Beruflich Dokumente
Kultur Dokumente
SECTION
EM
GI
MA
EM
LC
CONTENTS
PRECAUTIONS ...............................................................3
Parts Requiring Angular Tightening.............................3
Liquid Gasket Application Procedure ..........................3
PREPARATION................................................................4
Special Service Tools ..................................................4
Commercial Service Tools ...........................................6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .....................................................8
NVH Troubleshooting Chart Engine Noise .............9
OUTER COMPONENT PARTS .....................................10
COMPRESSION PRESSURE........................................12
Measurement of Compression Pressure...................12
OIL PAN .........................................................................13
Removal.....................................................................13
Installation..................................................................14
TIMING BELT.................................................................16
Removal.....................................................................17
Inspection...................................................................18
Belt Tensioner And Tensioner Spring....................19
Installation..................................................................19
Tension Adjustment....................................................20
After Belt Replacement .........................................20
After Engine Overhaul Or Engine Reassembly
(With Rocker Covers Removed) ...........................20
OIL SEAL REPLACEMENT ..........................................23
Valve Oil Seal........................................................23
Oil Seal Installing Direction...................................23
Camshaft Oil Seal .................................................23
Front Oil Seal ........................................................24
Rear Oil Seal.........................................................24
CYLINDER HEAD..........................................................25
Removal.....................................................................26
Disassembly...............................................................28
Inspection...................................................................29
Cylinder Head Distortion .......................................29
Camshaft Visual Check.........................................29
Camshaft Runout ..................................................29
Camshaft Cam Height...........................................29
Camshaft Journal Clearance ................................30
Camshaft End Play ...............................................30
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
CONTENTS
Replacing Pilot Bushing (M/T) Or Pilot
Converter (A/T) .....................................................52
SERVICE DATA AND SPECIFICATIONS (SDS) ..........53
General Specifications...............................................53
Inspection and Adjustment ........................................53
Cylinder Head .......................................................53
Valve......................................................................54
Valve spring ......................................................54
Hydraulic valve lifter .........................................54
Valve guide .......................................................54
Rocker shaft and rocker arm............................54
Intake valve seat ..............................................55
Exhaust valve seat ...........................................55
Camshaft And Camshaft Bearing .........................55
Cylinder Block .......................................................56
Cylinder Block .......................................................56
EM-2
(Contd.)
Connecting Rod ....................................................57
Piston, Piston Ring And Piston Pin.......................57
Available piston.................................................57
Available piston.................................................57
Piston ring.........................................................57
Piston pin..........................................................58
Crankshaft .............................................................58
Available Main Bearing .........................................58
No. 1 Main Bearing ...............................................58
No. 2 And 3 Main Bearing ....................................58
No. 4 Main Bearing ...............................................58
Under Size ............................................................59
Available Connecting Rod Bearing .......................59
Connecting rod bearing undersize ...................59
Miscellaneous Components ..................................59
Bearing clearance.............................................59
PRECAUTIONS
Parts Requiring Angular Tightening
SEM371C
c.
d.
e.
GI
EC
FE
CL
MT
AT
TF
PD
FA
AEM080
RA
BR
ST
RS
BT
HA
EL
IDX
EM-3
PREPARATION
Special Service Tools
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
Description
ST0501S000
( )
Engine stand assembly
1 ST05011000
( )
Engine stand
2 ST05012000
( )
Base
NT042
KV10106500
( )
Engine stand shaft
NT028
KV10110001
( )
Engine sub-attachment
NT032
ST10120000
(J24239-01)
Cylinder head bolt wrench
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
NT583
KV10112100
(BT8653-A)
Angle wrench
Unit: mm (in)
NT014
KV10110600
(J33986)
Valve spring compressor
NT033
KV10107501
( )
Valve oil seal drift
NT025
EM-4
PREPARATION
Special Service Tools (Contd)
Tool number
(Kent-Moore No.)
Tool name
KV10110300
( )
Piston pin press stand
assembly
1 KV10110310
( )
Cap
2 KV10110330
( )
Spacer
3 ST13030020
( )
Press stand
4 ST13030030
( )
Spring
5 KV10110340
( )
Drift
6 KV10110320
( )
Center shaft
GI
Description
MA
Disassembling and assembling piston with
connecting rod
EM
LC
EC
FE
CL
MT
AT
NT036
EM03470000
(J8037)
Piston ring compressor
TF
PD
NT044
ST16610001
(J23907)
Pilot bushing puller
FA
RA
NT045
KV10111100
(J37228)
Seal cutter
BR
ST
NT046
WS39930000
( )
Tube presser
RS
BT
NT052
KV10117100
(J3647-A)
Heated oxygen sensor
wrench
HA
EL
IDX
NT379
EM-5
PREPARATION
Special Service Tools (Contd)
Tool number
(Kent-Moore No.)
Tool name
Description
Loosening or tightening rear heated oxygen
sensor (For right bank)
KV10114400
(J38365)
Heated oxygen sensor
wrench
a: 22 mm (0.87 in)
NT636
Oxygen sensor
thread cleaner
(J-43897-18)
(J-43897-12)
AEM488
Description
Removing and installing spark plug
NT047
Pulley holder
NT035
NT048
NT030
Diameter
mm (in)
Intake
NT015
EM-6
Exhaust
10.5 (0.413)
6.6 (0.260)
PREPARATION
Commercial Service Tools (Contd)
Tool name
GI
Description
Intake:
d1 = 7.0 mm (0.276 in) dia.
d2 = 11.2 mm (0.441 in) dia.
Exhaust:
d1 = 8.0 mm (0.315 in) dia.
d2 = 12.2 mm (0.480 in) dia.
NT016
MA
EM
LC
EC
FE
CL
AEM489
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
EM-7
AEM459
EM-8
Top of
Ticking or
engine
clicking
Rocker cover
Cylinder
Rattle
head
Slap or
knock
Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil pan
Check item
Reference
page
MA
EM
LC
EC
Tappet noise
EM-34
*1
Camshaft
bearing noise
EM-30,
EM-29
Piston pin
noise
EM-43,
EM-50
CL
EM-45,
EM-44,
EM-44,
EM-44
MT
FE
Slap or rap
Piston slap
noise
Piston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend and torsion
Knock
Connecting
rod bearing
noise
EM-50,
EM-49
AT
Knock
Main bearing
noise
EM-47,
EM-47
TF
Timing belt
noise
(too tight)
EM-16
PD
Timing belt
noise
(too loose)
Other drive
belts
(Sticking or
slipping)
Whine or
hissing
Timing belt
cover
Clatter
Squeaking
or fizzing
Front of
engine
Source of
noise
While
driving
When
racing
When
idling
When
starting
Type of
noise
After
warm-up
Location of
noise
Before
warm-up
GI
Creaking
Other drive
belts
(Slipping)
Squall
Creak
Water pump
noise
FA
*2
RA
BR
A: Closely related
B: Related
C: Sometimes related
: Not related
*1: STEP 19 in Installation, CYLINDER HEAD
*2: MA section (Checking Drive Belts, ENGINE MAINTENANCE)
*3: LC section (Water Pump Inspection, ENGINE COOLING SYSTEM)
*3
ST
RS
BT
HA
EL
IDX
EM-9
AEM478
EM-10
EM-11
COMPRESSION PRESSURE
Measurement of Compression Pressure
1.
2.
3.
4.
5.
Warm up engine.
Turn ignition switch OFF.
Release fuel pressure.
Refer to Releasing Fuel Pressure in EC section.
Remove all spark plugs.
Clean area around plug with compressed air before
removing the spark plug.
Disconnect camshaft position sensor harness connector at the
distributor.
6.
SEM814C
SEM387C
EM-12
OIL PAN
Removal
1.
2.
3.
4.
5.
6.
7.
8.
Remove undercover.
Drain engine oil.
Remove stabilizer bracket bolts (RH & LH).
Remove front propeller shaft from front differential carrier.
Remove front drive shaft fixing bolts (RH & LH).
Remove front differential carrier bleeder hose.
Remove front suspension crossmember.
Remove differential front mounting bolts (RH & LH) and rear
mounting bolts.
9. Remove front differential carrier.
10. Remove front differential carrier mounting bracket.
11. Remove starter motor.
12. Remove transmission to rear engine mounting bracket nuts
(RH & LH).
13. Remove engine mounting bolts or nuts (RH & LH).
14. Remove power steering mounting brackets (RH & LH).
15. Lift up engine. If necessary, disconnect exhaust tube.
16. Remove relay rod. It is not necessary to disconnect pitman
arm.
17. Remove oil pan.
WARNING:
a. Place vehicle on a flat and solid surface.
b. Place chocks at front and rear of rear wheels.
c. You should not remove oil pan until exhaust system and
cooling system have completely cooled off.
Otherwise, you may burn yourself and/or fire may break
out in the fuel line.
d. When remove front and/or rear engine mounting bolts or
nuts, lift up slightly engine for safety work.
CAUTION:
a. In lifting engine, be careful not to hit against adjacent
parts, especially against accelerator wire casing end,
brake tube and brake master cylinder.
b. For tightening torque, refer to AT, MT and PD sections.
1.
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
SEM308F
BT
HA
EL
IDX
SEM111E
EM-13
OIL PAN
Removal (Contd)
2.
a.
SEM111E
b.
Slide Tool by tapping its side with a hammer, and remove oil
pan.
SEM112E
Installation
1.
Before installing oil pan, remove all traces of liquid gasket from
mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of
cylinder block.
SEM309F
2.
Apply sealant to oil pump gasket and rear oil seal retainer
gasket.
3.
SEM894B
SEM310F
EM-14
OIL PAN
Installation (Contd)
4.
5.
LC
SEM015E
EC
FE
CL
MT
AEM080
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
EM-15
TIMING BELT
CAUTION:
a. Do not bend or twist timing belt.
b. After removing timing belt, do not turn crankshaft and camshaft separately because valves will
strike piston heads.
c. Make sure that timing belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and
free from oil and water.
d. Installation should be carried out when engine is cold.
SEM311FA
EM-16
TIMING BELT
Removal
1.
2.
Be
3.
4.
5.
GI
MA
EM
LC
EC
FE
CL
MT
SEM347F
AT
Align punchmark on LH camshaft sprocket with punchmark on timing belt upper rear cover.
Align punchmark on crankshaft sprocket with notch on oil
TF
pump housing.
Temporarily install crank pulley bolt on crankshaft so that
crankshaft can be rotated.
PD
FA
RA
BR
ST
RS
SEM394CA
15. Loosen timing belt tensioner nut, turn tensioner, then remove
timing belt.
BT
HA
EL
IDX
SEM240A
EM-17
TIMING BELT
Inspection
Visually check the condition of timing belt.
Replace if any abnormality is found.
Item to check
Problem
Cause
Camshaft jamming
Distributor jamming
Damaged camshaft/crankshaft oil seal
SEM394A
Tensioner jamming
Overheated engine
Interference with belt cover
SEM395A
SEM396A
Oil/Coolant or water is
stuck to belt.
EM-18
TIMING BELT
Inspection (Contd)
GI
MA
EM
LC
SEM558
EC
Installation
1.
CL
MT
SEM510EA
AT
2. Install tensioner and tensioner spring.
If stud is once removed, apply locking sealant to threads of
stud on cylinder block side before installing.
TF
PD
FA
SEM243A
3.
BR
ST
RS
SEM829A
BT
4.
a.
EM-19
133
40
43
EL
IDX
TIMING BELT
Tension Adjustment
AFTER BELT REPLACEMENT
If the timing belt was replaced (or to adjust tension on a used belt)
follow the steps below.
1. Loosen tensioner lock nut, then turn tensioner clockwise and
counterclockwise with hexagon wrench at least two times.
AEM440
2.
3.
4.
5.
AEM446
SEM886B
5.
6.
SEM887BA
EM-20
TIMING BELT
Tension Adjustment (Contd)
7.
MA
EM
LC
SEM240E
MT
SEM889BA
PD
FA
SEM744DA
RA
BR
ST
RS
BT
HA
EL
IDX
EM-21
TIMING BELT
Tension Adjustment (Contd)
SEM313F
EM-22
SEM257A
4.
GI
EC
FE
CL
MT
AT
TF
PD
FA
SEM493F
RA
BR
ST
RS
SEM715A
BT
HA
EL
IDX
SEM284A
EM-23
SEM241E
SEM242E
EM-24
CYLINDER HEAD
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
SEM314F
EM-25
CYLINDER HEAD
CAUTION:
When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their
sliding surfaces.
SEM870BA
Removal
1.
2.
3.
Drain coolant by removing drain plugs from both sides of cylinder block.
SMA207C
SMA208C
EM-26
CYLINDER HEAD
Removal (Contd)
4.
5.
a.
b.
c.
d.
e.
f.
g.
h.
i.
Separate ASCD and accelerator control wire from intake manifold collector.
Remove intake manifold collector from engine. The following
parts should be disconnected to remove intake manifold collector.
Harness connectors for: IACV-AAC valve, Throttle position
sensor, Throttle position switch, Ignition coil, Power transistor,
EGRC-solenoid valve, and EGR temperature sensor.
Water hoses from collector
Heater hoses
PCV hose from RH rocker cover
Vacuum hoses for: EVAP canister, Master brake cylinder and
Pressure regulator.
Purge hose from EVAP canister
EGR tube
Earth harnesses
Air duct hose
GI
MA
EM
LC
EC
FE
CL
MT
AEM442
6.
7.
8.
Remove fuel feed and fuel return hoses from injector fuel tube AT
assembly.
Disconnect all injector harness connectors.
TF
Remove injector fuel tube assembly.
PD
FA
SEM817C
9.
a.
b.
c.
RA
Remove intake manifold from engine.
The following parts should be disconnected to remove intake
manifold.
BR
Engine coolant temperature switch harness connector
Thermal transmitter harness connector
Water hose from thermostat housing
ST
RS
SEM818C
BT
IDX
SEM819C
EM-27
CYLINDER HEAD
Removal (Contd)
15. Remove compressor and power steering pump.
16. Remove alternator.
17. Remove compressor and alternator bracket.
SEM316F
SEM317F
SEM926AA
Disassembly
1.
SEM335F
Hold hydraulic valve lifters with wire so that they will not
drop from lifter guide.
4. Remove oil seal and camshaft.
SEM304A
EM-28
CYLINDER HEAD
Disassembly (Contd)
5.
6.
GI
MA
EM
LC
SEM257A
Inspection
EC
SEM868A
FE
PD
CL
MT
AT
TF
FA
CAMSHAFT RUNOUT
1.
2.
RA
BR
ST
RS
SEM758A
2.
BT
HA
EL
IDX
SEM549A
EM-29
CYLINDER HEAD
Inspection (Contd)
CAMSHAFT JOURNAL CLEARANCE
SEM893BA
1.
2.
SEM879A
3.
SEM012A
3.
SEM392E
SEM393E
EM-30
CYLINDER HEAD
Inspection (Contd)
CAMSHAFT SPROCKET RUNOUT
1.
2.
3.
GI
MA
EM
LC
SEM872B
EC
Measure valve deflection in a right-angled direction with camshaft. (Valve and valve guide mostly wear in this direction.)
FE
Valve deflection limit (Dial gauge reading):
0.20 mm (0.0079 in)
CL
MT
SEM263A
2.
a.
b.
c.
AT
TF
PD
FA
RA
BR
ST
RS
SEM751A
BT
EL
IDX
SEM008A
EM-31
CYLINDER HEAD
Inspection (Contd)
2.
3.
4.
SEM264A
SEM088C
5.
SEM089C
VALVE SEATS
Check valve seats for any evidence of pitting at valve contact
surface, and reseat or replace if it has worn out excessively.
SEM090C
SEM795A
Bore out old seat until it collapses. The machine depth stop
should be set so that boring cannot continue beyond the bottom face of the seat recess in cylinder head.
Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 in)]:
Intake
44.500 - 44.516 mm (1.7520 - 1.7526 in)
Exhaust
37.500 - 37.516 mm (1.4764 - 1.4770 in)
EM-32
CYLINDER HEAD
Inspection (Contd)
Reaming should be done in circles concentric to the valve GI
guide center so that valve seat will have the correct fit.
3. Heat cylinder head to 150 to 160C (302 to 320F) by soaking
MA
in heated oil.
4. Press fit valve seat until it seats on the bottom.
EM
LC
5.
6.
7.
Intake
Exhaust
degree
45
45
mm (in)
1.75 (0.0689)
1.7 (0.067)
CL
MT
SEM892B
VALVE DIMENSIONS
AT
FA
SEM188A
VALVE SPRING
RA
Squareness
1.
2.
Measure S dimension.
Out-of-square:
Outer
Less than 2.2 mm (0.087 in)
Inner
Less than 1.9 mm (0.075 in)
If it exceeds the limit, replace spring.
BR
ST
RS
SEM207E
Pressure
EM113
EM-33
BT
HA
EL
IDX
CYLINDER HEAD
Inspection (Contd)
ROCKER SHAFT AND ROCKER ARM
1.
2.
3.
SEM761A
SEM762A
3.
SEM243E
SEM760A
Assembly
1.
SEM638B
EM-34
CYLINDER HEAD
Assembly (Contd)
2.
MA
EM
LC
SEM834B
3.
EC
Install valve lifters into valve lifter guide.
Assemble valve lifters to their original position and hold
all valve lifters with wire to prevent lifters from falling off.
FE
After installing, remove the wire.
CL
MT
SEM280A
4.
a.
b.
5.
AT
TF
PD
FA
SEM835BA
Installation
1.
a.
b.
RA
ST
RS
SEM836B
2.
BT
HA
EL
IDX
SEM861C
EM-35
CYLINDER HEAD
Installation (Contd)
SEM862C
3.
4.
SEM336F
SEM877A
5.
EM-36
CYLINDER HEAD
Installation (Contd)
j.
GI
MA
EM
LC
EC
FE
CL
MT
6.
AT
TF
PD
FA
SEM403C
7.
8.
9.
10.
Install
Install
Install
Install
RA
BR
ST
RS
SEM316F
BT
RH camshaft sprocket and LH camshaft sprocket are different parts. Be sure to install them in the correct location. HA
Identification mark
RH camshaft sprocket
R3
053
LH camshaft sprocket
L3
327
EM-37
EL
IDX
CYLINDER HEAD
Installation (Contd)
13. Install distributor.
a. Align mark on shaft with protruding mark on housing.
SEM837BA
b.
SEM337F
SEM817C
EM-38
ENGINE REMOVAL
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
AEM439
BT
HA
EL
IDX
EM-39
ENGINE REMOVAL
REAR ENGINE MOUNTING
AEM438
WARNING:
a. Situate vehicle on a flat and solid surface.
b. Place chocks at front and back of rear wheels.
c. Do not remove engine until exhaust system has completely cooled off. Otherwise, you may burn yourself
and/or fire may break out in fuel line.
d. For safety during subsequent steps, the tension of wires
should be slackened against the engine.
e. Before disconnecting fuel hose, release fuel pressure
from fuel line.
Refer to Releasing Fuel Pressure in EC section.
f. Before removing front axle from transmission, place
safety stands under designated front supporting points.
Refer to GI section for lifting points and towing.
g. Be sure to hoist engine and transmission in a safe manner.
h. For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
EM-40
ENGINE REMOVAL
GI
LC
SEM322F
SEM323F
Removal
EC
1.
2.
3.
FE
CL
MT
AT
TF
PD
FA
SEM324F
RA
BR
ST
RS
BT
HA
EL
IDX
EM-41
CYLINDER BLOCK
SEM325FA
EM-42
CYLINDER BLOCK
CAUTION:
Disassembly
GI
MA
EM
LC
EC
FE
CL
MT
SEM326FA
AT
Remove pistons with connecting rods.
When piston rings are not replaced, make sure that piston
PD
rings are mounted in their original positions.
FA
SEM877B
8.
RA
Remove bearing cap and crankshaft.
Before removing bearing cap, measure crankshaft end
play.
BR
Bolts should be loosened in two or three steps.
ST
RS
SEM551E
Inspection
PISTON AND PISTON PIN CLEARANCE
1.
BT
HA
EL
IDX
SEM684E
EM-43
CYLINDER BLOCK
Inspection (Contd)
2.
AEM024
SEM024AA
SEM822B
End gap:
Top ring: 0.21 - 0.40 mm (0.0083 - 0.0157 in)
2nd ring: 0.50 - 0.69 mm (0.0197 - 0.0272 in)
Oil ring: 0.20 - 0.69 mm (0.0079 - 0.0272 in)
Max. limit of ring gap:
Top ring: 0.54 mm (0.0213 in)
2nd ring: 0.80 mm (0.0315 in)
Oil ring: 0.95 mm (0.0374 in)
If out of specification, replace piston ring. If gap still exceeds the
limit even with a new ring, rebore cylinder and use oversized piston and piston rings.
Refer to SDS (EM-57).
When replacing the piston, check the cylinder block surface for
scratches or seizure. If scratches or seizure are found, hone
or replace the cylinder block.
SEM038F
EM-44
CYLINDER BLOCK
Inspection (Contd)
GI
MA
EM
LC
SEM003F
EC
CL
MT
SEM394E
AT
If out of specification, resurface it.
The resurfacing limit is determined by cylinder head resurfacing in engine.
TF
Amount of cylinder head resurfacing is A.
Amount of cylinder block resurfacing is B.
The maximum limit is as follows:
PD
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height
from crankshaft center:
FA
227.60 - 227.70 mm (8.9606 - 8.9645 in)
3. If necessary, replace cylinder block.
2.
PISTON-TO-BORE CLEARANCE
1.
SEM320A
Using a bore gauge, measure cylinder bore for wear, out-ofround and taper.
Standard inner diameter:
Engine serial number before VG33-424030
91.500 - 91.530 mm (3.6024 - 3.6035 in)
Engine serial number from VG33-424030
Except for No. 5 cylinder
91.500 - 91.530 mm (3.6024 - 3.6035 in)
For No. 5 cylinder
91.515 - 91.545 mm (3.6029 - 3.6041 in)
Refer to CYLINDER BLOCK in SDS.
Wear limit:
0.20 mm (0.0079 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder block
if necessary.
Out-of-round (X Y) standard:
0.015 mm (0.0006 in)
Taper (A B or A C) standard:
0.015 mm (0.0006 in)
2. Check for scratches and seizure. If seizure is found, hone it.
RA
SEM321AA
EM-45
BR
ST
RS
BT
HA
EL
IDX
CYLINDER BLOCK
Inspection (Contd)
If both cylinder block and piston are replaced with new
ones, select piston of the same grade number according
to the following table. These numbers are punched on
cylinder block and piston in either Arabic or Roman
numerals.
Combination of grade number for cylinder bore and piston
Engine serial number before VG33-424030
Cylinder bore
grade No.
Piston grade No.
2-1
3-2
3-3
4-4
4-5
5-6
2-1
3-2
3-3
4-4
4-5
5-6
SEM399F
3.
SEM258C
EM-46
CYLINDER BLOCK
Inspection (Contd)
When any cylinder needs boring, all other cylinders must GI
also be bored.
LC
CRANKSHAFT
1.
2.
EC
MT
SEM316A
3.
AT
TF
PD
FA
SEM434
BEARING CLEARANCE
RA
ST
RS
SEM208E
BT
HA
EL
IDX
SEM505A
EM-47
CYLINDER BLOCK
Inspection (Contd)
4.
5.
6.
7.
AEM033
a.
b.
SEM184A
8.
a.
SEM508A
b.
c.
SEM167B
EM-48
CYLINDER BLOCK
Inspection (Contd)
GI
MA
Crank shaft
main journal
grade number
A (Black)
B (Brown)
C (Green)
D (Yellow)
B (Brown)
C (Green)
D (Yellow)
E (Blue)
C (Green)
D (Yellow)
E (Blue)
F (Pink)
D (Yellow)
E (Blue)
F (Pink)
G (Purple)
EM
LC
EC
FE
Main journal grade number
Crankshaft
journal grade
number
A (Black)
B (Brown)
D (Green)
B (Brown)
D (Green)
E (Yellow)
C (Green)
E (Yellow)
F (Blue)
CL
MT
AT
TF
PD
FA
AEM027
4.
5.
6.
7.
AEM034
RA
BR
ST
RS
BT
CAUTION:
EM-49
CYLINDER BLOCK
Inspection (Contd)
CONNECTING ROD BUSHING CLEARANCE (Small end)
1.
2.
3.
SEM673E
SEM062A
AEM100
Assembly
PISTON
1.
2.
SEM400F
3.
SEM160B
EM-50
CYLINDER BLOCK
Assembly (Contd)
CRANKSHAFT
GI
1.
EM
LC
SEM208E
2.
SEM550EA
3.
EC
FE
CL
MT
AT
TF
PD
FA
SEM158B
Install bearings so that oil hole in connecting rod aligns with oil
hole of bearing.
ST
4.
RS
SEM159B
5.
a.
BT
EL
IDX
SEM620
EM-51
CYLINDER BLOCK
Assembly (Contd)
b.
EM329
6.
SEM512A
7.
SEM338F
2.
SEM916AA
AEM402
EM-52
General Specifications
Unit: kPa (kg/cm2, psi)/300 rpm
Cylinder arrangement
Displacement
V-6
cm3 (cu in)
mm (in)
Valve arrangement
OHC
Firing order
MA
Compression pressure
3,275 (199.84)
Standard
Minimum
1-2-3-4-5-6
EM
98 (1.0, 14)
LC
Oil
Valve timing
EC
Compression ratio
8.9
FE
Cylinder number
CL
MT
EM120
Unit: degree
a
240
244
60
51
AT
TF
SEM713A
PD
FA
RA
CYLINDER HEAD
Unit: mm (in)
Standard
Limit
Less than
0.03 (0.0012)
0.1 (0.004)
BR
ST
RS
BT
HA
SEM082B
EL
IDX
EM-53
Unit: mm (in)
Lifter outside diameter
15.947 - 15.957
(0.6278 - 0.6282)
16.000 - 16.013
(0.6299 - 0.6304)
0.043 - 0.066
(0.0017 - 0.0026)
Valve guide
Unit: mm (in)
SEM188
Intake
11.023 - 11.034
(0.4340 - 0.4344)
11.223 - 11.234
(0.4418 - 0.4423)
Exhaust
12.023 - 12.034
(0.4733 - 0.4738)
12.223 - 12.234
(0.4812 - 0.4817)
Outer
diameter
Exhaust
Service
Valve guide
Standard
Valve length L
Intake
Exhaust
Inner
diameter
(Finished
size)
Exhaust
Cylinder head
valve guide hole
diameter
Intake
Exhaust
Intake
10.975 - 10.996
(0.4321 - 0.4329)
11.175 - 11.196
(0.4400 - 0.4408)
Exhaust
11.975 - 11.996
(0.4715 - 0.4723)
12.175 - 12.196
(0.4793 - 0.4802)
4515 - 4545
Exhaust
Valve margin T
Standard
Intake
Exhaust
0.020 - 0.053
(0.0008 - 0.0021)
Exhaust
0.040 - 0.049
(0.0016 - 0.0019)
0.10 (0.0039)
0.20 (0.0079)
Intake
0 (0)
Exhaust
0 (0)
Unit: mm (in)
Rocker shaft
Valve spring
Outer diameter
Outer
51.2 (2.016)
Inner
44.1 (1.736)
Outer
Inner
Outer
2.2 (0.087)
Inner
1.9 (0.075)
17.979 - 18.000
(0.7078 - 0.7087)
Rocker arm
mm (in)
Pressure
N (kg, lb) at height mm (in)
Out-of-square
Max. tolerance
Intake
Stem to guide
clearance
Valve clearance
Free height
Inner diameter
Clearance between rocker arm and rocker
shaft
mm (in)
EM-54
18.007 - 18.028
(0.7089 - 0.7098)
0.007 - 0.049
(0.0003 - 0.0019)
GI
Unit: mm (in)
MA
EM
LC
EC
SEM893BA
Standard
Max. tolerance
0.060 - 0.105
(0.0024 - 0.0041)
0.15 (0.0059)
A:
47.000 - 47.025
(1.8504 - 1.8514)
B:
42.500 - 42.525
(1.6732 - 1.6742)
C:
48.000 - 48.025
(1.8898 - 1.8907)
A:
46.920 - 46.940
(1.8472 - 1.8480)
B:
42.420 - 42.440
(1.6701 - 1.6709)
C:
47.920 - 47.940
(1.8866 - 1.8874)
Less than
0.04 (0.0016)
0.1 (0.004)
0.03 - 0.06
(0.0012 - 0.0024)
Inner diameter of
camshaft bearing
SEM755A
Camshaft runout
[TIR*]
Camshaft end play
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
EM671
RS
Cam height A
Intake
Exhaust
0.15 (0.0059)
BT
HA
EL
SEM346F
IDX
EM-55
CYLINDER BLOCK
Unit: mm (in)
Unit: mm (in)
SEM321A
Surface flatness
Standard
Less than 0.03 (0.0012)
Limit
0.10 (0.0039)
Cylinder bore
Inner diameter
Standard (for No. 3
and 4 cylinders)
Grade No. 1
91.500 - 91.505 (3.6024 - 3.6026)
Grade No. 2
91.505 - 91.510 (3.6026 - 3.6027)
Grade No. 3
91.510 - 91.515 (3.6027 - 3.6029)
Grade No. 4
91.515 - 91.520 (3.6029 - 3.6031)
Grade No. 5
91.520 - 91.525 (3.6031 - 3.6033)
Grade No. 6
91.525 - 91.530 (3.6033 - 3.6035)
Standard (except for No. 3
and 4 cylinders)
Grade No. 1
91.500 - 91.510 (3.6024 - 3.6027)
Grade No. 2
91.510 - 91.520 (3.6027 - 3.6031)
Grade No. 3
91.520 - 91.530 (3.6031 - 3.6035)
Wear limit
0.20 (0.0079)
Out-of-round (X Y)
Less than 0.015 (0.0006)
Taper
Less than 0.015 (0.0006)
(A B or A C)
Main journal inner diameter
No. 1 main journal
Grade No. 3
66.645 - 66.651 (2.6238 - 2.6240)
Grade No. 4
66.651 - 66.657 (2.6240 - 2.6243)
Grade No. 5
66.657 - 66.663 (2.6243 - 2.6245)
Grade No. 6
66.663 - 66.669 (2.6245 - 2.6248)
No. 2, 3 and 4 main journals
Grade No. 0
66.645 - 66.654 (2.6238 - 2.6242)
Grade No. 1
66.654 - 66.663 (2.6242 - 2.6245)
Grade No. 2
66.663 - 66.672 (2.6245 - 2.6249)
Difference in inner diameter between cylinders
Standard
Less than 0.05 (0.0020)
SEM321A
Surface flatness
Standard
Less than 0.03 (0.0012)
Limit
0.10 (0.0039)
Cylinder bore
Inner diameter
Standard (for No. 3
and 4 cylinders)
Grade No. 1
91.500 - 91.505 (3.6024 - 3.6026)
Grade No. 2
91.505 - 91.510 (3.6026 - 3.6027)
Grade No. 3
91.510 - 91.515 (3.6027 - 3.6029)
Grade No. 4
91.515 - 91.520 (3.6029 - 3.6031)
Grade No. 5
91.520 - 91.525 (3.6031 - 3.6033)
Grade No. 6
91.525 - 91.530 (3.6033 - 3.6035)
Standard (for No. 1,
2 and 6 cylinders)
Grade No. 1
91.500 - 91.510 (3.6024 - 3.6027)
Grade No. 2
91.510 - 91.520 (3.6027 - 3.6031)
Grade No. 3
91.520 - 91.530 (3.6031 - 3.6035)
Standard (for No. 5
cylinder)
Grade No. 1
91.515 - 91.520 (3.6029 - 3.6031)
Grade No. 2
91.520 - 91.525 (3.6031 - 3.6033)
Grade No. 3
91.525 - 91.530 (3.6033 - 3.6035)
Grade No. 4
91.530 - 91.535 (3.6035 - 3.6037)
Grade No. 5
91.535 - 91.540 (3.6037 - 3.6039)
Grade No. 6
91.540 - 91.545 (3.6039 - 3.6041)
Wear limit
0.20 (0.0079)
Out-of-round (X Y)
Less than 0.015 (0.0006)
Taper
Less than 0.015 (0.0006)
(A B or A C)
Main journal inner diameter
No. 1 main journal
Grade No. 3
66.645 - 66.651 (2.6238 - 2.6240)
Grade No. 4
66.651 - 66.657 (2.6240 - 2.6243)
Grade No. 5
66.657 - 66.663 (2.6243 - 2.6245)
Grade No. 6
66.663 - 66.669 (2.6245 - 2.6248)
No. 2, 3 and 4 main journals
Grade No. 0
66.645 - 66.654 (2.6238 - 2.6242)
Grade No. 1
66.654 - 66.663 (2.6242 - 2.6245)
Grade No. 2
66.663 - 66.672 (2.6245 - 2.6249)
Difference in inner diameter between cylinders
Standard
Less than 0.05 (0.0020)
EM-56
Unit: mm (in)
Limit
Piston pin bushing inner
diameter*
Connecting rod big end
inner diameter
Side clearance
Standard
Limit
GI
Available piston
Unit: mm (in)
MA
EM
LC
EC
SEM882E
FE
Available piston
CL
AT
Grade No. 1
TF
Grade No. 2
Grade No. 3
0.25 (0.0098)
oversize (Service)
0.50 (0.0197)
oversize (Service)
MT
SEM882E
a dimension
RA
Standard
For No. 3 and 4
cylinders
Unit: mm (in)
Grade No. 3
0.25 (0.0098)
oversize (Service)
Top
0.50 (0.0197)
oversize (Service)
2nd
49.0 (1.929)
Oil
Standard
2nd
RS
0.024
(0.0009
0.030
(0.0012
0.015
(0.0006
0.076
0.0030)
0.070
0.0028)
0.185
0.0073)
0.21
(0.0083
0.50
(0.0197
0.20
(0.0079
0.40
0.0157)
0.69
0.0272)
0.69
0.0272)
0.11 (0.0043)
BT
0.10 (0.004)
HA
Ring gap
Top
Limit
Side clearance
Standard
For No. 3 and 4
cylinders
BR
ST
Piston ring
Grade No. 2
FA
49.0 (1.929)
Grade No. 1
a dimension
PD
EM-57
0.54 (0.0213)
0.80 (0.0315)
0.95 (0.0374)
EL
IDX
20.971 - 20.983
(0.8256 - 0.8261)
0 - 0.004 (0 - 0.0002)
0.005 - 0.017 (0.0002 - 0.0007)
CRANKSHAFT
Unit: mm (in)
SEM327A
Thickness T mm
(in)
1.822 - 1.825
(0.0717 - 0.0719)
Black
1.825 - 1.828
(0.0719 - 0.0720)
Brown
1.828 - 1.831
(0.0720 - 0.0721)
Green
1.831 - 1.834
(0.0721 - 0.0722)
1.834 - 1.837
(0.0722 - 0.0723)
Blue
1.837 - 1.840
(0.0723 - 0.0724)
Pink
1.840 - 1.843
(0.0724 - 0.0726)
Purple
Width W mm (in)
22.4 - 22.6
(0.882 - 0.890)
Identification
color
Yellow
SEM645
Grade
number
Thickness T mm
(in)
1.817 - 1.821
(0.0715 - 0.0717)
Black
1.821 - 1.825
(0.0717 - 0.0719)
Brown
1.825 - 1.829
(0.0719 - 0.0720)
1.829 - 1.833
(0.0720 - 0.0722)
Yellow
1.833 - 1.837
(0.0722 - 0.0723)
Blue
Width W mm (in)
18.9 - 19.1
(0.744 - 0.752)
Identification
color
Green
Thickness T mm (in)
Identification
color
Black
Brown
Green
Yellow
Blue
EM715
EM-58
UNDER SIZE
Thickness T
0.25
(0.0098)
No. 1 main
bearing
No. 2, 3 and No.
4 main bearing
Main journal
diameter Dm
MA
1.956 - 1.962
Grind so that
(0.0770 - 0.0772) bearing clearance
is the specified
1.948 - 1.956
valve.
(0.0767 - 0.0770)
EM
LC
Standard
Thickness
FE
Undersize
0.08 (0.0031)
0.12 (0.0047)
0.25 (0.0098)
EC
CL
MT
MISCELLANEOUS COMPONENTS
Bearing clearance
Unit: mm (in)
Flywheel/Drive plate
Runout [TIR]
Unit: mm (in)
AT
Standard
Limit
TF
0.090 (0.0035)
PD
0.014 - 0.054 (0.0006 - 0.0021)
0.090 (0.0035)
FA
RA
BR
ST
RS
BT
HA
EL
IDX
EM-59
NOTES
EM-60