Nm (1.0 ~ 1.2kgf.m, 7.3 ~ 8.8lb-ft)

17 Install oil pressure sensor.

. (1) Apply adhesive to 2 or 3 threads.
Adhesive : THREE BOND TB2403 or equivalent.
(2 Install the oil pressure sensor(A).
)
Tightening torque
15 ~ 22Nm (1.5 ~ 2.2kgf.m, 11 ~ 16lb-ft)

18 Install knock sensor(A).

.
Tightening torque
17 ~ 26Nm (1.7 ~ 2.6kgf.m, 12.5 ~ 19lb-ft)
19. Install water pump.
20 Install the power steering pump bracket(A).
.
Tightening torque
35 ~ 55Nm (3.5 ~ 5.5kgf.m, 25.8 ~ 40.6lb-ft)

21. Install the air conditioner compressor. (Refer to HA Group)

22. Install the alternator. (Refer to EE Group)
23 Install oil level gauge assembly.
. (1) Install a new O-ring on the oil level gauge.
(2) Apply engine oil on the O-ring.
(3 Install the oil level gauge assembly (A) with the bolt.
)
Tightening torque
12 ~ 15Nm (1.2 ~ 1.5kgf.m, 9 ~ 11lb-ft)

24. Install cylinder head.

25. Install timing belt.
26. Remove engine stand.
27 Install drive plate.
.
Tightening torque
73 ~ 77Nm (7.3 ~ 7.7kgf.m, 53 ~ 56lb-ft)

Engine Mechanical System > Cooling System > Description and Operation

Engine Coolant Refilling and Bleeding

Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot
fluid under high pressure escaping from the radiator.
 When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the
electrical parts or the paint. If any coolant spills, rinse it off immediately.

1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are
cool to the touch.
2. Remove radiator cap.
3. Loosen the drain plug, and drain the coolant.

4. Tighten the radiator drain plug(A) securely.

5. Remove, drain and reinstall the reservoir. Fill the tank halfway to the MAX mark with water, then up
to the MAX mark with antifreeze.
6. Fill fluid mixture with coolant and water slowly through the radiator cap. Gently squeeze the
upper/lower hoses of the radiator so as bleed air easily.

• Use only genuine antifreeze/coolant.

• For best corrosion protection, the coolant concentration 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 impair cooling efficiency and are not
recommended.

• Do not mix different brands of antifreeze/coolants.

• Do not use additional rust inhibitors or anti-rust products; they may not be compatible with
the coolant.

7. Start the engine and allow coolant to circulates.

When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
8. Repeat 7 until the cooling fan 3 ~ 5times and bleed air sufficiently out of the cooling system.
9. Install the radiator cap and fill the reservoir tank to the "MAX" line with coolant.
10. Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.
11. Stop the engine and allow coolant to cool.
12. Repeat steps 6 to 11 until the coolant level stays constant and all air is bleed out of the cooling
system.
 Recheck the coolant level in the reservoir tank for 2 ~ 3 days after replacing coolant.

Cap Testing
1. Remove the radiator cap, wet its seal with engine coolant, then install it on the pressure tester.

2. Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm², 14 ~ 19psi)

3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

Testing
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine
coolant, then install it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm² 14
~ 19psi).

3. Inspect for engine coolant leaks and a drop in pressure.

4. Remove the tester and reinstall the radiator cap.

Check for engine oil in the coolant and/or coolant in the engine oil.

Engine Mechanical System > Cooling System > Components and Components
Location
COMPONENTS
Engine Mechanical System > Cooling System > Repair procedures

REMOVAL

WATER PUMP
1. Drain the engine coolant.

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 belts.

3. Remove the timing belt.
4. Remove the timing belt idler.
5. Remove the water pump.
Remove the water pump(A) and gasket(B).

THERMOSTAT

Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
Do not remove the thermostat, even if the engine tends to overheat.

1. Remove the engine cover.

2. Drain engine coolant so its level is below thermostat.
3. Remove the lower hose.
4. Remove water inlet(A) and thermostat(B).
INSTALLATION

WATER PUMP
1 Install the water pump(A) and a new gasket(B) with the 8bolts.
.
Tightening torque
15 ~ 22Nm (1.5 ~ 2.2kgf.m, 11 ~ 16lb-ft)

Bolt Size Number

A 8 × 25 4
B 8 × 30 2
 C 8 × 32 1
D 8 × 40 1

2. Install the timing belt idler.

3. Install the timing belt.
4. Install drive belt.
5. Fill with engine coolant.
6. Start engine and check for leaks.
7. Recheck engine coolant level.

THERMOSTAT
1. Place thermostat in thermostat housing.
(1) Install the thermostat with the jiggle valve upward.
(2) Install a new to the thermostat(B).

2 Install water inlet(A).

.
Tightening torque
17 ~ 20Nm (1.7 ~ 2.0kgf.m, 12.5 ~ 14lb-ft)

3. Install the lower hose.

4. Fill with engine coolant.
5. Start engine and check for leaks.

INSPECTION

WATER PUMP
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant
pump assembly if necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant
pump assembly
 A small amount of “weeping” from the bleed hole is normal.

THERMOSTAT
1. Immerse the thermostat in water and gradually heat the water.

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 : 10mm(0.4in.) or more at 95°C (205°F)

If the valve lift is not as specified, replace the thermostat.

Engine Mechanical System > Lubrication System > Description and Operation

ENGINE OIL AND FILTER REPLACEMENT

• Prolonged and repeated contact with mineral oil will result in the removal of natural fats from
the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains
potentially harmful contaminants which may cause skin cancer.
• Exercise caution in order to minimize the length and frequency of contact of your skin to used
oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or
use 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 and used oil filter must be disposed of only at
designated disposal sites.
1. Drain engine oil.
A. Remove the oil filler cap.
B. Remove the oil drain plug(A), and drain the oil into a container.
2. Replace oil filter.
A. Remove the oil filter(B).
B. Check and clean the oil filter installation surface.
C. Check the part number of the new oil filter is as same as old one.
D. Apply clean engine oil to the gasket of a new oil filter.
E. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
F. Tighten it an additional 3/4 turn.
3 Refill with engine oil filter.
. A Clean and install the oil drain plug with a new gasket.
.
Tightening torque
35 ~ 45Nm (3.5 ~ 4.5kgf.m, 26 ~ 33lb-ft)

B Fill with fresh engine oil

.
Capacity
Total : 4.8L (5.07 US qts, 4.22 lmp qts)
Oil pan : 4.2 L (4.44 US qts, 3.70 lmp qts)
Drain and refill including oil filter :
4.5 L (4.76 US qts, 3.96 lmp qts)
Oil quality : Above API SJ/SL or SAE 5W-20

C. Install the oil filler cap.

4. Start engine and check for oil leaks.
5. Recheck engine oil level.

INSPECTION
1. Check engine oil quality
Check the oil for deterioration, entry of water, discoloring 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.
 Do not fill with engine oil above the "F" mark.

SELECTION OF ENGINE OIL

Recommended SAE viscosity grades :

For best performance and maximum protection of all types of operation, select only those
lubricants which :

1. Satisfy the requirement of the API classification.

2. Have proper SAE grade number for expected ambient temperature range.
3. Lubricants that do not have both an SAE grade number and API service classification on the
container should not be used.

Engine Mechanical System > Lubrication System > Components and

Components Location
COMPONENTS
Engine Mechanical System > Lubrication System > Repair procedures

REMOVAL
1. Drain engine oil.
2. Remove RH front wheel.
3. Remove RH side cover.
4. Remove the front exhaust pipe.
5. Remove the alternator from engine. (Refer to Alternator in EE group.)
6. Remove the drive belt.
7. Turn the crankshaft and align the white groove on the crankshaft pulley with the pointer on the
lower cover.
8. Remove the timing belt. (Refer to Timing system in this group.)
9. Remove the lower oil pan(A).

• Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer
in the direction of arrow.
• After tapping the SST with a plastic hammer along the direction of arrow around more
than 2/3 edge of the oil pan, remove it from the ladder frame.
• Do not turn over the SST abruptly without tapping. It is result in damage of the SST.

10. Remove oil screen.

Remove the 2bolts(B), oil screen(A) and gasket.
11. Remove the upper oil pan(A).

12. Remove the oil pump case(A).

(1) Remove the screws(B) from the pump housing, then separate the housing and cover(A).

(2) Remove the inner and outer rotors.

INSTALLATION
1 Install oil pump.
.
 (1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
(2 Install the oil pump cover(A) to front case with the 8screws(B).
)
Tightening torque
8 ~ 12Nm (0.8 ~ 1.2kgf.m, 6 ~ 8.8lb-ft)

2. Check that the oil pump turns freely.

3 Install the oil pump on the cylinder block.
. (1) Remove any old liquid gasket and be careful not to drop any oil on the contact surfaces of the
oil pump and cylinder block.
A. Using a razor blade and gasket scraper, remove all the old liquid gasket from the gasket
surfaces and sealing grooves.
B. Using a non-residue solvent, clean both sealing surfaces.
(2) Apply liquid gasket to the oil pump as shown in the illustration.
Use liquid gasket MS 721-40A.

• To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
• Do not install the parts if five minutes or more have elapsed since applying the liquid
gasket. Instead, reapply liquid gasket after removing the residue.
• After assembly, wait at least 30 minutes before filling the engine with oil.

(3) Place a new O-ring on the cylinder block.

(4) Engage the spline teeth of the oil pump drive gear with large teeth of the crankshaft, and slide
 the oil pump on the crankshaft.
(5 Install the oil pump with 5bolts.
) Uniformly tighten the bolts in several passes.

Tightening torque
12 ~ 15Nm (1.2 ~ 1.5kgf.m, 8.8 ~ 11lb-ft)

Bolt Size Number

A 8 × 25 3
B 8 × 35 1
C 8 × 45 1

4. Apply a light coat of oil to the seal lip.

5. Using the special tool(09214-33000), install the oil seal.

6 Install the upper oil pan.

. (1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket
surfaces.

Check that the mating surfaces are clean and dry before applying liquid gasket.

(2 Install the oil pan(A) with the 17bolts.

) Uniformly tighten the bolts in several passes.

Tightening torque
 18.6 ~ 23.5Nm (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft) : (1 ~ 15)
4.9 ~ 6.9Nm (0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb-ft) : (16,17)

• To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
• Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the residue.
• After assembly, wait at least 30 minutes before filling the engine with oil.

7 Install oil screen.

. Install a new gasket and oil screen(A) with 2bolts(B).

Tightening torque
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
8 Install the lower oil pan.
. (1) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Use liquid gasket MS 721-40A or equivalent.
A. To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
B. Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the residue.
C. After assembly, wait at least 30 minutes before filling the engine with oil.
(2 Install the lower oil pan 10bolts.
) Uniformly tighten the bolts serveral passes

Tightening torque
9.8 ~11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

9. Install the timing belt. (Refer to Timing system in this group.)

10. Install the drive belt
11. Install the alternator. (Refer to Alternator in EE group.)
12. Install the front exhaust pipe.
13. Install the RH front wheel.
14. Fill engine with oil.
15. Start engine and check for leaks.
16. Recheck engine oil level.
DISASSEMBLY
1. Remove the relief plunger.
Remove the plug(A), spring(B) and relief plunger(C).

INSPECTION
1. Inspect relief plunger.
Coat the valve with engine oil and check that it falls smoothly into the plunger hole by its own
weight.
If it does not, replace the relief plunger. If necessary, replace the front case.
2 Inspect relief valve spring.
. Inspect for distorted or broken relief valve spring.

Standard value
Free height : 43.8mm (91.724in.)
Load : 4.6kg/39.1mm (10lb/1.547in.)

3 Inspect rotor side clearance.

. Using a feeler gauge and precision straight edge, measure the clearance between the rotors and
precision straight edge.

Side clearance
0.04 ~ 0.095mm (0.0016 ~ 0.0037in.)
 If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the
front case.
4. If the tip clearance is greater than maximum, replace the rotor as a set.
5 Inspect rotor body clearance.
. Using a feeler gauge, measure the clearance between the outer rotor and body.

Body clearance
0.100 ~ 0.181mm (0.0039 ~ 0.0017in.)

If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace
the front case.

REASSEMBLY
1 Install relief plunger.
. Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A).

Tightening torque
40 ~ 50Nm (4.0 ~ 5.0kgf.m, 30 ~ 37lb-ft)

Engine Mechanical System > Intake And Exhaust System > Intake Manifold >
Components and Components Location
COMPONENTS

Engine Mechanical System > Intake And Exhaust System > Intake Manifold >
Repair procedures
REMOVAL
1. Remove the engine cover.
2. Remove air cleaner hose.
3. Remove surge tank assembly.
(1) Disconnect the accelerator cable.

(2) Disconnect the TPS connector(A).

(3) Disconnect the ISA connector(B).
(4) Disconnect the VIS actuator connector(C).
(5) Disconnect the injector connector(D).
(6) Disconnect the PCSV connector(E).

(7) Disconnect the PCSV hose.

(8) Disconnect the brake booster vacuum hose(A).
(9) Disconnect the PCV hose.
(10) Disconnect the IAT sensor connector(A).
(11) Disconnect the VIS actuator connector(B).

(12) Disconnect the ground cable(A) from the surge tank assembly.

(13) Remove the surge tank stay.

 (14) Remove the surge tank assembly(A).

Remove the injector assembly(A).

4. Remove the intake manifold(A) and gasket.

INSTALLATION
1 Install the intake manifold and gasket.
.
Tightening torque
19 ~ 21Nm (1.9 ~ 2.1kgf.m, 14 ~ 15lb-ft)

2. Install the injector assembly. (Refer to Injector in FL Group)

3 Install the surge tank assembly(A).
. (1 Install the surge tank assembly.
)
Tightening torque
15 ~ 20Nm (1.5 ~ 2.0kgf.m, 11 ~ 15lb-ft)
 (2 Install the surge tank stay.
)
Tightening torque
15 ~ 20Nm (1.5 ~ 2.0kgf.m, 11 ~ 15lb-ft)

(3) Install the ground cable.

(4) Connect the VIS actuator connector.
(5) Connect the IAT sensor connector.
(6) Connect the PCV hose.
(7) Connect the brake booster vacuum hose.
(8) Connect the PCSV hose.
(9) Connect the PCSV connector.
(10) Connect the injector connector.
(11) Connector the VIS actuator connector.
(12) Connector the ISA connector.
(13) Connector the TPS connector.
(14) Connector the actuator cable.

4. Install the air cleaner hose.

5. Install the engine cover.

Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold >
Components and Components Location

COMPONENTS
Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold >
Repair procedures

REMOVAL
1. Remove the under cover(A).
2. Remove the front exhaust pipe(A).

3. Disconnect the oxygen sensor connector.

4. Remove the heat protector(A).

5. Remove the exhaust manifold(A) and gasket(B).

INSTALLATION
1 Install the exhaust manifold(A) and gasket(B).
.
Tightening torque
30 ~ 35Nm (3.0 ~ 3.5kgf.m, 22 ~ 26lb-ft)

2 Install the heat protector(A).

.
Tightening torque
17 ~ 22Nm (1.7 ~ 2.2kgf.m, 12 ~ 16lb-ft)
3. Connect the oxygen sensor connector.
4 Install the front exhaust pipe(A).
.
Tightening torque
30 ~ 40Nm (3.0 ~ 4.0kgf.m, 22 ~ 30lb-ft)

5. Install the under cover(A).

Engine Mechanical System > Intake And Exhaust System > Front Exhaust Pipe
> Components and Components Location

COMPONENTS