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ENGINE MECHANICAL
SECTION EM EM
CONTENTS
PRECAUTIONS ...............................................................5 CAMSHAFT END PLAY............................................35
Parts Requiring Angular Tightening ............................5 CAMSHAFT SPROCKET RUNOUT ...........................35
Liquid Gasket Application Procedure ..........................5 VALVE GUIDE CLEARANCE ....................................35
PREPARATION ...............................................................6 VALVE GUIDE REPLACEMENT................................36
VALVE SEATS ........................................................37
Special Service Tools ..................................................6
REPLACING VALVE SEAT FOR SERVICE PARTS ....37
Commercial Service Tools.........................................10
VALVE DIMENSIONS...............................................38
VALVE SPRING .......................................................38
GA16DE VALVE LIFTER AND VALVE SHIM ...........................39
NOISE, VIBRATION AND HARSHNESS(NVH) Assembly ...................................................................39
TROUBLESHOOTING ...................................................11 Installation..................................................................40
NVH Troubleshooting Chart -- Engine Noise...........12 VALVE CLEARANCE....................................................45
OUTER COMPONENT PARTS .....................................13 Checking ....................................................................45
COMPRESSION PRESSURE........................................16 Adjusting ....................................................................45
Measurement of Compression Pressure...................16 ENGINE REMOVAL.......................................................48
OIL PAN.........................................................................17 Components...............................................................48
Components...............................................................17 Removal.....................................................................49
Removal.....................................................................17 Installation..................................................................51
Installation..................................................................18 CYLINDER BLOCK .......................................................52
TIMING CHAIN ..............................................................19 Components...............................................................52
Components...............................................................19 Disassembly...............................................................53
PISTON AND CRANKSHAFT ....................................53
Removal.....................................................................20
Inspection...................................................................53
Inspection...................................................................23
PISTON AND PISTON PIN CLEARANCE ..................53
Installation..................................................................23
PISTON RING SIDE CLEARANCE ............................54
OIL SEAL REPLACEMENT ..........................................28 PISTON RING END GAP..........................................54
VALVE OIL SEAL ....................................................28 CONNECTING ROD BEND AND TORSION ...............54
FRONT OIL SEAL ....................................................28 CYLINDER BLOCK DISTORTION AND WEAR...........55
REAR OIL SEAL ......................................................29 PISTON-TO-BORE CLEARANCE ..............................55
CYLINDER HEAD..........................................................30 CRANKSHAFT.........................................................57
Components...............................................................30 BEARING CLEARANCE ...........................................57
Removal.....................................................................31 CONNECTING ROD BUSHING CLEARANCE
Disassembly...............................................................33 (Small end) ..............................................................59
Inspection...................................................................33 REPLACEMENT OF CONNECTING ROD
CYLINDER HEAD DISTORTION ...............................33 BUSHING (Small end) ..............................................60
CAMSHAFT VISUAL CHECK ....................................34 FLYWHEEL/DRIVE PLATE RUNOUT ........................60
CAMSHAFT RUNOUT ..............................................34 Assembly ...................................................................60
CAMSHAFT CAM HEIGHT .......................................34 PISTON ..................................................................60
CAMSHAFT JOURNAL CLEARANCE ........................34 CRANKSHAFT.........................................................61
CONTENTS (Cont'd)
QG18DE PISTON AND CRANKSHAFT ..................................105
Inspection.................................................................106
NOISE, VIBRATION AND HARSHNESS (NVH) PISTON AND PISTON PIN CLEARANCE ................106
TROUBLESHOOTING ...................................................63 PISTON RING SIDE CLEARANCE ..........................106
NVH Troubleshooting -- Engine Noise.....................63 PISTON RING END GAP........................................106
OUTER COMPONENT PARTS .....................................65 CONNECTING ROD BEND AND TORSION .............107
Removal and Installation ...........................................65 CYLINDER BLOCK DISTORTION AND WEAR.........107
MEASUREMENT OF COMPRESSION PRESSURE ....68 PISTON-TO-BORE CLEARANCE ............................108
OIL PAN.........................................................................69 CRANKSHAFT.......................................................109
Components...............................................................69 BEARING CLEARANCE .........................................109
Removal.....................................................................69 CONNECTING ROD BUSHING CLEARANCE
(Small end) ............................................................111
Installation..................................................................70
REPLACEMENT OF CONNECTING ROD
TIMING CHAIN ..............................................................71
BUSHING (Small end) ............................................112
Components...............................................................71
FLYWHEEL/DRIVE PLATE RUNOUT ......................112
Removal.....................................................................72 Assembly .................................................................112
Inspection...................................................................76 PISTON ................................................................112
Installation..................................................................76 CRANKSHAFT.......................................................113
OIL SEAL.......................................................................81
Replacement..............................................................81 SR20DE
VALVE OIL SEAL ....................................................81
FRONT OIL SEAL ....................................................81 NOISE, VIBRATION AND HARSHNESS (NVH)
REAR OIL SEAL ......................................................82 TROUBLESHOOTING .................................................116
CYLINDER HEAD..........................................................83 NVH Troubleshooting -- Engine Noise...................117
Components...............................................................83 OUTER COMPONENT PARTS ...................................118
Removal.....................................................................84 COMPRESSION PRESSURE......................................121
Disassembly...............................................................86 Measurement of Compression Pressure.................121
Inspection...................................................................86 OIL PAN.......................................................................122
CYLINDER HEAD DISTORTION ...............................86 Removal...................................................................122
CAMSHAFT VISUAL CHECK ....................................86 Installation................................................................125
CAMSHAFT RUNOUT ..............................................87 TIMING CHAIN ............................................................127
CAMSHAFT CAM HEIGHT .......................................87
Components.............................................................127
CAMSHAFT JOURNAL CLEARANCE ........................87
Removal...................................................................128
CAMSHAFT END PLAY............................................88
Inspection.................................................................132
CAMSHAFT SPROCKET RUNOUT ...........................88
VALVE GUIDE CLEARANCE ....................................88 Installation................................................................132
VALVE GUIDE REPLACEMENT................................89 OIL SEAL REPLACEMENT ........................................141
VALVE SEATS ........................................................90 VALVE OIL SEAL ..................................................141
REPLACING VALVE SEAT FOR SERVICE PARTS ....90 FRONT OIL SEAL ..................................................141
VALVE DIMENSIONS...............................................91 REAR OIL SEAL ....................................................142
VALVE SPRING .......................................................91 CYLINDER HEAD........................................................143
VALVE LIFTER AND VALVE SHIM ...........................92 Components.............................................................143
Valve Clearance ........................................................92 Removal...................................................................144
CHECKING .............................................................92 Disassembly.............................................................144
ADJUSTING ............................................................93 Inspection.................................................................146
Assembly ...................................................................95 CYLINDER HEAD DISTORTION .............................146
Installation..................................................................95 CAMSHAFT VISUAL CHECK ..................................146
ENGINE REMOVAL.....................................................100 CAMSHAFT RUNOUT ............................................146
Removal and Installation .........................................100 CAMSHAFT CAM HEIGHT .....................................147
REMOVAL .............................................................101 CAMSHAFT JOURNAL CLEARANCE ......................147
INSTALLATION......................................................103 CAMSHAFT END PLAY..........................................147
CYLINDER BLOCK .....................................................104 CAMSHAFT SPROCKET RUNOUT .........................148
Components.............................................................104 VALVE GUIDE CLEARANCE ..................................148
VALVE GUIDE REPLACEMENT..............................148
Removal and Installation .........................................105
VALVE SEATS ......................................................149
Disassembly.............................................................105
REPLACING VALVE SEAT FOR SERVICE PARTS ..150
EM-2
CONTENTS (Cont'd)
VALVE DIMENSIONS.............................................150 CAMSHAFT AND CRANKSHAFT OIL SEAL
VALVE SPRING .....................................................150 INSTALLING DIRECTION AND MANNER ................186
HYDRAULIC LASH ADJUSTER ..............................151 CAMSHAFT OIL SEALS .........................................186
ROCKER ARM, SHIM AND ROCKER ARM GUIDE ..151 CRANKSHAFT FRONT OIL SEAL ...........................187
Assembly .................................................................152 CRANKSHAFT REAR OIL SEAL .............................187
Installation................................................................154 CYLINDER HEAD........................................................188
ENGINE REMOVAL.....................................................155 Components.............................................................188
Components.............................................................155 Removal...................................................................189
Removal...................................................................156 Disassembly.............................................................189
Installation................................................................157 Inspection.................................................................190
CYLINDER BLOCK .....................................................158 CYLINDER HEAD DISTORTION .............................190
Components.............................................................158 VALVE GUIDE CLEARANCE ..................................190
Disassembly.............................................................159 VALVE GUIDE REPLACEMENT..............................191
PISTON AND CRANKSHAFT ..................................159 VALVE SEATS ......................................................191
VALVE SEAT REPLACEMENT ...............................192
Inspection.................................................................159
VALVE DIMENSIONS.............................................193
PISTON AND PISTON PIN CLEARANCE ................159
VALVE SPRING SQUARENESS .............................193
PISTON RING SIDE CLEARANCE ..........................160
VALVE SPRING PRESSURE LOAD ........................193
PISTON RING END GAP........................................160
HYDRAULIC VALVE LIFTER ..................................194
CONNECTING ROD BEND AND TORSION .............160
COMBUSTION CHAMBER REPLACEMENT ............194
CYLINDER BLOCK DISTORTION AND WEAR.........161
CAMSHAFT VISUAL CHECK ..................................195
PISTON-TO-BORE CLEARANCE ............................161
CAMSHAFT END PLAY..........................................195
CRANKSHAFT.......................................................162
CAMSHAFT RUNOUT ............................................195
BEARING CLEARANCE .........................................163
CAMSHAFT CAM HEIGHT .....................................195
CONNECTING ROD BUSHING CLEARANCE
CAMSHAFT JOURNAL CLEARANCE ......................195
(Small end) ............................................................165
REPLACEMENT OF CONNECTING ROD
Assembly .................................................................196
BUSHING (Small end) ............................................166 Installation................................................................197
REPLACEMENT OF PILOT BUSHING (M/T) OR TURBOCHARGER.......................................................201
PILOT CONVERTER (CVT) ....................................166 Removal...................................................................201
FLYWHEEL/DRIVE PLATE RUNOUT ......................166 Disassembly.............................................................202
Assembly .................................................................166 Inspection.................................................................203
PISTON ................................................................166 OIL AND WATER TUBES .......................................203
CRANKSHAFT.......................................................167 ROTOR SHAFT .....................................................203
TURBINE WHEEL ..................................................204
CD20T COMPRESSOR WHEEL .........................................204
WASTEGATE VALVE .............................................205
NOISE, VIBRATION AND HARSHNESS (NVH) WASTEGATE VALVE ACTUATOR ..........................205
TROUBLESHOOTING .................................................169 Assembly .................................................................205
NVH Troubleshooting Chart -- Engine Noise.........170 Installation................................................................205
OUTER COMPONENT PARTS ...................................171 ENGINE REMOVAL.....................................................207
COMPRESSION PRESSURE......................................174 CYLINDER BLOCK .....................................................211
OIL PAN.......................................................................177 Components.............................................................211
Removal...................................................................177 Preparation ..............................................................212
Installation................................................................177 Disassembly.............................................................212
TIMING BELT ..............................................................179 PISTON AND CRANKSHAFT ..................................212
Camshaft Timing Belt ..............................................179 Inspection.................................................................213
REMOVAL .............................................................179 PISTON AND PISTON PIN CLEARANCE ................213
Inspection.................................................................181 PISTON RING SIDE CLEARANCE ..........................213
Installation................................................................182 PISTON RING END GAP........................................214
Injection Pump Timing Belt......................................183 MAIN BEARING CLEARANCE ................................214
REMOVAL .............................................................183 CONNECTING ROD BEARING CLEARANCE (Big
INSTALLATION......................................................184 end) ......................................................................215
OIL SEAL REPLACEMENT ........................................186 CONNECTING ROD AND PISTON PIN
CLEARANCE (Small end) .......................................216
VALVE OIL SEAL ..................................................186
CONNECTING ROD BEND AND TORSION .............217
EM-3
CONTENTS (Cont'd)
CRANKSHAFT.......................................................217 Connecting Rod .......................................................238
CYLINDER BLOCK DISTORTION ...........................218 Crankshaft................................................................238
CYLINDER BORE ..................................................218 Main Bearing............................................................239
PISTON-TO-BORE CLEARANCE ............................219 STANDARD ...........................................................239
Assembly .................................................................220 UNDERSIZE ..........................................................239
PISTON ................................................................220 Connecting Rod Bearing .........................................239
CRANKSHAFT.......................................................220 STANDARD SIZE ..................................................239
PISTON WITH CONNECTING ROD ........................221 UNDERSIZE ..........................................................239
FLYWHEEL RUNOUT ............................................222 Bearing Clearance ...................................................239
Miscellaneous Components.....................................239
GA16DE
SERVICE DATA AND SPECIFICATIONS (SDS) .......223 SR20DE
General Specifications.............................................223 SERVICE DATA AND SPECIFICATIONS (SDS) .......240
GENERAL SPECIFICATIONS .................................223
General Specifications.............................................240
Inspection and Adjustment ......................................224
Inspection and Adjustment ......................................241
ENGINE COMPRESSION PRESSURE ....................224
COMPRESSION PRESSURE .................................241
CYLINDER HEAD ..................................................224
CYLINDER HEAD ..................................................241
VALVE ..................................................................224
VALVE ..................................................................241
CAMSHAFT AND CAMSHAFT BEARING ................228
CAMSHAFT AND CAMSHAFT BEARING ................245
CYLINDER BLOCK ................................................228
CYLINDER BLOCK ................................................246
PISTON, PISTON RING AND PISTON PIN ..............229
PISTON, PISTON RING AND PISTON PIN ..............246
CONNECTING ROD...............................................229
CONNECTING ROD...............................................247
CRANKSHAFT.......................................................229
CRANKSHAFT.......................................................248
MAIN BEARING .....................................................230
AVAILABLE MAIN BEARING ..................................248
AVAILABLE CONNECTING ROD BEARING.............230
AVAILABLE CONNECTING ROD BEARING.............249
MISCELLANEOUS COMPONENTS .........................230
MISCELLANEOUS COMPONENTS .........................249
QG18DE
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS) .......231
SERVICE DATA AND SPECIFICATIONS (SDS) .......250
General Specifications.............................................231
General Specifications.............................................250
Compression Pressure ............................................231
Inspection and Adjustment ......................................251
Cylinder Head ..........................................................231 COMPRESSION PRESSURE .................................251
Valve ........................................................................232 CYLINDER HEAD ..................................................251
VALVE ..................................................................232 CAMSHAFT AND CAMSHAFT BEARING ................251
VALVE SPRING .....................................................232 VALVE ..................................................................251
VALVE LIFTER ......................................................232 VALVE LIFTER ......................................................253
VALVE CLEARANCE .............................................232 CYLINDER BLOCK ................................................253
VALVE GUIDE .......................................................233 PISTON, PISTON RING AND PISTON PIN ..............254
AVAILABLE SHIMS ................................................233 CONNECTING ROD...............................................254
VALVE SEAT.........................................................235 CRANKSHAFT.......................................................254
VALVE SEAT RESURFACE LIMIT ..........................236 AVAILABLE MAIN BEARINGS ................................255
Camshaft and Camshaft Bearing ............................236 TURBOCHARGER .................................................255
Cylinder Block..........................................................237 MISCELLANEOUS COMPONENTS .........................255
Piston, Piston Ring and Piston Pin .........................237
PISTON ................................................................237
PISTON RING .......................................................238
PISTON PIN ..........................................................238
EM-4
PRECAUTIONS
Parts Requiring Angular Tightening
Parts Requiring Angular Tightening
+ Some important engine parts are tightened using an angular-
tightening method rather than a torque setting method.
+ If these parts are tightened using a torque setting method,
dispersal of the tightening force (axial bolt force) will be two or
three times that of the dispersal produced by using the correct
angular-tightening method.
+ Although the torque setting values (described in this manual)
are equivalent to those used when bolts and nuts are tightened
with an angular-tightening method, they should be used for
reference only.
+ To assure the satisfactory maintenance of the engine, bolts
and nuts must be tightened using an angular-tightening
method.
+ Before tightening the bolts and nuts, ensure that the thread
and seating surfaces are clean and then coated with engine oil.
+ The bolts and nuts which require the angular-tightening
method are as follows:
(1) Cylinder head bolts ..... SR, GA, CD, QG
(2) Main bearing cap bolts ..... SR
(3) Connecting rod cap nuts ..... SR, GA, QG
Liquid Gasket Application Procedure
a. Before applying liquid gasket, use a scraper to remove
all traces of old liquid gasket from mating surface and
groove, and then completely clean any oil stains from
Inner
side these areas.
b. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
+ Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197
Groove Bolt hole in) wide for SR engine and 3.5 to 4.5 mm (0.138 to
0.177 in) wide for GA, QG and CD engine (for oil pan).
SEM164F + Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to
0.118 in) wide (in areas except oil pan).
c. Apply liquid gasket to inner surface around hole perim-
eter area.
(Assembly should be done within 5 minutes after coat-
ing.)
d. Wait at least 30 minutes before refilling with engine oil
and engine coolant.
Inner side
Groove
AEM080
EM-5
PREPARATION
Special Service Tools
Special Service Tools
Engine
Tool number application
Description
Tool name
GA SR CD QG
ST0501S000 When overhauling engine
Engine stand
assembly
V ST05011000
1
Engine stand
X X X X
V ST05012000
2
Base
NT042
KV10106500 When overhauling engine
Engine stand shaft
-- X -- X
NT028
KV10115300 When overhauling engine
Engine sub-attach-
ment
-- X -- --
NT008
Engine attachment When overhauling engine
assembly
V KV10106500
1
Engine attach-
ment
V KV10113300
2 X -- -- X
Sub-attach-
ment
NT029
V KV10108101
1 When overhauling engine
Engine attach-
ment
V
2 KV10102500
Engine stand -- -- X --
shaft
NT366
ST10120000 Loosening and tightening
Cylinder head bolt cylinder head bolt
wrench
X X -- X
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
NT583 Unit: mm (in)
EM-6
PREPARATION
Special Service Tools (Cont'd)
Engine
Tool number application
Description
Tool name
GA SR CD QG
KV10116200 Disassembling and
Valve spring assembling valve
compressor mechanism
V KV10115900
1
X X -- X
Attachment
NT022
KV101092S0 Disassembling and
Valve spring assembling valve
compressor mechanism
V KV10109210
1
Compressor
-- -- X --
V2 KV10109220
Adapter
NT021
KV10115600 Installing valve oil seal
Valve oil seal drift
Side A Side B
a: 20 (0.79) 20 (0.79)
Side A X X X
b: 13 (0.51) 14.2 (0.559)
(Side (Side -- (Side
c: 10.3 (0.406) 11 (0.43)
Side B A) B) A)
d: 8 (0.31) 8 (0.31)
e: 10.7 (0.421) 10.7 (0.421)
f: 5 (0.20) 5 (0.20)
NT603 Unit: mm (in)
KV10107902 Removing valve oil seal
Valve oil seal
puller
V KV10116100
1
X X X X
Valve oil seal
puller adapter
NT605
KV10115700 Adjusting shims
Dial gauge stand
X -- -- X
NT012
KV101151S0 Changing shims
Lifter stopper set
V KV10115110
1
Camshaft
pliers X -- -- X
V KV10115120
2
Lifter stopper
NT041
EM-7
PREPARATION
Special Service Tools (Cont'd)
Engine
Tool number application
Description
Tool name
GA SR CD QG
EM03470000 Installing piston assembly
Piston ring com- into cylinder bore
pressor
X X X X
NT044
KV10107400 Disassembling and
Piston pin press assembling piston pin
stand
V KV10107310
1
Center shaft
V ST13040020
2
Stand X X -- X
V ST13040030
3
Spring
V KV10107320
4
Cap
V ST13040050
5
Drift NT013
KV10109300* Removing and installing
Pulley holder camshaft sprocket
-- -- X --
a: 68 mm (2.68 in)
NT628 b: 8 mm (0.31 in) dia.
ED19600000* Measuring compression
Compression pressure
gauge set
-- -- X --
NT626
KV11100300 Loosening and tightening
Nozzle holder injector nozzle
socket
No. 2-4 injection -- -- X --
nozzle holder
socket NT563
KV119E0030 Loosening and tightening
No. 1 injection injector nozzle
nozzle holder
socket -- -- X --
NT648
KV10111100 Removing oil pan
Seal cutter
X X X X
NT046
*: Special tool or commercial equivalent
EM-8
PREPARATION
Special Service Tools (Cont'd)
Engine
Tool number application
Description
Tool name
GA SR CD QG
WS39930000 Pressing the tube of liquid
Tube presser gasket
X X X X
NT052
KV10112100 Tightening bolts for bearing
Angle wrench cap, cylinder head, etc.
X X X X
NT014
ST16610001* Removing pilot bushing
Pilot bushing puller
-- X X --
NT045
KV11102900* Removing injection pump
Pulley puller pulley
-- -- X --
NT647
KV101056S0* Preventing crankshaft from
Ring gear stopper rotating
V KV10105630
1
Adapter
V KV10105620
2
a: 3 (0.12)
Adapter b: 6.4 (0.252)
V KV10105610
3
c: 2.8 (0.110) -- -- X X
Plate assembly d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
NT617 Unit: mm (in)
*: Special tool or commercial equivalent
EM-9
PREPARATION
Commercial Service Tools
Commercial Service Tools
Engine
Tool name Description application
GA SR CD QG
Spark plug wrench Removing and installing
spark plug
X X -- X
16 mm
(0.63 in)
NT047
Valve seat cutter set Finishing valve seat dimen-
sions
X X X X
NT048
Piston ring expander Removing and installing
piston ring
X X X X
NT030
Valve guide drift Removing and installing
valve guide
SR Intake & Exhaust
a = 9.5 mm (0.374 in) dia. X X -- X
b = 5.0 mm (0.197 in) dia.
QG, GA Intake & Exhaust
a = 9.5 mm (0.374 in) dia.
NT015 b = 5.5 mm (0.217 in) dia.
Valve guide reamer Reaming valve guide V 1
or hole for oversize valve
guide V 2
SR Intake & Exhaust
d1 = 6.0 mm (0.236 in) dia. X X -- X
d2 = 10.175 mm (0.4006 in)
dia.
QG, GA Intake & Exhaust
d1 = 5.5 mm (0.217 in) dia.
d2 = 9.685 mm (0.3813 in)
NT016 dia.
Front oil seal drift Installing front oil seal
X X -- X
a = 75 mm (2.95 in) dia.
NT049 b = 45 mm (1.77 in) dia.
Rear oil seal drift Installing rear oil seal
X X -- X
a = 110 mm (4.33 in) dia.
NT049 b = 80 mm (3.15 in) dia.
EM-10
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING GA16DE
Camshaft bearing noise
Tappet noise
Timing chain and
chain tensioner
noise
VALVE MECHANISM
Valve
TIMING CHAIN
Water pump noise
Piston pin noise
ROTATION
MECHANISM
DRIVE BELT
Connecting rod
bearing noise
Piston slap
noise
Main bearing noise NEM341
EM-11
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING GA16DE
NVH Troubleshooting Chart -- Engine Noise
NVH Troubleshooting Chart -- Engine Noise
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 Source of Reference
When When When While Check item
noise noise warm- warm- noise page
starting idling revving driving
up up
Top of Ticking Tappet
C A -- A B -- Valve clearance EM-45
Engine or click noise
Rocker Camshaft Camshaft journal clear-
Cover Cyl- Rattle C A -- A B C bearing ance EM-34
inder Head noise Camshaft runout
Piston and piston pin
Slap or Piston pin clearance
-- A -- B B -- EM-53,59
knock noise Connecting rod bushing
clearance
Piston-to-bore clearance
Crankshaft Piston ring side clear-
Pulley Slap or Piston slap ance
A -- -- B B A EM-54, 55
rap noise Piston ring end gap
Cylinder Connecting rod bend
block (Side and torsion
of Engine)
Connect- Connecting rod bearing
Oil pan ing rod- clearance (Big end)
Knock A B C B B B EM-58, 59
bearing Connecting rod bushing
noise clearance (Small end)
Main bearing oil clear-
Main bear-
Knock A B -- A B C ance EM-57
ing noise
Crankshaft runout
Front of Timing
Timing chain cracks and
Engine Tapping chain and
wear
Timing or A A -- B B B chain ten- EM-23
Timing chain tensioner
Chain ticking sioner
operation
Cover noise
Other drive
Squeak
belts MA Section
or A B -- B -- C Drive belts deflection
(sticking or (``Checking
fizzing
slipping) Drive Belts'',
Other drive ``Engine Main-
Idler pulley bearing tenance'')
Front of Creaking A B A B A B belts
operation
Engine (slipping)
LC Section
Water (``Water Pump
Squeal
A B -- B A B pump Water pump operation Inspection'',
or creak
noise ``Engine Cool-
ing System'')
A: Closely related B: Related C: Sometimes related --: Not related
EM-12
OUTER COMPONENT PARTS GA16DE
SEC. 140c150c210c211c220c221c253
12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6) V
2
22 - 29 (2.2 - 3.0, 16 - 22)
V
1 12 - 17 (1.22 - 1.73, 8.8 - 12.5)
V
3 19.6 - 29.4 (2.00 - 3.00, 14.5 - 21.7)
V
4 12 - 18 (1.22 - 1.84, 8.8 - 13.3)
V
5 Gasket
V
7
V
6
15.7 - 20.6 (1.60 - 2.10, 11.6 - 15.2)
15.7 - 20.6
(1.60 - 2.10, 11.6 - 15.2)
15.7 - 20.6 (1.60 - 2.10, 11.6 - 15.2)
V
8
15.7 - 20.6 (1.60 - 2.10, 11.6 - 15.2) V
9
6.3 - 8.3 (0.641 - 0.851, 55.8 - 73.5) 6.3 - 8.3 (0.641 - 0.851, 55.8 - 73.5)
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