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ENGINE
A
SECTION
ENGINE MECHANICAL
EM EM
C
D
E
CONTENTS
SYMPTOM DIAGNOSIS .............................. 3
. Removal and Installation ........................................16 . F
Inspection ...............................................................17
.
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................ 3
. CAMSHAFT VALVE CLEARANCE .................. 18
G
NVH troubleshooting Chart ...................................... 3
. Inspection and Adjustment .....................................18
.
PRECAUTION .............................................. 5
. COMPRESSION PRESSURE ........................... 21
Inspection ...............................................................21
. H
PRECAUTIONS .................................................. 5
.
Precaution for Procedure without Cowl Top Cover 5 ...... REMOVAL AND INSTALLATION .............. 22
.
Precaution Necessary for Steering Wheel Rota- I
ENGINE COVER ............................................... 22
tion after Battery Disconnect .................................... 5.
Exploded View ........................................................22
.
Precaution for Supplemental Restraint System
Removal and Installation ........................................22
.
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
J
SIONER" .................................................................. 5
. DRIVE BELT AUTO TENSIONER AND IDLER
Draining Engine Coolant .......................................... 6. PULLEY ............................................................. 23
Disconnecting Fuel Piping ........................................ 6. Exploded View ........................................................23
.
Removal and Disassembly ....................................... 6 . K
Removal and Installation ........................................23
.
Inspection, Repair and Replacement ....................... 6 .
Assembly and Installation ........................................ 6. AIR CLEANER AND AIR DUCT ....................... 24
Parts Requiring Angle Tightening ............................ 7 . Exploded View ........................................................24
. L
Liquid Gasket ........................................................... 7
. Removal and Installation ........................................24 .
Inspection ...............................................................25
.
PREPARATION ........................................... 9
.
INTAKE MANIFOLD ......................................... 26 M
PREPARATION .................................................. 9
. Exploded View ........................................................26
.
Special Service Tools ............................................... 9
. Removal and Installation ........................................26
.
Commercial Service Tools ..................................... 10
. N
EXHAUST MANIFOLD ...................................... 29
PERIODIC MAINTENANCE ........................ 13
. Exploded View ........................................................29
.
Removal and Installation ........................................29 .
DRIVE BELT ......................................................13
. Inspection ...............................................................30
.
O
Exploded View ....................................................... 13
.
Checking ................................................................ 13
. OIL PAN (LOWER) ........................................... 32
Tension Adjustment ............................................... 13. Exploded View ........................................................32
. P
Removal and Installation ........................................ 13 . Removal and Installation ........................................32 .
Inspection ...............................................................34
.
AIR CLEANER FILTER .....................................15
.
Removal and Installation ........................................ 15
. FUEL INJECTOR AND FUEL TUBE ................ 35
Exploded View ........................................................35
.
SPARK PLUG ...................................................16
. Removal and Installation ........................................35 .
Exploded View ....................................................... 16
. Inspection ...............................................................38
.
Revision: 2009 March EM-1 2009 Z12
IGNITION COIL, SPARK PLUG AND ROCK- ENGINE STAND SETTING .............................. 79
.
ER COVER ........................................................ 40
. Setting .................................................................... 79
.
Exploded View ....................................................... 40
.
Removal and Installation ....................................... 40
. ENGINE UNIT ................................................... 81
.
Disassembly ........................................................... 81
.
TIMING CHAIN ................................................. 42
. Assembly ............................................................... 81
.
Exploded View ....................................................... 42
.
Removal and Installation ....................................... 43 . OIL PAN (UPPER) ............................................ 82
.
Inspection .............................................................. 51
. Exploded View ....................................................... 82
.
Removal and Installation ........................................ 82 .
CAMSHAFT ...................................................... 53
. Inspection ............................................................... 85
.
Exploded View ....................................................... 53
.
Removal and Installation ....................................... 53 . CYLINDER BLOCK .......................................... 86
.
Inspection .............................................................. 57
. Exploded View ....................................................... 86
.
Disassembly and Assembly ................................... 87 .
OIL SEAL .......................................................... 62
. Inspection ............................................................... 95
.
VALVE OIL SEAL .................................................... 62
. HOW TO SELECT PISTON AND BEARING .. 106
VALVE OIL SEAL : Removal and Installation ........ 62 . Description ........................................................... 106
.
Piston ................................................................... 106
.
FRONT OIL SEAL .................................................... 62
. Connecting Rod Bearing .................................... 107 .
FRONT OIL SEAL : Removal and Installation ....... 63 . Main Bearing ....................................................... 109 .
REAR OIL SEAL ...................................................... 63
.
SERVICE DATA AND SPECIFICATIONS
REAR OIL SEAL : Removal and Installation ......... 63 .
(SDS) ......................................................... 113
CYLINDER HEAD ............................................. 65
.
Exploded View ....................................................... 65
. SERVICE DATA AND SPECIFICATIONS
Removal and Installation ....................................... 66 . (SDS) ............................................................... 113
.
Disassembly and Assembly ................................... 67 . General Specification ........................................... 113 .
Inspection .............................................................. 71
. Drive Belt ............................................................. 113
.
Spark Plug ........................................................... 113
.
UNIT REMOVAL AND INSTALLATION .... 74
. Exhaust Manifold ................................................. 114 .
Camshaft .............................................................. 114
.
ENGINE ASSEMBLY ........................................ 74
. Cylinder Head ...................................................... 116
.
Exploded View ....................................................... 74
. Cylinder Block ...................................................... 118
.
Removal and Installation ....................................... 74 . Connecting Rod Bearing ...................................... 122 .
Inspection .............................................................. 77
. Main Bearing ........................................................ 122
.
UNIT DISASSEMBLY AND ASSEMBLY ... 79
Revision: 2009 March EM-2 2009 Z12
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH troubleshooting Chart INFOID:0000000004936665
EM
C
D
E
F
G
H
I
J
K
L
M
N
O
P
PBIC3932E
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
Revision: 2009 March EM-3 2009 Z12
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine
Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A -- A B -- Valve clearance EM-18
gine clicking noise
Rocker
cover Camshaft Camshaft journal oil
Cylinder Rattle C A -- A B C bearing clearance EM-114
head noise Camshaft runout
Piston to piston pin oil
Slap or Piston pin clearance
-- A -- B B -- EM-118
knock noise Connecting rod bushing
oil clearance
Piston to cylinder bore
Crank- clearance
shaft pul- Piston ring side clear-
Slap or Piston
ley A -- -- B B A ance EM-118
rap slap noise
Cylinder Piston ring end gap
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-118
Knock A B C B B B
bearing Connecting rod bearing EM-122
noise oil clearance
Main bearing oil clear-
Main bear- EM-122
Knock A B -- A B C ance
ing noise EM-118
Crankshaft runout
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear EM-51
A A -- B B B chain ten-
Front cov- ticking Timing chain tensioner EM-42
sioner
er operation
noise
Drive belt
Squeak-
(Sticking
ing or fizz- A B -- B -- C Drive belt deflection
or slip-
ing EM-13
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water CO-18,
Squall
A B -- B A B pump Water pump operation "Exploded
Creak
noise View"
A: Closely related B: Related C: Sometimes related --: Not related
Revision: 2009 March EM-4 2009 Z12
PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Procedure without Cowl Top Cover INFOID:0000000005048930
EM
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
C
D
E
PIIB3706J
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect F
INFOID:0000000005153868
NOTE:
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