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ENGINE MECHANICAL
SECTION EM
CONTENTS
QG Inspection...................................................................36
CYLINDER HEAD DISTORTION ...............................36
PRECAUTIONS ...............................................................5 CAMSHAFT VISUAL CHECK ....................................36
Parts Requiring Angular Tightening.............................5 CAMSHAFT RUNOUT ..............................................37
Liquid Gasket Application Procedure ..........................5 CAMSHAFT CAM HEIGHT .......................................37
PREPARATION ...............................................................6 CAMSHAFT JOURNAL CLEARANCE ........................37
Special Service Tools ..................................................6 CAMSHAFT END PLAY............................................38
Commercial Service Tools ...........................................8 CAMSHAFT SPROCKET RUNOUT ...........................38
NOISE, VIBRATION AND HARSHNESS (NVH) VALVE GUIDE CLEARANCE ....................................38
TROUBLESHOOTING ...................................................10 VALVE GUIDE REPLACEMENT ................................39
NVH Troubleshooting - Engine Noise .......................10 VALVE SEATS .........................................................40
REPLACING VALVE SEAT FOR SERVICE PARTS ....40
OUTER COMPONENT PARTS .....................................12
VALVE DIMENSIONS ...............................................41
Removal and Installation ...........................................12
VALVE SPRING .......................................................41
MEASUREMENT OF COMPRESSION PRESSURE ....16
VALVE LIFTER AND VALVE SHIM ............................41
DRIVE BELTS................................................................17 Valve Clearance.........................................................42
Checking ....................................................................17 CHECKING .............................................................42
AIR CLEANER...............................................................18 ADJUSTING ............................................................43
Changing Air Cleaner Filter .......................................18 Assembly ...................................................................45
VISCOUS PAPER TYPE ...........................................18 Installation..................................................................45
SPARK PLUG................................................................19 ENGINE ASSEMBLY.....................................................49
Checking and Changing ............................................19 Removal and Installation ...........................................49
OIL PAN.........................................................................20 REMOVAL ...............................................................50
Components...............................................................20 INSTALLATION........................................................51
Removal.....................................................................20 CYLINDER BLOCK .......................................................52
Installation..................................................................21 Components...............................................................52
TIMING CHAIN ..............................................................22 Removal and Installation ...........................................53
Components...............................................................22 Disassembly...............................................................53
Removal.....................................................................23 PISTON AND CRANKSHAFT ....................................53
Inspection...................................................................26 Inspection...................................................................54
Installation..................................................................27 PISTON AND PISTON PIN CLEARANCE ..................54
OIL SEAL.......................................................................31 PISTON RING SIDE CLEARANCE ............................54
Replacement..............................................................31 PISTON RING END GAP..........................................54
VALVE OIL SEAL .....................................................31 CONNECTING ROD BEND AND TORSION ...............55
FRONT OIL SEAL ....................................................31 CYLINDER BLOCK DISTORTION AND WEAR ...........55
REAR OIL SEAL ......................................................32 PISTON-TO-BORE CLEARANCE ..............................56
CYLINDER HEAD..........................................................33 CRANKSHAFT.........................................................57
Components...............................................................33 BEARING CLEARANCE ...........................................57
CONNECTING ROD BUSHING CLEARANCE
Removal.....................................................................34
(SMALL END) ..........................................................59
Disassembly...............................................................36
CONTENTS (Cont'd)
REPLACEMENT OF CONNECTING ROD AIR CLEANER...............................................................88
BUSHING (SMALL END) ..........................................60 Changing Air Cleaner Filter .......................................88
FLYWHEEL RUNOUT ..............................................60 VISCOUS PAPER TYPE ...........................................88
Assembly ...................................................................60 SPARK PLUG................................................................89
PISTON ..................................................................60 Checking and Changing Spark Plugs .......................89
CRANKSHAFT.........................................................61 Checking Ignition Leads ............................................90
SERVICE DATA AND SPECIFICATIONS (SDS) .........64 OIL PAN.........................................................................91
General Specifications...............................................64 Components...............................................................91
Compression Pressure ..............................................64 Removal.....................................................................91
Belt Deflection............................................................64 Installation..................................................................93
Spark Plug .................................................................65 TIMING CHAIN ..............................................................96
Cylinder Head ............................................................65 Components...............................................................96
Valve ..........................................................................65 Removal.....................................................................97
VALVE ....................................................................65
Inspection.................................................................100
VALVE SPRING .......................................................65
Installation................................................................100
VALVE LIFTER ........................................................66
OIL SEAL.....................................................................105
VALVE CLEARANCE................................................67
VALVE GUIDE .........................................................67 Replacement............................................................105
AVAILABLE SHIMS ..................................................67 VALVE OIL SEAL ...................................................105
VALVE SEAT ...........................................................70 FRONT OIL SEAL ..................................................105
VALVE SEAT RESURFACE LIMIT.............................71 REAR OIL SEAL ....................................................107
Camshaft and Camshaft Bearing ..............................71 CYLINDER HEAD........................................................108
Cylinder Block............................................................72 Components.............................................................108
Piston, Piston Ring and Piston Pin ...........................73 Removal...................................................................109
PISTON ..................................................................73 Disassembly............................................................. 111
PISTON RING .........................................................73 Inspection.................................................................113
PISTON PIN ............................................................73 CYLINDER HEAD DISTORTION .............................113
Connecting Rod .........................................................74 CAMSHAFT VISUAL CHECK ..................................114
Crankshaft..................................................................74 CAMSHAFT RUNOUT ............................................114
Main Bearing..............................................................74 CAMSHAFT CAM HEIGHT .....................................114
CAMSHAFT JOURNAL CLEARANCE ......................115
STANDARD .............................................................74
CAMSHAFT END PLAY..........................................115
UNDERSIZE ............................................................74
CAMSHAFT SPROCKET RUNOUT .........................116
Connecting Rod Bearing ...........................................75
VALVE GUIDE CLEARANCE ..................................116
STANDARD SIZE ....................................................75
VALVE GUIDE REPLACEMENT ..............................116
UNDERSIZE ............................................................75
VALVE SEATS .......................................................117
Bearing Clearance .....................................................75
REPLACING VALVE SEAT FOR SERVICE PARTS ..118
Miscellaneous Components.......................................75 VALVE DIMENSIONS .............................................119
VALVE SPRING .....................................................119
SR HYDRAULIC LASH ADJUSTER ..............................119
ROCKER ARM, SHIM AND ROCKER ARM GUIDE...120
PRECAUTIONS .............................................................76
Assembly .................................................................120
Parts Requiring Angular Tightening...........................76
Installation................................................................123
Liquid Gasket Application Procedure ........................76
ENGINE ASSEMBLY...................................................130
PREPARATION .............................................................77
Removal and Installation .........................................130
Special Service Tools ................................................77
REMOVAL .............................................................131
Commercial Service Tools .........................................79 INSTALLATION......................................................132
NOISE, VIBRATION AND HARSHNESS (NVH) CYLINDER BLOCK .....................................................133
TROUBLESHOOTING ...................................................80 Components.............................................................133
NVH Troubleshooting - Engine Noise .......................81 Removal and Installation .........................................134
OUTER COMPONENT PARTS .....................................82 Disassembly.............................................................134
Removal and Installation ...........................................82 PISTON AND CRANKSHAFT ..................................134
MEASUREMENT OF COMPRESSION PRESSURE ....85 Inspection.................................................................134
DRIVE BELTS................................................................86 PISTON AND PISTON PIN CLEARANCE ................134
Checking ....................................................................86 PISTON RING SIDE CLEARANCE ..........................135
EM-2
CONTENTS (Cont'd)
PISTON RING END GAP........................................135 MEASUREMENT OF COMPRESSION PRESSURE ..164
CONNECTING ROD BEND AND TORSION .............136 DRIVE BELTS..............................................................166
CYLINDER BLOCK DISTORTION AND WEAR .........136 Inspection.................................................................166
PISTON-TO-BORE CLEARANCE ............................137 Adjustment ...............................................................166
CRANKSHAFT.......................................................138 AIR CONDITIONER COMPRESSOR BELT ..............167
BEARING CLEARANCE .........................................138 ALTERNATOR & WATER PUMP BELT ...................167
CONNECTING ROD BUSHING CLEARANCE
Removal...................................................................167
(SMALL END) ........................................................141
Installation................................................................168
REPLACEMENT OF CONNECTING ROD
AIR CLEANER.............................................................169
BUSHING (SMALL END) ........................................141
REPLACEMENT OF PILOT CONVERTER (CVT) .....141 Changing Air Cleaner Filter .....................................169
DRIVE PLATE RUNOUT ........................................142 VISCOUS PAPER TYPE .........................................169
Assembly .................................................................142 OIL PAN.......................................................................170
PISTON ................................................................142 Components.............................................................170
CRANKSHAFT.......................................................143 Removal...................................................................170
SERVICE DATA AND SPECIFICATIONS (SDS) .......146 Installation................................................................172
General Specifications.............................................146 TIMING CHAIN ............................................................175
Compression Pressure ............................................146 Secondary Timing Chain .........................................175
Cylinder Head ..........................................................146 REMOVAL .............................................................175
Valve ........................................................................147 INSPECTION .........................................................177
VALVE ..................................................................147 INSTALLATION......................................................177
VALVE SPRING .....................................................147 Primary Timing Chain ..............................................180
HYDRAULIC LASH ADJUSTER (HLA) .....................147 REMOVAL .............................................................181
VALVE GUIDE .......................................................148 INSPECTION .........................................................183
VALVE SHIM CLEARANCE ADJUSTMENT ..............148 INSTALLATION......................................................183
AVAILABLE SHIM ..................................................149 INTAKE MANIFOLD ....................................................188
VALVE SEAT .........................................................150 Removal and Installation .........................................188
Camshaft and Camshaft Bearing ............................151 PREPARATIVE WORK ...........................................188
Cylinder Block..........................................................152 FUEL PIPING ........................................................189
Piston, Piston Ring and Piston Pin .........................153 INTAKE MANIFOLD ...............................................189
PISTON ................................................................153 EGR VOLUME CONTROL VALVE ...........................189
PISTON RING .......................................................153 WATER HOSE .......................................................189
PISTON PIN ..........................................................153 Inspection.................................................................190
Connecting Rod .......................................................154 INTAKE MANIFOLD ...............................................190
Crankshaft................................................................155 SWIRL CONTROL VALVE ......................................190
Main Bearing............................................................156 CATALYST ..................................................................191
STANDARD ...........................................................156 Removal and Installation .........................................191
UNDERSIZE ..........................................................156 PREPARATIVE WORK ...........................................191
Connecting Rod Bearing .........................................156 THREE WAY CATALYST .......................................191
GUSSET ...............................................................192
STANDARD SIZE ..................................................156
UNDERSIZE ..........................................................156 EXHAUST MANIFOLD, TURBOCHARGER ...............193
Bearing Clearance ...................................................157 Removal and Installation .........................................193
Miscellaneous Components.....................................157 PREPARATIVE WORK ...........................................193
EXHAUST MANIFOLD AND TURBOCHARGER .......193
EXHAUST MANIFOLD GASKET .............................194
YD Disassembly and Assembly.....................................194
PRECAUTIONS ...........................................................158 TURBOCHARGER .................................................194
Parts Requiring Angular Tightening.........................158 Inspection.................................................................195
Liquid Gasket Application Procedure ......................158 EXHAUST MANIFOLD ...........................................195
TURBOCHARGER .................................................195
PREPARATION ...........................................................159
ROCKER COVER ........................................................198
Special Service Tools ..............................................159
Removal and Installation .........................................198
Commercial Service Tools .......................................161
PREPARATIVE WORK ...........................................198
NOISE, VIBRATION AND HARSHNESS (NVH)
ROCKER COVER ..................................................198
TROUBLESHOOTING .................................................163
CYLINDER HEAD........................................................200
NVH Troubleshooting - Engine Noise .....................163
EM-3
CONTENTS (Cont'd)
Components.............................................................200 PISTON RING END GAP........................................226
Removal...................................................................201 CONNECTING ROD BEND AND TORSION .............227
PREPARATIVE WORK ...........................................201 CYLINDER BLOCK DISTORTION AND WEAR .........227
CAMSHAFT ...........................................................201 PISTON-TO-BORE CLEARANCE ............................228
CYLINDER HEAD ..................................................202 CRANKSHAFT.......................................................229
Disassembly.............................................................202 MAIN BEARING HOUSING INNER DIAMETER ........230
Inspection.................................................................203 BEARING CLEARANCE .........................................230
CYLINDER HEAD DISTORTION .............................203 MAIN BEARING CRUSH HEIGHT ...........................234
CAMSHAFT VISUAL CHECK ..................................204 MAIN BEARING CAP BOLT DEFORMATION ...........234
CAMSHAFT RUNOUT ............................................204 CONNECTING ROD BUSHING CLEARANCE
CAMSHAFT CAM HEIGHT .....................................204 (SMALL END) ........................................................234
CAMSHAFT JOURNAL CLEARANCE ......................204 CONNECTING ROD BOLT DEFORMATION ............235
CAMSHAFT END PLAY..........................................205 FLYWHEEL RUNOUT ............................................235
CAMSHAFT SPROCKET RUNOUT .........................205 OIL JET ................................................................235
VALVE GUIDE CLEARANCE ..................................205 OIL JET RELIEF VALVE .........................................235
VALVE GUIDE REPLACEMENT ..............................206 Assembly .................................................................236
VALVE SEATS .......................................................207 PISTON ................................................................236
REPLACING VALVE SEAT FOR SERVICE PARTS ..207 CRANKSHAFT.......................................................236
VALVE DIMENSIONS .............................................209 REPLACEMENT OF PILOT BUSHING.....................239
VALVE SPRING .....................................................209 SERVICE DATA AND SPECIFICATIONS (SDS) .......241
VALVE LIFTER ......................................................209 General Specifications.............................................241
Assembly .................................................................210 Compression Pressure ............................................241
Installation................................................................210 Belt Deflection..........................................................241
CYLINDER HEAD GASKET SELECTION .................210 Cylinder Head ..........................................................241
CYLINDER HEAD BOLT DEFORMATION CHECK ...211 Valve ........................................................................242
CYLINDER HEAD-TO-BLOCK DIFFERENCE VALVE ..................................................................242
CHECK .................................................................212 VALVE CLEARANCE..............................................242
LIQUID GASKET APPLICATION ON REAR CHAIN AVAILABLE SHIMS ................................................242
CASE ....................................................................212 VALVE SPRING .....................................................243
CYLINDER HEAD INSTALLATION ..........................212 VALVE LIFTER ......................................................243
GLOW PLUG INSTALLATION .................................212 VALVE GUIDE .......................................................244
CAMSHAFT INSTALLATION ...................................213 Valve Seat................................................................245
Valve Clearance.......................................................214 Camshaft and Camshaft Bearing ............................247
CHECKING ...........................................................214 Cylinder Block..........................................................248
ADJUSTING ..........................................................215 Piston, Piston Ring and Piston Pin .........................248
ENGINE ASSEMBLY...................................................218 AVAILABLE PISTON ..............................................248
Removal and Installation .........................................218 PISTON RING .......................................................249
REMOVAL .............................................................219 PISTON PIN ..........................................................249
INSTALLATION......................................................220 Connecting Rod .......................................................249
CYLINDER BLOCK .....................................................221 Crankshaft................................................................249
Components.............................................................221 Available Main Bearing............................................250
Removal and Installation .........................................222 UNDERSIZE ..........................................................250
Disassembly.............................................................222 Available Connecting Rod Bearing..........................250
PISTON AND CRANKSHAFT ..................................222 CONNECTING ROD BEARING ...............................250
Inspection.................................................................225 UNDERSIZE ..........................................................251
CRANKSHAFT END PLAY .....................................225 Miscellaneous Components.....................................251
CONNECTING ROD SIDE CLEARANCE .................225 BEARING CLEARANCE .........................................251
PISTON AND PISTON PIN CLEARANCE ................226
PISTON RING SIDE CLEARANCE ..........................226
EM-4
PRECAUTIONS QG
Parts Requiring Angular Tightening
Parts Requiring Angular Tightening NLEM0001
+ Use an angle wrench for the final tightening of the following
engine parts:
a) Cylinder head bolts
b) 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 NLEM0002
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-5
PREPARATION QG
Special Service Tools
Special Service Tools NLEM0003
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-6
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-7
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 NLEM0004
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-8
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-9
NLEM0005
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING QG
NVH Troubleshooting -- Engine Noise
NVH Troubleshooting -- Engine Noise NLEM0005S01
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-42
Engine click noise
Rocker
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-54, 59
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-54, 55,
rap noise Piston ring side clearance 56
Piston ring end gap
Connecting rod bend and
torsion
Knock A B C B B B Connecting Connecting rod bearing EM-58, 59
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-57
ing noise ance
Crankshaft runout
Front of Tapping A A -- B B B Timing Timing chain cracks and EM-26
Engine Tim- or 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-17
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 Water pump operation LC-14
creak pump noise
A: Closely related B: Related C: Sometimes related --: Not related
EM-10
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING QG
NVH Troubleshooting -- Engine Noise (Cont'd)
SEM937F
EM-11
OUTER COMPONENT PARTS QG
Removal and Installation
Removal and Installation NLEM0006
YEM002
1. Oil pressure switch 6. Intake manifold upper support 11. Water pump pulley
2. EGR valve 7. Intake manifold lower 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-12
OUTER COMPONENT PARTS QG
Removal and Installation (Cont'd)
YEM003
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-13
OUTER COMPONENT PARTS QG
Removal and Installation (Cont'd)
YEM004
1. Throttle position sensor 4. Injector 7. Intake manifold
2. IACV-AAC valve 5. Injector tube 8. Canister purge control valve
3. Throttle body 6. Pressure regulator
EM-14
OUTER COMPONENT PARTS QG
Removal and Installation (Cont'd)
YEM005
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-15
NLEM0007
MEASUREMENT OF COMPRESSION PRESSURE QG
1. Warm up engine.
2. Turn ignition switch OFF.
3. Release fuel pressure.
Refer to EC-43, "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
Standard
1,324 (13.24, 13.5, 192)/350
SEM973E
Minimum
1,128 (11.28, 11.5, 164)/350
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
AEM308
improperly. Inspect and repair valve and valve seat. Refer
to SDS, EM-70. 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-69, "How
to Erase DTC" if any DTC appears.
EM-16
DRIVE BELTS QG
Checking
Checking NLEM0042
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.
3. Turn crankshaft two revolutions and re-check drive belt deflec-
tion.
Adjust if belt deflections exceed the limit.
Belt deflection:
Unit: mm (in)
Used belt deflection
Deflection of
Deflection after new belt
Limit
adjustment
With air condi-
5.3 - 5.7 4.5 - 5.0
tioner compres- 8.1 (0.319)
(0.209 - 0.224) (0.177 - 0.197)
sor
Alternator
Without air con-
6.5 - 7.0 5.5 - 6.1
ditioner com- 10.2 (0.402)
(0.256 - 0.276) (0.217 - 0.240)
pressor
4.4 - 4.9 3.9 - 4.4
Power steering oil pump 7.1 (0.280)
(0.173 - 0.193) (0.154 - 0.173)
Applied pushing force 98 N (10 kg, 22 lb)
Inspect drive belt deflections when engine is cold.
EM-17
AIR CLEANER QG
Changing Air Cleaner Filter
Changing Air Cleaner Filter NLEM0043
VISCOUS PAPER TYPE NLEM0043S01
The viscous paper type filter does not need cleaning between
renewals.
SMA373C
EM-18
SPARK PLUG QG
Checking and Changing
Checking and Changing NLEM0044
1. Disconnect ignition coil harness connectors.
2. Remove ignition coils.
SEM870F
3. Remove spark plugs with spark plug wrench.
4. Clean plugs in sand blast cleaner.
5. Check insulator for cracks or chips, gasket for damage or dete-
rioration and electrode for wear and burning. If they are exces-
sively worn away, replace with new spark plugs.
6. Check spark plug gap.
Spark plug
NGK Champion
Standard BKR5E-11 RC10YC4
SMA294A
Type Hot BKR4E-11 --
Cold BKR6E-11 --
Plug gap mm (in) 1.0 - 1.1 (0.039 - 0.043)
7. Install spark plugs.
Spark plug:
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