6A-1 ENGINE MECHANICALENGINECONTENTSEngine Mechanical 6A . . . . . . . . . . . . . . . . . . . . . . Engine Cooling 6B . . . . . . . . . . . . . . . . . . . . . . . . . Engine Fuel 6C . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Electrical 6D1 . . . . . . . . . . . . . . . . . . . . . . . . gnition System 6D2 . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Charging System 6D3 . . . . . . . . . . . . Driveability and Emissions 6E . . . . . . . . . . . . . . . . Engine Exhaust 6F . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication 6G . . . . . . . . . . . . . . . . . . . . . . Engine Speed Control System 6H . . . . . . . . . . . . nducton 6J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE MECHANICALCONTENTSService Precaution 6A2 . . . . . . . . . . . . . . . . . . . . . . General Description 6A3 . . . . . . . . . . . . . . . . . . . . . Engine Diagnosis 6A4 . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Cover LH 6A18 . . . . . . . . . . . . . . . . . Removal 6A18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Cover RH 6A21 . . . . . . . . . . . . . . . . . Removal 6A21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Chamber 6A24 . . . . . . . . . . . . . . . . . . . . . . Removal 6A24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold LH 6A26 . . . . . . . . . . . . . . . . . . . . . Removal 6A26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold RH 6A27 . . . . . . . . . . . . . . . . . . . . Removal 6A27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pulley 6A28 . . . . . . . . . . . . . . . . . . . . . . . Removal 6A28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Belt 6A29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6A29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft 6A33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6A33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head 6A37 . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6A37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Oil Controller , Valve Spring and Valve Guide 6A39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6A39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston, Piston Ring and Connecting Rod 6A40 . . . Removal 6A40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Main Bearings 6A42 . . . . . . . . . . . . Removal 6A42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Oil Seal 6A47 . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6A47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Assembly 6A48 . . . . . . . . . . . . . . . . . . . . . . . . Removal 6A48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nstallation 6A48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head 6A52 . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Associated Parts 6A52 . . . . . Disassembly 6A52 . . . . . . . . . . . . . . . . . . . . . . . . . . Clean 6A53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nspection and Repair 6A53 . . . . . . . . . . . . . . . . . . Reassembly 6A53 . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring, Oil Controller, Valve, Valve Guide 6A56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts 6A56 . . . . . . . Disassembly 6A56 . . . . . . . . . . . . . . . . . . . . . . . . . . nspection and Repair 6A57 . . . . . . . . . . . . . . . . . . Reassembly 6A60 . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Clearance Adjustments 6A61 . . . . . . . . . . . . . Camshaft 6A63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft and Associated Parts 6A63 . . . . . . . . . Disassembly 6A63 . . . . . . . . . . . . . . . . . . . . . . . . . . nspection and Repair 6A64 . . . . . . . . . . . . . . . . . . Reassembly 6A66 . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft 6A69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Associated Parts 6A69 . . . . . . . . Disassembly 6A69 . . . . . . . . . . . . . . . . . . . . . . . . . . nspection and Repair 6A70 . . . . . . . . . . . . . . . . . . nspection and Repair 6A71 . . . . . . . . . . . . . . . . . . Reassembly 6A73 . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 ENGINE MECHANICALPiston and Connecting Rod 6A77 . . . . . . . . . . . . . . . Piston, Connecting Rod and Associate Parts 6A77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 6A77 . . . . . . . . . . . . . . . . . . . . . . . . . . nspection and Repair 6A78 . . . . . . . . . . . . . . . . . . Reassembly 6A82 . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block 6A85 . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block and Associated Parts 6A85 . . . . . Disassembly 6A85 . . . . . . . . . . . . . . . . . . . . . . . . . . nspection and Repair 6A86 . . . . . . . . . . . . . . . . . . Reassembly 6A87 . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specification 6A90 . . . . . . . . . . . . . . Special Tool 6A96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service PrecautionWARNING: IF SO EQUIPPED WITH ASUPPLEMENTAL RESTRAINT SYSTEM (SRS),REFER TO THE SRS COMPONENT AND WIRINGLOCATION VIEW IN ORDER TO DETERMINEWHETHER YOU ARE PERFORMING SERVICE ON ORNEAR THE SRS COMPONENTS OR THE SRSWIRING. WHEN YOU ARE PERFORMING SERVICEON OR NEAR THE SRS COMPONENTS OR THE SRSWIRING, REFER TO THE SRS SERVICEINFORMATION. FAILURE TO FOLLOW WARNINGSCOULD RESULT IN POSSIBLE AIR BAGDEPLOYMENT, PERSONAL INJURY, OROTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: AIways use the correct fastener in theproper Iocation. When you repIace a fastener, useONLY the exact part number for that appIication.ISUZU wiII caII out those fasteners that require arepIacement after removaI. ISUZU wiII aIso caII outthe fasteners that require thread Iockers or threadseaIant. UNLESS OTHERWISE SPECIFIED, do notuse suppIementaI coatings (Paints, greases, or othercorrosion inhibitors) on threaded fasteners orfastener joint interfaces. GeneraIIy, such coatingsadverseIy affect the fastener torque and the jointcIamping force, and may damage the fastener. Whenyou instaII fasteners, use the correct tighteningsequence and specifications. FoIIowing theseinstructions can heIp you avoid damage to parts andsystems.6A-3 ENGINE MECHANICALGeneraI DescriptionEngine CIeanIiness And CareAn automobile engine is a combination of manymachined, honed, polished and lapped surfaces withtolerances that are measured in the thousandths of amillimeter (ten thousandths of an inch). Accordingly,when any internal engine parts are serviced, care andcleanliness are important. Throughout this section, itshould be understood that proper cleaning and protectionof machined surfaces and friction areas is part of therepair procedure. This is considered standard shoppractice even if not specifically stated.A liberal coating of engine oil should be applied to allfriction areas during assembly to protect and lubricatethe surfaces on initial operation.Whenever valve train components, pistons, pistonrings, connecting rods, rod bearings, and crankshaftjournal bearings are removed for service, they shouldbe retained in order.At the time of installation, they should be installed inthe same locations and with the same matingsurfaces as when removed.Battery cables should be disconnected before anymajor work is performed on the engine. Failure todisconnect cables may result in damage to wireharness or other electrical parts.The six cylinders of this engine are identified bynumbers; Right side cylinders 1, 3 and 5, Left sidecylinders 2, 4 and 6, as counted from crankshaftpulley side to flywheel side.GeneraI Information on Engine ServiceThe following information on engine service should benoted carefully, as it is important in preventing damageand contributing to reliable engine performance:When raising or supporting the engine for any reason,do not use a jack under the oil pan. Due to the smallclearance between the oil pan and the oil pumpstrainer, jacking against the oil pan may causedamage to the oil pickup unit.The 12volt electrical system is capable of damagingcircuits. When performing any work where electricalterminals could possibly be grounded, the groundcable of the battery should be disconnected at thebattery.Any time the intake air duct or air cleaner is removed,the intake opening should be covered. This willprotect against accidental entrance of foreignmaterial into the cylinder which could cause extensivedamage when the engine is started.CyIinder BIockThe cylinder block is made of aluminum diecast castingfor 75 Vtype six cylinders. t has a rear plate integratedstructure and employs a deep skint. The cylinder liner iscast and the liner inner diameter and crankshaft journaldiameter are classified into grades. The crankshaft issupported by four bearings of which width of No.3 bearingon the body side is different in order to support the thrustbearing. The bearing cap is made of nodular cast iron andeach bearing cap uses four bolts and two side bolts.CyIinder HeadThe cylinder head, made of aluminum alloy castingemploys a pentroof type combustion chamber with aspark plug in the center. The intake and exhaust valvesare placed in Vtype design. The ports are crossflowtype.VaIve Trainntake and exhaust camshaft on the both side of banksare driven through an camshaft drive gear by timing belt.The valves are operated by the camshaft and the valveclearance is adjusted to select suitable thickness shim.Intake ManifoIdThe intake manifold system is composed of the aluminumcast common chamber and intake manifold attached withsix fuel injectors.Exhaust ManifoIdThe exhaust manifold is made of nodular cast iron.Pistons and Connecting RodsAluminum pistons are used after selecting the grade thatmeets the cylinder bore diameter. Each piston has twocompression rings and one oil ring. The piston pin is madeof chromium steel is offset 1mm toward the thrust side,and the thrust pressure of piston to the cylinder wall variesgradually as the piston travels. The connecting rods aremade of forged steel. The connecting rod bearings aregraded for correct seze selection.Crankshaft and BearingsThe crankshaft is made of Ductile castiron. Pins andjournals are graded for correct size selection for theirbearing.Engine LubricationThe oil discharged by a trochoidtype oil pump driven bythe crankshaft is fed through fullflow oil filter and to the oilgallery provided under the crankshaft bearing cap. The oilis then led to the crankshaft journals and cylinder head.The crank pins are lubricated with oil from crankshaftjournals through oil holes. Also, an oil jet is fed to eachcylinder from crankshaft juornals on the connecting rodfor piston cleaning. The oil pan flange is dealed with liquidpacking only; do not deform or damage the flange surfaceduring removal or installation.6A-4 ENGINE MECHANICALEngine DiagnosisHard Starting1. Starting Motor Does Not Turn OverTroubIeshooting ProcedureTurn on headlights and starter switch.Condition PossibIe cause CorrectionHeadlights go out or dimconsiderablyBattery run down or under charged Recharge or replace batteryconsiderablyTerminals poorly connected Clean battery posts and terminalsand connect properlyStarting motor coil circuit shorted Overhaul or replaceStarting motor defective Overhaul or replace2. Ignition TroubIe - Starting Motor Turns Over But Engine Does Not StartSpark TestDisconnect an igniton coil from any spark plug. Connectthe spark plug tester 5884006070, start the engine,and check if a spark is generated in the spark plug tester.Before starting the engine, make sure that the spark plugtester is properly grounded. To avoid electrical shock, donot touch the part where insulation of the igniton coil isbroken while the engine is running.Condition PossibIe cause CorrectionSpark jumps across gap Spark plug defective Clean, adjust spark gap or replacegnition timing incorrect Refer to gnition SystemFuel not reaching fuel injector(s) orengineRefer to i tem 3 (Trouble i n fuelsystem)Valve timing incorrect AdjustEngine lacks compression Refer to item 4 (Engi ne lackscompression)No sparking takes place gnition coil disconnected or broken Connect properly or replaceElectronic gnition System withmoduleReplacePoor connections in engine harness CorrectPowertrain Control Module cabledisconnected or defectiveCorrect or replace3. TroubIe In FueI SystemCondition PossibIe cause CorrectionStarting motor turns over and sparkoccurs but engine does not startFuel tank empty Filloccurs but engine does not start.Water in fuel system CleanFuel filter clogged Replace filterFuel pipe clogged Clean or replaceFuel pump defective ReplaceFuel pump circuit open Correct or replaceEvaporative Emission ControlSystem circuit cloggedCorrect or replaceMultiport Fuel njection System faulty Refer to Electronic Fuel njectionsection6A-5 ENGINE MECHANICAL4. Engine Lacks CompressionCondition PossibIe cause CorrectionEngine lacks compression Spark plug loosely fitted or sparkplug gasket defectiveTighten to specified torque or replacegasketValve timing incorrect AdjustCylinder head gasket defective Replace gasketValve incorrectly seated Lap valveValve stem seized Replace valve and valve guideValve spring weakened or broken ReplaceCylinder or piston rings worn Overhaul enginePiston ring seized Overhaul engine.Engine Compression Test Procedure1. Start and run the engine until the engine reachesnormal operating temperature.2. Turn the engine off.3. Remove all the spark plugs.4. Remove ignition coil fuse (15A) and disable theignition system.5. Remove the fuel pump relay from the relay and fusebox.6. Engage the starter and check that the cranking speedis approximately 300 rpm.7. nstall cylinder compression gauge into spark plughole.8. With the throttle valve opened fully, keep the starterengaged until the compression gage needle reachesthe maximum level. Note the reading.9. Repeat the test with each cylinder.f the compression pressure obtained falls below thelimit, engine overhaul is necessary.Limit; 1000 kPa (145 psi)6A-6 ENGINE MECHANICALRough Engine IdIing or Engine StaIIingCondition PossibIe cause CorrectionTrouble in fuel injection system dle air control valve defective ReplaceThrottle shutting off incomplete Correct or replaceThrottle position sensor circuit openor shortedCorrect or replaceFuel injector circuits open or shorted Correct or replaceFuel injectors damaged ReplaceFuel pump relay defective ReplaceMass Airflow Sensor circuit open orpoor connectionsCorrect or replaceMass Airflow Sensor defective ReplaceManifold Absolute Pressure Sensorcircuit open or poor connectionsCorrect or replaceManifold Absolute Pressure SensordefectiveReplaceEngine Coolant Temperature Sensorcircuit open or poor connectionsCorrect or replaceEngine Coolant Temperature SensordefectiveReplacentake Air Temperature sensor circuitopen or poor connectionsCorrect or replacentake Air Temperature sensordefectiveReplaceKnock Sensor (KS) cable broken orpoor connectionsCorrect or replaceKS defective ReplaceKS Module circuits open or ground Correct or replaceKS Module defective ReplaceVehicle Speed Sensor circuit open orshortedCorrect or replaceVehicle Speed Sensor defective ReplaceTrouble in emission control system Powertrain Control Module defective ReplaceExhaust Gas Recirculation Valvecircuit open or poor connectionsCorrect or replaceExhaust Gas Recirculation ValvefaultyReplaceCanister purge valve circuit open orpoor connectionsCorrect or replaceCanister purge valve defective ReplaceEvaporative Emission CanisterPurge control valve defectiveReplaceTrouble in ignition system Refer to Hard Start6A-7 ENGINE MECHANICALCondition Correction PossibIe causeOthers Engine lacks compression Refer to Hard StartValve incorrectly seated Lap valveAir Cleaner Filter clogged Replace filter elementValve timing incorrect Readjustdle air control valve broken ReplaceFast idle solenoid defective ReplacePositive Crankcase Ventilation valvedefective or cloggedReplaceRough Engine RunningCondition PossibIe cause CorrectionEngine misfires periodically gnition coil layer shorted ReplaceSpark plugs fouling Clean or install hotter type plugSpark plug(s) insulator nose leaking ReplaceFuel injector(s) defective ReplacePowertrain control module faulty ReplaceEngine knocks periodically Spark plugs running too hot nstall colder type spark plugsPowertrain control module faulty ReplaceEngine lacks power Spark plugs fouled CleanFuel injectors defective ReplaceMass Airflow Sensor or ntakeAirflow Sensor circuit defectiveCorrect or replaceManifold Absolute Pressure (MAP)Sensor or Manifold AbsolutePressure Sensor circuit defectiveCorrect or replaceEngine Coolant Temperature Sensoror Engine Coolant TemperatureSensor circuit defectiveCorrect or replacePowertrain Control Module faulty Replacentake Air Temperature Sensor orntake Air Temperature Sensorcircuit defectiveCorrect or replaceThrottle Position Sensor or ThrottlePosition Sensor circuit defectiveCorrect or replaceKnock Sensor or Knock Sensorcircuits defectiveCorrect or replaceKnock Sensor Module or KnockSensor Module circuits defectiveCorrect or replace6A-8 ENGINE MECHANICALHesitationCondition PossibIe cause CorrectionHesitation on acceleration Throttle Position Sensor adjustmentincorrectReplace throttle valve assemblyThrottle Position Sensor circuit openor shortedCorrect or replaceExcessive play in accelerator linkage Adjust or replaceMass Airflow Sensor circuit open orpoor connectionsCorrect or replaceMass Airflow Sensor defective ReplaceManifold Absolute Pressure (MAP)Sensor circuit open or shortedCorrect or replaceMAP Sensor defective Replacentake Air Temperature (AT) Sensorcircuit open or shortedCorrect or replaceKnock Sensor (KS) Circuit open orpoor connectionsCorrect or replaceKS defective ReplaceKS Module circuits open or shorted Correct or replaceKS Module defective ReplaceAT Sensor defective ReplaceHesitation at high speeds Fuel tank strainer clogged Clean or replace(Fuel pressure too low)Fuel pipe clogged Clean or replaceFuel filter clogged ReplaceDefective fuel pump system Check and replaceFuel Pressure Control Valve leaking ReplaceHesitation at high speeds(Fuel injector not working normally)Power supply or ground circuit forMultiport Fuel njection Systemshorted or openCheck and correct or replaceFuel njector defective ReplaceCable of Multiport Fuel njectionSystem circuit open or poorconnectionsCorrect or replace6A-9 ENGINE MECHANICALCondition Correction PossibIe causeHesitation at high speeds Powertrain Control Module defective ReplaceThrottle Position Sensor cablebroken or poor connectionsCorrect or replaceThrottle Position Sensor defective ReplaceEngine Coolant Temperature Sensorcircuit open or shortedCorrect or replaceEngine Coolant Temperature SensordefectiveReplaceMass Airflow Sensor circuit open orpoor connectionsCorrect or replaceMass Airflow Sensor defective ReplaceMAP Sensor cable broken or poorconnectionsCorrect or replaceMAP Sensor defective ReplaceAT Sensor circuit open or poorconnectionsCorrect or replaceAT Sensor defective ReplaceKS circuit open or poor connections Correct or replaceKS defective ReplaceKS Module circuit open or shorted Correct or replaceKS Module defective ReplaceThrottle valve not fully opened Check and correct or replaceAir Cleaner Filter clogged Replace filter elementPower supply voltage too low Check and correct or replace6A-10 ENGINE MECHANICALEngine Lacks PowerCondition PossibIe cause CorrectionTrouble in fuel system Fuel Pressure Control Valve notworking normallyReplaceFuel injector clogged Clean or replaceFuel pipe clogged CleanFuel filter clogged or fouled ReplaceFuel pump drive circuit not workingnormallyCorrect or replaceFuel tank not sufficiently breathingdue to clogged EvaporativeEmission Control System circuitClean or replaceWater in fuel system Cleannferior quality fuel in fuel system Use fuel of specified octane ratingPowertrain Control Module suppliedpoor voltageCorrect circuitThrottle Position Sensor cablebroken or poor connectionsCorrect or replaceThrottle Position Sensor defective ReplaceMass Airflow Sensor not workingnormallyReplaceManifold Absolute Pressure Sensornot working normallyReplacentake Air Temperature Sensor notworking normallyReplaceEngine Coolant Temperature Sensorcircuit open or shortedCorrect or replaceEngine Coolant Temperature SensordefectiveReplacePowertrain Control Module defective ReplaceTrouble in intake or exhaust system Air Cleaner Filter clogged Replace filter elementAir duct kinked or flattened Correct or replacegnition failure Refer to Hard Start TroubleshootingGuideHeat range of spark plug inadequate nstall spark plugs of adequate heatrangegnition coil defective Replace6A-11 ENGINE MECHANICALCondition Correction PossibIe causeEngine overheating Level of Engine Coolant too low ReplenishFan clutch defective Replacencorrect fan installed ReplaceThermostat defective ReplaceEngine Coolant pump defective Correct or replaceRadiator clogged Clean or replaceRadiator filler cap defective ReplaceLevel of oil in engine crankcase toolow or wrong engine oilChange or replenishResistance in exhaust systemincreasedClean exhaust system or replacedefective partsThrottle Position Sensor adjustmentincorrectReplace with Throttle Valve ASMThrottle Position Sensor circuit openor shortedCorrect or replaceCylinder head gasket damaged ReplaceEngine overcooling Thermostat defective Replace (Use a thermostat set toopen at 82 C (180 F))Engine lacks compression Refer to Hard StartOthers Tire inflation pressure abnormal Adjust to recommended pressuresBrake drag AdjustClutch slipping Adjust or replaceLevel of oil in engine crankcase toohighCorrect level of engine oilExhaust Gas Recirculation ValvedefectiveReplaceEngine NoisyAbnormal engine noise often consists of various noisesoriginating in rotating parts, sliding parts and othermoving parts of the engine. t is, therefore, advisable tolocate the source of noise systematically.Condition PossibIe cause CorrectionNoise from crank journals or fromcrank bearings(Faulty crank journals and crankOil clearance increased due to worncrank journals or crank bearingsReplace crank bearings andcrankshaft or regrind crankshaft andinstall the undersize bearingbearings usually make dull noise thatbecomes more evident whenaccelerating)Crankshaft out of round Replace crank bearings andcrankshaft or regrind crankshaft andinstall the undersize bearingCrank bearing seized Crank bearing seized. Replace crankbearings and crankshaft or regrindcrankshaft and install the undersizebearingTroubIeshooting ProcedureShort out each spark plug in sequence using insulatedspark plug wire removers. Locate cylinder with defectivebearing by listening for abnormal noise that stops whenspark plug is shorted out.6A-12 ENGINE MECHANICALCondition PossibIe cause CorrectionNoise from connecting rods or fromconnecting rod bearings(Faulty connecting rods orBearing or crankshaft pin worn Replace connecting rod bearingsand crankshaft or regrind crankshaftpin and install the undersize bearingconnecting rod bearings usuallymake an abnormal noise slightlyhigher than the crank bearing noise,which becomes more evident whenCrankpin out of round Replace connecting rod bearingsand crankshaft or regrind crankshaftpin and install the undersize bearingwhich becomes more evident whenengine is accelerated)Connecting rod bent Correct or replaceg )Connecting rod bearing seized Replace connecting rod bearingsand crankshaft or regrind crankshaftpin and install the undersize bearingTroubIeshooting ProcedureAbnormal noise stops when the spark plug on the cylinderwith defective part is shorted out.Condition PossibIe cause CorrectionPiston and cylinder noise(Faulty piston or cylinder usuallyk bi d h i lPiston clearance increased due tocylinder wearReplace piston and cylinder bodymakes a combined mechanicalthumping noise which increasesPiston seized Replace piston and cylinder bodygwhen engine is suddenly acceleratedbut diminishes gradually as thePiston ring broken Replace piston and cylinder bodybut diminishes gradually as theengine warms up) Piston defective Replace pistons and othersTroubIeshooting ProcedureShort out each spark plug and listen for change in enginenoise.Condition PossibIe cause CorrectionPiston pin noise(Piston makes noise each time itgoes up and down)Piston pin or piston pin hole worn Replace piston, pi ston pi n andconnecting rod assyTroubIeshooting ProcedureThe slapping sound stops when spark plug on badcylinder is shorted out.Condition PossibIe cause CorrectionTiming belt noise Timing belt tension is incorrect Replace pusher or adjust the tensionpulley or replace timing beltTensioner bearing defective ReplaceTiming belt defective ReplaceTiming pulley defective ReplaceTiming belt comes in contact withtiming coverReplace timing belt and timing coverValve noise Valve clearance incorrect Replace adjusting shimValve and valve guide seized Replace valve and valve guideValve spring broken or weakened ReplaceValve seat offpositioned CorrectCamshaft worn out ReplaceCrankshaft noise Crankshaft end play excessive(noise occurs when clutch isengaged)Replace thrust bearing6A-13 ENGINE MECHANICALCondition Correction PossibIe causeEngine knocking Preignition due to use of spark plugsof inadequate heat rangenstall Spark Plugs of adequate heatrangeCarbon deposits in combustionchambersCleanFuel too low in octane rating Replace fuelWide Open Throttle enrichmentsystem failureRefer to Section 6ESelection of transmission gearincorrectCaution operator of incorrect gearselectionEngine overheating Refer to Engine Lacks PowerOthers Water pump defective ReplaceDrive belt slipping Replace auto tentioner or drive beltAbnormaI CombustionCondition PossibIe cause CorrectionTrouble in fuel system Fuel pressure control valve defective ReplaceFuel filter clogged ReplaceFuel pump clogged Clean or replaceFuel tank or fuel pipe clogged Clean or replaceFuel injector clogged Clean or replaceFuel pump relay defective ReplacePower supply cable for fuel pumpbroken or poor connectionsReconnect, correct or replaceMass Airflow (MAF) sensor circuitopen or defectiveCorrect or replaceMAF Sensor defective ReplaceManifold Absolute Pressure Sensorcircuit open or shortedCorrect or replaceManifold Absolute Pressure SensordefectiveReplaceEngine Coolant Temperature (ECT)Sensor circuit open or shortedCorrect or replaceECT Sensor defective ReplaceThrottle Position Sensor adjustmentincorrectReadjustThrottle Position Sensor defective ReplaceThrottle Position Sensor connectorpoor connectionsReconnectVehicle Speed Sensor cable poorconnections or defectiveCorrect or replaceVehicle Speed Sensor loosely fixed Fix tightlyVehicle Speed Sensor in wrongcontact or defectiveReplacePowertrain Control Module cablepoor connections or defectiveCorrect or replace6A-14 ENGINE MECHANICALCondition Correction PossibIe causeTrouble in emission control system Heated Oxygen Sensor circuit open Correct or replaceHeated Oxygen Sensor defective ReplaceSignal vacuum hose loosely fitted ordefectiveCorrect or replaceEGR Valve circuit open or shorted Correct or replaceExhaust Gas Recirculation ValvedefectiveReplaceECT Sensor circuit open or shorted Correct or replaceCanister Purge Valve circuit open orshortedCorrect or replaceCanister Purge Valve defective ReplaceECT Sensor defective ReplacePositive Crankcase Ventilation(PCV) valve and hose cloggedCorrect or replaceEvaporator system Refer to Section 6ETrouble in ignition system Refer to Engine Lacks PowerTrouble in cylinder head parts Carbon deposits in combustionchamberRemove carbonCarbon deposit on valve, valve seatand valve guideRemove carbonEngine OiI Consumption ExcessiveCondition PossibIe cause CorrectionOil leaking Oil pan drain plug loose Retighten or replace gasketCrankcase fixing bolts loosened RetightenOil pan setting bolts loosened RetightenOil pan gasket broken Replace gasketFront cover retaining bolts loose orgasket brokenRetighten or replace gasketHead cover fixing bolts loose orgasket brokenRetighten or replace gasketOil cooler adapter cracked ReplaceOil cooler center bolt loose RetightenOil cooler Oring broken ReplaceOil cooler piping loose or broken Retighten or replaceOil filter adapter cracked ReplaceOil filter attaching bolt loose or rubbergasket brokenRetighten or replace oil filterOil cooler broken ReplaceCrankshaft front or rear oil sealdefectiveReplace oil sealOil pressure unit loose or broken Retighten or replaceBlowby gas hose broken Replace hosePositive Crankcase Ventilation ValvecloggedCleanEngine/Transmission coupling failed Replace oil seal6A-15 ENGINE MECHANICALCondition Correction PossibIe causeOil leaking into combustionchambers due to poor seal in valveValve stem oil seal defective Replacechambers due to oor seal in valvesystemValve stem or valve guide worn Replace valve and valve guideOil leaking into combustionchambers due to poor seal in cylindertCylinders and pistons wornexcessivelyReplace cylinder body assembly andpistonspartsPiston ring gaps incorrectlypositionedCorrectPiston rings set with wrong side up CorrectPiston ring sticking Replace cylinder body assembly andpistonsPiston ring and ring groove worn Replace pistons and othersReturn ports in oil rings clogged Clean piston and replace ringsPositive Crankcase VentilationSystem malfunctioningPositive Crankcase Ventilation ValvecloggedCleanOthers mproper oil viscosity Use oi l of recommended S.A.E.viscosityContinuous high speed drivingand/or severe usage such as trailertowingContinuous high speed operationand/or severe usage will normallycause increased oil consumptionFueI Consumption ExcessiveCondition PossibIe cause CorrectionTrouble in fuel system Mixture too rich or too lean due totrouble in fuel injection systemRefer to Abnormal CombustionFuel cut function does not work Refer to Abnormal CombustionTrouble in ignition system Misfiring or abnormal combustiondue to trouble in ignition systemRefer to Hard Start or AbnormalCombustionOthers Engine idle speed too high Reset dle Air Control ValveReturning of accelerator controlsluggishCorrectFuel system leakage Correct or replaceClutch slipping CorrectBrake drag CorrectSelection of transmission gearincorrectCaution operator of incorrect gearselectionExcessive Exhaust GasRecirculation flow due to trouble inExhaust Gas Recirculation systemRefer to Abnormal Combustion6A-16 ENGINE MECHANICALLubrication ProbIemsCondition PossibIe cause CorrectionOil pressure too low Wrong oil in use Replace with correct engine oilRelief valve sticking ReplaceOil pump not operating properly Correct or replaceOil pump strainer clogged Clean or replace strainerOil pump worn ReplaceOil pressure gauge defective Correct or replaceCrankshaft bearing or connectingrod bearing wornReplaceOil contamination Wrong oil in use Replace with correct engine oilOil filter clogged Replace oil filterCylinder head gasket damage Replace gasketBurned gases leaking Replace piston and piston rings orcylinder body assemblyOil not reaching valve system Oil passage in cylinder head orcylinder body cloggedClean or correctEngine OiI Pressure Check1. Check for dirt, gasoline or water in the engine oil.a. Check the viscosity of the oil.b. Change the oil if the viscosity is outside thespecified standard.c. Refer to the Maintenance and Lubrication sectionof this manual.2. Check the engine oil level.The level should fall somewhere between the ADDand the FULL marks on the oil level dipstick.f the oil level does not reach the ADD mark on theoil level dipstick, engine oil must be added.3. Remove the oil pressure unit.4. nstall an oil pressure gauge.5. Start the engine and allow the engine to reach normaloperating temperature (About 80 C).6. Measure the oil pressure.OiI pressure shouId be:392-550 kPa (56.9-80.4 psi) at 3000 rpm.7. Stop the engine.8. Remove the oil pressure gauge.9. nstall the oil pressure unit.10. Start the engine and check for leaks.6A-17 ENGINE MECHANICALMaIfunction Indicator LampThe instrument panel CHECK ENGNE Malfunctionndicator Lamp (ML) illuminates by self diagnosticsystem when the system checks the starting of engine, orsenses malfunctions.Condition PossibIe cause CorrectionCHECK ENGNE ML does notilluminate at the starting of engineBulb defective Replaceilluminate at the starting of engineML circuit open Correct or replaceCommand signal circuit to operateself diagnostic system shortedCorrect or replaceEngine Control Module (PCM) cableloosely connected, disconnected ordefectiveCorrect or replacePCM defective ReplaceCHECK ENGNE ML illuminates,and stays onDeterioration of heated oxygensensor internal elementReplaceHeated oxygen sensor connectorterminal improper contactReconnect properlyHeated oxygen sensor lead wireshortedCorrectHeated oxygen sensor circuit open Correct or replaceDeterioration of engine coolanttemperature sensor internal elementReplaceEngine coolant temperature sensorconnector terminal improper contactReconnect properlyEngine coolant temperature sensorlead wire shortedCorrectEngine coolant temperature sensorcircuit openCorrect or replaceThrottle position sensor open orshorted circuitsCorrect or replaceDeterioration of crankshaft positionsensorReplaceCrankshaft position sensor circuitopen or shortedCorrect or replaceVehicle speed sensor circuit open Correct or replaceManifold absolute pressure sensorcircuit open or shortedCorrect or replacentake air temperature sensor circuitopen or shortedCorrect or replaceFuel injector circuit open or shorted Correct or replacePCM driver transistor defective Replace PCMMalfunctioning of PCM RAM(Random Access Memory) or ROM(Read Only Memory)Replace PCM6A-18 ENGINE MECHANICALCyIinder Head Cover LHRemovaI1. Disconnect battery ground cable.2. Drain engine coolant from faucet bottom of radiator.3. Remove engine cover from the dowels on thecommon chamber.F06RW0184. Remove air cleaner duct assembly (3) and air cleanerelement (4).130RW001Legend(1) Positive Crankcase Ventilation Hose Connector(2) ntake Air Temperature Sensor(3) Air Cleaner Duct Assembly(4) Air Cleaner Element(5) Mass Air Flow SensorNOTE: Disconnect the mass air flow (MAF) sensorconnector, intake air temperature (AT) sensor connector,and positive crankcase ventilation (PCV) hose beforehand the air cleaner duct assembly is removed.5. Disconnect following wiring connectors and bondingcable:Manifold Absolute Pressure (MAP) sensorVacuum Switching Valve (VSV) for nduction AirControl Valve (ACV) actuatorgnition coils for left bankFuel injectors for left bankdle air control (AC) valveThrottle position sensor (TPS)Bonding cableOthers as necessitated6. Disconnect following vacuum hoses:Brake master VACCanisterVSV for ACV actuatorDuty solenoid valvePCV7. Disconnect radiator upper and lower hoses8. Remove engine harness from the cylinder headcover.9. Remove the upper fan guide.10. Remove cooling fan and clutch assembly.11. Remove drive belt by pushing down the autotensioner using spanner as illustrated.F06RW0196A-19 ENGINE MECHANICALLegend(1) Crankshaft Pulley(2) Generator(3) Auto Tensioner(4) dle Pulley(5) Cooling Fan Pulley(6) Power Steering Oil Pump(7) Drive Belt(8) Air Conditioner Compressor12. Remove power steering oil pump pulley.13. Remove fan pulley and bracket assembly.14. Remove idle pulley assembly.15. Remove auto tensioner assembly.16. Remove crankshaft pulley using 5884001330crankshaft holder.17. Remove timing belt covers from the right bank side tothe left bank side in order.18. Remove ignition coil assemblies for the left side bank.060RW018Legend(1) gnition Coil Connectors(2) Bolts(3) gnition Coil Assemblies19. Remove cylinder head cover assembly.InstaIIation1. nstall cylinder head cover.Clean the sealing surface of cylinder head andcylinder head cover to remove oil and sealingmaterials completely.Apply sealant (TB-1207B or equivalent) of beaddiameter 2-3 mm at eight place of arched area ofcamshaft bracket on front and rear sides.The cylinder head cover must be installed within 5minutes after sealant application to preventpremature hardening of sealant.014RW144Tighten bolts to the specified torque.Torque : 9 Nm (0.9 Kgm/78 Ib in)010RW0082. nstall ignition coil assemblies and tighten the fixingbolts to the specified torque.Torque : 4 Nm (0.4 Kgm/35 Ib in)3. nstall timing belt covers from left bank side to rightbank side, and tighten the fixing bolts and nut to thespecified torque.Torque : 19 Nm (1.9 Kgm/14 Ib ft)4. nstall crankshaft pulley and tighten the fixing boltusing 5884001330 crankshaft holder to thespecified torque.Torque : 167 Nm (17.0 Kgm/123 Ib ft)6A-20 ENGINE MECHANICAL5. nstall auto tensioner assembly and tighten the fixingbolts to the specified torque.Torque :Shorter BoIt : 20 Nm (2.0 Kgm/14 Ib ft)Longer BoIt : 39 Nm (4.0 Kgm/29 Ib ft)6. nstall idle pulley and bracket assembly and tightenthe fixing bolt to the specified torque.Torque : 52 Nm (5.3 Kgm/38 Ib ft)7. nstall fan pulley and bracket assembly and tightenthe fixing bolts and nut to the specified torque.Torque : 22 Nm (2.2 Kgm/16 Ib ft)8. nstall power steering oil pump pulley and tighten thefixing bolt to the specified torque.Torque : 78 Nm (8.0 Kgm/58 Ib ft)9. nstall drive belt by pushing down the auto tensionerusing spanner as shown in the removal step of drivebelt.10. nstall cooling fan and clutch assembly and tightenthe fixing bolts to the specified torque.Torque : 10 Nm (1.0 Kgm/87 Ib in)11. nstall upper fan guide and clip both side and tightenthe fixing bolts to the specified torque.Torque : 4 Nm (0.4 Kgm/35 Ib in)12. nstall engine harness and tighten the fixing bolts ofthe retaining clip and bracket to the specified torque.Torque : 4 Nm (0.4 Kgm/35 Ib in)13. Connect radiator upper and lower hoses and clipthem securely.14. Connect vacuum hoses of those which weredisconnected in the removal step.15. Connect wiring connectors and bonding cable ofthose which were disconnected in the removal step.16. nstall air cleaner element and air cleaner ductassembly, and clip the both end securely.17. Connect MAF sensor connector, AT sensorconnector and PCV hose.18. nstall engine cover mating with the dowels.6A-21 ENGINE MECHANICALCyIinder Head Cover RHRemovaI1. Disconnect battery ground cable.2. Remove battery from the vehicle.3. Drain engine coolant from faucet bottom of radiator.4. Remove engine cover from the dowels on thecommon chamber.F06RW0185. Remove air cleaner duct assembly (3) and air cleanerelement (4).130RW001Legend(1) Positive Crankcase Ventilation Hose Connector(2) ntake Air Temperature Sensor(3) Air Cleaner Duct Assembly(4) Air Cleaner Element(5) Mass Air Flow SensorNOTE: Disconnect the mass air flow (MAF) sensorconnector, intake air temperature (AT) sensor connector,and positive crankcase ventilation (PCV) hose beforehand the air cleaner duct assembly is removed.6. Disconnect following wiring connectors and bondingcable:Exhaust Gas Recirculation (EGR) valveFuel injectors for right bankgnition coils for right bankBonding cableOthres as necessitated7. Disconnect radiator upper and lower hoses.8. Remove engine harness from the cylinder headcover.9. Remove the upper fan guide.10. Remove cooling fan and clutch assembly.11. Remove drive belt by pushing down the autotensioner using spanner as illustrated.F06RW019Legend(1) Crankshaft Pulley(2) Generator(3) Auto Tensioner(4) dle Pulley(5) Cooling Fan Pulley(6) Power Steering Oil Pump(7) Drive Belt(8) Air Conditioner Compressor12. Remove fan pulley and bracket assembly.13. Remove idle pulley assembly.14. Remove auto tensioner assembly.15. Remove crankshaft pulley using 5884001330crankshaft holder.6A-22 ENGINE MECHANICAL16. Remove timing belt covers for right bank side.17. Reomve timing belt covers for right bank side.060RW001Legend(1) gnition Coil Connectors(2) Bolts(3) gnition Coil Assemblies18. Remove ignition coil assemblies for the right sidebank.19. Remove cylinder head cover assembly.InstaIIation1. nstall cylinder head cover.Clean the sealing surface of cylinder head andcylinder head cover to remove oil and sealingmaterials completely.Apply sealant (TB-1207B or equivalent) of beaddiameter 2-3 mm at eight place of arched area ofcamshaft bracket on front and rear sides.The cylinder head cover must be installed within 5minutes after sealant application before the sealanthardens.014RW143Tighten bolts in turn to the specified torque.Torque : 8.8 Nm (0.9 Kgm/78 Ib in)010RW0072. nstall ignition coil assemblies and tighten the fixingbolts to the specified torque.Torque : 4 Nm (0.4 Kgm/35 Ib in)3. nstall timing belt cover and tighten the fixing bolts andnut to the specified torque.Torque : 19 Nm (1.9 Kgm/14 Ib ft)4. nstall crankshaft pulley and tighten the fixing boltusing 5884001330 crankshaft holder to thespecified torque.Torque : 167 Nm (17 Kgm/123 Ib ft)5. nstall auto tensioner assembly and tighten the fixingbolts to the specified torque.Torque :Shorter BoIt : 20 Nm (2.0 Kgm/14.8 Ib ft)Longer BoIt : 39 Nm (4.0 Kgm/28.8 Ib ft)6A-23 ENGINE MECHANICAL6. nstall idle pulley assembly and tighten the fixing boltto the specified torque.Torque : 52 Nm (5.3 Kgm/38.4 Ib ft)7. nstall fan pulley and bracket assembly and tightenthe fixing bolts and nut to the specified torque.Torque : 22 Nm (2.2 Kgm/16.2 Ib ft)8. nstall drive belt by pushing down the auto tensionerusing spanner as shown in the removal step of drivebelt.9. nstall cooling fan clutch assembly and tighten thefixing bolts to the specified torque.Torque : 10 Nm (1.0 Kgm/88.5 Ib in)10. nstall upper fan guide and clip both side and tightenthe fixing bolts to the specified torque.Torque : 4 Nm (0.4 Kgm/35.4 Ib in)11. nstall engine harness and tighten the fixing bolts ofthe retaining clip and brackets to the specified torque.Torque : 4 Nm (0.4 Kgm/35.4 Ib in)12. Connect radiator upper and lower hoses and clipthem securely.13. Connect wiring connectors and bonding cable ofthose which were disconnected in the removal step.14. nstall air cleaner element and air cleaner ductassembly, and the clip both end securely.15. Connect MAF sensor connector, AT sensorconnector and PCV hose.16. nstall engine cover mating with the dowels.6A-24 ENGINE MECHANICALCommon ChamberRemovaI1. Disconnect battery ground cable.2. Remove air cleaner duct assembly.130RW001Legend(1) Positive Crankcase Ventilation Hose Connector(2) ntake Air Temperature Sensor(3) Air Cleaner Duct Assembly(4) Air Cleaner Element(5) Air Flow Sensor3. Disconnect accelerator pedal cable from throttle bodyand cable bracket.4. Disconnect vacuum booster hose from commonchamber.5. Disconnect connector from manifold absolutepressure sensor, idle air control valve, throttleposition sensor, solenoid valve, electric vacuumsensing valve, and EGR valve.6. Disconnect vacuum hose on canister VSV andpositive crankcase ventilation hose, fuel railassembly with pressure control valve bracket.7. Remove ventilation hose from throttle valve andintake duct and remove water hose.8. Remove the four throttle body fixing bolts.9. Remove exhaust gas recirculation valve assemblyfixing bolt and nut on common chamber and removeEGR valve assembly.10. Remove two bolts from common chamber rear sidefor remove fuel hose bracket.11. Remove common chamber four bolts and four nutsthen remove the common chamber.025RW001Legend(1) Common Chamber(2) Throttle Valve Assembly(3) BoltInstaIIation1. nstall common chamber and tighten bolts and nuts tothe specified torque.Torque :BoIt : 25 Nm (2.5 Kgm/18 Ib ft)Nut : 25 Nm (2.5 Kgm/18 Ib ft)2. nstall fuel hose bracket and tighten bolts to specifiedtorque.Torque : 10 Nm (1.0 Kgm/89 Ib in)3. nstall exhaust gas recirculation valve assembly andtighten bolt and nut to the specified torque.Torque : 25 Nm (2.5 Kgm/18 Ib ft)4. nstall throttle body and tighten bolts to the specifiedtorque.Torque : 25 Nm (2.5 Kgm/18 Ib ft)5. nstall ventilating hose to throttle valve and intakeduct.6. Connect vacuum hoses on canister VSV and positivecrankcase ventilation hose. Tighten bolts for fuel railassembly with pressure control valve bracket.Torque : 25 Nm (2.5 Kgm/18 Ib ft)7. Connect each connector without fail.8. Connect vacuum booster hose.9. Connect accelerator pedal cable.Accelerator pedal cable adjustment1. Loosen the adjusting nut and screw cap.2. Pull outer cable while fully closing the throttlevalve.6A-25 ENGINE MECHANICAL3. Tighten adjusting nut and lock nut temporarily.4. Loosen adjusting nut by three turns and tightenlock nut.Then manually operating the throttle valve, makesure that the valve lever returns up to the stopperscrew.f it does not reach the stopper screw, repeat fromstep 1.035RW004Legend(1) Clearance(2) Lock Nut(3) Adjusting Nut10. nstall air cleaner duct assembly.130RW001Legend(1) Positive Crankcase Ventilation Hose Connector(2) ntake Air Temperature Sensor(3) Air Cleaner Duct Assembly(4) Air Cleaner Element.(5) Mass Air Flow Sensor6A-26 ENGINE MECHANICALExhaust ManifoId LHRemovaI1. Disconnect battery ground cable.2. Remove air cleaner duct assembly.130RW001Legend(1) Positive Crankcase Ventilation Hose Connector(2) ntake Air Temperature Sensor(3) Air Cleaner Duct Assembly(4) Air Cleaner Element(5) Mass Air Flow Sensor3. Remove exhaust front pipe three stud nuts fromexhaust side and two nuts from rear end of exhaustfront pipe.150RW062Legend(1) Exhaust Front Pipe LH4. Remove heat protector two fixing bolts then the heatprotector.5. Remove a bolt on engine LH side for air conditioner(A/C) compressor bracket and loosen two bolts forA/C compressor then move A/C compressor to frontside.6. Remove exhaust manifold eight fixing nuts andremove exhaust manifold from the engine.InstaIIation1. nstall exhaust manifold and tighten exhaust manifoldfixing nuts to the specified torque with new nuts.Torque: 57 Nm (5.8 Kgm/42 Ib ft)2. nstall heat protector.3. nstall exhaust front pipe and tighten three stud nutsand two nuts to the specified torque.Torque : Stud nuts: 67 Nm (6.8 Kgm/49 Ib ft)Nuts: 43 Nm (4.4 Kgm/32 Ib ft)150RW062Legend(1) Exhaust Front Pipe LH4. Set A/C compressor to normal position and tightentwo bolts and a bolt to the specified torque.Torque : 40 Nm (4.1 Kgm/30 Ib ft)5. nstall air cleaner duct assembly.6A-27 ENGINE MECHANICALExhaust ManifoId RHRemovaI1. Disconnect battery ground cable.2. Remove torsion bar. Refer to removal procedure inFront Suspension section.3. Remove exhaust front pipe three stud nuts and twonuts then disconnect exhaust front pipe.150RW061Legend(1) Exhaust Front Pipe RH(2) O2 Sensor (for GM)4. Remove heat protector two fixing bolts then the heatprotector.5. Remove exhaust gas recirculation (EGR) pipe fixingbolt and nut from exhaust manifold, remove a nutfrom EGR valve and a bolt from rear side of cylinderhead for bracket of EGR pipe then remove the EGRpipe.056RW001Legend(1) Exhaust Gas Recirculation (EGR) Valve(2) EGR Pipe6. Remove exhaust manifold eight fixing nuts then theexhaust manifold.InstaIIation1. nstall exhaust manifold and tighten bolts to thespecified torque.Torque : 57 Nm (5.8 Kgm/42 Ib ft)2. nstall the EGR pipe, tighten bolt and nut on exhaustmanifold to specified torque.Torque : 28 Nm (2.9 Kgm/21 Ib ft)Tighten nut to EGR valve to the specified torque.Torque : 44 Nm (4.5 Kgm/33 Ib ft)Tighten the bolt for EGR pipe bracket to specifiedtorque.Torque : 25 Nm (2.5 Kgm/18 Ib ft)3. nstall heat protector4. nstall exhaust front pipe and tighten three stud nutsand two nuts to the specified torque.Torque:Stud nuts: 67 Nm (6.8 Kgm/49 Ib ft)Nuts: 43 Nm (4.4 Kgm/32 Ib ft)5. nstall the torsion bar and readjust the vehicle height.Refer to installation and vehicle height adjustmentprocedure for Front Suspension.6A-28 ENGINE MECHANICALCrankshaft PuIIeyRemovaI1. Disconnect battery ground cable.2. Remove air cleaner assembly.130RW001Legend(1) Positive Crankcase Ventilation Hose Connector(2) ntake Air Temperature Sensor(3) Air Cleaner Duct Assembly(4) Air Cleaner Element(5) Mass Air Flow Sensor3. Remove radiator upper fan shroud from radiator.4. Move serpentine belt tensioner to loose side usingwrench then remove serpentine belt.850RW001Legend(1) Crankshaft Pulley(2) Cooling Fan Pulley(3) Tensioner(4) Generator(5) Air Conditioner Compressor(6) Power Steering Oil Pump(7) Serpentine Belt5. Remove cooling fan assembly four fixing nuts, thenthe cooling fan assembly.6. Remove crankshaft pulley assembly using J-8614-01crankshaft holder, hold crankshaft pulley thenremove center bolt and pulley.InstaIIation1. nstall crankshaft pulley using J-8614-01 crankshaftholder, hold the crankshaft pulley and tighten centerbolt to the specified torque.Torque : 167 Nm (17.0 Kgm/123 Ib ft)2. nstall cooling fan assembly and tighten bolts/nuts tothe specified torque.Torque : 22 Nm (2.2 Kgm/16 Ib ft) for fan puIIeyand fan bracket.Torque : 10 Nm (1.0 Kgm/88.5 Ib in) for fan andcIutch assembIy.3. Move serpentine belt tensioner to loose side usingwrench, then install serpentine belt to normalposition.4. nstall radiator upper fan shroud.5. nstall air cleaner assembly.6A-29 ENGINE MECHANICALTiming BeItRemovaI1. Disconnect battery ground cable.2. Remove air cleaner assembly.3. Remove radiator upper fan shroud from radiator.4. Move drive belt tensioner to loose side using wrenchthen remove drive belt.850RW001Legend(1) Crankshaft Pulley(2) Cooling Fan Pulley(3) Tensioner(4) Generator(5) Air Conditioner Compressor(6) Power Steering Oil Pump(7) Drive Belt5. Remove cooling fan assembly four nuts, then thecooling fan assembly.6. Remove cooling fan drive pulley assembly.7. Remove idle pulley assembly.8. Remove serpentine belt tensioner assembly.9. Remove power steering pump assembly.10. Remove crankshaft pulley assembly using5884001330 crankshaft holder, hold crankshaftpulley remove center bolt, then the pulley.11. Remove right side timing belt cover then left sidetiming belt cover.12. Remove lower timing belt cover13. Remove pusher.CAUTION: The pusher prevents air from enteringthe oiI chamber. Its rod must aIways be facingupward.014RW011Legend(1) Up Side(2) Down Side(3) Direction For nstallation(4) Locking Pin14. Remove timing belt.CAUTION:1. Do not bend or twist the beIt, otherwise its corecouId be damaged. The beIt shouId not be bent ata radius Iess than 30 mm.2. Do not aIIow oiI or other chemicaI substances tocome in contact with the beIt. They wiII shortenthe Iife.3. Do not attempt to pry or stretch the beIt with ascrew driver or any other tooI during instaIIation.4. Store timing beIt in a cooI and dark pIace. Neverexpose the beIt direct sunIight or heat.6A-30 ENGINE MECHANICALInstaIIationNOTE: For correct belt installation, the letter on the beltmust be able to be read as viewed from the front of thevehicle.014RY00042Legend(1) Crankshaft Timing Pulley(2) RH Bank Camshaft Drive Gear Pulley(3) Water Pump Pulley(4) dle Pulley(5) LH Bank Camshaft Drive Gear Pulley(6) Tension Pulley014RY00043Legend(7) Alignment Mark on Oil Pump.(8) Alignment Mark on Timing Belt(9) Alignment Mark (notch) on Crankshaft TimingPulley.(10) Alignment Mark (groove) on Crankshaft TimingPulley.014RW006Legend(1) Timing Belt(2) Engine Rotation Direction(3) Cylinder Head Side1. nstall timing belt.1. Align the mark (notch) of crankshaft timing pulley(2) with mark on oil pump (1).Align the mark (groove) on the crankshaft timingpulley (3) with alignment mark (white dots line) onthe timing belt (4).NOTE: When timing marks are aligned, No.2 piston willbe on Top Dead Center.014RW003Legend(1) Alignment Mark on Oil Pump(2) Groove on Crankshaft Timing Pulley(3) Alignment Mark on Crankshaft Timing Pulley(4) Alignment Mark on Timing Belt6A-31 ENGINE MECHANICAL2. Align the alignment mark on the RH bankcamshaft drive gear pulley (2) to the alignmentmark of the cylinder head cover RH (3).3. Align the alignment mark (white line) on the timingbelt (1) with alignment mark on the RH bankcamshaft drive gear pulley (2) (on the left side asviewed from the front of the vehicle) and put thetiming belt on the camshaft drive gear pulley.Secure the belt with a double clip or equivalentclip.014RW00004Legend(1) Alignment Mark on Timing Belt (White line).(2) Alignment Mark on Camshaft Drive GearPulley.(3) Alignemnt Mark on Cylinder Head Cover RH.4. Align the alignment mark on the LH bankcamshaft drive gear pulley (2) to the alignmentmark of the cylinder head cover LH (3).5. Align the alignment mark (white line) on the timingbelt (1) with the alignment mark on the LH bankcamshaft drive gear pulley (2).When aligning the timing marks, use a wrench toturn the camshaft drive gear pulley, then set thetiming mark between timing belt and camshaftdrive gear pulley and put the timing belt on thecamshaft drive gear pulley.Secure the belt with a double clip or equivalentclip.NOTE: t is recommended for easy installation that thebelt be secured with a double clip or equivalent clip afterit is installed the timing belt to each pulley.014RW00005Legend(1) Alignment Mark on Timing Belt (White line).(2) Alignment Mark on Camshaft Drive GearPulley.(3) Alignemnt Mark on Cylinder Head Cover LH.6. nstall crankshaft pulley temporarily and tightencenter bolt by hand (do not use a wrench).Turn the crankshaft pulley clockwise to give somebelt slack between the crankshaft timing pulleyand the RH bank camshaft drive gear pulley.2. nstall pusher and tighten bolt to the specified torque.Torque : 25 Nm (2.5 Kgm/18 Ib ft)1. nstall the pusher while pushing the tension pulleyto the belt.2. Pull out pin from the pusher.NOTE: When reusing the pusher, press the pusher withapproximately 100Kg to retract the rod, and insert a pin(1.4 mm piano wire).014RW0116A-32 ENGINE MECHANICALLegend(1) Up Side(2) Down Side(3) Direction for nstallation(4) Locking Pin3. Remove double clips or equivalent clips, fromtiming belt pulleys.Turn the crankshaft pulley clockwise by two turns.3. nstall timing belt cover.Remove crankshaft pulley that was installed in step1 item 5.Tighten bolts to the specified torque.Torque: 19 Nm (1.9 Kgm/14 Ib ft)020RW004Legend(1) Timing Belt Cover RH(2) Timing Belt Cover LH(3) Timing Belt Cover Lower020RW003Legend(1) Timing Belt Cover(2) Rubber Bushing(3) Sealing Rubber(4) Cylinder Body4. nstall crankshaft pulley using 5884001330, holdthe crankshaft pulley and tighten center bolt to thespecified torque.Torque : 167 Nm (17.0 Kgm/123 Ib ft)5. nstall fan pulley bracket and tighten fixing bolts to thespecified torque.Torque : 22 Nm (2.2 Kgm/16 Ib ft)6. nstall power steering pump assembly and tighten tothe specified torque.Torque : M8 boIt : 22 Nm (2.2 Kgm/16 Ib ft)M10 boIt : 46 Nm (4.7 Kgm/34 Ib ft)7. nstall cooling fan assembly and tighten bolts/nuts tothe specified torque.Torque : 22 Nm (2.2 Kgm/16 Ib ft) for fan puIIeyand fan bracket.Torque : 10 Nm (1.0 Kgm/88.5 Ib in) for fan andcIutch assembIy.8. Move drive belt tensioner to loose side using wrench,then install drive belt to normal position.850RW001Legend(1) Crankshaft Pulley(2) Cooling Fan Pulley(3) Auto Tensioner(4) Generator(5) Air Conditioner Compressor(6) Power Steering Oil Pump(7) dle Pulley(8) Drive Belt9. nstall radiator upper fan shroud.10. nstall air cleaner assembly.6A-33 ENGINE MECHANICALCamshaftRemovaI1. Disconnect battery ground cable.2. Remove crankshaft pulley.Refer to removal procedure for Crankshaft Pulley inthis manual.3. Remove timing belt.Refer to removal procedure for Timing Belt in thismanual.4. Remove cylinder head cover LH.Refer to removal procedure for Cylinder HeadCover LH in this manual.5. Remove cylinder head cover RH.Refer to removal procedure for Cylinder HeadCover RH in this manual.6. Remove twenty fixing bolts from inlet and exhaustcamshaft bracket on one side bank, then camshaftbrackets.014RW0277. Remove camshaft assembly.8. Remove fixing bolt for camshaft drive gear pulley.9. Remove three fixing bolts from camshaft drive gearretainer, then camshaft drive gear assembly.014RW026Legend(1) Right Bank(2) Left Bank(3) Timing Mark on RetainerInstaIIation1. nstall camshaft drive gear assembly and tightenthree bolts to the specified torque.Torque : 10 Nm (1.0 Kgm/89 Ib in)2. Tighten bolt for camshaft drive gear assembly pulleyto the specified torque.Torque : 98 Nm (10.0 Kgm/72 Ib ft)3. Tighten sub gear setting bolt.1. Use the 5884024430 gear spring lever to turnsub gear to right direction until it aligns with the M5bolt hole between camshaft driven gear and subgear.2. Tighten the M5 bolt to a suitable torque to preventthe sub gear from moving.6A-34 ENGINE MECHANICAL014RW0414. nstall camshaft assembly and camshaft brackets,tighten twenty bolts on one side bank to the specifiedtorque.1. Apply engine oil to camshaft journal and bearingsurface of camshaft bracket.2. Align timing mark on intake camshaft (one dot forright bank, two dot for left bank) and exhaustcamshaft (one dot for right bank, two dots for leftbank) to timing mark on camshaft drive gear (onedot).014RW020Legend(1) ntake Camshaft Timing Gear for Right Bank(2) ntake Camshaft Timing Gear for Left Bank(3) Exhaust Camshaft Timing Gear(4) Discrimination Mark(L: Left bank intake, R: Right bank intake)(LE: Left bank exhaust, RE: Right bankexhaust)014RW023Legend(1) Right Bank Camshaft Drive Gear(2) Left Bank Camshaft Drive Gear(3) Timing Mark on Drive Gear(4) Dowel Pin6A-35 ENGINE MECHANICAL014RW024Legend(1) Right Bank(2) Left Bank(3) Alignment Mark on Camshaft Drive Gear(4) Alignment Mark on Camshaft(5) Alignment Mark on Retainer3. Tighten twenty bolts on numerical order an oneside bank as shown in the illustration.Torque : 10 Nm (1.0 Kgm/89 Ib in)014RW0315. nstall cylinder head cover RH.Refer to installation procedure for CYLNDERHEAD COVER RH in this manual.6. nstall cylinder head cover LH.Refer to installation procedure for CYLNDERHEAD COVER LH in this manual.7. nstall timing belt.Refer to installation procedure for TMNG BELT inthis manual.8. nstall crankshaft pulley.Refer to installation procedure for CRANKSHAFTPULLEY in this manual.Accelerator pedal cable adjustment1. Loosen adjusting nut and lock nut.2. Pull outer cable while closing fully the throttlevalve.3. Tighten adjusting nut and lock nut temporarily.6A-36 ENGINE MECHANICAL4. Loosen adjusting nut by three turns and tightenlock nut.Then, manually operating the throttle valve, makesure that the valve lever returns up to the stopperscrew.f it does not reach the stopper screw, repeat fromstep 1.035RW004Legend(1) Clearance(2) Lock Nut(3) Adjusting Nut6A-37 ENGINE MECHANICALCyIinder HeadRemovaI1. Remove engine hood.2. Disconnect battery ground cable.3. Drain radiator coolant.4. Drain engine oil.5. Remove crankshaft pulley.Refer to removal procedure for Crankshaft Pulley inthis manual.6. Remove timing belt.Refer to removal procedure for Timing Belt in thismanual.7. Remove cylinder head cover LH.Refer to removal procedure for Cylinder HeadCover LH in this manual.8. Remove cylinder head cover RH.Refer to removal procedure for Cylinder HeadCover RH in this manual.9. Remove common chamber.Refer to removal procedure for Common Chamberin this manual.10. Remove cylinder head assembly.1. Loosen eights bolts for tight cylinder head.2. Remove cylinder head assembly.014RW028Legend(1) Cylinder Head(2) Cylinder Head Bolt(3) CamshaftInstaIIation1. nstall cylinder head assembly to cylinder block.1. Put cylinder head gasket on the cylinder block.NOTE: There is discrimination mark R for right bankand L for left bank on the cylinder head gasket as shownin the illustration.Do not reuse cylinder head gasket.011RW0052. Align dowel pin hole to dowel pin on the cylinderblock.3. Tighten two bolts temporarily by hand to preventthe cylinder head assembly from moving.4. Using 9851142090 cylinder head bolt wrench,tighten bolts in numerical order as shown in theillustration to the specified torque.NOTE: Do not reuse cylinder head bolts.Do not apply any lubricant to the cylinder head bolts.Torque :Temporary : 29 Nm (3.0 Kgm/21 Ib ft)FinaI : 64 Nm (6.5 Kgm/47 Ib ft)014RW0296A-38 ENGINE MECHANICAL2. nstall common chamber.Refer to installation procedure for CommonChamber in this manual.3. nstall cylinder head cover RH.Refer to installation procedure for Cylinder HeadCover RH in this manual.4. nstall cylinder head cover LH.Refer to installation procedure for Cylinder HeadCover LH in this manual.5. nstall timing belt.Refer to installation procedure for Timing Belt in thismanual.6. nstall crankshaft pulley.Refer to installation procedure for CrankshaftPulley in this manual.Accelerator pedal cable adjustment1. Loosen adjusting nut and lock nut.2. Pull outer cable while closing fully the throttlevalve.3. Tighten adjusting nut and lock nut temporarily.4. Loosen adjusting nut by three turns and tightenlock nut.Then, manually operating the throttle valve, makesure that the valve lever returns up to the stopperscrew.f it does not reach the stopper screw, repeat fromstep 1.035RW004Legend(1) Clearance(2) Lock Nut(3) Adjusting Nut6A-39 ENGINE MECHANICALVaIve Stem OiI ControIIer , VaIve Spring and VaIve GuideRemovaI1. Disconnect battery ground cable.2. Drain engine oil.Drain engine coolant.3. Remove cylinder head assembly.Refer to removal procedure for Cylinder Head inthis manual.4. Remove camshaft.Refer to removal procedure for Camshaft in thismanual.5. Remove tappets with shim.NOTE: Do not damage shim surface.6. Remove valve springs using 5884024460 valvespring compressor and 5884025470 valve springcompressor adapter then remove upper valve springseat and lower seat.014RW0427. Remove oil controller using 5884006230 oilcontroller remover, remove each valve stem oilcontroller.8. Remove valve guide using 5884025490 valveguide replacer.InstaIIation1. nstall valve guide using 5884024420 valve guideinstaller.2. nstall oil controller using 5884006240 oilcontroller installer.3. nstall lower valve spring seat, valve spring and uppervalve spring seat then put split collars on the upperspring seat, using 5884024460 valve springcompressor and 5884025470 valve springcompressor adapter to install the split collars.014RW0424. nstall tappet with shim.5. nstall camshaft assembly.Refer to installation procedure for Camshaft in thismanual.6. nstall cylinder head assembly.Refer to installation procedure for Cylinder Head inthis manual.7. Fill engine oil until full level.8. Fill engine coolant.6A-40 ENGINE MECHANICALPiston, Piston Ring and Connecting RodRemovaIF06RW011Legend(1) Cylinder Head(2) Crankcase with Oil Pan(3) Oil Pipe(4) Oil Strainer(5) Oil Gallery(6) Piston with Connecting Rod Assembly1. Remove cylinder head assembly.Refer to removal procedure for Cylinder Head inthis manual.2. Remove crankcase with Oil Pan.Refer to removal procedure for Oil Pan andCrankcase in this manual.6A-41 ENGINE MECHANICAL3. Remove oil strainer fixing bolts, remove oil strainerassembly with O-ring.050RW002Legend(1) Oil Pump(2) Oil Strainer(3) Oil Gallery(4) From Oil Filter(5) To Oil Filter4. Remove three fixing bolts, oil pipe with O-ring.5. Remove eight fixing bolts, oil gallery.6. Remove piston with connecting rod assembly, beforeremoving the bearing cap, remove carbon on the topof cylinder bore and push piston with connecting rodout from the top of cylinder bore.InstaIIation1. nstall piston with connecting rod assembly.Apply engine oil to cylinder bore, connecting rodbearing and crank pin.When installing the piston, its front mark must facethe engine front side.The bearing cap number must be the same asconnecting rod number.Apply engine oil to the thread and seating surface ofeach nut.Tighten nuts to the specified torque.Torque : 54 Nm (5.5 Kgm/40 Ib ft)After tightening the nuts, make sure that thecrankshaft rotates smoothly.NOTE: Do not apply engine oil to the bearing back facesand connecting rod bearing fitting surfaces.015RW003Legend(1) Piston Front Mark(2) Piston Grade(3) Connecting Rod Front Mark2. nstall oil gallery and tighten the bolts in two steps, inthe order shown in illustration.Torque :1st step : 29 Nm (3.0 Kgm/21 Ib ft)2nd step : 55 -65051RS0093. nstall oil pipe with O-ring.Torque : 10 Nm (1.0 Kgm/89 Ib in)4. nstall oil strainer assembly with O-ring.Torque : 25 Nm (2.5 Kgm/18 Ib ft)5. nstall crankcase with Oil Pan.Refer to installation procedure for Oil Pan andCrankcase in this manual.6. nstall cylinder head assembly.Refer to installation procedure for Cylinder Head inthis manual.6A-42 ENGINE MECHANICALCrankshaft and Main BearingsRemovaIF06RW010Legend(1) Engine Assembly(2) Crankshaft Pulley(3) Timing Belt Cover(4) Timing Belt(5) Crankcase with Oil Pan(6) Oil Pipe(7) Oil Strainer(8) Oil Pump Assembly(9) Cylinder Body Side Bolt(10) Oil Gallery(11) Flywheel(12) Rear Oil Seal Retainer(13) Connecting Rod Cap(14) Crankshaft Main Bearing Cap(15) Crankshaft and Main Bearing1. Remove engine assembly.Refer to removal procedure for Engine Assembly inthis manual.2. Remove timing belt.Refer to removal procedure for Timing Belt in thismanual.3. Remove oil pan and crankcase.Refer to removal procedure for Oil Pan andCrankcase in this manual.4. Remove oil pipe with O-ring.5. Remove oil strainer assembly with O-ring.6A-43 ENGINE MECHANICAL6. Remove oil pump assembly.Refer to removal procedure for Oil Pump in thismanual.7. Remove cylinder body side bolts.8. Remove oil gallery.9. Remove flywheel.10. Remove rear oil seal retainer.Refer to removal procedure for Rear Oil Seal in thismanual.11. Remove connecting rod caps.12. Remove crankshaft main bearing caps.13. Remove crankshaft and main bearings.InstaIIation1. nstall crankshaft and main bearings.nstall main bearing in the cylinder block and mainbearing cap respectively.Apply new engine oil to upper and lower mainbearings.NOTE:Do not apply engine oil to the bearing back faces.Make sure that main bearings are in correct position.nstall crankshaft with care.Apply engine oil to the thrust washer.nstall thrust washer on No.3 journal.Oil grooves in thrust washer must face thecrankshaft.015RS012015RS0132. nstall crankshaft main bearing caps.Apply engine oil to the thread and seating surface ofeach bearing cap fixing bolt.NOTE:Do not apply engine oil to the bearing back faces.nstall bearing caps in the order of numbers, startingwith cylinder block front side.Tighten main bearing fixing bolts to the specifiedtorque.Torque : 39 Nm (4.0 Kgm/29 Ib ft)After tightening the bolts, make sure that thecrankshaft rotates smoothly.3. nstall connecting rod caps.The cap number must be same as connecting rodnumber.Apply engine oil to the thread and seating surface ofeach nut.Tighten nuts to the specified torque.Torque : 54 Nm (5.5 Kgm/40 Ib ft)After tightening the nuts, make sure that thecrankshaft rotates smoothly.4. nstall rear oil seal retainer.Remove oil on cylinder block and retainer fittingsurface.Apply sealant (TB1207B or equivalent) to retainerfitting surface as shown in illustration.6A-44 ENGINE MECHANICALThe oil seal retainer must be installed within 5minutes after sealant application before the sealanthardens.015RW002Legend(1) Around Bolt Holes(2) Around Dowel PinApply engine oil to oil seal lip and align a dowel pinhole in the cylinder block with that in the retainer.Tighten retainer fixing bolts to the specified torque.Torque : 18 Nm (1.8 Kgm/13 Ib ft)015RW0015. nstall flywheel.Clean tapped holes in the crankshaft.Remove oil on crankshaft and flywheel fittingsurface.NOTE:Do not reuse the bolts.Do not apply oil or thread lock to the bolts.Tighten fixing bolts to the specified torque.Torque : 54 Nm (5.5 Kgm/40 Ib ft)015RS0186. nstall oil gallery.Clean contact surface of oil gallery and mainbearing cap.Apply engine oil to oil gallery fixing bolts and tightenthe bolts in two steps, in the order shown inillustration.Torque :1st step : 29 Nm (3.0 Kgm/21 Ib ft)2nd step : 55 -657. nstall cylinder body side bolts and tighten bolts inorder to the specified torque.Torque : 39 Nm (4.0 Kgm/29 Ib ft)NOTE: Do not apply the oil to the bolts.012RS0078. nstall oil pump assembly.Remove oil on cylinder block and oil pump mountingsurface.6A-45 ENGINE MECHANICALApply sealant (TB1207B or equivalent) to the oilpump mounting surface.The oil pump assembly must be installed within 5minutes after sealant application before the sealanthardens.Apply engine oil to oil seal lip.nstall oil pump in the cylinder block and tightenfixing bolts to the specified torque.Torque : 25 Nm (2.5 Kgm/18 Ib ft)051RW002Legend(1) Around Bolt Holes(2) Around Dowel Pin051RW0019. nstall oil strainer with O-ring, tighten to the specifiedtorque.Torque : 25 Nm (2.5 Kgm/18 Ib ft)10. nstall oil pipe with O-ring, tighten fixing bolts to thespecified torque.Torque : 25 Nm (2.5 Kgm/18 Ib ft)11. nstall crankcase.Remove oil on crankcase mounting surface and drythe surface.Properly apply a 4.5 mm (0.7 in) wide bead ofsealant (TB1207C or equivalent) to the crankcasemounting surface. The bead must be continuous.The crankcase must be installed within 5 minutesafter sealant application before the sealanthardens.Tighten fixing bolts to the specified torque.Torque : 10 Nm (1.0 Kgm/89 Ib in)013RW010013RW00412. nstall oil panRemove oil on oil pan mounting surface and dry thesurface.Properly apply a 4.5 mm (0.7 in) wide bead ofsealant (TB1207C or equivalent) to the oil panmounting surface. The bead must be continuous.The oil pan must be installed within 5 minutes aftersealant application to prevent premature hardeningof sealant.6A-46 ENGINE MECHANICALTighten fixing bolts to the specified torque.Torque : 25 Nm (2.5 Kgm/18 Ib ft)013RW003013RW00213. nstall timing belt.Refer to installation procedure for Timing Belt in thismanual.14. nstall engine assembly.Refer to installation procedure for Engine in thismanual.6A-47 ENGINE MECHANICALRear OiI SeaIRemovaI1. Remove transmission assembly.Refer to removal procedure for Transmissionsection in this manual.2. Remove flywheel.3. Remove rear oil seal using a seal remover.NOTE: Take care not to damage the crankshaft or oil sealretainer when removing oil seal.InstaIIation1. Apply engine oil to oil seal lip and install oil seal using5884022860.015RS0172. nstall flywheel.Clean tapped holes in the crankshaft.Remove oil on the crankshaft and flywheelmounting surface.Tighten fixing bolts to the specified torque.NOTE: Do not reuse the bolts and do not apply oil orthread lock to the bolts.Torque : 54 Nm (5.5 Kgm/40 Ib ft)015RS0183. nstall transmission.See Transmission section in this manual.CAUTION: When assembIing the engine andtransmission, confirm that doweIs have beenmounted in the specified positions at the engineside. Take care that doweI positions are differentbetween the manuaI transmission and the automatictransmission.Otherwise, the transmission may be damaged.012RS0096A-48 ENGINE MECHANICALEngine AssembIyRemovaI035RW0271. Disconnect battery ground and positive cable.2. Remove battery.3. Make alignment mark on the engine hood and hingesbefore removal in order to return the hood to originalposition exactly.4. Remove engine hood.5. Drain radiator coolant.6. Disconnect accelerator cable and automatic cruisecontrol cable from throttle valve on commonchamber.7. Disconnect air duct with air cleaner cover.8. Remove air cleaner assembly.9. Disconnect canister vacuum hose.10. Disconnect vacuum booster hose.11. Disconnect three engine harness connectors.12. Disconnect harness connector to transmission (leftfront side of engine compartment), disconnect shifton the fly harness connector from front side of frontaxle and remove transmission harness bracket fromengine left side.13. Disconnect ground cable between engine and frame.14. Disconnect bonding cable connector on the back ofright dash panel.15. Disconnect bonding cable terminal on the left bank.16. Disconnect starter harness connector from starter.17. Disconnect generator harness connector fromgenerator.18. Disconnect coolant reserve tank hose from radiator.19. Remove radiator upper and lower hoses.20. Remove upper fan shroud.21. Remove cooling fan assembly four fixing nuts, thenthe cooling fan assembly.22. Move drive belt tensioner to loose side using wrenchthen remove drive belt.23. Remove power steering pump fixing bolts, thenpower steering pump. Place the power steering pumpalong with piping on the body side.24. Remove air conditioning compressor fixing bolts frombracket and place the compressor along with pipingon the body side.25. Remove O2 sensor harness connectors from exhaustfront pipe.26. Remove three exhaust pipe fixing nuts from eachbank.27. Remove two exhaust pipe fixing nuts from eachexhaust pipe, then move exhaust pipe to rear side ofvehicle.28. Remove flywheel dust covers.29. Disconnect two heater hoses from engine.30. Disconnect fuel hoses from right side of transmission.CAUTION: PIug fueI pipes on engine side and fueIhoses from fueI tank.31. Remove transmission assembly. Refer toTransmission section in this manual.32. Support the engine by engine hoist.33. Remove two left side engine mount fixing bolts fromengine mount on chassis side.34. Remove two right side engine mount fixing bolts fromengine mount on chassis side.35. Remove engine assembly.InstaIIationCAUTION: When assembIing the engine andtransmission, confirm that doweIs have beenmounted in the specified positions at the engineside. Take care that doweI positions are differentbetween the manuaI transmission and the automatictransmission.6A-49 ENGINE MECHANICALIf the engine is assembIed in the condition that thedoweIs have not been mounted in the specified posi-tions, the transmission may be damaged the trans-mission.012RS0091. nstall engine assembly. Tighten engine mount fixingbolts to frame to the specified torque.Torque: 41 Nm (4.2 Kgm/30 Ib ft)2. Reconnect fuel hose to fuel pipe on engine.3. nstall transmission assembly. Refer to Transmissionsection in this manual.4. Reconnect two heater hoses to engine.5. nstall flywheel dust covers.6. nstall exhaust pipe and temporally tighten two (eachbank) rear exhaust flange nuts then tighten three studnuts (each bank) between exhaust manifold andexhaust pipe, finally tighten rear side nuts to thespecified torque.Torque:Nuts: 43 Nm (4.4 Kgm/32 Ib ft)Stud nuts: 67 Nm (6.8 Kgm/49 Ib ft)150RW061Legend(1) Exhaust Front Pipe RH(2) O2 Sensor (for GM)150RW062Legend(1) Exhaust Front Pipe LH7. Reconnect O2 sensor connector.8. nstall cooling fan assembly and tighten bolts/nuts tothe specified torque.Torque : 22 Nm (2.2 Kgm/16 Ib ft) for fan puIIeyand fan bracket.Torque : 10 Nm (1.0 Kgm/88.5 Ib in) for fan andcIutch assembIy.6A-50 ENGINE MECHANICAL9. nstall air conditioner compressor to engine andtighten to the specified torque.Torque :M8 boIts : 22 Nm (2.2 Kgm/16 Ib ft)M10 boIts : 43 Nm (4.4 Kgm/32 Ib ft)10. nstall power steering pump, tighten fixing bolt to thespecified torque.Torque :M8 boIts : 22Nm (2.2 Kgm/16 Ib ft)M10 boIts : 46 Nm (4.7 Kgm/34 Ib ft)11. Move drive belt tensioner to loose side using wrench,then install drive belt to normal position.850RW001Legend(1) Crankshaft Pulley(2) Cooling Fan Pulley(3) Tensioner(4) Generator(5) Air Conditioner Compressor(6) Power Steering Oil Pump(7) Drive Belt12. nstall upper fan shroud.13. Reconnect radiator upper and lower hoses.14. Reconnect coolant reserve tank hose to radiator.15. Reconnect generator harness connector.16. Reconnect starter harness connector.17. Reconnect bonding cable terminal on left bank18. Reconnect bonding cable terminal on the back of rightdash panel.19. Reconnect ground cable between engine andchassis.20. Reconnect harness connector to transmission andinstall transmission harness bracket on engine leftside.21. Reconnect three engine harness connectors.22. Reconnect vacuum booster hose.23. Reconnect canister vacuum hose.24. nstall air cleaner assembly.25. Reconnect air duct.26. Reconnect accelerator cable and automatic cruisecontrol cable to throttle valve on common chamber.035RW007Legend(1) Throttle Valve Assembly(2) Throttle Lever(3) dle Air Control Valve(4) Throttle Position Sensor27. nstall engine hood to the original position.Refer to installation procedure for Body section inthis manual.Accelerator pedal cable adjustment1. Loosen adjusting nut and lock nut.2. Pull outer cable while fully closing the throttlevalve.3. Tighten adjusting nut and lock nut temporarily.4. Loosen adjusting nut by three turns and tightenlock nut.Then, manually operating the throttle valve, makesure that the valve lever returns up to the stopperscrew.6A-51 ENGINE MECHANICALf it does not reach the stopper screw, repeat fromstep 1.130RW004Legend(1) Clearance(2) Lock Nut(3) Adjusting Nut6A-52 ENGINE MECHANICALCyIinder HeadCyIinder Head and Associated Parts011RW008Legend(1) Spark Plug(2) Cylinder Head Bolt(3) Camshaft Drive Gear Pulley Fixing Bolt(4) Camshaft Drive Gear Pulley(5) Camshaft Bracket Fixing Bolt(6) Camshaft Bracket(7) Camshaft Exhaust(8) Camshaft ntake(9) Retainer Fixing Bolt(10) Retainer Assembly(11) Tappet with Shim(12) Split Collar(13) Valve Spring and Spring Upper Seat(14) ValveDisassembIyNOTE:During disassembly, be sure that the valve traincomponents are kept together and identified so thatthey can be reinstalled in their original locations.Before removing the cylinder head from the engineand before disassembling the valve mechanism,perform a compression test and note the results.1. Remove camshaft drive gear pulley fixing bolt (3),then pulley (4).6A-53 ENGINE MECHANICAL2. Remove camshaft bracket fixing bolt (5), camshaftbracket (6), then camshaft exhaust (7), and intakeside (8).3. Remove tappet with shim (11).4. Use the 5884024460 valve spring compressorand 5884025470 valve spring compressoradapter to remove the split collar (12), valve springwith upper seat (13) and valve (14).014RW0425. Remove spark plug (1).CAUTION: Do not remove the spark pIugs when thehead and pIugs are hot. CIean dirt and debris fromspark pIug recess areas before removaI.CIeanCyIinder headCarefully remove all varnish, soot and carbon from thebare metal. Do not use a motorized wire brush on anygasket sealing surface.Inspection and Repair1. Cylinder head gasket and mating surfaces for leaks,corrosion and blowby. f the gasket has failed,determine the cause. nsufficient torque on head bolts. mproper installation Loose or warped cylinder head Missing dowel pins Warped case surface2. Cylinder head for cracks, especially between valveseats and in the exhaust ports.3. Cylinder head deck for corrosion, sand particles inhead and porosity.CAUTION:Do not attempt to weId the cyIinder head. RepIaceit.Do not reuse cyIinder head boIts.4. Cylinder head deck, common chamber and exhaustmanifold mating surfaces for flatness. Thesesurfaces may be reconditioned by milling. f thesurfaces are out of flat by more than specification,the surface should be ground to within specifications.Replace the head if it requires machining beyond therepairable limit.Head surface and manifoId surfaceStandard: 0.05 mm (0.002 in) or IessWarpage Iimit: 0.2 mm (0.0079 in)Maximum RepairabIe Iimit: 0.2 mm (0.0079 in)Head heightStandard height : 133.2 mm (5.2441 in)Warpage Iimit : 0.2 mm (0.0079 in)Maximum RepairabIe Iimit : 133.0 mm (5.2362 in)011RW0195. Water jacket sealing plugs seating surfaces.ReassembIy1. nstall Spark plug and tighten all the spark plugs tospecified torque.Torque: 18 Nm (1.8 Kgm/13 Ib ft)2. Tighten sub gear setting bolt.1. Use 5884024430 gear spring lever to turn subgear to right direction until the M5 bolt aligns withthe hole between camshaft driven gear and subgear.6A-54 ENGINE MECHANICAL2. Tighten the M5 bolt to a suitable torque to preventthe sub gear from moving .014RW0253. nstall camshaft drive gear assembly and tightenthree bolts to the specified torque.Torque: 10 Nm (1.0 Kgm/89 Ib in)4. nstall camshaft assembly and camshaft brackets,tighten twenty bolts on one side bank to the specifiedtorque.1. Apply engine oil to camshaft journal and bearingsurface of camshaft bracket.2. Align timing mark on intake camshaft (one dot forright bank, two dots for left bank) and exhaustcamshaft (one dot for right bank, two dots for leftbank) to timing mark on camshaft drive gear (onedot).014RW020Legend(1) ntake Camshaft Timing Gear for Right Bank(2) ntake Camshaft Timing Gear for Left Bank(3) Exhaust Camshaft Timing Gear(4) Discrimination MarkL: Left Bank ntakeR: Right Bank ntakeLE: Left Bank ExhaustRE: Right Bank Exhaust014RW023Legend(1) Right Bank Camshaft Drive Gear(2) Left Bank Camshaft Drive Gear(3) Timing Mark on Drive Gear(4) Dowel Pin6A-55 ENGINE MECHANICAL014RW024Legend(1) Right Bank(2) Left Bank(3) Alignment Mark on Camshaft Drive Gear(4) Alignment Mark on Camshaft(5) Alignment Mark on Retainer3. Tighten twenty bolts in numerical order on oneside bank as shown in the illustration.Torque: 10 Nm (1.0 Kgm/89 Ib in)014RW0315. Tighten bolt for camshaft drive gear assembly pulleyto the specified torque.Torque: 98 Nm (10.0 Kgm/72 Ib ft)6A-56 ENGINE MECHANICALVaIve Spring, OiI ControIIer, VaIve, VaIve GuideVaIve Spring, OiI ControIIer, VaIve, VaIve Guide and Associated Parts014RW039Legend(1) Camshaft Bracket Fixing Bolts(2) Camshaft Assembly nlet(3) Camshaft Assembly Exhaust(4) Shim(5) Tappet(6) Split Collar(7) Spring Upper Seat(8) Valve Spring(9) Oil Controller(10) Spring Lower Seat(11) Valve Guide(12) ValveDisassembIy1. Remove camshaft bracket fixing bolts (1).2. Remove camshaft assembly (intake).3. Remove camshaft assembly (Exhaust side).4. Remove shim (4) and tappet (5).6A-57 ENGINE MECHANICAL5. Use 5884024460 valve spring compressor and5884025470 valve spring compressor adapter toremove split collar.014RW0426. Remove valve spring.7. Remove valve.8. Remove oil controller and spring lower seat.9. Remove the valve guide using the 5884024420valve guide replacer.Inspection and RepairVaIve SpringCAUTION: VisuaIIy inspect the vaIve springs andrepIace them if damage or abnormaI wear is evident.1. Measure the free height of the springs. The springsmust be replaced if the free height is below thespecified limit.Standard : 44.6 mm (1.7559 in)Limit : 43.6 mm (1.7165 in)014RS0042. Measure the valve spring squareness with a steelsquare and replace the valve springs if the measuredvalue exceeds the specified limit.Limit : 2 mm (0.0787 in)014RS0053. Using a spring tester to compress the springs to theinstalled height, measure the compressed springtension, and replace the springs if the measuredtension is below the specified limit.At instaIIed height: 35.0 mm (1.38 in)Standard: 196 N (44 Ib)Limit: Less than 181 N (41 Ib)014RS006VaIve GuideCAUTION: Take care not to damage the vaIve seatcontact surface, when removing carbon adhering tothe vaIve head. CarefuIIy inspect the vaIve stem forscratchs or abnormaI wear. If these conditions arepresent, the vaIve and the vaIve guide must berepIaced as a set.6A-58 ENGINE MECHANICAL1. Measure the valve stem diameter with a micrometer.f the valve stem diameter is less than the specifiedlimit, the valve and the valve guide must be replacedas a set.Diameter of VaIve StemIntakeStandard : 5.977 mm-5.959 mm(0.2353 in-0.2346 in)Limit : 5.90 mm (0.2323 in)ExhaustStandard : 5.952 mm-5.970 mm(0.2343 in-0.2350 in)Limit : 5.90 mm (0.2323 in)014RS0072. Measure the inside diameter of the valve guide with amicrometer. Subtract the measured outer diameter ofthe valve stem from the measured inner diameter ofthe valve guide. f the value exceeds the specifiedlimit, the valve and the valve guide must be replacedas a set.Inside Diameter of the VaIe GuideInIet cIearanceStandard : 0.023 mm-0.056 mm(0.0009 in-0.0002 in)Limit : 0.20 mm (0.00787 in)Exhaust cIearanceStandard : 0.030 mm-0.063 mm(0.0012 in-0.0025 in)Limit : 0.20 mm (0.00787 in)VaIve Guide RepIacement1. Using Valve guide replacer: 5884024420, driveout the valve guide from the combustion chamberside.014RS0082. Apply engine oil to the outside of the valve guide.Using valve guide replacer 5884024420, drive ina new valve guide from the camshaft side, and checkthe valve guide height.VaIve guide upper end height: 13.0 mm (0.5118in)(Measured from the cyIinder head upper face)014RW0463. Check the clearance. f the clearance is less than thespecified value, ream the inside diameter of valveguide. Using a sharp 6 mm reamer, ream the valveguide to obtain the specified clearance.VaIve Seat1. Measure the protrusion of the valve stem when a newvalve is installed in the cylinder head. f the protrusionof the valve stem exceeds the limit, replace the valveseat insert or the cylinder head assembly.Protrusion of vaIve stemIntakeStandard: 39.32 mm (1.5480 in)6A-59 ENGINE MECHANICALLimit: 39.47 mm (1.5539 in)ExhaustStandard: 39.30 mm (1.5472 in)Limit: 39.45 mm (1.5531 in)014RW0472. Measure the valve seat contact width. Make thenecessary corrections if the seat contact surface isdamaged or rough or if the contact width wearexceeds the limit.VaIve seat contact widthStandard: 1.1 mm (0.0433 in)Limit: 1.7 mm (0.0669 in)014RS011Contact Surface AngIe on VaIve Seat onVaIve1. Measure contact surface angle on valve seat.2. f the measured value exceeds the limit, replacevalve, valve guide and valve seat as a set.VaIve contact surface angIe: 45014RS012VaIve Seat Insert Correction1. Remove the carbon from the valve seat insertsurface.2. Use a valve cutter to minimize scratches and otherrough areas. This will bring the contact width back tothe standard value. Remove only the scratches andrough areas. Do not cut away too much. Take care notto cut away unblemished areas of the valve seatsurface.VaIve seat angIe degree: 90014RW0593. Apply abrasive compound to the valve seat insertsurface.4. nsert the valve into the valve guide.5. Turn the valve while lapping it to fit the valve seatinsert.6A-60 ENGINE MECHANICAL6. Check that the valve contact width is correct.7. Check that the valve seat insert surface is in contactwith the entire circumference of the valve.014RS014VaIve Seat Insert RepIacement1. Arc weld the rod at several points. Be careful not todamage the aluminum section.2. Allow the rod to cool for a few minutes. This will causethe valve seat to shrink.3. Strike the rod and pull it out.014RS0154. Carefully clean the valve seat pressfit section on thecylinder head side.5. Heat the pressfit section with steam or some othermeans to cause expansion. Cool the valve seat withdry ice or some other means.6. nsert the pressfit section into the valve seathorizontally.Standard fitting interference: 0.14 mm-0.09 mm(0.0055 in-0.0035 in)7. After insertion, use a seat grinder to grind finish theseating face. Carefully note the seating angle, thecontact width, and the depression.8. Lap the valve and the seat.ReassembIy1. nstall valve guide (1) to cylinder head. Apply engineoil to the outside of the valve guide. Using valve guidereplacer 5884024420, drive in a new valve guidefrom the camshaft side.2. nstall oil controller (3) and spring lower seat (2).Using oil contro