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ENGINE MECHANICAL
B ENGINE
SECTION
ENGINE MECHANICAL
EM
A
EM
C
D
CONTENTS
QG
PRECAUTIONS ......................................................... 5 . Precautions for Drain Coolant ................................. 5 . Precautions for Disconnecting Fuel Piping ............. 5 . Precautions for Removal and Disassembly ............ 5 . Precautions for Inspection, Repair and Replacement ........................................................................ 5 . Precautions for Assembly and Installation .............. 5 . Parts Requiring Angular Tightening ........................ 5 . Precautions for Liquid Gasket ................................. 6 . REMOVAL OF LIQUID GASKET SEALING ......... 6 . LIQUID GASKET APPLICATION PROCEDURE 6 ..... PREPARATION .......................................................... 7 . Special Service Tools .............................................. 7 . Commercial Service Tools ....................................... 9 . NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ..............................................11 . NVH Troubleshooting --Engine Noise ...................11 . Use the Chart Below to Help You Find the Cause of the Symptom. .................................................... 12 . DRIVE BELTS .......................................................... 13 . Checking Drive Belts ............................................. 13 . Tension Adjustment ............................................... 14 . POWER STEERING PUMP AND WATER PUMP BELT .................................................................. 14 . ALTERNATOR AND AIR CONDITIONER COMPRESSOR BELT ................................................ 14 . Removal and Installation ....................................... 15 . REMOVAL .......................................................... 15 . INSTALLATION .................................................. 15 . AIR CLEANER AND AIR DUCT .............................. 16 . Removal and Installation ....................................... 16 . REMOVAL .......................................................... 16 . INSTALLATION .................................................. 16 . Changing Air Cleaner Element .............................. 17 . INTAKE MANIFOLD ................................................ 18 . Removal and Installation ....................................... 18 . REMOVAL .......................................................... 18 . INSPECTION AFTER REMOVAL ...................... 20 . INSTALLATION .................................................. 20 . EXHAUST MANIFOLD AND CATALYTIC CONVERTER ................................................................... 21 . Removal and Installation ....................................... 21 . REMOVAL .......................................................... 22 . INSPECTION AFTER REMOVAL ...................... 23 . INSTALLATION .................................................. 23 . Disassembly and Assembly ................................... 24 . M/T MODELS ..................................................... 24 . A/T MODELS ...................................................... 24 . DISASSEMBLY .................................................. 24 . ASSEMBLY ........................................................ 24 . OIL PAN AND OIL STRAINER ................................ 25 . Removal and Installation ....................................... 25 . REMOVAL .......................................................... 25 . INSTALLATION .................................................. 26 . INSPECTION AFTER INSTALLATION ............... 26 . IGNITION COIL ........................................................ 27 . Removal and Installation ....................................... 27 . REMOVAL .......................................................... 27 . INSTALLATION .................................................. 27 . SPARK PLUG (CONVENTIONAL) .......................... 28 . Removal and Installation ....................................... 28 . REMOVAL .......................................................... 28 . INSPECTION AFTER REMOVAL ...................... 28 . INSTALLATION .................................................. 28 . FUEL INJECTOR AND FUEL TUBE ....................... 29 . Removal and Installation ....................................... 29 . REMOVAL .......................................................... 29 . INSTALLATION .................................................. 30 . INSPECTION AFTER INSTALLATION ............... 31 . ROCKER COVER .................................................... 32 . Removal and Installation ....................................... 32 . REMOVAL .......................................................... 32 . INSTALLATION .................................................. 33 . CAMSHAFT ............................................................. 35 . Removal and Installation ....................................... 35 . REMOVAL .......................................................... 35 . INSTALLATION .................................................. 38 .
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EM-1
INSPECTION AFTER REMOVAL ....................... 42 . Valve Clearance ..................................................... 45 . INSPECTION ...................................................... 45 . ADJUSTMENT (SHIMLESS TYPE) ................... 46 . ADJUSTMENT (SHIM TYPE) ............................. 47 . TIMING CHAIN ......................................................... 50 . Removal and Installation ....................................... 50 . REMOVAL .......................................................... 50 . INSPECTION AFTER REMOVAL ....................... 54 . INSTALLATION ................................................... 54 . INSPECTION AFTER INSTALLATION ............... 56 . OIL SEAL ................................................................. 57 . Removal and Installation of Valve Oil Seal ............ 57 . REMOVAL .......................................................... 57 . INSTALLATION ................................................... 57 . Removal and Installation of Front Oil Seal ............ 58 . REMOVAL .......................................................... 58 . INSTALLATION ................................................... 58 . Removal and Installation of Rear Oil Seal ............. 58 . REMOVAL .......................................................... 58 . INSTALLATION ................................................... 58 . CYLINDER HEAD .................................................... 60 . On-Vehicle Service ................................................ 60 . CHECKING COMPRESSION PRESSURE ........ 60 . Removal and Installation ....................................... 61 . REMOVAL .......................................................... 61 . INSTALLATION ................................................... 62 . Disassembly and Assembly ................................... 63 . DISASSEMBLY .................................................. 63 . ASSEMBLY ........................................................ 64 . Inspection After Disassembly ................................ 65 . CYLINDER HEAD DISTORTION ....................... 65 . VALVE DIMENSIONS ......................................... 65 . VALVE GUIDE CLEARANCE ............................. 66 . VALVE GUIDE REPLACEMENT ........................ 66 . VALVE SEAT CONTACT .................................... 67 . VALVE SEAT REPLACEMENT .......................... 68 . VALVE SPRING SQUARENESS ........................ 69 . VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD .............................. 69 . ENGINE ASSEMBLY ............................................... 70 . Removal and Installation ....................................... 70 . REMOVAL .......................................................... 71 . INSTALLATION ................................................... 72 . INSPECTION AFTER INSTALLATION ............... 72 . CYLINDER BLOCK .................................................. 74 . Disassembly and Assembly ................................... 74 . DISASSEMBLY .................................................. 75 . ASSEMBLY ........................................................ 79 . How to Select Piston and Bearing ......................... 84 . DESCRIPTION ................................................... 84 . HOW TO SELECT PISTON ................................ 84 . HOW TO SELECT CONNECTING ROD BEARING ..................................................................... 85 .
HOW TO SELECT MAIN BEARING ...................86 . Inspection After Disassembly .................................87 . CRANKSHAFT SIDE CLEARANCE ...................87 . CONNECTING ROD SIDE CLEARANCE ..........88 . PISTON AND PISTON PIN CLEARANCE ..........88 . PISTON RING SIDE CLEARANCE ....................89 . PISTON RING END GAP ...................................89 . CONNECTING ROD BEND AND TORSION ......90 . CONNECTING ROD BEARING (BIG END) .......90 . CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END) ..........................................90 . CYLINDER BLOCK DISTORTION .....................91 . INNER DIAMETER OF MAIN BEARING HOUSING ......................................................................92 . PISTON TO CYLINDER BORE CLEARANCE ...92 OUTER DIAMETER OF CRANKSHAFT JOURNAL .....................................................................93 . OUTER DIAMETER OF CRANKSHAFT PIN .....93 . OUT-OF-ROUND AND TAPER OF CRANKSHAFT ................................................................93 . CRANKSHAFT RUNOUT ...................................94 . OIL CLEARANCE OF CONNECTING ROD BEARING ............................................................94 . OIL CLEARANCE OF MAIN BEARING ..............94 . CRUSH HEIGHT OF MAIN BEARING ...............95 . FLYWHEEL RUNOUT ........................................95 . SERVICE DATA AND SPECIFICATIONS (SDS) .....96 . Standard and Limit .................................................96 . GENERAL SPECIFICATIONS ............................96 . INTAKE MANIFOLD AND EXHAUST MANIFOLD ..................................................................96 . DRIVE BELTS .....................................................96 . SPARK PLUG .....................................................97 . CYLINDER HEAD ...............................................97 . VALVE .................................................................97 . CAMSHAFT AND CAMSHAFT BEARING ........ 103 . CYLINDER BLOCK ........................................... 104 . PISTON, PISTON RING AND PISTON PIN ..... 104 . CONNECTING ROD ......................................... 105 . CRANKSHAFT .................................................. 105 . MAIN BEARING ................................................ 106 . CONNECTING ROD BEARING ........................ 106 . MISCELLANEOUS COMPONENTS ................. 107 . Tightening Torque ................................................ 107 .
YD
PRECAUTIONS ...................................................... 109 . Precautions for Drain Coolant .............................. 109 . Precautions for Disconnecting Fuel Piping .......... 109 . Precautions for Removal and Disassembly ......... 109 . Precautions for Inspection, Repair and Replacement ..................................................................... 109 . Precautions for Assembly and Installation ........... 109 . Parts Requiring Angular Tightening ..................... 109 . Precautions for Liquid Gasket .............................. 110 . REMOVAL OF LIQUID GASKET SEALING ..... 110 . LIQUID GASKET APPLICATION PROCEDURE. 110
EM-2
PREPARATION ....................................................... 111 . Special Service Tools ........................................... 111 . Commercial Service Tools ....................................114 . NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................................115 . NVH Troubleshooting --Engine Noise .................115 . Use the Chart Below to Help You Find the Cause of the Symptom. ...................................................116 . DRIVE BELTS .........................................................117 . Checking Drive Belts ............................................117 . Tension Adjustment ..............................................117 . AIR CONDITIONER COMPRESSOR BELT .....118 . ALTERNATOR AND WATER PUMP BELT .......118 . Removal and Installation ......................................118 . REMOVAL .........................................................118 . INSTALLATION .................................................118 . AIR CLEANER AND AIR DUCT .............................119 . Removal and Installation ......................................119 . REMOVAL .........................................................119 . INSTALLATION .................................................119 . CHANGING AIR CLEANER ELEMENT ............119 . CHARGE AIR COOLER ........................................ 121 . Removal and Installation ..................................... 121 . REMOVAL ........................................................ 121 . INSPECTION AFTER REMOVAL .................... 122 . INSTALLATION ................................................ 122 . INTAKE MANIFOLD .............................................. 123 . Removal and Installation ..................................... 123 . REMOVAL ........................................................ 123 . INSPECTION AFTER REMOVAL .................... 124 . INSTALLATION ................................................ 124 . INSPECTION AFTER INSTALLATION ............ 125 . CATALYST ............................................................. 126 . Removal and Installation ..................................... 126 . REMOVAL ........................................................ 127 . INSTALLATION ................................................ 127 . EXHAUST MANIFOLD AND TURBOCHARGER . 128 Removal and Installation ..................................... 128 . REMOVAL ........................................................ 129 . INSTALLATION ................................................ 130 . INSPECTION AFTER INSTALLATION ............ 130 . Disassembly and Assembly ................................ 131 . REMOVAL ........................................................ 132 . INSPECTION AFTER REMOVAL .................... 132 . Turbocharger ....................................................... 133 . ROTOR SHAFT CLEARANCE ........................ 134 . ROTOR SHAFT END PLAY ............................. 134 . TURBINE WHEEL ............................................ 134 . COMPRESSOR WHEEL ................................. 134 . TURBOCHARGER BOOST CONTROL ACTUATOR ............................................................... 135 . TROUBLE DIAGNOSIS OF TURBOCHARGER 136 . OIL PAN AND OIL STRAINER .............................. 137 . Removal and Installation ..................................... 137 . REMOVAL ........................................................ 137 . INSPECTION AFTER REMOVAL .................... 139 . INSTALLATION ................................................ 139 . INSPECTION AFTER INSTALLATION ............ 141 .
GLOW PLUG ......................................................... 142 . Removal and Installation ..................................... 142 . REMOVAL ........................................................ 142 . INSTALLATION ................................................ 142 . VACUUM PUMP ..................................................... 143 . Removal and Installation ..................................... 143 . INSPECTION BEFORE REMOVAL ................. 143 . REMOVAL ........................................................ 143 . INSTALLATION ................................................ 144 . INSPECTION AFTER INSTALLATION ............. 144 . Disassembly and Assembly ................................. 145 . DISASSEMBLY ................................................ 145 . ASSEMBLY ...................................................... 145 . INJECTION TUBE AND FUEL INJECTOR ........... 147 . Removal and Installation ..................................... 147 . REMOVAL ........................................................ 147 . INSTALLATION ................................................ 148 . INSPECTION AFTER INSTALLATION ............. 149 . FUEL PUMP ........................................................... 150 . Removal and Installation ..................................... 150 . REMOVAL ........................................................ 150 . INSPECTION AFTER REMOVAL .................... 155 . INSTALLATION ................................................ 155 . ROCKER COVER .................................................. 160 . Removal and Installation ..................................... 160 . REMOVAL ........................................................ 160 . INSTALLATION ................................................ 161 . INSPECTION AFTER INSTALLATION ............. 161 . CAMSHAFT ........................................................... 162 . Removal and Installation ..................................... 162 . REMOVAL ........................................................ 162 . INSPECTION AFTER REMOVAL .................... 163 . INSTALLATION ................................................ 166 . Valve Clearance .................................................. 167 . INSPECTION ................................................... 167 . ADJUSTMENTS ............................................... 168 . SECONDARY TIMING CHAIN ............................... 171 . Removal and Installation ..................................... 171 . REMOVAL ........................................................ 171 . INSPECTION AFTER REMOVAL .................... 173 . INSTALLATION ................................................ 174 . PRIMARY TIMING CHAIN ..................................... 176 . Removal and Installation ..................................... 176 . REMOVAL ........................................................ 178 . INSPECTION AFTER REMOVAL .................... 180 . INSTALLATION ................................................ 181 . CYLINDER HEAD .................................................. 186 . On-Vehicle Service .............................................. 186 . CHECKING COMPRESSION PRESSURE ...... 186 . Removal and Installation ..................................... 187 . REMOVAL ........................................................ 187 . INSPECTION AFTER REMOVAL .................... 188 . INSTALLATION ................................................ 188 . Disassembly and Assembly ................................. 191 . DISASSEMBLY ................................................ 191 . ASSEMBLY ...................................................... 192 . INSPECTION AFTER DISASSEMBLY ............. 192 .
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EM-3
ENGINE ASSEMBLY ............................................. 197 . Removal and Installation ..................................... 197 . REMOVAL ........................................................ 198 . INSTALLATION ................................................. 200 . INSPECTION AFTER INSTALLATION ............. 200 . CYLINDER BLOCK ................................................ 201 . Disassembly and Assembly ................................. 201 . DISASSEMBLY ................................................ 202 . ASSEMBLY ...................................................... 206 . How to Select Piston and Bearing ....................... 210 . DESCRIPTION ................................................. 210 . HOW TO SELECT PISTON .............................. 210 . HOW TO SELECT CONNECTING ROD BEARING ................................................................... 211 . HOW TO SELECT MAIN BEARING ................. 212 . Inspection After Disassembly .............................. 213 . CRANKSHAFT SIDE CLEARANCE ................. 213 . CONNECTING ROD SIDE CLEARANCE ........ 214 . PISTON TO PISTON PIN CLEARANCE .......... 214 . PISTON RING SIDE CLEARANCE .................. 214 . PISTON RING END GAP ................................. 215 . CONNECTING ROD BEND AND TORSION .... 215 . CONNECTING ROD BIG END INNER DIAMETER .................................................................. 216 . CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END) ........................................ 216 . CYLINDER BLOCK TOP SURFACE DISTOR-
TION ................................................................. 217 . MAIN BEARING HOUSING INNER DIAMETER.217 PISTON TO CYLINDER BORE CLEARANCE . 217 CRANKSHAFT JOURNAL OUTER DIAMETER.218 CRANKSHAFT PIN OUTER DIAMETER .........218 . CRANKSHAFT OUT-OF-ROUND AND TAPER.219 CRANKSHAFT RUNOUT ................................. 219 . CONNECTING ROD BEARING OIL CLEARANCE ................................................................ 219 . MAIN BEARING OIL CLEARANCE .................. 220 . MAIN BEARING CRUSH HEIGHT ................... 220 . MAIN BEARING CAP BOLT DEFORMATION .. 220 . CONNECTING ROD BOLT DEFORMATION ... 221 . OIL JET ............................................................. 221 . OIL JET RELIEF VALVE ................................... 221 . MOVEMENT AMOUNT OF FLYWHEEL .......... 221 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 223 . Standard and Limit ............................................... 223 . GENERAL SPECIFICATIONS .......................... 223 . INTAKE MANIFOLD AND EXHAUST MANIFOLD ................................................................ 223 . DRIVE BELTS ................................................... 223 . CYLINDER HEAD ............................................. 224 . VALVE ............................................................... 224 . CAMSHAFT AND CAMSHAFT BEARING ........ 228 . CYLINDER BLOCK ........................................... 228 . PISTON, PISTON RING AND PISTON PIN ..... 229 . CONNECTNG ROD .......................................... 230 . CRANKSHAFT .................................................. 230 . AVAILABLE MAIN BEARING ............................ 231 . AVAILABLE CONNECTING ROD BEARING .... 231 . MISCELLANEOUS COMPONENTS ................. 231 . Tightening Torque ................................................ 232 .
EM-4
PRECAUTIONS
[QG]
PRECAUTIONS Precautions for Drain Coolant
[QG]
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PFP:00001
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EBS00QDT
Drain coolant when engine is cooled.
EM
EBS00QDU
Precautions for Disconnecting Fuel Piping
q q q
Before starting work, make sure no fire or spark producing items are in the work area. Release fuel pressure before disassembly. After disconnecting pipes, plug openings to stop fuel leakage.
EBS00QDV
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Precautions for Removal and Disassembly
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When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations. Exercise maximum care to avoid damage to mating or sliding surfaces. Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified.
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Precautions for Inspection, Repair and Replacement
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Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.
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Precautions for Assembly and Installation
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Use torque wrench to tighten bolts or nuts. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified. Replace with new gasket, packing, oil seal or O-ring. Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction and blockage. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well. Release air within route after draining coolant. After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage.
EBS00QDY
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Parts Requiring Angular Tightening
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Use an angle wrench for the final tightening of the following engine parts. Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular tightening) Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil.
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EM-5
PRECAUTIONS
[QG]
Precautions for Liquid Gasket
REMOVAL OF LIQUID GASKET SEALING
After removing the mounting bolts and nuts, separate the mating surface using a seal cutter and remove the liquid gasket. CAUTION: Be careful not to damage the mating surfaces. q In areas where the cutter is difficult to use, use a plastic hammer to lightly tap the areas where the liquid gasket is applied. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces.
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EBS00QDZ
PBIC0275E
LIQUID GASKET APPLICATION PROCEDURE
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Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface. Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts, and bolt holes. Wipe the gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials. Attach the liquid gasket to the tube presser. Use Genuine Liquid Gasket or equivalent.
PBIC0003E
Apply the gasket without breaks to the specified location with the specified dimensions. q If there is a groove for the liquid gasket application, apply the gasket to the groove. q As for the bolt holes, normally apply the gasket inside the holes. If specified, it should be applied outside the holes. Make sure to read the text of service manual. q Within five minutes of gasket application, install the mating component. q If the liquid gasket protrudes, wipe it off immediately. q Do not retighten after the installation. q After 30 minutes or more have passed from the installation, fill the engine oil and coolant. CAUTION: If there are specific instructions in the service manual, observe them.
4.
EMA0622D
EM-6
PREPARATION
[QG]
PREPARATION Special Service Tools
Tool number Tool name ST0501S000 Engine stand assembly 1. ST05011000 Engine stand 2. ST05012000 Base
NT042
PFP:00002
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EBS00QE0
Description Disassembling and assembling
EM
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Overhauling engine
Engine attachment assembly 1. KV10106500 Engine attachment 2. KV10113300 Sub-attachment
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NT029
KV10114400 Heated oxygen sensor wrench
Loosening or tightening heated oxygen sensor a: 22 mm (0.87 in)
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NT636
ST10120000 Cylinder head bolt wrench
Loosening and tightening cylinder head bolt a: 13 mm (0.51 in) dia. b: 12 mm (0.47 in) c: 10 mm (0.39 in)
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NT583
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Disassembling valve mechanism
KV10116200 Valve spring compressor 1. KV10115900 Attachment
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NT022
KV10115600 Valve oil seal drift
Installing valve oil seal
NT024
KV10107902 Valve oil seal puller
Removing valve oil seal
NT011
EM-7
PREPARATION
[QG]
Tool number Tool name KV101151S0 Lifter stopper set 1. KV10115110 Camshaft pliers 2. KV10115120 Lifter stopper
NT041
Description Changing shims
EM03470000 Piston ring compressor
Installing piston assembly into cylinder bore
NT044
1. ST15243000 Valve seat drift 2. KV11103710 Adapter 3. KV11103720 Adapter
PBIC1120E
Installing valve seat drift
KV10111100 Seal cutter
Removing oil pan
NT046
WS39930000 Tube presser
Pressing the tube of liquid gasket
NT052
KV10112100 Angle wrench
Tightening bolts for bearing cap, cylinder head, etc. in angle
NT014
EM-8
PREPARATION
[QG]
Tool number Tool name ST16610001 Pilot bushing puller Description Removing pilot bushing
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NT045
KV101056S0* Rear gear stopper 1. KV10105620 Adapter 2. KV10105610 Plate assembly
NT773
Preventing crankshaft from rotating
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Commercial Service Tools
Tool name Spark plug wrench Description Removing and installing spark plug
EBS00QE1
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NT047
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Removing crankshaft pulley
Crankshaft pulley puller
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PBIC0887E
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Removing and installing engine
Manual lift table caddy
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Valve seat cutter set
Finishing valve seat dimensions
NT048
Piston ring expander
Removing and installing piston ring
NT030
EM-9
PREPARATION
[QG]
Tool name Valve guide drift Description Removing and installing valve guide Intake & Exhaust: a: 9.5 mm (0.374 in) dia. b: 5.5 mm (0.217 in) dia.
NT015
Valve guide reamer
Reaming valve guide 1 or hole for oversize valve guide 2 Intake & Exhaust: d1 : 5.5 mm (0.217 in) dia. d2 : 9.685 mm (0.3813 in) dia.
NT016
Front oil seal drift
Installing front oil seal a: 50 mm (1.97 in) dia. b: 44 mm (1.73 in) dia.
NT049
Rear oil seal drift
Installing rear oil seal a: 102 mm (4.02 in) dia. b: 90 mm (3.54 in) dia.
NT049
EM-10
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[QG]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting --Engine Noise
PFP:00003
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SEM937F
EM-11
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[QG]
Use the Chart Below to Help You Find the Cause of the Symptom.
1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts.
Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head Type of noise Ticking or clicking Rattle Before warmup C After warmup A When starting -- When idling A When racing B While driving -- Source of noise Tappet noise Camshaft bearing noise Piston pin noise Check item
EBS00QE3
Reference page
Valve clearance Camshaft journal clearance Camshaft runout Piston and piston pin clearance Connecting rod bushing clearance Piston-to-bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion Connecting rod bushing clearance (Small end) Connecting rod bearing clearance (Big end) Main bearing oil clearance Crankshaft runout Timing chain cracks and wear Timing chain tensioner operation
EM-45 EM-42 EM-42
C
A
--
A
B
C
Slap or knock
--
A
--
B
B
--
EM-88 EM-90
Crankshaft pulley Cylinder block (Side of engine) Oil pan
Slap or rap
A
--
--
B
B
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Piston slap noise
EM-92 EM-89
Knock
A
B
C
B
B
B
Connecting rod bearing noise Main bearing noise Timing chain and chain tensioner noise Drive belts (Sticking or slipping) Drive belts (Slipping) Water pump noise
EM-90 EM-94
Knock Front of engine Timing chain cover
A
B
--
A
B
C
EM-94 EM-94
Tapping or ticking
A
A
--
B
B
B
EM-54 EM-50
Squeaking or fizzing Front of engine Creaking Squall Creak A: Closely related
A
B
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B
--
C
Drive belts deflection EM-13 Idler pulley bearing operation Water pump operation LC-14
A
B
A
B
A
B
A
B
--
B
A
B
B: Related
C: Sometimes related
--: Not related
EM-12
DRIVE BELTS
[QG]
DRIVE BELTS Checking Drive Belts
PFP:02117
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EBS00QE4
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MBIA0034E
Before inspecting the engine, make sure the engine has cooled down; wait approximately 30 minutes after the engine has been stopped. q Visually inspect all belts for wear, damage, or cracks on contacting surfaces and edge areas. q When measuring deflection, apply 98 N (10 kg, 22 lb) at the w marked point. CAUTION: When measuring belt tension immediately after belt is installed, first set the tension to the standard. Then, rotate crankshaft for more than two turns in order to eliminate variance in belt deflection between the pulleys. Re-measure and adjust the tension to the standard.
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Deflection adjustment Unit: mm (in) Used belt Limit Without air conditioner compressor Alternator With air conditioner compressor Power steering oil pump Applied pushing force 8.1 (0.319) 7.1 (0.280) 10.2 (0.402) After adjustment 6.5 - 7.0 (0.256 - 0.276) 5.3 - 5.7 (0.209 - 0.224) 4.4 - 4.9 (0.173 - 0.193) 98 N (10 kg, 22 lb) New belt 5.5 - 6.1 (0.217 - 0.240) 4.5 - 5.0 (0.177 - 0.197) 3.9 - 4.4 (0.154 - 0.173)
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EM-13
DRIVE BELTS
[QG]
Tension Adjustment
Portion Power steering pump and water pump belt Alternator and air conditioner compressor belt Belt tightening method for adjustment Adjusting bolt on power steering pump Adjusting bolt on idler pulley
EBS00QE5
CAUTION: q When belt is replaced with a new one, tighten it a little stronger than current one to accommodate for insufficient adaptability with pulley grooves. PBIC0531E q When tension of belt being used exceeds "Retightening limit", adjust it to value for "Used belt". q When installing belt, make sure that it is correctly engaged with pulley groove. q Keep oil and water away from belt. q Do not twist or bend belt excessively. q When adjusting belt, remove snap retainer from adjusting bolt thread (to prevent the retainer from becoming pinched or missing). q After adjustment, be sure to install snap retainer to adjusting bolt thread. NOTE: Snap retainer can prevent adjusting bolt from dropping due to vibration during driving.
POWER STEERING PUMP AND WATER PUMP BELT
1. 2. 3. Loosen lock nut (A) and power steering pump mounting nut (B). Turn adjusting bolt (C) to adjust. Refer to EM-13, "Checking Drive Belts" . Tighten lock nut (A) and power steering pump mounting nut (B) in this order. Nut A : : 16.6 - 23.5 N·m (1.7 - 2.4 kg-m, 13 - 17 ft-lb) Nut B : : 31.4 - 42.2 N·m (3.2 - 4.3 kg-m, 24 - 31 ft-lb)
PBIC0532E
ALTERNATOR AND AIR CONDITIONER COMPRESSOR BELT
1. 2. 3. 4. Remove RH splash cover (with undercover attached). Loosen lock nut (G). Turn adjusting bolt (H) to adjust. Refer to EM-13, "Checking Drive Belts" . Tighten lock nut (G). Nut G : : 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)
EM-14
DRIVE BELTS
[QG]
Removal and Installation
REMOVAL
q
EBS00QE6
A
Loosen each belt while referring to "Tension Adjustment", and remove them one by one starting from the one in front.
EM
INSTALLATION
1. 2. Install belts to pulley in reverse order of removal. Adjust belt tension. CAUTION: q When checking belt tension immediately after installation, first, adjust to specified value. Then, after turning crankshaft more than two turns, re-adjust to specified value to avoid variation in deflection between pulleys. q Tighten idler pulley lock nut by hand and measure tension without looseness. Tighten each adjusting bolt and nut to the specified torque. Make sure that tension of each belt is within the standard.
C
D
3. 4.
E
F
G
H
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J
K
L
M
EM-15
AIR CLEANER AND AIR DUCT
[QG]
AIR CLEANER AND AIR DUCT Removal and Installation
PFP:16500
EBS00QE7
PBIC0533E
1. 4. 7.
Air cleaner case (upper) Mass air flow sensor Grommet
2. 5. 8.
Resonator O-ring Air cleaner element
3. 6. 9.
Air duct Air cleaner case (lower) Bracket
REMOVAL
1. 2. 3. Remove air cleaner case assembly, air duct and resonator. q Add marks as necessary for easier installation. Remove harness connector from mass air flow sensor. Remove mass air flow sensor. CAUTION: Handle mass air flow sensor with following cares. q Do not shock it. q Do not disassembly it. q Do not touch its sensor. q Do not deform mass air flow sensor's wire mesh. Remove left fender protector and resonator. Attach each joint aligning marks put at removal. Screw clamps firmly. Install in the reverse order of removal.
4. 1. 2.
INSTALLATION
EM-16
AIR CLEANER AND AIR DUCT
[QG]
Changing Air Cleaner Element
The viscous paper type filter does not need cleaning between renewals.
EBS00QE8
A
EM
C
D
SMA373C
E
F
G
H
I
J
K
L
M
EM-17
INTAKE MANIFOLD
[QG]
INTAKE MANIFOLD Removal and Installation
PFP:14003
EBS00QE9
KBIA1363E
1. 4. 7.
Electric throttle control actuator EVAP canister purge volume control solenoid valve Hose clamp
2. 5. 8.
Gasket Vacuum hose Intake manifold support (front)
3. 6. 9.
Intake manifold collector Vacuum hose Harness bracket
10. Vacuum hose 13. Gasket 16. Intake manifold support (rear) 19. Grounding wire
11. Intake manifold 14. Vacuum hose 17. Harness bracket
12. PCV hose 15. Gasket 18. Intake manifold support (engine rear)
REMOVAL
WARNING: To avoid the danger of being scalded, never drain the coolant when the engine is hot. 1. Release fuel pressure. Refer to EC-52, "FUEL PRESSURE RELEASE" (WITH EURO-OBD), EC-579, "FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD). 2. Remove air duct and air cleaner case. Refer to EM-16, "Removal and Installation" . 3. Disconnect harness on engine top surface, and move it aside. 4. Disconnect fuel injector/fuel tube assembly from intake manifold, and move it aside. q It is not necessary to disconnect fuel hose. 5. Disconnect the following vacuum hoses. 6. Disconnect blow-by hose (between intake manifold collector and rocker cover).
EM-18
INTAKE MANIFOLD
[QG]
7. Loosen mounting bolts in reverse order shown in figure to remove electric throttle control actuator. CAUTION: q Do not shock it. q Do not disassembly and adjusting. NOTE: Remove intake manifold collector and electronic throttle control as a single assembly, then remove electronic throttle control itself.
PBIC0534E
A
EM
C
D
8. 9.
Remove bolt on cylinder head side of intake manifold collector. Loosen intake manifold collector nuts and bolts in reverse of the order shown in the figure. q Do not remove intake manifold collector at this stage.
E
F
G
KBIA1365E
10. Move harness, which is fixed on intake manifold support, with bracket. 11. Remove intake manifold supports (rear, front, engine rear).
H
I
J
K
KBIA1366E
12. Loosen nuts and bolts in reverse order shown in the figure, and remove intake manifold from cylinder head. 13. Disconnect intake manifold collector from intake manifold, and pull out between engine and body.
L
M
PBIC0535E
EM-19
INTAKE MANIFOLD
[QG]
INSPECTION AFTER REMOVAL Surface Distortion
q
Using straightedge and feeler gauge, inspect surface distortion of intake manifold collector and intake manifold surface. Limit : 0.1 mm (0.004 in)
PBIC0536E
INSTALLATION
q
Install in the reverse order of removal paying attention to the following. Temporarily attach before installing intake manifold collector. Tighten in numerical order as shown in the figure.
Tightening Intake Manifold
q q
PBIC0535E
Tightening Intake Manifold Collector
q q
Temporarily attach before installing intake manifold. Tighten in numerical order as shown in the figure.
KBIA1366E
Installation of Electric Throttle Control Actuator
q
Tighten mounting bolts for electric throttle control actuator in numerical order shown in figure. : 17.7 - 21.6 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb) CAUTION: When electric throttle control actuator is replaced, perform idle air volume learning. Refer to BASIC SERVICE PROCEDURE, EC-49, "Idle Air Volume Learning" (WITH EURO-OBD), EC-576, "Idle Air Volume Learning" (WITHOUT EURO-OBD).
PBIC0534E
q
EM-20
EXHAUST MANIFOLD AND CATALYTIC CONVERTER
[QG]
EXHAUST MANIFOLD AND CATALYTIC CONVERTER Removal and Installation
PFP:14004
A
EBS00QEA
EM
C
D
E
F
G
H
I
J
MBIA0035E
K
1. 4. 7. Heated oxygen sensor 1 Stud bolt Exhaust manifold cover 2. 5. 8. Ground nut Exhaust manifold and catalytic converter assembly Heated oxygen sensor harness bracket 3. 6. Gasket Support
L
M
EM-21
EXHAUST MANIFOLD AND CATALYTIC CONVERTER
[QG]
MBIA0036E
1. 4. 7.
Heated oxygen sensor 1 (bank 2) Stud bolt Support
2. 5. 8.
Ground nut Gasket Heated oxygen sensor 2 (bank 1)
3. 6. 9.
Heated oxygen sensor 1 (bank 1) Exhaust manifold and catalytic converter assembly Heated oxygen sensor 2 (bank 2)
Heated oxygen sensor harness 10. bracket
11. Exhaust manifold cover
REMOVAL
1. 2. 3. 4. 5. Remove undercover. Disconnect exhaust front tube from catalytic converter. Refer to FE-11, "Exhaust System". Remove exhaust manifold support from both sides of catalytic converter. Disconnect heated oxygen sensor harness connector. Remove heated oxygen sensors. q Follow below steps to remove each heated oxygen sensor.
EM-22
EXHAUST MANIFOLD AND CATALYTIC CONVERTER
[QG]
Using heated oxygen sensor wrench, remove heated oxygen sensor. CAUTION: q Be careful not to damage heated oxygen sensor. q When using heated oxygen sensor wrench, tighten to the middle of specified torque because length of tool may induce sight indication increase. (Do not tighten to the maximum specified torque) q Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen sensor, resulting in the MI coming on.
q
A
EM
C
PBIC0541E
D
6. 7.
Remove exhaust manifold cover. Loosen mounting nuts in reverse order shown in figure to remove exhaust manifold and catalytic converter assembly.
E
F
G
PBIC0542E
H
INSPECTION AFTER REMOVAL
Surface Distortion q Use a reliable straightedge and feeler gauge to check the flatness of exhaust manifold fitting surface. Limit : 0.3 mm (0.012 in)
I
J
K
PBIC0543E
L
INSTALLATION
q q
q
Install in the reverse order of removal after this step. Tighten mounting nuts for exhaust manifold and catalytic converter assembly in order shown in figure. Before installing exhaust manifold support, apply liquid gasket to contact surface on engine side. Use Genuine Liquid Gasket or equivalent.
M
PBIC0542E
Installation of Heated Oxygen Sensor CAUTION: q Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen sensor, resulting in the MI coming on.
EM-23
EXHAUST MANIFOLD AND CATALYTIC CONVERTER
[QG]
Disassembly and Assembly
M/T MODELS
EBS00QEB
YEM049
1.
Exhaust manifold
2.
Catalytic converter
3.
Catalytic converter cover
A/T MODELS
PBIC0546E
1. 4. 7.
Exhaust manifold Wire mesh washer Heated oxygen sensor harness bracket
2. 5.
Gasket Catalytic converter cover
3. 6.
Converter cap Catalytic converter
DISASSEMBLY
1. Remove catalytic converter cover. 2. Disconnect exhaust manifold and catalytic converter. CAUTION: Be careful not to damage catalytic converter.
ASSEMBLY
q
Assemble in reverse order of disassembly.
EM-24
OIL PAN AND OIL STRAINER
[QG]
OIL PAN AND OIL STRAINER Removal and Installation
PFP:11110
A
EBS00QEC
EM
C
D
E
F
MBIA0037E
G
1. 4.
Oil strainer Oil pan
2.
Washer
3.
Drain plug
H
REMOVAL
WARNING: To avoid the danger of being scalded, never drain the engine oil when the engine is hot. 1. Remove engine RH undercover. 2. Drain engine oil. Refer to LC-8, "Changing Engine Oil". 3. Remove exhaust front tube. Refer to FE-11, "Exhaust System". 4. Using a transmission jack, be sure to support the bottom of transsexual, and remove center member. 5. Remove gusset and engine rear plate (lower) [A/T vehicle].
I
J
K
L
M
SEM067F
6.
Loosen and remove mounting nuts and bolts in reverse order shown in figure.
SEM072F
EM-25
OIL PAN AND OIL STRAINER
[QG]
7. Insert Tool (Seal cutter) between oil pan and cylinder block. Slide tool by tapping on the side of the tool with a hammer. Remove oil pan. Remove oil strainer.
8.
SEM365EA
INSTALLATION
1. Install oil strainer. NOTE: Gasket and O-ring are not used for sealed area with oil pump. Install oil pan drain plug. q Referring to "Components", install drain plug washer. Apply a continuous bead of liquid gasket to position shown in figure. Use Genuine Liquid Gasket or equivalent.
2. 3.
PBIC0549E
4.
Tighten mounting nuts and bolts in order shown in figure. q Install mounting nuts and bolts as follows. Mounting bolt: [Shank length under : Nos. 1 - 10, 13, 14 head 10 mm (0.39 in)] [Shank length under : Nos. 11, 12 head 12 mm (0.47 in)]
5.
6.
q q
Install center member. Refer to ENGINE ASSEMBLY, EM-70, "Removal and Installation" . Install remaining parts in the reverse order of removal. Check for leakage of engine oil when engine is warmed. Pour engine oil or start engine at least 30 minutes after oil pan is installed.
SEM072F
INSPECTION AFTER INSTALLATION
EM-26
IGNITION COIL
[QG]
IGNITION COIL Removal and Installation
PFP:22448
A
EBS00QED
EM
C
D
E
F
MBIA0038E
G
1.
Ignition coil
2.
Spark plug
3.
Rocker cover
REMOVAL
1. 2. Remove ignition coil harness connector from ignition coil. Remove ignition coil. CAUTION: q Do not shock it. q Do not disassemble it. Install in the reverse order of removal.
H
I
J
INSTALLATION
q
K
L
M
EM-27
SPARK PLUG (CONVENTIONAL)
[QG]
SPARK PLUG (CONVENTIONAL) Removal and Installation
REMOVAL
Disconnect ignition coil harness connector from ignition coil. Remove ignition coil. Remove spark plugs with a spark plug wrench (commercial service tool). Spark plug
Make Standard type Hot type Cold type NGK LFR5A-11 LFR4A-11 LFR6A-11 Champion REC10YC4 -- --
PFP:22401
EBS00QEE
1. 2. 3.
SMA581C
INSPECTION AFTER REMOVAL
Check spark plug gap. Adjust or replace if necessary. Standard
q
: 1.0 - 1.1 mm (0.039 - 0.043 in)
Use a wire brush for cleaning, if necessary.
SMA476
INSTALLATION
Install in the reverse order of removal, paying attention to the following. Spark plug: : 19.6 - 29.4 N·m (2.0 - 3.0 kg-m, 15 - 21 ft-lb)
EM-28
FUEL INJECTOR AND FUEL TUBE
[QG]
FUEL INJECTOR AND FUEL TUBE Removal and Installation
PFP:16600
A
EBS00QEF
EM
C
D
E
F
G
H
I
MBIA0039E
1. 4.
Fuel tube Clip
2. 5.
Fuel feed hose Fuel injector
3. 6.
O-ring Intake manifold
J
CAUTION: q Apply new engine oil when installing the parts that specified to do so in the figure. q Do not remove or disassembly parts unless instructed as shown in the figure.
K
REMOVAL
1. 2. 3. Release fuel pressure. Refer to EC-52, "FUEL PRESSURE RELEASE" (WITH EURO-OBD), EC-579, "FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD). Disconnect harness for fuel injector, and move it aside. Remove fuel hose. CAUTION: After removal, install blind plug to fuel hose to prevent the fuel from draining. Remove fuel tube and injector assembly with the following procedure: Loosen mounting bolts in reverse order shown in figure.
L
M
4. a.
PBIC0617E
b.
Pull out fuel injector/fuel tube assembly toward engine rear side.
EM-29
FUEL INJECTOR AND FUEL TUBE
[QG]
CAUTION: Do not touch fuel injector nozzle with intake manifold or other parts. Remove fuel injector from fuel tube. q Release clip and remove it. q Pull fuel injector straight out of fuel tube. CAUTION: q Be careful not to damage nozzle part. q Avoid any impact such as a dropping. q Do not disassemble or adjust it.
5.
PBIC0620E
INSTALLATION
1. When installing O-ring to fuel injector, follow instructions described below. CAUTION: q Handle O-ring with bare hands. Never wear gloves. q Lubricate O-ring with new engine oil. q Do not clean O-ring with solvent. q Make sure that O-ring and its mating part are free of foreign material. q Be careful not to scratch it with a tool or fingernails during installation. Also be careful not to twist or stretch O-ring. If O-ring is stretched while being attached, do not insert it into fuel tube immediately. q Insert O-ring straight into fuel tube. Do not angle or twist it. Install fuel injector to fuel tube with the following procedure. Insert clip into clip mounting groove on fuel injector. q Insert clip so that lug "A" of fuel injector matches notch "A" of the clip. CAUTION: q Do not reuse clip. Replace it with a new one. q Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube with clip attached. q Insert it while matching it to the axial center. q Insert fuel injector so that lug "B" of fuel tube matches notch "B" of the clip. q Make sure that fuel tube flange is securely fixed in flange fixing groove on clip. Make sure that installation is complete by checking that fuel injector does not rotate or come off.
2. a.
b.
c.
PBIC1021E
EM-30
FUEL INJECTOR AND FUEL TUBE
[QG]
3. Tighten mounting bolts in two steps in numerical order shown in figure. 1st step : 11.8 - 13.7 N·m (1.2 - 1.4 kg-m, 9 - 10 ft-lb) 2nd step : 16.7 - 23.5 N·m (1.7 - 2.4 kg-m, 12 - 17 ft-lb) 4. Install fuel feed hose. CAUTION: Install hose clamp avoiding interference with bulge, and securely tighten it Install remaining parts in the reverse order of removal.
EM A
C
PBIC0617E
5.
INSPECTION AFTER INSTALLATION
q
D
1. 2.
Check for fuel leakage with following procedure. Turn ignition switch ON (do not start engine), and check connections for leakage by applying fuel pressure to fuel piping. Start engine, and re-check connections for fuel leakage by increasing engine speed.
E
F
G
H
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J
K
L
M
EM-31
ROCKER COVER
[QG]
ROCKER COVER Removal and Installation
PFP:13264
EBS00QEG
MBIA0040E
1. 4. 7.
PCV hose PCV control valve O-ring
2. 5. 8.
Rocker cover PCV hose Oil filter cap
3. 6. 9.
Grommet Intake valve timing control solenoid valve Gasket
10. Gasket 13. O-ring
11. Rocker cover oil seal 14. Camshaft position sensor (PHASE)
12. Gasket
CAUTION: Apply new engine oil when installing the parts that specified to do so in the figure.
REMOVAL
1. 2. 3. 4. 5. Move harnesses on top surface and right side of rocker cover, and move them aside. Remove ignition coil. Refer to EM-27, "Removal and Installation" . Disconnect PCV hoses on rocker cover side. If necessary, remove PCV control valve. If necessary, remove intake valve timing control solenoid valve and camshaft position sensor (PHASE). CAUTION: q Do not shock it. q Do not disassemble it. q Tip of camshaft position sensor (PHASE) generates strong magnetic fields. Keep it away from metal particles or objects affected by magnetic fields.
EM-32
ROCKER COVER
[QG]
6. Loosen bolts in reverse order shown in the figure.
A
EM
C
KBIA1376E
D
7.
If replacement is necessary, remove rocker cover oil seal using flat-head screwdriver. CAUTION: Be careful not to damage rocker cover. Install rocker cover oil seal. q Using drift with outer diameter 97 mm (3.82 in) and inner diameter 83 mm (3.27 in) to 88 mm (3.46 in) (commercial service tool), press oil seal in. NOTE: There are 2 types of oil seal. If oil seal with flat bottom surface is pressed in, drift with any inner diameter can be used. q Press oil seal in until it is flush with installation surface.
KBIA1377E
E
INSTALLATION
1.
F
G
H
I
2. a.
b.
Install rocker cover in following steps. Install gasket on top of No. 1 camshaft bracket. q Position gasket aligning its shape with camshaft bracket side. Align positioning stopper pin with hole on gasket, and install. Install gasket (for circumference, square type) to installation groove of rocker cover.
J
K
L
KBIA1379E
c.
Apply liquid gasket to positions shown in figure, then install rocker cover.
M
PBIC0555E
EM-33
ROCKER COVER
[QG]
d. Tighten mounting screws to specified torque in 2 or more steps in numerical order shown in figure. Bolt length: 25 mm (0.98 in) 65 mm (2.56 in) 20 mm (0.79 in) Bolt position :1 :2 : Except the above (all circumference)
KBIA1376E
3. 4. 5.
Install intake valve timing control solenoid valve and camshaft position sensor (PHASE). q Tighten bolt after fully inserting it into rocker cover. Install PCV valve. q Insert until flange contacts grommet tightly. Install remaining parts in the reverse order of removal.
EM-34
CAMSHAFT
[QG]
CAMSHAFT Removal and Installation
PFP:13001
A
EBS00QEH
EM
C
D
E
F
G
H
I
J
PBIC0965E
K
1. 4. 7. Camshaft bracket Washer Valve lifter 2. 5. 8. Camshaft sprocket (INT) Cylinder head front cover Adjusting shim (If so equipped) 3. 6. 9. Camshaft sprocket (EXH) Chain tensioner Camshaft (EXH)
L
10. Camshaft (INT)
CAUTION: Prior to installation, apply engine oil to the parts marked in the figure.
M
REMOVAL
1. 2. 3. a. b. Remove rocker cover. Refer to EM-32, "Removal and Installation" . Remove cylinder head front cover. q Move harness secured to front surface beforehand. Set No. 1 cylinder at TDC of its compression stroke. Remove RH splash cover (integrated with undercover). Rotate crankshaft pulley clockwise and align yellow paint mark with timing indicator.
MBIB0193E
EM-35
CAMSHAFT
[QG]
c. Confirm mating marks stamped on intake and exhaust sprockets are located as shown. q If not, rotate crankshaft pulley as shown and align them. Referring to mating marks on intake and exhaust camshaft sprockets, put paint mating marks on timing chain links.
d.
MBIB0194E
4.
a.
Set intake camshaft sprocket to most advanced position. CAUTION: Removal/installation of intake camshaft sprocket is required to maintain most advanced position because of following reasons. Therefore, follow procedure exactly. q Sprocket and vane (camshaft in front) rotate and become offset within specific angle range. q When engine is stationary, vane is located at most retarded position. Vane is fixed to sprocket by internal lock pin. Therefore, it does not rotate. q If camshaft sprocket mounting bolts are turned under above circumstance, lock pin will be damaged by lateral load (shear stress). It may cause non-standard operation. q Set intake camshaft sprocket to most advanced position as follows. MBIB0195E NOTE: "Rotating direction" means direction viewed from engine front side. CAUTION: Do not remove chain tensioner before performing this step. Using a wrench, hold hexagonal part so that intake camshaft does not move.
MBIB0196E
b.
Using an air gun, apply air pressure to intake valve timing control solenoid valve advanced side oil passage on top surface of No. 1 camshaft bracket. Compression pressure : 300 kPa (3.00 bar, 3.06 kg/cm2 , 43.5 psi) or more Keep applying air pressure until step "d" is completed. CAUTION: q Be careful not to damage oil passage from interference of air gun tip. MBIB0197E q Thoroughly wipe off oil before applying air pressure. When applying air pressure, cover around air gun using a rag. Wear protective glasses if necessary.
q
EM-36
CAMSHAFT
[QG]
c. Slowly turn intake camshaft in direction A (counterclockwise: intake manifold side). q Perform while applying air pressure. CAUTION: Be careful not to dislocate camshaft retaining spanner. During above step, operating click (a sound indicating internal lock pin is disengaged) is heard from inside of intake camshaft sprocket. After hearing it, slowly turn intake camshaft in direction B (clockwise: exhaust manifold side), and set to most advanced position. KBIA1414J q Perform while applying air pressure. q When vane rotates solely against sprocket, lock pin is disengaged even if operating click is not heard. q If lock pin is not disengaged, apply vibration by jiggling the camshaft with a spanner. q If lock pin is not disengaged with above step, hit intake camshaft in front by using plastic hammer. The following status indicates that most advanced position is achieved: vane starts rotating on its own, then sprocket also starts rotating when camshaft is turned. When above status is achieved, this step is complete. q Most advanced position is confirmed when stopper pin groove and lock pin breathing groove are aligned.
A
EM
d.
C
D
E
e.
F
G
H
MBIB0198E
f.
Stop air, insert stopper pin [approximately 3 mm (0.12 in) dia., length of inserted part is approximately 15 mm (0.59 in)] into pinhole on camshaft sprocket to fix most advanced position. NOTE: In the figure, an Allen wrench [a/f 2.5 mm (0.091 in), short part: approximately 20 mm (0.79 in), long part: approximately 50 mm (1.97 in)] is used for stopper pin as an example. CAUTION: Load (spring reaction force) is not applied to stopper pin. Pin is easily detached. Therefore, secure it with vinyl tape to prevent detachment. Remove chain tensioner. q Remove in the following order. Press plate down, and release stopper tab. Insert plunger into tensioner body until it stops. Secure plate by passing stopper pin (such as a hard wire) through plate hole and body hole. (Plunger is also secured.) Remove mounting bolts, and remove chain tensioner.
I
J
K
PBIC0966E
L
5. a. b. c. d.
M
MBIB0201E
EM-37
CAMSHAFT
[QG]
6. While holding hexagonal part of camshaft with a spanner, loosen mounting bolts and remove intake and exhaust camshaft sprockets. CAUTION: q Be careful that tool does not interfere with A/C piping. q Avoid securing camshaft at other than hexagonal part and loosening mounting bolts by utilizing tension of timing chain.
EMD0826D
Handle intake camshaft sprocket, taking care of following. CAUTION: q Secure stopper pin with vinyl tape to prevent detachment. q Avoid dropping it or subjecting it to impact. q Do not disassemble. (Do not loosen 3 bolts on front surface.)
q
MBIB0202E
a.
b. c. d. 7.
8.
9.
NOTE: If stopper pin is detached and lock pin is engaged at most retarded position during removal, recover as follows. Reinstall stopper pin to intake camshaft, and tighten intake camshaft sprocket mounting bolts so that air does not leak. CAUTION: Tightening torque for mounting bolts must be minimum so that air does not leak, preventing damage on internal lock pin. Apply air pressure to disengage lock pin, and turn vane to most advanced position. (This step can be performed with timing chain removed.) Reinstall stopper pin. Remove intakecamshaft sprocket from camshaft. Remove camshaft brackets. q Loosen mounting bolts in several steps in reverse order shown in figure. Remove camshaft. CAUTION: Be careful not to damage signal plate on rear end of intake camshaft and crankshaft. Remove adjusting shims and valve lifters. q Identify installation position of each valve. Arrange removed valves so they cannot be mixed up.
PBIC0969E
INSTALLATION
1. Install valve lifters and adjusting shims. q Install them in their original positions. q Install adjusting shim with its stamped mark facing downward (valve lifter side).
EM-38
CAMSHAFT
[QG]
2. Install camshaft. q Intake and exhaust camshafts are distinguished by checking difference between front and rear end shapes. NOTE: Some exhust camshafts have a groove on the rear end.
A
EM
C
MBIB0204E
D
q
Install camshafts so that dowel pins on their front ends are positioned as shown.
E
F
G
PBIC0967E
3.
Install camshaft brackets. q Completely remove any foreign material on back surfaces of camshaft brackets and top surface of cylinder head. q Referring to marks on top surfaces of camshaft brackets, install them to their original positions and in their original directions.
H
I
J
MBIB0206E
K
4. a.
Tighten camshaft bracket mounting bolts as follows: Different bolts are used depending on installation location. Refer to following and install appropriate bolts. Bolt color : 1 to 10 in figure 11 and 12 in figure : black (reamer bolt) : gold
L
M
b.
First tighten bolts 9 through 12, then tighten bolts 1 through 8 in numerical order. : 2.0 N·m (0.2 kg-m, 18 in-lb)
PBIC0969E
c.
Tighten in numerical order shown in figure. : 5.9 N·m (0.6 kg-m, 52 in-lb)
d.
Tighten again in numerical order shown in figure. : 9.0 - 11.8 N·m (0.92 - 1.2 kg-m, 80 - 104 in-lb)
5.
Install intake camshaft sprocket as follows. q Before installation, make sure that stopper pin is inserted in intake camshaft sprocket. NOTE: Service parts are provided with pin inserted.
EM-39
CAMSHAFT
[QG]
CAUTION: Stopper pin is easily detached. Secure it with vinyl tape to prevent detachment. Install timing chain by aligning its mating mark (marked when timing chain is removed) with mark on camshaft sprocket. q Align dowel pin on camshaft front surface and pinhole on sprocket backside, then install.
a.
MBIB0208E
b.
While holding hexagonal part of camshaft with a spanner, tighten intake camshaft sprocket mounting bolts. q Make sure that stopper pin is not detached.
MBIB0209E
6. a.
b.
c. 7.
Install exhaust camshaft sprocket as follows. Install timing chain by aligning its mating mark (marked when timing chain is removed) with mark on camshaft sprocket. q Align dowel pin on camshaft front surface and pinhole on sprocket, then install. While holding hexagonal part of camshaft with a spanner, tighten exhaust camshaft sprocket mounting bolts. NOTE: Tightening torque is different from intake side tightening torque. Make sure that mating marks on intake/exhaust camshaft sprockets and mating mark on timing chain are aligned. Install chain tensioner. q Hold plate and plunger with a stopper pin, then install them. q After installation, remove stopper pin and release plunger. q Make sure again that mating marks on intake/exhaust camshaft sprockets and mating mark on timing chain are aligned.
MBIB0210E
MBIB0211E
EM-40
CAMSHAFT
[QG]
8. Remove stopper pin from intake camshaft sprocket.
A
EM
C
PBIC0966E
D
9.
Slowly turn crankshaft pulley clockwise to set intake camshaft sprocket to most retarded position.
E
F
G
MBIB0213E
q
q
q
Sprocket begins turning after crankshaft does. Once sprocket starts turning, keep turning crankshaft until the vane (camshaft) also begins turning. Most retarded position should now be achieved. Most retarded position is confirmed when stopper pin groove is at a clockwise offset from lock pin breathing groove. While turning crankshaft slightly more counterclockwise, confirm that lock pin is engaged when vane and sprocket turn together.
MBIB0214E
H
I
J
K
10. Install cylinder head front cover. q Apply liquid gasket (Use Genuine Liquid Gasket or equivalent) continuously as shown in figure. q Install it by aligning dowel pin on cylinder head. 11. Check and adjust valve clearance. Refer to EM-44, "Valve Lifter Clearance" . 12. From this step, install in the reverse order of removal.
L
M
PBIC0968E
EM-41
CAMSHAFT
[QG]
INSPECTION AFTER REMOVAL Camshaft Runout
q
q q
q
Place a V-block on a surface plate to support No. 2 and No. 5 journals on camshaft. CAUTION: Do not support No. 1 journal (camshaft sprocket mounting side), because its diameter is different from that of the other 4 journals. Set a dial gauge vertically onto journal No. 3. Rotate the camshaft in one direction by hand and read indication on the gauge. A half of reading value is actual bend. Standard : 0.02 mm (0.0008 in) or less
MBIB0215E
Camshaft Cam Height
q
Measure with a micrometer. Intake Exhaust : 40.217 - 40.407 mm (1.5833 - 1.5908 in) : 39.205 - 39.395 mm (1.5435 - 1.5510 in)
MBIB0216E
Camshaft Journal Clearance
Outer Diameter of Camshaft Journal q Measure with a micrometer. Standard No. 1 : 27.935 - 27.955 mm (1.0998 - 1.1006 in) dia. No. 2 to No. 5 : 23.935 - 23.955 mm (0.9423 - 0.9431 in) dia.
MBIB0217E
Inner Diameter of Camshaft Bracket q Tighten camshaft bracket bolts to the specified torque. q Using an inside micrometer, measure inner diameter of the camshaft bracket. Standard No. 1 : 28.000 - 28.021 mm (1.1024 - 1.1032 in) dia. No. 2 to No. 5 : 24.000 - 24.021 mm (0.9449 - 0.9457 in) dia. Calculation of Camshaft Journal Clearance (Oil clearance) = (Camshaft bracket inner diameter) - (Camshaft journal outer diameter)
MBIB0218E
EM-42
CAMSHAFT
[QG]
Standard : 0.045 - 0.086 mm (0.0018 - 0.0028 in)
q
A
If outside the standard, refer to standard of each unit part and replace camshaft or cylinder head as appropriate. EM NOTE: Camshaft bracket is machined with cylinder head. Replace them as cylinder head assembly.
C
Camshaft End play
q
Position a dial gauge onto front end of camshaft in thrust direction. Read indication of dial gauge while moving camshaft back and forth (axial direction). Standard Intake Exhaust : 0.070 - 0.143 mm (0.0028 - 0.0056 in) : 0.115 - 0.188 mm (0.0045 - 0.0074 in)
D
E
q
q
If outside the standard, replace camshaft with new one. Then measure it again. If still outside the standard, replace cylinder head with new one. Using a dial gauge, measure camshaft sprocket runout. Limit: Intake Exhaust : 0.2 mm (0.008 in) : 0.15 mm (0.0059 in)
F
MBIB0219E
Camshaft Sprocket Runout
q
G
H
I
J
PBIC0930E
Valve Lifter and Adjusting Shim (Shim type)
Check surfaces of valve lifter and shim for cracks and wear.
K
L
M
SEM160D
Valve Lifter Clearance
Outer Diameter of Valve Lifter
EM-43
CAMSHAFT
[QG]
q
Measure outer diameter with a micrometer. Standard : 29.960 - 29.975 mm (1.1795 - 1.1801 in) dia.
MBIB0220E
Valve Lifter Hole Diameter q Using an inside micrometer, measure valve lifter hole diameter on cylinder head. Standard : 30.000 - 30.021 mm (1.1811 - 1.1819 in) dia.
MBIB0221E
Calculation of Valve Lifter Clearance (Clearance) = (Valve lifter hole inner diameter) - (Valve lifter outer diameter) Standard
q
: 0.025 - 0.061 mm (0.0010 - 0.0024 in)
If outside the standard, refer to standard of each OD and hole ID and then replace valve lifter or cylinder head as appropriate. Check if surface of valve lifter has any wear or cracks.
Valve Lifter (Shimless type)
q
KBIA0182E
Valve Lifter Clearance
Outer Diameter of Valve Lifter q Measure outer diameter of valve lifter. Valve lifter outer diameter (Intake and exhaust) : 29.960 - 29.975 mm (1.1795 - 1.1801 in) dia.
JEM798G
EM-44
CAMSHAFT
[QG]