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ENGINE MECHANICAL
SECTION EM
CONTENTS
QG Inspection...................................................................36
CYLINDER HEAD DISTORTION ...............................36
PRECAUTIONS ...............................................................4 CAMSHAFT VISUAL CHECK ....................................36
Parts Requiring Angular Tightening.............................4 CAMSHAFT RUNOUT ..............................................37
Liquid Gasket Application Procedure ..........................4 CAMSHAFT CAM HEIGHT .......................................37
PREPARATION ...............................................................5 CAMSHAFT JOURNAL CLEARANCE ........................37
Special Service Tools ..................................................5 CAMSHAFT END PLAY............................................38
Commercial Service Tools ...........................................7 CAMSHAFT SPROCKET RUNOUT ...........................38
NOISE, VIBRATION AND HARSHNESS (NVH) VALVE GUIDE CLEARANCE ....................................38
TROUBLESHOOTING .....................................................9 VALVE GUIDE REPLACEMENT ................................39
NVH Troubleshooting - Engine Noise .........................9 VALVE SEATS .........................................................40
REPLACING VALVE SEAT FOR SERVICE PARTS ....40
OUTER COMPONENT PARTS .....................................11
VALVE DIMENSIONS ...............................................41
Removal and Installation ...........................................11
VALVE SPRING .......................................................41
MEASUREMENT OF COMPRESSION PRESSURE ....14
VALVE LIFTER AND VALVE SHIM ............................42
DRIVE BELTS................................................................15 Valve Clearance.........................................................43
Checking ....................................................................15 CHECKING .............................................................43
AIR CLEANER...............................................................17 ADJUSTING ............................................................44
Cleaning and Changing .............................................17 Assembly ...................................................................45
VISCOUS PAPER TYPE ...........................................17 Installation..................................................................46
DRY PAPER TYPE ..................................................17 ENGINE ASSEMBLY.....................................................50
SPARK PLUG................................................................18 Removal and Installation ...........................................50
Checking and Changing ............................................18 REMOVAL ...............................................................51
OIL PAN.........................................................................19 INSTALLATION........................................................52
Components...............................................................19 CYLINDER BLOCK .......................................................53
Removal.....................................................................19 Components...............................................................53
Installation..................................................................20 Removal and Installation ...........................................54
TIMING CHAIN ..............................................................22 Disassembly...............................................................54
Components...............................................................22 PISTON AND CRANKSHAFT ....................................54
Removal.....................................................................23 Inspection...................................................................55
Inspection...................................................................26 PISTON AND PISTON PIN CLEARANCE ..................55
Installation..................................................................27 PISTON RING SIDE CLEARANCE ............................55
OIL SEAL.......................................................................31 PISTON RING END GAP..........................................55
Replacement..............................................................31 CONNECTING ROD BEND AND TORSION ...............56
VALVE OIL SEAL .....................................................31 CYLINDER BLOCK DISTORTION AND WEAR ...........56
FRONT OIL SEAL ....................................................31 PISTON-TO-BORE CLEARANCE ..............................57
REAR OIL SEAL ......................................................32 CRANKSHAFT.........................................................58
CYLINDER HEAD..........................................................33 BEARING CLEARANCE ...........................................58
Components...............................................................33 CONNECTING ROD BUSHING CLEARANCE
(SMALL END) ..........................................................60
Removal.....................................................................34
Disassembly...............................................................36
CONTENTS (Cont'd)
REPLACEMENT OF CONNECTING ROD ALTERNATOR & WATER PUMP BELT .....................86
BUSHING (SMALL END) ..........................................61 Removal.....................................................................86
FLYWHEEL/DRIVE PLATE RUNOUT ........................61 Installation..................................................................87
Assembly ...................................................................61 AIR CLEANER...............................................................88
PISTON ..................................................................61 Changing Air Cleaner Filter .......................................88
CRANKSHAFT.........................................................62 VISCOUS PAPER TYPE ...........................................88
SERVICE DATA AND SPECIFICATIONS (SDS) .........65 OIL PAN.........................................................................89
General Specifications...............................................65 Components...............................................................89
Compression Pressure ..............................................65 Removal.....................................................................89
Belt Deflection............................................................66 Installation..................................................................91
Spark Plug .................................................................66 TIMING CHAIN ..............................................................94
Cylinder Head ............................................................66 Secondary Timing Chain ...........................................94
Valve ..........................................................................67 REMOVAL ...............................................................94
VALVE ....................................................................67 INSPECTION ...........................................................96
VALVE SPRING .......................................................67 INSTALLATION........................................................96
VALVE LIFTER ........................................................67 Primary Timing Chain ................................................99
VALVE CLEARANCE................................................68 REMOVAL .............................................................100
VALVE GUIDE .........................................................68 INSPECTION .........................................................102
AVAILABLE SHIMS ..................................................68 INSTALLATION......................................................102
VALVE SEAT ...........................................................71 INTAKE MANIFOLD ....................................................107
VALVE SEAT RESURFACE LIMIT.............................72
Removal and Installation .........................................107
Camshaft and Camshaft Bearing ..............................72 PREPARATIVE WORK ...........................................107
Cylinder Block............................................................73 FUEL PIPING ........................................................108
Piston, Piston Ring and Piston Pin ...........................74 INTAKE MANIFOLD ...............................................108
PISTON ..................................................................74 EGR VOLUME CONTROL VALVE ...........................108
PISTON RING .........................................................74 WATER HOSE .......................................................108
PISTON PIN ............................................................75 Inspection.................................................................109
Connecting Rod .........................................................75 INTAKE MANIFOLD ...............................................109
Crankshaft..................................................................75 THREE WAY CATALYST ...........................................110
Main Bearing..............................................................75 Removal and Installation .........................................110
STANDARD .............................................................75 PREPARATIVE WORK ...........................................110
UNDERSIZE ............................................................76 THREE WAY CATALYST .......................................110
Connecting Rod Bearing ...........................................76 GUSSET ............................................................... 111
STANDARD SIZE ....................................................76 EXHAUST MANIFOLD, TURBOCHARGER ...............112
UNDERSIZE ............................................................76 Removal and Installation .........................................112
Bearing Clearance .....................................................76 PREPARATIVE WORK ...........................................112
Miscellaneous Components.......................................76 EXHAUST MANIFOLD AND TURBOCHARGER .......112
EXHAUST MANIFOLD GASKET .............................113
YD Disassembly and Assembly.....................................113
TURBOCHARGER .................................................113
PRECAUTIONS .............................................................77 Inspection.................................................................114
Parts Requiring Angular Tightening...........................77 EXHAUST MANIFOLD ...........................................114
Liquid Gasket Application Procedure ........................77 TURBOCHARGER .................................................114
PREPARATION .............................................................78 ROCKER COVER ........................................................117
Special Service Tools ................................................78 Removal and Installation .........................................117
Commercial Service Tools .........................................80 PREPARATIVE WORK ...........................................117
NOISE, VIBRATION AND HARSHNESS (NVH) ROCKER COVER ..................................................117
TROUBLESHOOTING ...................................................82 CYLINDER HEAD........................................................119
NVH Troubleshooting - Engine Noise .......................82 Components.............................................................119
MEASUREMENT OF COMPRESSION PRESSURE ....83 Removal...................................................................120
DRIVE BELTS................................................................85 PREPARATIVE WORK ...........................................120
Inspection...................................................................85 CAMSHAFT ...........................................................120
Adjustment .................................................................85 CYLINDER HEAD ..................................................121
AIR CONDITIONER COMPRESSOR BELT ................86 Disassembly.............................................................121
Inspection.................................................................122
EM-2
CONTENTS (Cont'd)
CYLINDER HEAD DISTORTION .............................122 PISTON-TO-BORE CLEARANCE ............................146
CAMSHAFT VISUAL CHECK ..................................123 CRANKSHAFT.......................................................147
CAMSHAFT RUNOUT ............................................123 MAIN BEARING HOUSING INNER DIAMETER ........148
CAMSHAFT CAM HEIGHT .....................................123 BEARING CLEARANCE .........................................148
CAMSHAFT JOURNAL CLEARANCE ......................123 MAIN BEARING CRUSH HEIGHT ...........................152
CAMSHAFT END PLAY..........................................124 MAIN BEARING CAP BOLT DEFORMATION ...........152
CAMSHAFT SPROCKET RUNOUT .........................124 CONNECTING ROD BUSHING CLEARANCE
VALVE GUIDE CLEARANCE ..................................124 (SMALL END) ........................................................152
VALVE GUIDE REPLACEMENT ..............................125 CONNECTING ROD BOLT DEFORMATION ............153
VALVE SEATS .......................................................126 FLYWHEEL RUNOUT ............................................153
REPLACING VALVE SEAT FOR SERVICE PARTS ..126 OIL JET ................................................................153
VALVE DIMENSIONS .............................................128 OIL JET RELIEF VALVE .........................................153
VALVE SPRING .....................................................128 Assembly .................................................................154
VALVE LIFTER ......................................................128 PISTON ................................................................154
Assembly .................................................................129 CRANKSHAFT.......................................................154
Installation................................................................129 REPLACEMENT OF PILOT BUSHING.....................157
CYLINDER HEAD GASKET SELECTION .................130 SERVICE DATA AND SPECIFICATIONS (SDS) .......159
CYLINDER HEAD BOLT DEFORMATION CHECK ...131 General Specifications.............................................159
CYLINDER HEAD-TO-BLOCK DIFFERENCE Compression Pressure ............................................159
CHECK .................................................................131 Belt Deflection..........................................................159
LIQUID GASKET APPLICATION ON REAR CHAIN Cylinder Head ..........................................................159
CASE ....................................................................131
Valve ........................................................................160
CYLINDER HEAD INSTALLATION ..........................131
VALVE ..................................................................160
GLOW PLUG INSTALLATION .................................132
VALVE CLEARANCE..............................................160
CAMSHAFT INSTALLATION ...................................132
AVAILABLE SHIMS ................................................160
Valve Clearance.......................................................133 VALVE SPRING .....................................................161
CHECKING ...........................................................133 VALVE LIFTER ......................................................162
ADJUSTING ..........................................................134 VALVE GUIDE .......................................................162
ENGINE ASSEMBLY...................................................136 Valve Seat................................................................163
Removal and Installation .........................................136 Camshaft and Camshaft Bearing ............................165
REMOVAL .............................................................137
Cylinder Block..........................................................166
INSTALLATION......................................................138
Piston, Piston Ring and Piston Pin .........................166
CYLINDER BLOCK .....................................................139
AVAILABLE PISTON ..............................................166
Components.............................................................139 PISTON RING .......................................................167
Removal and Installation .........................................140 PISTON PIN ..........................................................167
Disassembly.............................................................140 Connecting Rod .......................................................167
PISTON AND CRANKSHAFT ..................................140 Crankshaft................................................................167
Inspection.................................................................143 Available Main Bearing............................................168
CRANKSHAFT END PLAY .....................................143 UNDERSIZE ..........................................................168
CONNECTING ROD SIDE CLEARANCE .................143
Available Connecting Rod Bearing..........................169
PISTON AND PISTON PIN CLEARANCE ................144
CONNECTING ROD BEARING ...............................169
PISTON RING SIDE CLEARANCE ..........................144
UNDERSIZE ..........................................................169
PISTON RING END GAP........................................144
Miscellaneous Components.....................................169
CONNECTING ROD BEND AND TORSION .............145
BEARING CLEARANCE .........................................169
CYLINDER BLOCK DISTORTION AND WEAR .........145
EM-3
PRECAUTIONS QG
Parts Requiring Angular Tightening
Parts Requiring Angular Tightening NJEM0001
+ Use an angle wrench for the final tightening of the following
engine parts:
a) Cylinder head bolts
b) Main bearing cap bolts
c) Connecting rod cap nuts
+ Do not use a torque value for final tightening.
+ The torque value for these parts are for a preliminary step.
+ Ensure thread and seat surfaces are clean and coated with
engine oil.
Liquid Gasket Application Procedure NJEM0002
1. Use a scraper to remove old liquid gasket from mating
surfaces and grooves. Also, completely clean any oil from
these areas.
2. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
+ For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in).
+ For areas except oil pan, be sure liquid gasket diameter is
2.0 to 3.0 mm (0.079 to 0.118 in).
SEM164F 3. Apply liquid gasket around the inner side of bolt holes
(unless otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and
engine coolant.
AEM080
EM-4
PREPARATION QG
Special Service Tools
Special Service Tools NJEM0003
Tool number
Description
Tool name
ST0501S000 Disassembling and assembling
Engine stand assembly
(1) ST05011000
Engine stand
(2) ST05012000
Base
NT042
Engine attachment Overhauling engine
assembly
(1) KV10106500
Engine attachment
(2) KV10113300
Sub-attachment
NT029
ST10120000 Loosening and tightening cylinder head bolt
Cylinder head bolt a: 13 mm (0.51 in) dia.
wrench b: 12 mm (0.47 in)
c: 10 mm (0.39 in)
NT583
KV10116200 Disassembling valve mechanism
Valve spring compressor
(1) KV10115900
Attachment
NT022
KV10115600 Installing valve oil seal
Valve oil seal drift
NT024
KV10107902 Displacement valve lip seal
Valve oil seal puller
NT011
EM-5
PREPARATION QG
Special Service Tools (Cont'd)
Tool number
Description
Tool name
KV101151S0 Changing shims
Lifter stopper set
(1) KV10115110
Camshaft pliers
(2) KV10115120
Lifter stopper
NT041
EM03470000 Installing piston assembly into cylinder bore
Piston ring compressor
NT044
KV10107400 Disassembling and assembling piston pin
Piston pin press stand
(1) KV10107310
Center shaft
(2) ST13040020
Stand
(3) ST13040030
Spring
(4) KV10107320
Cap
(5) ST13040050
Drift
NT013
KV10111100 Removing oil pan
Seal cutter
NT046
WS39930000 Pressing the tube of liquid gasket
Tube presser
NT052
KV10112100 Tightening bolts for bearing cap, cylinder head,
Angle wrench etc.
NT014
ST16610001 Removing pilot bushing
Pilot bushing puller
NT045
EM-6
PREPARATION QG
Special Service Tools (Cont'd)
Tool number
Description
Tool name
Front (heated) oxygen Loosening or tightening heated oxygen sensor
sensor wrench with 22 mm (0.87 in) hexagon nut
NT379
KV101056S0* Preventing crankshaft from rotating
Rear gear stopper
(1) KV10105620
Adapter
(2) KV10105610
Plate assembly
NT773
Commercial Service Tools NJEM0004
Tool name Description
Spark plug wrench Removing and installing spark plug
NT047
Valve seat cutter set Finishing valve seat dimensions
NT048
Piston ring expander Removing and installing piston ring
NT030
Valve guide drift Removing and installing valve guide
Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
NT015
EM-7
PREPARATION QG
Commercial Service Tools (Cont'd)
Tool name Description
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: 52 mm (2.05 in) dia.
b: 40 mm (1.57 in) dia.
NT049
Rear oil seal drift Installing rear oil seal
a: 103 mm (4.06 in) dia.
b: 84 mm (3.31 in) dia.
NT049
Oxygen sensor thread Reconditioning the exhaust system threads before
cleaner installing a new oxygen sensor. Use with anti-
seize lubricant shown below.
a: 18 mm dia. with a pitch of 1.5 mm for Zirco-
nia Oxygen Sensor
b: 12 mm dia. with a pitch of 1.25 mm for Tita-
nia Oxygen Sensor
NT778
Anti-seize lubricant (Per- Lubricating oxygen sensor thread cleaning tool
matexTM 133AR or when reconditioning exhaust system threads
equivalent meeting MIL
specification MIL-A-907)
NT779
EM-8
NJEM0005
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING QG
NVH Troubleshooting -- Engine Noise
NVH Troubleshooting -- Engine Noise NJEM0005S01
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 Type of Before After When Source of Reference
When When While Check item
noise noise warm- warm- start- noise page
idling racing driving
up up ing
Top of Ticking or C A -- A B -- Tappet Valve clearance EM-43
Engine click noise
Rocket
Cover Cyl- Rattle C A -- A B C Camshaft Camshaft journal clear- EM-37
inder Head bearing ance
noise Camshaft runout
Crankshaft Slap or -- A -- B B -- Piston pin Piston and piston pin EM-55, 60
Pulley knock noise clearance
Cylinder Connecting rod bushing
block (Side clearance
of Engine)
Oil pan Slap or A -- -- B B A Piston slap Piston-to-bore clearance EM-55, 56,
rap noise Piston ring side clearance 57
Piston ring end gap
Connecting rod bend and
torsion
Knock A B C B B B Connecting Connecting rod bearing EM-59, 60
rod-bearing clearance (Big end)
noise Connecting rod bushing
clearance (Small end)
Knock A B -- A B C Main bear- Main bearing oil clear- EM-58
ing noise ance
Crankshaft runout
Front of Tapping or A A -- B B B Timing Timing chain cracks and EM-26
Engine Tim- ticking chain and wear
ing Chain chain ten- Timing chain tensioner
Cover sioner noise operation
Front of Squeak or A B -- B -- C Other drive Drive belts deflection EM-15
Engine fizzing belts (stick-
ing or slip-
ping)
Creaking A B A B A B Other drive Idler pulley bearing
belts (slip- operation
ping)
Squall or A B -- B A B Water pump Water pump operation LC-14
creak noise
A: Closely related B: Related C: Sometimes related --: Not related
EM-9
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING QG
NVH Troubleshooting -- Engine Noise (Cont'd)
SEM937F
EM-10
OUTER COMPONENT PARTS QG
Removal and Installation
Removal and Installation NJEM0006
SEM302G
1. Oil pressure switch 6. Intake manifold upper support 11. Water pump pulley
2. EGR valve 7. Intake manifold rear supports 12. EGR solenoid valve
3. EGR tube 8. Oil filter 13. EGR guide tube
4. Air relief plug 9. Thermostat 14. EGR gas temperature sensor
5. Intake manifold 10. Water pump
EM-11
OUTER COMPONENT PARTS QG
Removal and Installation (Cont'd)
SEM303G
1. Throttle position sensor 5. Injector tube 9. Throttle opener
2. IACV-AAC valve 6. Pressure regulator 10. One way valve
3. Throttle body 7. Intake manifold 11. Vacuum tank
4. Injector 8. Canister purge control valve 12. Swirl control solenoid valve
EM-12
OUTER COMPONENT PARTS QG
Removal and Installation (Cont'd)
SEM304G
1. Crankshaft pulley 6. Thermal transmitter 10. Converter cap
2. Engine coolant temperature 7. Water drain plug 11. Converter cover
3. Gasket 8. Heated oxygen sensor 1 (front) 12. Ignition coil
4. Exhaust manifold 9. Three way catalyst 13. Spark plug
5. Exhaust manifold cover
EM-13
NJEM0007
MEASUREMENT OF COMPRESSION PRESSURE QG
1. Warm up engine.
2. Turn ignition switch OFF.
3. Release fuel pressure.
Refer to EC-35, "Releasing Fuel Pressure".
4. Remove ignition coils.
5. Remove spark plugs.
+ Clean area around plug with compressed air before removing
the spark plug.
6. Attach a compression tester to No. 1 cylinder.
7. Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown above.
+ Always use a fully-charged battery to obtain specified
engine speed.
Compression pressure: kPa (bar, kg/cm2, psi)/rpm
QG18DE
Standard
SEM973E
1,324 (13.24, 13.5, 192)/350
Minimum
1,128 (11.28, 11.5, 164)/350
Maximum allowable difference between cylinders
98 (0.98, 1.0, 14)/350
QG15DE
Standard
1,372 (13.720, 13.99, 198.9)/350
Minimum
1,176 (11.759, 11.99, 170.5)/350
AEM308 Maximum allowable difference between cylinders
98 (0.98, 1.0, 14)/350
10. If cylinder compression in one or more cylinders is low, pour a
small amount of engine oil into the cylinder through the spark
plug hole and retest compression.
+ If adding oil improves cylinder compression, piston rings
may be worn or damaged. If so, replace piston rings after
checking piston.
+ If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. Refer
to SDS, EM-71. If valve or valve seat is damaged
excessively, replace them.
+ If compression in any two adjacent cylinders is low and if add-
ing oil does not improve compression, there is leakage past the
gasket surface. If so, replace cylinder head gasket.
11. Reinstall spark plugs, ignition coils and fuel pump fuse.
12. Perform "Self-diagnosis Procedure" referring to EC-65, "How
to Erase DTC" if any DTC appears.
EM-14
DRIVE BELTS QG
Checking
Checking NJEM0042
SEM100G
1. Inspect for cracks, fraying, wear or oil adhesion. If necessary,
replace with a new one.
+ When replacing belt, make sure the new belt has the same
number of ribs as the old one.
2. Inspect drive belt deflections by pushing on the belt midway
between pulleys.
Adjust if belt deflections exceed the limit.
Belt deflection:
Unit: mm (in)
Used belt deflection
Applied engine Deflection Deflection
Limit after of new belt
adjustment
With air 5.3 - 5.7 4.5 - 5.0
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