Manual de Taller de Motor Luv D-Max (6VE1) Gasolina

ENGINE MECHANICAL (6VE1 3.
5L) 6A-1
ENGINE
CONTENTS
Engine Mechanical................................................. 6A Driveability and Emissions.....................................6E
Engine Cooling........................................................ 6B Engine Exhaust .......................................................6F
Engine Fuel ............................................................. 6C Engine Lubrication ..................................................6G
Engine Electrical..................................................... 6D1 Engine Speed Control System ..............................6H
Ignition System ....................................................... 6D2 Induction...................................................................6J
Starting and Changing System............................. 6D3
ENGINE MECHANICAL (6VE1 3.5L)

CONTENTS
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Service Precaution ................................................. 6A-2 Removal................................................................ 6A-39
General Description ............................................... 6A-3 Installation............................................................. 6A-39
Engine Diagnosis.................................................... 6A-4 Piston, Piston Ring and Connecting Rod ............ 6A-40
Cylinder Head Cover LH........................................ 6A-21 Removal................................................................ 6A-40
Removal ............................................................... 6A-21 Installation............................................................. 6A-41
Installation ............................................................ 6A-21 Crankshaft and Main Bearings.............................. 6A-43
Cylinder Head Cover RH ....................................... 6A-23 Removal................................................................ 6A-43
Installation ............................................................ 6A-23 Rear Oil Seal ........................................................... 6A-48
Common Chamber................................................. 6A-24 Removal................................................................ 6A-48
Installation ............................................................ 6A-25 Engine Assembly .................................................... 6A-49
Exhaust Manifold LH.............................................. 6A-26 Removal................................................................ 6A-49
Installation ............................................................ 6A-26 Cylinder Head.......................................................... 6A-52
Exhaust Manifold RH ............................................. 6A-27 Cylinder Head and Associated Parts ................ 6A-52
Removal ............................................................... 6A-27 Disassembly ......................................................... 6A-53
Installation ............................................................ 6A-27 Clean ..................................................................... 6A-53
Crankshaft Pulley ................................................... 6A-28 Inspection and Repair ......................................... 6A-53
Removal ............................................................... 6A-28 Reassembly.......................................................... 6A-54
Installation ............................................................ 6A-28 Valve Spring, Oil Controller, Valve, Valve
Timing Belt .............................................................. 6A-29 Guide ....................................................................... 6A-56
Removal ............................................................... 6A-29 Valve Spring, Oil Controller, Valve, Valve
Installation ............................................................ 6A-30 Guide and Associated Parts ............................. 6A-56
Camshaft ................................................................. 6A-34 Disassembly ......................................................... 6A-57
Removal ............................................................... 6A-34 Inspection and Repair ......................................... 6A-57
Installation ............................................................ 6A-34 Reassembly.......................................................... 6A-61
Cylinder Head ......................................................... 6A-37 Camshaft.................................................................. 6A-64
Removal ............................................................... 6A-37 Camshaft and Associated Parts ........................ 6A-64
Installation ............................................................ 6A-37 Disassembly ......................................................... 6A-64
Valve Stem Oil Controller , Valve Spring Inspection and Repair ......................................... 6A-65
and Valve Guide .................................................... 6A-39 Reassembly.......................................................... 6A-67
6A-2 ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft ............................................................... 6A-71

Crankshaft and Associated Parts ..................... 6A-71
Disassembly ........................................................ 6A-71
Inspection and Repair ........................................ 6A-73
Reassembly ......................................................... 6A-75
Piston and Connecting Rod .................................. 6A-79
Piston, Connecting Rod and Associate
Parts .................................................................... 6A-79
Disassembly ........................................................ 6A-79
Reassembly ......................................................... 6A-84
Cylinder Block ......................................................... 6A-87
Cylinder Block and Associated Parts ............... 6A-87
Disassembly ........................................................ 6A-88
Reassembly ......................................................... 6A-89
Main Data and Specification ................................. 6A-93
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Special Tool ......................................................... 6A-99
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL CAUTION: Always use the correct fastener in the
RESTRAINT SYSTEM (SRS). REFER TO THE SRS proper location. When you replace a fastener, use
COMPONENT AND WIRING LOCATION VIEW IN ONLY the exact part number for that application.
ORDER TO DETERMINE WHETHER YOU ARE ISUZU will call out those fasteners that require a
PERFORMING SERVICE ON OR NEAR THE SRS replacement after removal. ISUZU will also call out
COMPONENTS OR THE SRS WIRING. WHEN YOU the fasteners that require thread lockers or thread
ARE PERFORMING SERVICE ON OR NEAR THE sealant. UNLESS OTHERWISE SPECIFIED, do not
SRS COMPONENTS OR THE SRS WIRING, REFER use supplemental coatings (Paints, greases, or
TO THE SRS SERVICE INFORMATION. FAILURE TO other corrosion inhibitors) on threaded fasteners or
FOLLOW WARNINGS COULD RESULT IN fastener joint interfaces. Generally, such coatings
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL adversely affect the fastener torque and the joint
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM clamping force, and may damage the fastener.
REPAIRS. When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
ENGINE MECHANICAL (6VE1 3.5L) 6A-3
General Description Cylinder Block

The cylinder block is made of aluminum die-cast casting
Engine Cleanliness And Care for 75°V-type six cylinders. It has a rear plate integrated
structure and employs a deep skirt. The cylinder liner is
An automobile engine is a combination of many
cast and the liner inner diameter and crankshaft journal
machined, honed, polished and lapped surfaces with
diameter are classified into grades. The crankshaft is
tolerances that are measured in the thousandths of a
supported by four bearings of which width is different
millimeter (ten thousandths of an inch). Accordingly,
between No.2, No.3 and No.1, No.4; the width of No.3
when any internal engine parts are serviced, care and
bearing on the body side is different in order to support
cleanliness are important. Throughout this section, it
the thrust bearing. The bearing cap is made of nodular
should be understood that proper cleaning and
cast iron and each bearing cap uses four bolts and two
protection of machined surfaces and friction areas is
side bolts.
part of the repair procedure. This is considered
standard shop practice even if not specifically stated.
Cylinder Head
· A liberal coating of engine oil should be applied to
all friction areas during assembly to protect and The cylinder head, made of aluminum alloy casting
lubricate the surfaces on initial operation. employs a pent-roof type combustion chamber with a
· Whenever valve train components, pistons, piston spark plug in the center. The intake and exhaust valves
rings, connecting rods, rod bearings, and are placed in V-type design. The ports are cross-flow
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crankshaft journal bearings are removed for type.
service, they should be retained in order.
Valve Train
· At the time of installation, they should be installed
in the same locations and with the same mating Intake and exhaust camshaft on the both side of banks
surfaces as when removed. are driven through an camshaft drive gear by timing
· Battery cables should be disconnected before any belt. The valves are operated by the camshaft and the
major work is performed on the engine. Failure to valve clearance is adjusted to select suitable thickness
disconnect cables may result in damage to wire shim.
harness or other electrical parts.
· The six cylinders of this engine are identified by
Intake Manifold
numbers; Right side cylinders 1, 3 and 5, Left side The intake manifold system is composed of the
cylinders 2, 4 and 6, as counted from crankshaft aluminum cast common chamber and intake manifold
pulley side to flywheel side. attached with six fuel injectors.
General Information on Engine Service Exhaust Manifold

The following information on engine service should be The exhaust manifold is made of nodular cast iron.
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance. Pistons and Connecting Rods
· When raising or supporting the engine for any Aluminum pistons are used after selecting the grade
reason, do not use a jack under the oil pan. Due to that meets the cylinder bore diameter. Each piston has
the small clearance between the oil pan and the oil two compression rings and one oil ring. The piston pin
pump strainer, jacking against the oil pan may made of chromium steel is offset 1mm toward the thrust
cause damage to the oil pick-up unit. side, and the thrust pressure of piston to the cylinder
· The 12-volt electrical system is capable of wall varies gradually as the piston travels. The
damaging circuits. When performing any work connecting rods are made of forged steel. The
where electrical terminals could possibly be connecting rod bearings are graded for correct size
grounded, the ground cable of the battery should selection.
be disconnected at the battery.
· Any time the intake air duct or air cleaner is Crankshaft and Bearings
removed, the intake opening should be covered. The crankshaft is made of Ductile cast-iron. Pins and
This will protect against accidental entrance of journals are graded for correct size selection for their
foreign material into the cylinder which could bearing.
cause extensive damage when the engine is
started. Engine Control Module (ECM)
The ECM location is on the common charmber.
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Symptom Possible Cause Action

Headlights go out or dim considerably Battery run down or under charged Recharge or replace battery
Terminals poorly connected Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted Overhaul or replace
Starting motor defective Overhaul or replace
2. Ignition Trouble - Starting Motor Turns Over But
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Engine Does Not Start Spark Test
Disconnect an ignition coil from any spark plug.
Connect the spark plug tester 5-8840-0383-0, start the
engine, and check if a spark is generated in the spark
plug tester. Before starting the engine, make sure that
the spark plug tester is properly grounded. To avoid
electrical shock, do not touch the part where insulation
of the ignition coil is broken while the engine is running.

Spark jumps across gap Spark plug defective Clean or replace
Ignition timing incorrect Refer to Ignition System
Fuel not reaching fuel injector(s) or Refer to item 3 (Trouble in fuel
engine system)
Valve timing incorrect Adjust
Engine lacks compression Refer to item 4 (Engine lacks
compression)
No sparking takes place Ignition coil disconnected or broken Connect properly or replace
Electronic Ignition System with Replace
module
Poor connections in engine harness Correct
Engine Control Module cable Correct or replace
disconnected or defective
3. Trouble In Fuel System

Starting motor turns over and spark Fuel tank empty Fill
occurs but engine does not start.
Water in fuel system Clean
Fuel filter clogged Replace filter
Fuel pipe clogged Clean or replace
Fuel pump defective Replace
Fuel pump circuit open Correct or replace
Evaporative Emission Control System Correct or replace
circuit clogged
Multiport Fuel Injection System faulty Refer to “Electronic Fuel Injection"
section
4. Engine Lacks Compression

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Engine lacks compression Spark plug loosely fitted Tighten to specified torque
Valve timing incorrect Adjust
Cylinder head gasket defective Replace gasket
Valve incorrectly seated Lap valve
Valve stem seized Replace valve and valve guide
Valve spring weakened or broken Replace
Cylinder or piston rings worn Overhaul engine
Piston ring seized Overhaul engine.
9. Repeat the test with each cylinder.

Engine Compression Test Procedure If the compression pressure obtained falls below
1. Start and run the engine until the engine reaches the limit, engine overhaul is necessary.
normal operating temperature. Limit; 1000 kPa (145 psi)
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and
fuse box.
6. Engage the starter and check that the cranking
speed is approximately 300 rpm.
7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the
starter engaged until the compression gage needle
reaches the maximum level. Note the reading.
Rough Engine Idling or Engine Stalling

Trouble in fuel injection system Idle air control valve defective Replace
Throttle shutting off incomplete Replace
Throttle position sensor circuit open Correct or replace
or shorted
Fuel injector circuits open or shorted Correct or replace
Fuel injectors damaged Replace
Fuel pump relay defective Replace
Mass Airflow Sensor circuit open or Correct or replace
poor connections
Mass Airflow Sensor defective Replace
Engine Coolant Temperature Sensor Correct or replace
circuit open or poor connections
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Engine Coolant Temperature Sensor Replace
defective
Intake Air Temperature sensor circuit Correct or replace
open or poor connections
Intake Air Temperature sensor Replace
defective
Vehicle Speed Sensor circuit open or Correct or replace
shorted
Vehicle Speed Sensor defective Replace
Trouble in emission control system EGR valve defective Replace
EGR valve circuit open or poor Correct or replace
connection
Engine Control Module defective Replace
Canister purge valve circuit open or Correct or replace
poor connections
Canister purge valve defective Replace
Evaporative Emission Canister Purge Replace
control valve defective
Trouble in ignition system Refer to “Hard Start"
Others Engine lacks compression Refer to “Hard Start"
Valve incorrectly seated Lap valve
Air Cleaner Filter clogged Replace filter element
Valve timing incorrect Readjust
Idle air control valve broken Replace
Fast idle solenoid defective Replace
Positive Crankcase Ventilation valve Replace
defective or clogged
Rough Engine Running

Engine misfires periodically Ignition coil layer shorted Replace
Spark plugs fouling Clean or install hotter type plug
Spark plug(s) insulator nose leaking Replace
Fuel injector(s) defective Replace
Engine control module faulty Replace
Engine knocks periodically Spark plugs running too hot Install colder type spark plugs
Engine control module faulty Replace
Engine lacks power Spark plugs fouled Clean
Fuel injectors defective Replace
Mass Airflow Sensor or Intake Airflow Correct or replace
Sensor circuit defective
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or Engine Coolant Temperature
Sensor circuit defective
Engine Control Module faulty Replace
Intake Air Temperature Sensor or Correct or replace
Intake Air Temperature Sensor circuit
defective
Throttle Position Sensor or Throttle Correct or replace
Position Sensor circuit defective
Hesitation
Hesitation on acceleration Throttle Position Sensor adjustment Replace throttle valve assembly
incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
Excessive play in accelerator linkage Adjust or replace
poor connections
Intake Air Temperature (IAT) Sensor Correct or replace
circuit open or poor connections
IAT Sensor defective Replace
Hesitation at high speeds Fuel tank strainer clogged Clean or replace
(Fuel pressure too low)
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Fuel pipe clogged Clean or replace
Fuel filter clogged Replace
Defective fuel pump system Check and replace
Fuel Pressure Control Valve leaking Replace
Hesitation at high speeds Power supply or ground circuit for Check and correct or replace
(Fuel injector not working normally) Multiport Fuel Injection System
shorted or open
Fuel Injector defective Replace
Cable of Multiport Fuel Injection Correct or replace
System circuit open or poor
connections

Hesitation at high speeds Engine Control Module defective Replace
Throttle Position Sensor cable broken Correct or replace
or poor connections
Throttle Position Sensor defective Replace
circuit open or shorted
defective
poor connections
IAT Sensor circuit open or poor Correct or replace
connections
IAT Sensor defective Replace
Throttle valve not fully opened Check and correct or replace
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Air Cleaner Filter clogged Replace filter element
Power supply voltage too low Check and correct or replace
Engine Lacks Power

Trouble in fuel system Fuel Pressure Control Valve not Replace
working normally
Fuel injector clogged Clean or replace
Fuel pipe clogged Clean
Fuel filter clogged or fouled Replace
Fuel pump drive circuit not working Correct or replace
normally
Fuel tank not sufficiently breathing Clean or replace
due to clogged Evaporative Emission
Control System circuit
Water in fuel system Clean
Inferior quality fuel in fuel system Use fuel of specified octane rating
Engine Control Module supplied poor Correct circuit
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voltage
Throttle Position Sensor cable broken Correct or replace
or poor connections
Mass Airflow Sensor not working Replace
normally
Manifold Absolute Pressure Sensor Replace
not working normally
Intake Air Temperature Sensor not Replace
working normally
circuit open or shorted
defective
Engine Control Module defective Replace
Trouble in intake or exhaust system Air Cleaner Filter clogged Replace filter element
Air duct kinked or flattened Correct or replace
Exhaust system clogged Correct or replace
Ignition failure ———— Refer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequate Install spark plugs of adequate heat
range
Ignition coil defective Replace

Engine overheating Level of Engine Coolant too low Replenish
Fan clutch defective Replace
Thermostat defective Replace
Engine Coolant pump defective Correct or replace
Radiator clogged Clean or replace
Radiator filler cap defective Replace
Level of oil in engine crankcase too Change or replenish
low or wrong engine oil
Resistance in exhaust system Clean exhaust system or replace
increased defective parts
Throttle Position Sensor adjustment Replace with Throttle Valve ASM
incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
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Cylinder head gasket damaged Replace
Engine overcooling Thermostat defective Replace (Use a thermostat set to
open at 82C (180F))
Engine lacks compression ———— Refer to Hard Start
Others Tire inflation pressure abnormal Adjust to recommended pressures
Brake drag Adjust
Clutch slipping Adjust or replace
Level of oil in engine crankcase too Correct level of engine oil
high
EGR valve defective Replace
Engine Noisy
Abnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and other
moving parts of the engine. It is, therefore, advisable to
locate the source of noise systematically.

Noise from crank journals or from Oil clearance increased due to worn Replace crank bearings and
crank bearings crank journals or crank bearings crankshaft or regrind crankshaft and
(Faulty crank journals and crank install the undersize bearing
bearings usually make dull noise that
becomes more evident when
accelerating)
Crankshaft out of round Replace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
Crank bearing seized Crank bearing seized Replace crank
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bearings and crankshaft or regrind
crankshaft and install the undersize
bearing
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defective
bearing by listening for abnormal noise that stops when
spark plug is shorted out.

Noise from connecting rods or from Bearing or crankshaft pin worn Replace connecting rod bearings and
connecting rod bearings crankshaft or regrind crankshaft pin
(Faulty connecting rods or connecting and install the undersize bearing
rod bearings usually make an
abnormal noise slightly higher than
the crank bearing noise, which
becomes more evident when engine
is accelerated)
Crankpin out of round Replace connecting rod bearings and
crankshaft or regrind crankshaft pin
and install the undersize bearing
Connecting rod bent Correct or replace
Connecting rod bearing seized Replace connecting rod bearings and
crankshaft or regrind crankshaft pin
and install the undersize bearing
Abnormal noise stops when the spark plug on the
cylinder with defective part is shorted out.

Piston and cylinder noise Piston clearance increased due to Replace piston and cylinder body
(Faulty piston or cylinder usually cylinder wear
makes a combined mechanical
thumping noise which increases
when engine is suddenly accelerated
but diminishes gradually as the
engine warms up)
Piston seized Replace piston and cylinder body
Piston ring broken Replace piston and cylinder body
Piston defective Replace pistons and others
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Short out each spark plug and listen for change in
engine noise.

Piston pin noise Piston pin or piston pin hole worn Replace piston, piston pin and
(Piston makes noise each time it connecting rod assembly
goes up and down)
The slapping sound stops when spark plug on bad
cylinder is shorted out.

Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the tension
pulley or replace timing belt
Tensioner bearing defective Replace
Timing belt defective Replace
Timing pulley defective Replace
Timing belt comes in contact with Replace timing belt and timing cover
timing cover
Valve noise Valve clearance incorrect Replace adjusting shim
Valve and valve guide seized Replace valve and valve guide
Valve spring broken or weakened Replace
Valve seat off–positioned Correct
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Camshaft worn out Replace
Crankshaft noise Crankshaft end play excessive (noise Replace thrust bearing
occurs when clutch is engaged)
Engine knocking Preignition due to use of spark plugs Install Spark Plugs of adequate heat
of inadequate heat range range
Carbon deposits in combustion Clean
chambers
Fuel too low in octane rating Replace fuel
Wide Open Throttle enrichment Refer to Section 6E
system failure
Selection of transmission gear Caution operator of incorrect gear
incorrect selection
Engine overheating Refer to “Engine Lacks Power"
Others Water pump defective Replace
Drive belt slipping Replace auto tentioner or drive belt
Abnormal Combustion
Trouble in fuel system Fuel pressure control valve defective Replace
Fuel filter clogged Replace
Fuel pump clogged Clean or replace
Fuel tank or fuel pipe clogged Clean or replace
Fuel injector clogged Clean or replace
Fuel pump relay defective Replace
Power supply cable for fuel pump Reconnect, correct or replace
broken or poor connections
Mass Airflow (MAF) Sensor circuit Correct or replace
open or defective
MAF Sensor defective Replace
Engine Coolant Temperature (ECT) Correct or replace
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Sensor circuit open or shorted
ECT Sensor defective Replace
Throttle Position Sensor adjustment Readjust
incorrect
Throttle Position Sensor connector Reconnect
poor connections
Vehicle Speed Sensor cable poor Correct or replace
connections or defective
Vehicle Speed Sensor loosely fixed Fix tightly
Vehicle Speed Sensor in wrong Replace
contact or defective
Engine Control Module cable poor Correct or replace
connections or defective

Trouble in emission control system Heated Oxygen Sensor circuit open Correct or replace
Heated Oxygen Sensor defective Replace
Signal vacuum hose loosely fitted or Correct or replace
defective
EGR Valve circuit open or shorted Correct or replace
EGR Valve defective Replace
ECT Sensor circuit open or shorted Correct or replace
Canister Purge Valve circuit open or Correct or replace
shorted
Canister Purge Valve defective Replace
ECT Sensor defective Replace
Positive Crankcase Ventilation (PCV) Correct or replace
valve and hose clogged
Evaporator system Refer to Section 6E
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Trouble in ignition system ———— Refer to “Engine Lacks Power"
Trouble in cylinder head parts Carbon deposits in combustion Remove carbon
chamber
Carbon deposit on valve, valve seat Remove carbon
and valve guide
Engine Oil Consumption Excessive

Oil leaking Oil pan drain plug loose Retighten or replace gasket
Crankcase fixing bolts loosened Retighten
Oil pan setting bolts loosened Retighten
Oil pan gasket broken Replace gasket
Front cover retaining bolts loose or Retighten or replace gasket
gasket broken
Head cover fixing bolts loose or Retighten or replace gasket
gasket broken
Oil filter adapter cracked Replace
Oil filter attachings bolt loose or Retighten or replace oil filter
rubber gasket broken
Oil cooler broken Replace
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Crankshaft front or rear oil seal Replace oil seal
defective
Oil pressure unit loose or broken Retighten or replace
Blow–by gas hose broken Replace hose
Positive Crankcase Ventilation Valve Clean
clogged
Engine/Transmission coupling failed Replace oil seal
Oil leaking into combustion chambers Valve stem oil seal defective Replace
due to poor seal in valve system
Valve stem or valve guide worn Replace valve and valve guide
Oil leaking into combustion chambers Cylinders and pistons worn Replace cylinder body assembly and
due to poor seal in cylinder parts excessively pistons
Piston ring gaps incorrectly Correct
positioned
Piston rings set with wrong side up Correct
Piston ring sticking Replace cylinder body assembly and
pistons
Piston ring and ring groove worn Replace pistons and others
Return ports in oil rings clogged Clean piston and replace rings
Positive Crankcase Ventilation Positive Crankcase Ventilation Valve Clean
System malfunctioning clogged
Others Improper oil viscosity Use oil of recommended S.A.E.
viscosity
Continuous high speed driving and/or Continuous high speed operation
severe usage such as trailer towing and/or severe usage will normally
cause increased oil consumption
Fuel Consumption Excessive

Trouble in fuel system Mixture too rich or too lean due to Refer to “Abnormal Combustion"
trouble in fuel injection system
Fuel cut function does not work Refer to “Abnormal Combustion"
Trouble in ignition system Misfiring or abnormal combustion due Refer to “Hard Start" or “Abnormal
to trouble in ignition system Combustion"
Others Engine idle speed too high Reset to Section 6E
Returning of accelerator control Correct
sluggish
Fuel system leakage Correct or replace
Clutch slipping Correct
Brake drag Correct
Selection of transmission gear Caution operator of incorrect gear
incorrect selection
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Lubrication Problems
Oil pressure too low Wrong oil in use Replace with correct engine oil
Relief valve sticking Replace
Oil pump not operating properly Correct or replace
Oil pump strainer clogged Clean or replace strainer
Oil pump worn Replace
Oil pressure gauge defective Correct or replace
Crankshaft bearing or connecting rod Replace
bearing worn
Oil contamination Wrong oil in use Replace with correct engine oil
Oil filter clogged Replace oil filter
Cylinder head gasket damage Replace gasket
Burned gases leaking Replace piston and piston rings or
cylinder body assembly
Oil not reaching valve system Oil passage in cylinder head or Clean or correct
cylinder body clogged
Engine Oil Pressure Check

1. Check for dirt, Fuel or water in the engine oil.
a. Check the viscosity of the oil.
b. Check the viscosity of the oil.
c. Change the oil if the viscosity is outside the
specified standard.
d. Refer to the “Maintenance and Lubrication"
section of this manual.
2. Check the engine oil level.
The level should fall somewhere between the
“ADD" and the “FULL" marks on the oil level
dipstick.
If the oil level does not reach the “ADD" mark on
the oil level dipstick, engine oil must be added.
3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach
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normal operating temperature (About 80°C).
6. Measure the oil pressure.
Oil pressure should be:
392- -550 kPa (56.9- -80.4 psi) at 3000 rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.
Malfunction Indicator Lamp

The instrument panel “CHECK ENGINE" Malfunction
Indicator Lamp (MIL) illuminates by self diagnostic
system when the system checks the starting of engine,
or senses malfunctions. ”CHECK ENGINE" MIL does
not illuminate at the starting of engine

“CHECK ENGINE" MIL does not Bulb defective Replace
illuminate at the starting of engine
MIL circuit open Correct or replace
Command signal circuit to operate Correct or replace
self diagnostic system shorted
Engine Control Module (ECM) cable Correct or replace
loosely connected, disconnected or
defective
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ECM defective Replace
“CHECK ENGINE" MIL illuminates, Deterioration of heated oxygen Replace
and stays on sensor internal element
Heated oxygen sensor connector Reconnect properly
terminal improper contact
Heated oxygen sensor lead wire Correct
shorted
Heated oxygen sensor circuit open Correct or replace
Deterioration of engine coolant Replace
temperature sensor internal element
Engine coolant temperature sensor Reconnect properly
connector terminal improper contact
Engine coolant temperature sensor Correct
lead wire shorted
Engine coolant temperature sensor Correct or replace
circuit open
Throttle position sensor open or Correct or replace
shorted circuits
Deterioration of crankshaft position Replace
sensor
Crankshaft position sensor circuit Correct or replace
open or shorted
Vehicle speed sensor circuit open Correct or replace
Intake air temperature sensor circuit Correct or replace
open or shorted
Fuel injector circuit open or shorted Correct or replace
ECM driver transistor defective Replace ECM
Malfunctioning of ECM RAM Replace ECM
(Random Access Memory) or ROM
(Read Only Memory)
Cylinder Head Cover LH

7. Remove eight fixing bolts, then the cylinder head
Removal cover.
1. Disconnect battery ground cable.
2. Disconnect positive crankcase ventilation hose.
3. Remove camshaft angle sensor connector.
4. Remove ground cable fixing bolt on cylinder head
cover.
5. Ignition coil connector and ignition coil.
· Disconnect the three connectors from the
ignition coils.
· Remove harness bracket bolt on cylinder head
cover.
· Remove fixing bolts on ignition coils.
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010RW001
Installation
1. Install cylinder head cover.
· Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
· Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area
of camshaft bracket on front and rear sides.
· The cylinder head cover must be installed with
in 5 minutes after sealant application to prevent
060RW078
hardening of sealant.
Legend
· Tighten bolts to the specified torque.
(1) Ignition Coil Connector Torque : 9 N××m (0.9 kg××m/7 lb ft)
(2) Bolt
(3) Ignition Coil Assemblies
6. Remove fixing bolt for fuel injector harness

bracket.
010RW006
2. Install fuel injection harness bracket and tighten

bolt to the specified torque.
Torque : 8 N××m (0.8 kg××m/8 lb ft)
3. Connect ignition coil connector and ignition coil,
then tighten bolt to the specified torque.
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060RW078
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly
4. Connect ground cable and tighten bolts to the

specified torque.
5. Connect camshaft angle sensor connector.
6. Install positive crankcase ventilation hose.
Cylinder Head Cover RH
Removal
2. Remove air cleaner duct assembly.
3. Disconnect ventilation hose from cylinder head
cover.
4. Disconnect three ignition coil connectors from
ignition coils and remove harness bracket bolts on
cylinder head cover then remove ignition coil fixing
bolts on ignition coils and remove ignition coils.
5. Remove heater pipe fixing bolts from the bracket.
6. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.
7. Remove eight fixing bolts then the cylinder head
cover.
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014RW019
2. Install exhaust gas recirculation pipe and tighten to

specified torque.
Torque :
Exhaust manifold side: 29 N××m (3.0 kg××m/21 lb ft)
Flare nut: 44 N××m (4.5 kg××m/33 lb ft)
Cylinder head side: 20 N××m (2.0 kg××m/14 lb ft)
3. Tighten fuel injector harness bracket bolts to
specified torque then reconnect fuel injector
harness connector.
Torque : 8 N××m (0.8 kg××m/5.7 lb ft)
4. Install heater pipe bolt to the specified torque.
5. Connect ignition coil connector and tighten ignition
coil fixing bolts to specified torque.
010RW002 Torque : 4 N××m (0.4 kg××m/3 lb ft)
6. Connect ventilation hose to cylinder head.
Installation
7. Install air cleaner duct assembly.
1. Install cylinder head cover.
· Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
· Apply sealant (TB-1207B or equivalent) of bead
diameter 2&dash;3 mm at eight place of arched
area of camshaft bracket on front and rear
sides.
· The cylinder head cover must be installed
within 5 minutes after sealant application to
prevent premature hardening of sealant.
· Tighten bolts to the specified torque.
Common Chamber
Legend
Removal (1) Cable Bracket
1. Disconnect battery ground cable. (2) Ratchet ring
2. Remove air cleaner duct assembly. (3) Outer Cap
3. Remove the ECM. (4) Lock
· Disconnect the two connectors from the ECM. (5) Paint Mark
· Remove fixing bolts on the common chamber. (6) Arrow Mark
· Remove fixing bolts for ground cable.
5. Remove the accelerator control cable from the
throttle.
6. Disconnect vacuum booster hose from common
chamber.
7. Disconnect connector from manifold absolute
pressure sensor, idle air control valve, throttle
position sensor, solenoid valve, electric vacuum
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sensing valve.
8. Disconnect vacuum hose on canister VSV and
positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket.
9. Remove ventilation hose from throttle valve and
intake duct and remove water hose.
10. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber.
11. Remove two bolts from common chamber rear
side for remove fuel hose bracket.
060RW025 12. Remove common chamber four bolts and four
4. Remove the accelerator control cable from nuts then remove the common chamber.
accelerator control cable bracket.
· Slide the lock in direction A
· Rotate the ratchet ring in indirection an arrow
90°
025RW001
Legend
(1) Common Chamber
(2) Throttle Valve Assembly
RTW46ASH000201
(3) Bolt
13. Remove the four throttle body fixing bolts.

Legend
Installation (1) Cable Bracket
1. Install throttle body and tighten bolts to the (2) Ratchet ring
specified torque. (3) Outer Cap
Torque : 25 N××m (2.5 kg××m/18 lb ft) (4) Lock
2. Install common chamber and tighten bolts and (5) Paint Mark
nuts to the specified torque.
(6) Arrow Mark
Torque :
Bolt : 18 N××m (1.8 kg××m/13 lb ft) 10. Install the cable clips to accelerator control cable.
Nut : 18 N××m (1.8 kg××m/13 lb ft) 11. Install air cleaner duct assembly.
3. Install fuel hose bracket and tighten bolts to
specified torque.
Torque : 10 N××m (1.0 kg××m/89 lb in)
4. Install ventilating hose to throttle valve and intake
duct.
5. Connect vacuum hoses on canister VSV and
positive crankcase ventilation hose. Tighten bolts
for fuel rail assembly with pressure control valve
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bracket.
6. Connect each connector without fail.
7. Connect vacuum booster hose.
8. Install the ECM.
· Tighten the four bolts.
· Connect the two connectors.
· Tighten the two ground cable bolts.
9. Install accelerator control cable to accelerator
cable bracket.
· Rotate the ratchet ring in direction an arrow 90°
· Confirm marking of outer cap must be upper
side.
· Slider the lock of outer cap must be upper side.
· Confirm ratchet ring is locked.
060RW093
Exhaust Manifold LH
Removal Installation
1. Disconnect battery ground cable. 1. Install exhaust manifold and tighten exhaust
2. Disconnect O2 sensor connector. manifold fixing nuts to the specified torque with
3. Remove torsion bar. Refer to removal procedure in new nuts.
Front Suspension section. Torque: 52 N××m (5.3 kg××m/38 lb ft)
4. Remove exhaust front pipe three stud nuts from 2. Install heat protector.
exhaust side and two nuts from rear end of 3. Install exhaust front pipe and tighten three stud
exhaust front pipe. nuts and two nuts to the specified torque.
Torque:
Stud nuts: 67 N××m (6.8 kg××m/49 lb ft)
Nuts: 43 N××m (4.4 kg××m/32 lb ft)
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RTW36FSH000201
5. Remove heat protector two fixing bolts then the

heat protector.
6. Remove a bolt on engine LH side for air RTW36FSH000201
conditioner (A/C) compressor bracket and loosen 4. Install the torsion bar and readjust the vehicle
two bolts for A/C compressor then move A/C height. Refer to installation and vehicle height
compressor to front side. adjustment procedure for front suspension.
7. Remove exhaust manifold eight fixing nuts and 5. Set A/C compressor to normal position and tighten
remove exhaust manifold from the engine. two bolts and a bolt to the specified torque.
6. Reconnect O2 sensor connector.
7. Install air cleaner duct assembly.
Exhaust Manifold RH
1. Disconnect battery ground cable. 1. Install exhaust manifold and tighten bolts to the
2. Remove exhaust front pipe three stud nuts and specified torque.
two nuts then disconnect exhaust front pipe. Torque: 52 N××m (5.3 kg××m/38 lb ft)
2. Install EGR pipe.
Torque: 29 N××m (3.0 kg××m/22 lb ft)
3. Install heat protector
4. Install exhaust front pipe and tighten three stud
nuts and two nuts to the specified torque.
Torque:
Stud nuts: 67 N××m (6.8 kg××m/49 lb ft)
Nuts: 43 N××m (4.4 kg××m/32 lb ft)
5. Install steering shaft. Refer to installation
procedure in Steering section.
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RTW36FSH000101
3. Remove steering shaft. Refer to removal

procedure in Steering section.
4. Remove heat protector two fixing bolts then the
heat protector.
5. Remove EGR pipe.
6. Remove exhaust manifold eight fixing nuts then
the exhaust manifold.
Crankshaft Pulley
1. Disconnect battery ground cable. 1. Install crankshaft pulley using 5-8840-0133-0
2. Remove air cleaner assembly. crankshaft holder, hold the crankshaft pulley and
3. Remove radiator upper fan shroud from radiator. tighten center bolt to the specified torque.
4. Move serpentine belt tensioner to loose side using Torque: 167 N××m (17.0 kg××m/123 lb ft)
wrench then remove serpentine belt. 2. Install cooling fan assembly and tighten bolts/nuts
to the specified torque.
Torque: 25 N××m (2.5 kg××m/18 lb ft) for fan pulley
and fan bracket.
Torque: 10 N××m (1.0 kg××m/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
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5. Install air cleaner assembly.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Serpentine Belt
5. Remove cooling fan assembly four fixing nuts,

then the cooling fan assembly.
6. Remove crankshaft pulley assembly using
5-8840-0133-0 crankshaft holder, hold crankshaft
pulley then remove center bolt and pulley.
Timing Belt
13. Remove pusher.
Removal
CAUTION: The pusher prevents air from entering
1. Disconnect battery ground cable. the oil chamber. Its rod must always be facing
2. Remove air cleaner assembly. upward.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using
wrench then remove drive belt.
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014RW011
Legend
(1) Up Side
850RW001
(2) Down Side
Legend
(3) Direction For Installation
(4) Locking Pin
(3) Tensioner 14. Remove timing belt.
(4) Generator
(5) Air Conditioner Compressor CAUTION:
(6) Power Steering Oil Pump 1. Do not bend or twist the belt, otherwise its
(7) Drive Belt core could be damaged. The belt should not be
bent at a radius less than 30 mm.
5. Remove cooling fan assembly four nuts, then the 2. Do not allow oil or other chemical substances
cooling fan assembly. to come in contact with the belt. They will
shorten the life.
6. Remove cooling fan drive pulley assembly.
3. Do not attempt to pry or stretch the belt with a
7. Remove idle pulley assembly.
screw driver or any other tool during
8. Remove serpentine belt tensioner assembly. installation.
9. Remove power steering pump assembly. 4. Store timing belt in a cool and dark place.
10. Remove crankshaft pulley assembly using Never expose the belt direct sunlight or heat.
5-8840-0133-0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
Installation Legend
For correct belt installation, the letter on the belt must (7) Alignment Mark on Oil Pump.
be able to be read as viewed from the front of the (8) Alignment Mark on Timing Belt
vehicle. (9) Alignment Mark (notch) on Crankshaft Timing
Pulley
(10) Alignment Mark (groove) on Crankshaft Timing
Pulley.
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014RY00042
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley 014RW006
(4) Idle Pulley Legend
(5) LH Bank Camshaft Drive Gear Pulley (1) Timing Belt
(6) Tension Pulley (2) Engine Rotation Direction
(3) Cylinder Head Side
1. Install timing belt.

1. Align the mark (notch) of crankshaft timing
pulley (2) with mark on oil pump (1).
Align the mark (groove) on the crankshaft
timing pulley (3) with alignment mark (white
dots line) on the timing belt (4).
014RY00043
NOTE: When timing marks are aligned, No.2 piston will

be on Top Dead Center. Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.
4. Align the alignment mark on the LH bank

camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover LH (3).
5. Align the alignment mark (white line) on the
timing belt (1) with the alignment mark on the
LH bank camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench
to turn the camshaft drive gear pulley, then set
the timing mark between timing belt and
camshaft drive gear pulley and put the timing
belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
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clip.
014RW003
NOTE: It is recommended for easy installation that the
Legend
belt be secured with a double clip or equivalent clip after
(1) Alignment Mark on Oil Pump it is installed the timing belt to each pulley.
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt
2. Align the alignment mark on the RH bank

camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover RH (3).
3. Align the alignment mark (white line) on the
timing belt (1) with alignment mark on the RH
bank camshaft drive gear pulley (2) (on the left
side as viewed from the front of the vehicle)
and put the timing belt on the camshaft drive
gear pulley.
Secure the belt with a double clip or equivalent
clip.
014RW00005
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.
6. Install crankshaft pulley temporarily and tighten

center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give
some belt slack between the crankshaft timing
pulley and the RH bank camshaft drive gear
pulley.
014RW00004
2. Install pusher and tighten bolt to the specified 3. Install timing belt cover.
torque. Remove crankshaft pulley that was installed in
Torque: 25 N××m (2.5 Kg××m/18 lb ft) step 1 item 5.
1. Install the pusher while pushing the tension Tighten bolts to the specified torque.
pulley to the belt. Torque: 18 N××m (1.8 kg××m/13 lb ft)
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).
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020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
014RW011
(3) Timing Belt Cover Lower
Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
3. Remove double clips or equivalent clips, from

timing belt pulleys.
Turn the crankshaft pulley clockwise by two
turns.
020RW003
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body
4. Install crankshaft pulley using 5-8840-0133-0, hold 9. Install radiator upper fan shroud.
the crankshaft pulley and tighten center bolt to the 10. Install air cleaner assembly.
specified torque.
5. Install fan pulley bracket and tighten fixing bolts to
the specified torque.
6. Install power steering pump assembly and tighten
Torque:
M8 bolt: 25 N××m (2.5 kg××m/18 lb ft)
M10 bolt: 43 N××m (4.4 kg××m/32 lb ft)
7. Install cooling fan assembly and tighten bolts/nuts
and fan bracket.
Torque: 10 N××m (1.0 kg××m/7 lb ft) for fan and
clutch assembly.
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wrench, then install drive belt to normal position.
850RW001
Legend
(3) Tensioner
(4) Generator
(7) Drive Belt
Camshaft
Removal
2. Remove crankshaft pulley.
· Refer to removal procedure for Crankshaft
Pulley in this manual.
3. Remove timing belt.
· Refer to removal procedure for Timing Belt in
this manual.
4. Remove cylinder head cover LH.
· Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.
Cover RH in this manual.
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6. Remove twenty fixing bolts from inlet and exhaust
camshaft bracket on one side bank, then camshaft 014RW026
brackets. Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer
Installation
1. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
2. Tighten bolt for camshaft drive gear assembly
pulley to the specified torque.
3. Tighten sub gear setting bolt.
1. Use 5-8840-2443-0 to turn sub gear to right
direction until it aligns with the M5 bolt hole
between camshaft driven gear and sub gear.
014RW027 2. Tighten the M5 bolt to a suitable torque to
7. Remove camshaft assembly. prevent the sub gear from moving.
8. Remove fixing bolt for camshaft drive gear pulley.
9. Remove three fixing bolts from camshaft drive
gear retainer, then camshaft drive gear assembly.
014RW041 014RW023
4. Install camshaft assembly and camshaft brackets, Legend
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tighten twenty bolts on one side bank to the (1) Right Bank Camshaft Drive Gear
specified torque.
(2) Left Bank Camshaft Drive Gear
1. Apply engine oil to camshaft journal and
(3) Timing Mark on Drive Gear
bearing surface of camshaft bracket.
(4) Dowel Pin
2. Align timing mark on intake camshaft (one dot
for right bank, two dot for left bank) and
exhaust camshaft (one dot for right bank, two
dots for left bank) to timing mark on camshaft
drive gear (one dot).
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
(LI: Left bank intake, RI: Right bank intake)
(LE: Left bank exhaust, RE: Right bank exhaust)
014RW024
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Legend (3) Alignment Mark on Camshaft Drive Gear
(1) Right Bank (4) Alignment Mark on Camshaft
(2) Left Bank (5) Alignment Mark on Retainer
3. Tighten twenty bolts on numerical order an one 8. Install crankshaft pulley.

side bank as shown in the illustration. · Refer to installation procedure for
Torque : 10 N××m (1.0 kg××m/7 lb ft) CRANKSHAFT PULLEY in this manual.
014RW031
5. Install cylinder head cover RH.

· Refer to installation procedure for CYLINDER
HEAD COVER RH in this manual.
6. Install cylinder head cover LH.
· Refer to installation procedure for CYLINDER
HEAD COVER LH in this manual.
· Refer to installation procedure for TIMING
BELT in this manual.
Cylinder Head
1. Remove engine hood. 1. Install cylinder head assembly to cylinder block.
2. Disconnect battery ground cable. 1. Put cylinder head gasket on the cylinder block.
3. Drain radiator coolant. NOTE: There is discrimination mark “R" for right
4. Drain engine oil. bank and “L" for left bank on the cylinder head
5. Remove crankshaft pulley. gasket as shown in the illustration.
· Refer to removal procedure for Crankshaft Do not reuse cylinder head gasket.
Pulley in this manual.
this manual.
7. Remove cylinder head cover LH.
Cover LH in this manual.
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8. Remove cylinder head cover RH.
Cover RH in this manual.
9. Remove common chamber.
· Refer to removal procedure for Common
Chamber in this manual.
10. Remove cylinder head assembly.
1. Loosen eights bolts for tight cylinder head.
011RW005
2. Align dowel pin hole to dowel pin on the

cylinder block.
3. Tighten two bolts temporarily by hand to
prevent the cylinder head assembly from
moving.
4. Using 9-8511-4209-0 cylinder head bolt
wrench, tighten bolts in numerical order as
shown in the illustration to the specified torque.
014RW028
Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft
NOTE: Do not reuse cylinder head bolts. 6. Install crankshaft pulley.

Do not apply any lubricant to the cylinder head bolts. · Refer to installation procedure for Crankshaft
Torque: Pulley in this manual.
Temporary: 29 N××m (3.0 kg××m/21 lb ft)
Final: 64 N××m (6.5 kg××m/47 lb ft)
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014RW029
2. Install common chamber.

· Refer to installation procedure for Common
Chamber in this manual.
3. Install cylinder head cover RH.
· Refer to installation procedure for Cylinder
Head Cover RH in this manual.
4. Install cylinder head cover LH.
Head Cover LH in this manual.
· Refer to installation procedure for Timing Belt in
this manual.
Valve Stem Oil Controller, Valve Spring and Valve Guide
1. Disconnect battery ground cable. 1. Install valve guide using 5-8840-2442-0 valve
· Drain engine oil. guide installer.
2. Drain engine coolant. 2. Install oil controller using 5-8840-0624-0 oil
3. Remove cylinder head assembly. controller installer.
· Refer to removal procedure for Cylinder Head 3. Install lower valve spring seat, valve spring and
in this manual. upper valve spring seat then put split collars on the
upper spring seat, using 5-8840-2442-0 valve
4. Remove camshaft.
spring compressor and 5-8840-0624-0 valve
· Refer to removal procedure for Camshaft in this spring compressor adapter to install the split
manual. collars.
5. Remove tappets with shim.
NOTE: Do not damage shim surface.
6. Remove valve springs using 5-8840-2446-0
valve spring compressor and 5-8840-2547-0
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valve spring compressor adapter then remove
upper valve spring seat and lower seat.
014RW042
4. Install tappet with shim.

5. Install camshaft assembly.
· Refer to installation procedure for Camshaft in
this manual.
6. Install cylinder head assembly.
014RW042
7. Remove oil controller using 5-8840-0623-0 oil
Head in this manual.
controller remover, remove each valve stem oil
controller. 7. Fill engine oil until full level.
8. Remove valve guide using 5-8840-2549-0 valve 8. Fill engine coolant.
guide replacer.
Piston, Piston Ring and Connecting Rod
Removal
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F06RW011
Legend (4) Oil Strainer

(1) Cylinder Head (5) Oil Gallery
(2) Crankcase with Oil Pan (6) Piston with Connecting Rod Assembly
(3) Oil Pipe

in this manual.
2. Remove crankcase with oil pan.
· Refer to removal procedure for Oil Pan and
Crankcase in this manual.
3. Remove oil strainer fixing bolts, remove oil strainer

assembly with O-ring.
015RW003
Legend
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050RW002 (1) Piston Front Mark
Legend (2) Piston Grade
(1) Oil Pump (3) Connecting Rod Front Mark
(2) Oil Strainer
(3) Oil Gallery 2. Install oil gallery and tighten the bolts in two steps,
(4) From Oil Filter in the order shown in illustration.
(5) To Oil Filter Torque:
1st step: 29 N××m (3.0 kg××m/21 lb ft)
4. Remove three fixing bolts, oil pipe with O-ring. 2nd step: 55°°-65°°
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly,
before removing the bearing cap, remove carbon
on the top of cylinder bore and push piston with
connecting rod out from the top of cylinder bore.
Installation
1. Install piston with connecting rod assembly.
· Apply engine oil to cylinder bore, connecting
rod bearing and crank pin.
· When installing the piston, its front mark must
face the engine front side.
· The bearing cap number must be the same as
connecting rod number.
· Apply engine oil to the thread and seating
surface of each nut.
· Tighten nuts to the specified torque.
051RS009
3. Install oil pipe with O-ring.
· After tightening the nuts, make sure that the
crankshaft rotates smoothly.
4. Install oil strainer assembly with O-ring.
NOTE: Do not apply engine oil to the bearing back
faces and connecting rod bearing fitting surfaces. Torque: 25 N××m (2.5 kg××m/18 lb ft)
5. Install crankcase with oil pan.
· Refer to installation procedure for Oil Pan and
6. Install cylinder head assembly.

Head in this manual.
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Crankshaft and Main Bearings
Removal
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F06RW010
Legend (8) Oil Pump Assembly

(1) Engine Assembly (9) Cylinder Body Side Bolt
(2) Crankshaft Pulley (10) Oil Gallery
(3) Timing Belt Cover (11) Flywheel
(4) Timing Belt (12) Rear Oil Seal Retainer
(5) Crankcase with Oil Pan (13) Connecting Rod Cap
(6) Oil Pipe (14) Crankshaft Main Bearing Cap
(7) Oil Strainer (15) Crankshaft and Main Bearing
1. Remove engine assembly.

· Refer to removal procedure for Engine
Assembly in this manual.
this manual.
3. Remove oil pan and crankcase.
· Refer to removal procedure for Oil Pan and
4. Remove oil pipe with O-ring.
5. Remove oil strainer assembly with O-ring.
6. Remove oil pump assembly.
· Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel. 015RS012
10. Remove rear oil seal retainer.
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· Refer to removal procedure for Rear Oil Seal in
this manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.
Installation
1. Install crankshaft and main bearings.
· Install main bearing in the cylinder block and
main bearing cap respectively.
Apply new engine oil to upper and lower main
bearings.
NOTE:
· Do not apply engine oil to the bearing back faces.
· Make sure that main bearings are in correct
position. 015RS013
· Install crankshaft with care. 2. Install crankshaft main bearing caps.

· Apply engine oil to the thrust washer. · Apply engine oil to the thread and seating
· Install thrust washer on No.3 journal. surface of each bearing cap fixing bolt.
· Oil grooves in thrust washer must face the NOTE:
crankshaft. · Do not apply engine oil to the bearing back faces.
· Install bearing caps in the order of numbers,
starting with cylinder block front side.
· Tighten main bearing fixing bolts to the specified
torque.
· After tightening the bolts, make sure that the
3. Install connecting rod caps.
· The cap number must be same as connecting
rod number.
· Apply engine oil to the thread and seating
surface of each nut.
· Tighten nuts to the specified torque. · Tighten retainer fixing bolts to the specified
Torque: 54 N××m (5.5 kg××m/40 lb ft) torque.
· After tightening the nuts, make sure that the Torque: 18 N××m (1.8 kg××m/13 lb ft)
4. Install rear oil seal retainer.
· Remove oil on cylinder block and retainer fitting
surface.
· Apply sealant (TB1207B or equivalent) to
retainer fitting surface as shown in illustration.
· The oil seal retainer must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
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015RW001
5. Install flywheel.
· Clean tapped holes in the crankshaft.
· Remove oil on crankshaft and flywheel fitting
surface.
NOTE:
· Do not reuse the bolts.
· Do not apply oil or thread lock to the bolts.
· Tighten fixing bolts to the specified torque.
015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
· Apply engine oil to oil seal lip and align a dowel

pin hole in the cylinder block with that in the
retainer.
015RS018
6. Install oil gallery. · Install oil pump in the cylinder block and tighten
· Clean contact surface of oil gallery and main fixing bolts to the specified torque.
bearing cap. Torque: 25 N××m (2.5 kg××m/18 lb ft)
Apply engine oil to oil gallery fixing bolts and
tighten the bolts in two steps, in the order
shown.
Torque:
1st step: 29 N××m (3.0 kg××m/21 lb ft)
2nd step: 55°°-65°°
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
NOTE: Do not apply the oil to the bolts.
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051RW002
Legend
(2) Around Dowel Pin
012RS007
8. Install oil pump assembly.

· Remove oil on cylinder block and oil pump
mounting surface.
· Apply sealant (TB1207B or equivalent) to the oil
pump mounting surface.
· The oil pump assembly must be installed within
5 minutes after sealant application to prevent
· Apply engine oil to oil seal lip.
051RW001
9. Install oil strainer with O-ring, tighten to the

specified torque.
10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque.
11. Install crankcase. · Properly apply a 4.5 mm (0.7 in) wide bead of
· Remove oil on crankcase mounting surface sealant (TB1207C or equivalent) to the oil pan
and dry the surface. mounting surface. The bead must be
· Properly apply a 4.5 mm (0.7 in) wide bead of continuous.
sealant (TB1207C or equivalent) to the · The oil pan must be installed within 5 minutes
crankcase mounting surface. The bead must after sealant application to prevent premature
be continuous. hardening of sealant.
· The crankcase must be installed within 5 · Tighten fixing bolts to the specified torque.
minutes after sealant application to prevent Torque: 25 N××m (2.5 kg××m/18 lb ft)
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013RW003
013RW010
013RW002

· Refer to installation procedure for Timing Belt in
013RW004
this manual.
12. Install oil pan 14. Install engine assembly.
· Remove oil on oil pan mounting surface and · Refer to installation procedure for Engine
dry the surface. Assembly in this manual.
Rear Oil Seal
Removal
1. Remove transmission assembly.
· See Transmission section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil
seal retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal
using 5-8840-2286-0.
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015RS018
3. Install transmission.
· See Transmission section in this manual.
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the
automatic transmission. Otherwise, the
transmission may be damaged.
015RS017
2. Install flywheel.
· Clean tapped holes in the crankshaft.
· Remove oil on the crankshaft and flywheel
mounting surface.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
012RS009
Engine Assembly
17. Disconnect starter harness connector from starter.
Removal 18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from
radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
wrench then remove drive belt.
24. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering
pump along with piping on the body side.
25. Remove air conditioning compressor fixing bolts
from bracket and place the compressor along with
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piping on the body side.
26. Remove four O2 sensor harness connectors (two
each bank) from exhaust front pipe.
P1010068 27. Remove three exhaust pipe fixing nuts from each
1. Disconnect battery ground and positive cable. bank.
2. Remove battery. 28. Remove two exhaust pipe fixing nuts from each
3. Make alignment mark on the engine hood and exhaust pipe, then move exhaust pipe to rear side
hinges before removal in order to return the hood of vehicle.
to original position exactly. 29. Remove flywheel dust covers.
4. Remove engine hood. 30. Disconnect two heater hoses from engine.
5. Drain radiator coolant. 31. Disconnect fuel hose from right side of
6. Disconnect accelerator cable and automatic cruise transmission.
control cable from throttle valve on common
chamber. CAUTION: Plug fuel pipe on engine side and fuel
hose from fuel tank.
7. Remove the ECM.
· Disconnect the two connectors from the ECM. 32. Remove transmission assembly. Refer to
·. Remove fixing bolts on the common chamber. Transmission section in this manual.
· Remove fixing bolts for ground cable. 33. Support the engine by engine hoist.
8. Disconnect air duct with air cleaner cover. 34. Remove two left side engine mount fixing bolts
from engine mount on chassis side.
9. Remove air cleaner assembly.
35. Remove two right side engine mount fixing bolts
10. Disconnect canister vacuum hose.
from engine mount on chassis side.
11. Disconnect vacuum booster hose.
36. Remove engine assembly.
12. Disconnect three engine harness connectors.
13. Disconnect harness connector to transmission (left Installation
front side of engine compartment), disconnect shift
on the fly harness connector from front side of CAUTION: When assembling the engine and
front axle and remove transmission harness transmission, confirm that dowels have been
bracket from engine left side. mounted in the specified positions at the engine
14. Disconnect ground cable between engine and side. Also take care that dowel positions are
different between the manual transmission and the
frame.
automatic transmission. Otherweise, the
15. Disconnect bonding cable connector on the back transmission may be damaged.
of right dash panel.
16. Disconnect bonding cable terminal on the left
bank.
8. Install cooling fan assembly and tighten bolts/nuts

and fan bracket.
Torque : 10 N××m (1.0 kg××m/7 lb ft) for fan and
clutch assembly.
9. Install air conditioner compressor to engine and
tighten to the specified torque.
10. Install power steering pump, tighten fixing bolt to
the specified torque.
Torque :
M8 bolts : 25 N××m (2.5 kg××m/18 lb ft)
M10 bolts : 43 N××m (4.4 kg××m/32 lb ft)
wrench, then install drive belt to normal position.
012RS009
1. Install engine assembly. Tighten engine mount
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fixing bolts to frame to the specified torque.
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to
Transmission section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two
(each bank) rear exhaust flange nuts then tighten
three stud nuts (each bank) between exhaust
manifold and exhaust pipe, finally tighten rear side
stud nuts to the specified torque.
850RW001
Legend
(3) Tensioner
(4) Generator
(7) Drive Belt
12. Install upper fan shroud.

13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
LTW36FSH000101
7. Reconnect O2 sensor connector. 17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of
right dash panel.
19. Reconnect ground cable between engine and 29. Install the cable clips to accelerator control cable.
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect accelerator cable to throttle valve on
common chamber.
27. Install the ECM.
· Tighten the four bolts.
·Connect the two connectors.
·Tighten the two ground cable bolts.
28. Install engine hood to the origine position.
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· Refer to installation procedure for Body section
in this manual.
· Install accelerator control cable to accelerator
cable bracket.
· Rotate the ratchet ring in direction an arrow 90°
· Confirm marking of outer cap must be upper
side.
· Slider the lock in direction B.
· Confirm ratchet ring is locked.
RTW46ASH000201
Legend
(1) Cable Bracket
(2) Ratchet ring
(3) Outer Cap
(4) Lock
(5) Paint Mark
(6) Arrow Mark
Cylinder Head
Cylinder Head and Associated Parts
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011RW008
Legend (8) Camshaft Intake

(1) Spark Plug (9) Retainer Fixing Bolt
(2) Cylinder Head Bolt (10) Retainer Assembly
(3) Camshaft Drive Gear Pulley Fixing Bolt (11) Tappet with Shim
(4) Camshaft Drive Gear Pulley (12) Split Collar
(5) Camshaft Drive Gear Pulley (13) Valve Spring and Spring Upper Seat
(6) Camshaft Bracket (14) Valve
(7) Camshaft Exhaust
Disassembly Inspection and Repair

NOTE: 1. Cylinder head gasket and mating surfaces for
· During disassembly, be sure that the valve train leaks, corrosion and blow-by. If the gasket has
components are kept together and identified so failed, determine the cause.
that they can be reinstalled in their original -Insufficient torque on head bolts
locations. -Improper installation
· Before removing the cylinder head from the engine -Loose or warped cylinder head
and before disassembling the valve mechanism, -Missing dowel pins
perform a compression test and note the results.
-Warped case surface
1. Remove camshaft drive gear pulley fixing bolt (3),
2. Cylinder head for cracks, especially between valve
then pulley (4).
seats and in the exhaust ports.
2. Remove camshaft bracket fixing bolt (5), camshaft
3. Cylinder head deck for corrosion, sand particles in
bracket (6), then camshaft exhaust (7), and intake
head and porosity.
side (8).
3. Remove tappet with shim (11). CAUTION:
4. Use the 5-8840-2446-0 valve spring compressor · Do not attempt to weld the cylinder head.
and 5-8840-2547-0 valve spring compressor Replace it.
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adapter to remove the split collar (12), valve spring
· Do not reuse cylinder head bolts.
with upper seat (13) and valve (14).
4. Cylinder head deck, common chamber and
exhaust manifold mating surfaces for flatness.
These surfaces may be reconditioned by milling. If
the surfaces are “out of flat" by more than
specification, the surface should be ground to
within specifications. Replace the head if it
requires machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362
in)
014RW042
5. Remove spark plug (1).

CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.
011RW019
5. Water jacket sealing plugs seating surfaces.
Reassembly
1. Install spark plug and tighten all the spark plugs to
specified torque.
Torque: 18 Nm (1.8 kgm/13 lb ft)
2. Tighten sub gear setting bolt.
1. Use 5-8840-2443-0 gear spring lever to turn
sub gear to right direction until the M5 bolt
aligns with the hole between camshaft driven
gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to
prevent the sub gear from moving.
014RW020
Legend
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(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust
014RW041

three bolts to the specified torque.
4. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the
specified torque.
1. Apply engine oil to camshaft journal and
bearing surface of camshaft bracket.
2. Align timing mark on intake camshaft (one dot
for right bank, two dots for left bank) and
exhaust camshaft (one dot for right bank, two
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(4) Dowel Pin
014RW024
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3. Tighten twenty bolts in numerical order on each

bank as shown in the illustration.
014RW031

pulley to the specified torque.
Valve Spring, Oil Controller, Valve, Valve Guide
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts
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014RW039
Legend (7) Spring Upper Seat

(1) Camshaft Bracket Fixing Bolts (8) Valve Spring
(2) Camshaft Assembly Inlet (9) Oil Controller
(3) Camshaft Assembly Exhaust (10) Spring Lower Seat
(4) Shim (11) Valve Guide
(5) Tappet (12) Valve
(6) Split Collar
Disassembly
1. Remove camshaft bracket fixing bolts (1).
2. Remove camshaft assembly (intake).
3. Remove camshaft assembly (Exhaust side).
4. Remove shim (4) and tappet (5).
5. Use the 5-8840-2446-0 valve spring compressor
and 5-8840-2547-0 valve spring compressor
adapter to remove split collar.
014RS004
2. Measure the valve spring squareness with a steel
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square and replace the valve springs if the
measured value exceeds the specified limit.
Limit: 2 mm (0.079 in)
014RW042
6. Remove valve spring.

7. Remove valve.
8. Remove oil controller and spring lower seat.
9. Remove the valve guide using the 5-8840-2442-0
valve guide replacer.
Inspection and Repair

Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is
014RS005
evident.
3. Using a spring tester to compress the springs to
1. Measure the free height of the springs. The the installed height, measure the compressed
springs must be replaced if the free height is below spring tension, and replace the springs if the
the specified limit. measured tension is below the specified limit.
Standard: 44.6 mm (1.756 in) At installed height: 35.0 mm (1.38 in)
Limit: 43.6 mm (1.717 in) Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
LNW21BSH056701 014RS007
2. Measure the inside diameter of the valve guide
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Valve Guide with a micrometer. Subtract the measured outer
diameter of the valve stem from the measured
CAUTION: Take care not to damage the valve seat inner diameter of the valve guide. If the value
contact surface, when removing carbon adhering to exceeds the specified limit, the valve and the valve
the valve head. Carefully inspect the valve stem for
guide must be replaced as a set.
scratchs or abnormal wear. If these conditions are
present, the valve and the valve guide must be Inside Diameter of the Vale Guide
replaced as a set. Inlet clearance
1. Measure the valve stem diameter with a Standard : 0.023 mm- -0.056 mm(0.0009
micrometer. If the valve stem diameter is less than -0.0002 in)
in-
the specified limit, the valve and the valve guide Limit : 0.20 mm (0.00787 in)
must be replaced as a set. Exhaust clearance
Diameter of Valve Stem Standard : 0.030 mm- -0.063 mm(0.0012
Intake -0.0025 in)
in-
Standard: 5.977 mm- -5.959 mm Limit : 0.20 mm (0.00787 in)
-0.2346 in)
(0.2353 in-
Limit: 5.90 mm (0.2323 in)
Exhaust
Standard: 5.952 mm- -5.970 mm
-0.2350 in)
(0.2343 in-
Limit: 5.90 mm (0.2323 in)
Valve Guide Replacement Valve Seat

1. Using Valve guide replacer: 5 ?8840 ?2442 ?0, 1. Measure the protrusion of the valve stem when a
drive out the valve guide from the combustion new valve is installed in the cylinder head. If the
chamber side. protrusion of the valve stem exceeds the limit,
replace the valve seat insert or the cylinder head
assembly.
Protrusion of valve stem
Intake
Standard: 39.32 mm (1.5480 in)
Limit: 39.47 mm (1.5539 in)
Exhaust
Standard: 39.30 mm (1.5472 in)
Limit: 39.45 mm (1.5531 in)
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014RS008
2. Apply engine oil to the outside of the valve guide.

Using valve guide replacer 5 ?8840 ?2442 ?0,
drive in a new valve guide from the camshaft side,
and check the valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)
014RW047
014RW046
3. Check the clearance. If the clearance is less than

the specified value, ream the inside diameter of
valve guide. Using a sharp 6 mm reamer, ream the
valve guide to obtain the specified clearance.
2. Measure the valve seat contact width. Make the

necessary corrections if the seat contact surface is Valve Seat Insert Correction
damaged or rough or if the contact width wear 1. Remove the carbon from the valve seat insert
exceeds the limit. surface.
Valve seat contact width 2. Use a valve cutter to minimize scratches and other
Standard: 1.1 mm (0.0433 in) rough areas. This will bring the contact width back
Limit: 1.7 mm (0.0669 in) to the standard value. Remove only the scratches
and rough areas. Do not cut away too much. Take
care not to cut away unblemished areas of the
valve seat surface.
Valve seat angle degree: 90°°
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014RS011
Contact Surface Angle on Valve Seat on

Valve
1. Measure contact surface angle on valve seat. 014RW059
2. If the measured value exceeds the limit, replace 3. Apply abrasive compound to the valve seat insert
valve, valve guide and valve seat as a set. surface.
Valve contact surface angle: 45°° 4. Insert the valve into the valve guide.
5. Turn the valve while lapping it to fit the valve seat
insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in
contact with the entire circumference of the valve.
014RS012
014RS014
Valve Seat Insert Replacement Reassembly

1. Arc weld the rod at several points. Be careful not 1. Install valve guide (1) to cylinder head. Apply
to damage the aluminum section. engine oil to the outside of the valve guide. Using
2. Allow the rod to cool for a few minutes. This will valve guide replacer 5-8840-2442-0, drive in a
cause the valve seat to shrink. new valve guide from the camshaft side.
3. Strike the rod and pull it out. 2. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer 5-8840-0623-0, drive
in a new oil controller.
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014RS015
4. Carefully clean the valve seat press-fit section on

the cylinder head side. 014RW058
5. Heat the press-fit section with steam or some 3. Install valve to valve guide. Before install valve
other means to cause expansion. Cool the valve guide apply engine oil to the outside of the valve
seat with dry ice or some other means. stem.
6. Insert the press-fit section into the valve seat 4. Install valve spring to cylinder head. Attach the
horizontally. valve spring to the lower spring seat. The painted
area of the valve spring should be facing
Standard fitting interference: 0.14 mm- -0.09 mm
downward.
(0.0055 in--0.0035 in)
7. After insertion, use a seat grinder to grind finish
the seating face. Carefully note the seating angle,
the contact width, and the depression.
8. Lap the valve and the seat.
014RS020
5. Install lower valve spring seat, valve spring and

upper valve spring seat then put split collars on the
upper spring seat, using the 5-8840-2446-0 valve
spring compresor and 5-8840-2547-0 valve
spring compressor adapter to install the split
collars.
014RW081
Legend
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(1) Cam
(2) Shim
(3) Tappet
014RW042
6. Install tappet with shim.

Valve Clearance Standard Value (cold)
7. Install camshaft assembly.
· Refer to installation procedure for Camshaft in Intake: 0.23 mm--0.33 mm
this manual. -0.0130 in)
(0.0091 in-
Exhaust: 0.25 mm- -0.35 mm
Valve Clearance Adjustments -0.0138 in)
(0.0098 in-
NOTE: To adjust valve clearance, apply engine oil to
the cam as well as to the adjusting shim (2) with the Selection of Adjusting Shim
cylinder head built on the cylinder block, give a few Shim to be selected = (Thickness of removed
turns to the camshaft by means of timing pulley shim) + (Valve clearance measurement - Standard
tightening bolt, and measure valve clearance when the value) Based on the above formula, the best suited
nose of cam is just opposite to maximum cam lift (1) as shim should be selected from 41 sorts of shim
shown in illustration below. (differently thick at 0.02mm (0.0008 in) intervals from
2.40mm (0.0945 in) through 3.2mm (0.1260 in) thick).
Install the shim and check valve clearance.
Replacement of Shim
Let the cam push down the edge of tappet by using
5-8840-2444-0 valve clearance adjusting tool and
push out the shim with a flat blade screw driver as
shown in illustrations below.
014RW084
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014RW082
014RW083
Camshaft
Camshaft and Associated Parts
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014RW040
Legend (6) Camshaft Drive Gear Pulley

(1) Camshaft Bracket Fixing Bolt (7) Retainer Fixing Bolt
(2) Camshaft Bracket (8) Retainer
(3) Camshaft Assembly Intake (9) Camshaft Drive Gear
(4) Camshaft Assembly Exhaust (10) Oil Seal
(5) Pulley Fixing Bolt
Disassembly
1. Remove fixing bolt (5) for camshaft drive gear
pulley using 5-8840-2447&-ndash;0 universal
holder.

1. Use a micrometer to measure the cam lobe height
and uneven wear. Replace the camshaft if either
the lobe height or the uneven wear exceeds the
specified limit.
Lobe height: 44.709 mm (1.7602 in)
Uneven wear: 0.05 mm (0.0020 in)
014RW060
2. Remove twenty fixing bolts from inlet and exhaust
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camshaft bracket on one side bank, then camshaft
brackets (2).
014RW043
2. Use a micrometer to measure the diameter and

the uneven wear of the camshaft journals.
Replace the camshaft if the diameter or the
uneven wear exceeds the specified limit.
Journal Diameter
Standard: 25.972 mm- -25.993 mm (1.0225
-1.0233 in)
in-
Limit: 25.8 mm (1.0157 in)
Uneven wear: 0.05 mm (0.0020 in)
014RW027
3. Remove camshaft assembly (3), (4).

4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gear
assembly.
014RS023
3. Place the camshaft on V-blocks. 2. Subtract the camshaft outside diameter from the
Slowly rotate the camshaft and measure the camshaft bracket housing inside diameter.
runout with a dial indicator. Oil Clearance
Replace the camshaft if the runout exceeds the Standard : 0.027 mm- -0.078 mm(0.0011 in- -0.0031
specified limit. in)
Run out Limit : 0.11 mm (0.0043 in)
Limit: 0.1 mm (0.0039 in)
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014RW037
014RW044
5. Replace the cylinder head and/or camshaft if the
4. Measure the camshaft journal oil clearance. measured oil clearance exceeds the specified
1. Measure the camshaft bracket housing inside limit.
diameter. 1. Carefully clean the camshaft journal, the
NOTE: Tighten camshaft bracket (2) to specified torque camshaft bracket, and the cylinder head.
before measuring the camshaft bracket inside diameter. 2. Install camshaft assembly and camshaft
Torque : 10 N××m (1.0 kg××m/7 lb ft) brackets (2), tighten twenty bolts (1) on one
side bank to the specified torque.
014RW031
014RW031
3. Measure the camshaft thrust clearance with a dial 3. Install camshaft assembly and camshaft brackets,
indicator. Replace the camshaft and/or the cylinder tighten twenty bolts on one side bank to the
head if the camshaft thrust clearance exceeds the specified torque.
specified limit. 1. Apply engine oil to camshaft journal and
Camshaft thrust Clearance bearing surface of camshaft bracket.
Standard : 0.03 mm- -0.08 mm(0.0012 in -0.0031 2. Align timing mark on intake camshaft (one dot
in) for right bank, two dots for left bank) and
Limit : 0.12 mm (0.0047 mm) exhaust camshaft (one dot for right bank, two
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014RW035
Reassembly 014RW020
Legend
three bolts to specified torque. (1) Intake Camshaft Timing Gear for Right Bank
Torque: 10 N××m (1.0 kg××m/7 lb ft) (2) Intake Camshaft Timing Gear for Left Bank
2. Tighten sub gear setting bolt. (3) Exhaust Camshaft Timing Gear
1. Use 5-8840-2443-0 to turn sub gear to right (4) Discerning Mark
direction until the M5 bolt hole aligns between LI: Left Bank Intake
camshaft driven gear and sub gear. RI: Right Bank Intake
2. Tighten M5 bolt suitable torque for prevent LE: Left Bank Exhaust
moving the sub gear. RE: Right Bank Exhaust
014RW041
014RW023
Legend
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(1) Right Bank Camshaft Drive Gear
(4) Dowel Pin
014RW024
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3. Tighten twenty bolts in numerical order on one 4. If the oil seal requires replacement, use the
side bank as shown in the illustration. 5-8840-2445-0 to install the oil seal.
014RW034
014RW031

pulley to the specified torque using the
5-8840-2447-0 universal holder.
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014RW060
Crankshaft
Crankshaft and Associated Parts
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013RW009
Legend (8) Piston and Connecting Rod Assembly

(1) Cylinder Head Assembly (9) Flywheel
(2) Crankcase with Oil Pan (10) Rear Oil Seal Retainer and Oil Seal
(3) Oil Pipe and O-Ring (11) Main Bearing Cap
(4) Oil Strainer and O-Ring (12) Crankshaft
(5) Oil Pump Assembly (13) Main Bearing Cap Fixing Bolts
(6) Cylinder Block Side Bolts (14) Oil Gallery Fixing Bolts
(7) Oil Gallery
2. Remove crankcase with oil pan (2). Refer to “Oil

Disassembly Pan and Crankcase" in this manual.
1. Remove cylinder head assembly (1). Refer to CAUTION: Take care not to damage or deform the
“Head" in this manual. sealing flange surface of crankcase.
3. Remove oil pipe and O-ring (3).

4. Remove oil strainer and O-ring (4).
5. Remove oil pump assembly (5).
6. Remove crankcase side bolts (6).
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to “Piston, Piston Ring and Connecting Rod"
in this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).

1. Crankshaft
Set the dial indicator as shown in the illustration
015RS004
and measure the crankshaft thrust clearance. If
the thrust clearance exceeds the specified limit, 3. Remove the crankshaft. Remove the main
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replace the thrust bearings as a set. bearings.
Thrust Clearance 4. Clean the upper and lower bearings as well as the
crankshaft main journal.
Standard : 0.06 mm- -0.24 mm
5. Check the bearings for damage or excessive wear.
(0.0024 in--0.0094 in)
The bearings must be replaced as a set if damage
Limit : 0.30 mm (0.0118 in)
or excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to
their original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.
015RS003
Main Bearing Clearance

1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
Arrange the removed main bearing caps in the
015RS005
cylinder number order.
9. Install main bearing caps, oil gallery and crank
Remove the main bearings. case bolts in the order shown, and tighten each
bolt to the specified torque.
NOTE: Do not apply engine oil to the crank case side
bolts. (0.0007 in--0.0017 in)

Main bearing cap bolts. Limit : 0.08 mm (0.0031 in)
Torque: 39 N××m (4.0 Kg××m/29 lb ft)
Oil gallery fixing bolts.
Torque:
1st step: 29 N××m (3.0 Kg××m/21 lb ft)
2nd step 55°° ~ 65°°
Crank case side bolts
Torque : 39 N××m (4.0 Kg××m/29 lb ft)
NOTE: Do not allow the crankshaft to rotate.
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015RS008
12. Clean the plastigage from the bearings and the

crankshaft.
Remove the crankshaft and the bearings.
Crankshaft (12) Inspection

Inspect the surface of the crankshaft journal and crank
pins for excessive wear and damage. Inspect the oil
seal fitting surfaces for excessive wear and damage.
015RS006 Inspect the oil ports for obstructions.
10. Remove the main bearing caps in the sequence
shown in the illustration. Inspection and Repair
1. Carefully set the crankshaft on the V-blocks.
Slowly rotate the crankshaft and measure the
runout. If the crankshaft runout exceeds the
specified limit, the crankshaft must be replaced.
Runout : 0.04 mm (0.0016 in)
015RS004
11. Measure the plastigage width and determine the

oil clearance. If the oil clearance exceeds the
specified limit, replace the main bearings as a set
and/or replace the crankshaft.
015RS007
2. Measure the diameter and the uneven wear of 2. The crankshaft journal diameter grade mark (1)
main journal and crank pin. If the crankshaft wear are stamped on the No.1 crankshaft balancer (2)
exceeds the specified limit, crankshaft must be as shown in the illustration.
replaced.
Main journal diameter : 63.918 mm- -63.933 mm
-2.5170 in.)
(2.5165 in.-
Crank pin diameter : 53.922 mm- -53.937 mm
-2.1235 in.)
(2.1229 in.-
Uneven wear limit : 0.005 mm (0.0002 in)
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015R200005
3. Match the cylinder block journal grade marks and

the crankshaft journal grade marks in the table
below to determine the correct crankshaft bearing
size.
The size color code is painted to side of the
015RS009
crankshaft bearings.
Crankshaft Bearing Selection

Crankshaft bearing selection is based on the measured
diameters of the crankshaft journals and the bearing
inserts.
1. The grade mark (1) for cylinder block journal are
stamped on the lower face of cylinder block as
RTW31BSH000601
RTW31BSH000701
Grade Cylinder Block Crank Shaft Journal Grade Color Code Oil Clearance
Mark Journal Diameter Mark (Reference)
68.994-69.000 63.918-63.925 0.024-0.043
1 2 Blue
(2.7163-2.7165) (2.5165-2.5167) (0.0009-0.0017)
63.926-63.933 0.022-0.041
1 Brown
(2.5168-2.5170) (0.0009-0.0016)
68.987-68.993 63.918-63.925 0.023-0.042
2 2
(2.7160-2.7163) (2.5165-2.5167) (0.0009-0.0016)
63.926-63.933 0.021-0.040
1 Green
(2.5168-2.5170) (0.0008-0.0016)
68.980-68.986 63.918-63.925 0.022-0.041
3 2
(2.7157-2.7160) (2.5165-2.5167) (0.0009-0.0016)
63.926-63.933 0.020-0.039
1 Yellow
(2.5168-2.5170) (0.0008-0.0015)
Reassembly
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1. Crankshaft (12)
· Install the main bearings to the cylinder block
and the main bearing caps.
· Be sure that they are positioned correctly.
· Apply new engine oil to the upper and lower
main bearing faces.
NOTE: Do not apply engine oil to the main bearing back
faces.
015RS013
2. Rear oil seal (10)

· Remove the oil from the cylinder block and the
retainer mounting surface.
· Apply sealant (TB-1207B or equivalent) to the
retainer mounting surface, following the pattern
The retainer must be installed within 5 minutes
after sealant application before the sealant
hardens.
015RS012
Legend
(1) Numver 1 and 4 main bearing upper and lower
(2) Numver 2 and 3 main bearing upper
(3) Numver 2 and 3 main bearing lower
· Carefully mount the crankshaft.

· Apply engine oil to the thrust washer.
· Assemble the thrust washer to the No.3 bearing
journal. The oil grooves must face the
crankshaft.
015RW002 015RS017
Legend 3. Flywheel (9)
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(1) Around Bolt Holes 1. Thoroughly clean and remove the oil from the
(2) Around Dowel Pin threads of crankshaft.
2. Remove the oil from the crankshaft and
· Apply engine oil to the oil seal lip. flywheel mounting faces.
· Align the cylinder block dowel pin holes with the 3. Mount the flywheel on the crankshaft and then
rear retainer dowel pins. install the washer.
· Tighten the rear retainer fixing bolts. New bolts 4. Hold the crankshaft to prevent from rotating
should be used when installing rear retainer. then install the bolts in the order shown to the
specified torque.
NOTE: Be very careful not to disengage the oil seal
garter spring during installation of the rear retainer. NOTE: Do not reuse the bolt and do not apply oil or
thread lock to the bolt.
If the seal was removed from retainer for
replacement, apply engine oil to the oil seal lip
and install the oil seal using 5-8840-2286-0 oil
seal installer.
015RS018
4. Piston and connecting rod assembly (8)

· Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft
015RW001
pins. Check to see that the piston ring end gaps
are correctly positioned.
015RS019 015RS020
Legend 5. Install oil gallery (7) and tighten the bolts in 2
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(1) No.1 Compression Ring steps, in the order shown.
(2) No.2 Compression Ring 1st step: 29 N××m (3.0 Kg××m/22 lb ft)
(3) Oil Ring Side Rail Upper 2nd step: 55°° ~ 65°°
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark
· Insert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
· Match the numbered caps with the numbers on
the connecting rods. Align the punched marks
on the connecting rods and caps.
· Apply engine oil to the threads and seating
faces of the nuts.
· Tighten the nuts.
After tightening the cap nuts, check to see that
the crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back 051RS009
faces. 6. Cylinder block side bolts (6)
· Tighten all the bolts to the specified torque in
the order shown.
NOTE: Do not apply engine oil to the crank case side
bolts.
Legend
(1) Portion Between Bolt Holes
(2) Bolt Hole Portion
11. Install cylinder head assembly, refer to “Cylinder

head" in this manual.
012RS001
7. Install oil pump assembly (5), refer to “Oil pump" in
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this manual.
8. Install oil strainer and O-ring (4).
9. Install oil pipe and O-ring (3) and tighten the bolts.
10. Install crankcase with oil pan (2).
1. Completely remove all residual sealant,
lubricant and moisture from the sealing
surfaces. The surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB¾
1207C or its equivalent) to the contact surfaces
of the oil pan. There must be no gaps in the
bead.
3. The crankcase assembly must be installed
within 5 minutes after sealant application to
prevent premature hardening of the sealant.
4. Tighten the bolts and nuts to the specified
torque.
Torque : 10 N××m (1.0 Kg××m/7 lb ft)
013RW010
Piston and Connecting Rod
Piston, Connecting Rod and Associate Parts
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015RW019
Legend (7) Piston and Connecting Rod Assembly

(1) Cylinder Head Assembly (8) Piston Ring
(2) Cylinder Head Gasket (9) Piston Pin
(3) Crankcase with Oil Pan (10) Piston
(4) Oil Pipe and O-Ring (11) Connecting Rod
(5) Oil Strainer and O-Ring (12) Connecting Rod Cap
(6) Oil Gallery
2. Remove cylinder head gasket (2).

Disassembly 3. Remove crankcase with oil pan (3). Refer to ”Oil
1. Remove cylinder head assembly (1). Refer to Pan and Crankcase" in this manual.
“Cylinder Head Removal" in this manual. 4. Remove oil pipe and O-ring (4).
5. Remove oil strainer and O-ring (5). NOTE: Keep the parts removed from each cylinder
6. Remove oil gallery (6). separate. All parts must be reinstalled in their original
7. Remove connecting rod cap with connecting rod positions. Heating the connecting rod will permit easy
lower bearing (12). removal of the piston pin.
8. Remove piston and connecting rod assembly (7).
NOTE: Before removing piston and connecting rod
assembly, measure thrust clearance.
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015RX001
Legend
(1) Press Ram
015RS031
(2) Piston
· Remove any ridge or carbon build up from the (3) Connecting Rod
top end of the cylinder. (4) Piston Pin
9. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the 11. Piston (10)
cylinder number order. 12. Connecting rod (11)

Pistons (10)
Carefully clean away all the carbon adhering to the
piston head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston for
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must
be replaced.
Piston Diameter
1. Measure the piston outside diameter with
micrometer at the piston grading position and a
right angle to the piston pin.
015RS022 Piston grading position (from piston head)
10. Remove the piston pin (9) using 5-8840-0551-0 Piston grading position : 43.0 mm (1.6929 in)
piston pin service set and piston support with a
press.
015RV014 012RS002
The size mark (1) for piston outside diameter is
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represented as shown in illustration below. Piston Rings (8)
Outside Diameter Any worn or damaged part discovered during engine
Size Mark A : 93.360 mm- -93.370 mm overhaul must be replaced with a new one.
-3.6760 in)
(3.6756 in- 1. Ring end gap measurement
Size Mark B : 93.371 mm- -93.380 mm · Insert the piston ring into the bore.
-3.6764 in)
(3.6760 in- · Push the ring by the piston, at a right angle to
Size Mark C : 93.381 mm- -93.390 mm the wall, into the point at which the cylinder
-3.6768 in)
(3.6764 in- bore diameter is the smallest.
· Measure the ring end gap.
Compression Ring
1st ring
Standard: 0.300 mm-0.400 mm
(0.0118 in-0.0157 in)
Limit: 1.0 mm (0.0394 in)
2nd ring
(0.0177 in-0.0236 in)
Limit: 1.2 mm (0.0472 in)
Oil ring
(0.0059 in-0.0177 in)
Limit: 1.05 mm (0.0413 in)
015RS025
Measure the cylinder bore inside diameter (refer

to ”Cylinder Block" in this manual).
015RS026 015RS028
· The No.1 compression ring must be set with
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direction of origin. Piston Pin (9)
· No.2 compression ring: Positioning mark (1) is NOTE: Do not reuse the old piston pin.
painted as shown in the illustration. 1. Use a micrometer to measure the new piston pin
outside diameter in both directions at three
different positions.
2. Measure the inside diameter of the connecting rod
small end. If the fitting interference between the
small end and pin does not conform to the
specified value, the connecting rod must be
replaced.
(0.0009 in--0.0015 in)
015RS027
2. Measure the clearance between the piston ring

groove and the piston ring with a feeler gauge. If
the piston ring groove / piston ring clearance
exceeds the specified limit, the piston must be
replaced.
Compression Ring Clearance
(0.0006 in. -0.0015 in) 015RS029
Limit : 0.15mm (0.0059 in)

3. Insert the new pin into the piston and rotate it. If
the pin rotates smoothly with no backlash, the
clearance is normal. If there is backlash or
roughness, measure the clearance. If the
clearance exceeds the specified limit, the piston
must be replaced.
Clearance
(0.0004 in. -0.0007 in)
Limit : 0.040 mm (0.0016 in)
Connecting Rods (11)

1. Check the connecting rod alignment If either the
bend or the twist exceeds the specified limit, the
connecting rod must be replaced.
Bend per 100 mm (3.937 in)
Limit: 0.15 (0.0059)
015RS031
Twist per 100 mm (3.937 in)
3. Measure the oil clearance between the connecting
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Limit: 0.20 (0.0078) rod and the crankshaft.
1. Remove the connecting rod cap nuts and the
rod caps (12).
Arrange the removed rod caps in the cylinder
number order.
2. Clean the rod bearings and the crankshaft pins.
3. Carefully check the rod bearings. If even one
bearing is found to be damaged or badly worn,
the entire bearing assembly must be replaced
as a set. Reinstall the bearings in their original
positions. Apply plastigage to the crank pin.
015RS030
2. Measure the connecting rod thrust clearance. Use

a feeler gauge to measure the thrust clearance at
the large end of the connecting rod If the clearance
exceeds the specified limit, the connecting rod
must be replaced.
(0.0063 in. -0.0138 in)
Limit : 0.40 mm (0.0157 in)
015RS032
4. Reinstall the rod caps (12) to their original

positions.
Tighten the rod cap nuts.
NOTE: Do not allow the crankshaft to rotate. 7. Clean the plastigage from the bearings and the
5. Remove the rod caps. crankshaft pins.
6. Measure the width of the plastigage and determine
the oil clearance. If the oil clearance exceeds the -rod Bearing Selection
Con-
limit, replace the rod bearing as a set. Select and install the new connecting rod bearings,
Standard : 0.019 mm- -0.043 mm paying close attention to the connecting rod big end
(0.0007 in- -0.0017 in) diameter size mark (1).
Limit : 0.08 mm (0.003 in) NOTE: Take care not to confuse the alignment mark (2)
and the size mark (1) during the installation procedure.
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015RS008
015RS034
Connecting Rod
Big end Bore Crankshaft Pin Color of Oil Clearance
1 Size Mark Bearing Thickness
Diameter Diameter Size Mark (Reference)
(Reference)
56.994-57.000 1.512-1.516 0.025-0.054
A Yellow
(2.2439-2.2441) (0.0595-0.0597) (0.0010-0.0021)
56.988-56.994 53.922-53.937 1.508-1.512 0.027-0.056
B Green
(2.2436-2.2439) (2.1229-2.1235) (0.0594-0.0595) (0.0011-0.0022)
56.982-56.988 1.504-1.508 0.029-0.058
C Pink
(2.2434-2.2436) (0.0592-0.0594) (0.0011-0.0023)
Reassembly
1. Install connecting rod
2. Install piston
3. Install piston pin
· Apply a thin coat of engine oil to the piston pin.
Try to insert the piston pin into the piston pin
hole with normal finger pressure.
NOTE: When changing piston / connecting rod
combinations, do not change the piston / piston pin
combination and do not reuse the old piston pin.
· Attach the piston to the connecting rod with the
piston front mark and the connecting rod front
mark on the same side.
RUW36ASH000501 015RS027
· With 5-8840-0551-0 Piston pin service set · Install piston rings in the following sequence.
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and a press, press fit the piston pin. 1. Oil ring
NOTE: Heat the connecting rod small end to a suitable 1. Expander ring
temperature to ensure smooth installation. 2. Upper side rail
3. Lower side rail
2. 2nd compression ring
· The 2nd compression ring must be set with the
T2 mark facing up.
3. 1st compression ring
· The compression ring must be set with
direction of origin.
· After installation, apply engine oil to the entire
circumference of the piston rings. Check to see
that all the rings rotate smoothly.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
4. Install piston ring with the piston ring expander.

The No.2 compression ring must be set with the
T2 mark (1) facing up.
015RS038
5. Install piston and connecting rod assembly.

· Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces
and nuts.
· Tighten the connecting rod cap nuts
NOTE: Do not apply engine oil to the bearing back
faces.
6. Oil gallery, refer to “Crankshaft and main bearing"
in this manual.
7. Oil strainer and O-ring.
8. Oil pipe and O-ring.
9. Install crankcase with oil pan, refer to “Oil pan and
Crankcase" in this manual.
10. Install cylinder head gasket.
11. Install Cylinder head assembly.
· Refer to “Cylinder head" in this manual.
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Cylinder Block
Cylinder Block and Associated Parts
Legend (8) Oil Gallery

012RW010
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(1) Cylinder Head Assembly (9) Piston and Connecting Rod Assembly
(2) Cylinder Head Gasket (10) Flywheel
(3) Crankcase with Oil Pan (11) Rear Oil Seal Retainer Assembly
(4) Oil Pipe and O-Ring (12) Main Bearing Cap
(5) Oil Strainer and O-Ring (13) Crankshaft
(6) Oil Pump Assembly (14) Cylinder Block
(7) Cylinder Block Side Bolts
Disassembly
2. Remove cylinder head gasket.
3. Remove crankcase with oil pan.
4. Remove oil pipe and O-ring.
5. Remove oil strainer and O-ring.
6. Remove oil pump assembly.
7. Remove crankcase side bolts.
8. Remove oil gallery.
9. Remove piston and connecting rod assembly.
10. Remove flywheel.
11. Remove rear oil seal retainer assembly.
12. Remove main bearing cap.
13. Remove crankshaft.
14. Remove cylinder block. 012RS004
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Inspection and Repair Cylinder Bore
1. Remove the cylinder head gasket and any other Use a cylinder gauge to measure the cylinder bore
material adhering to the upper surface of the diameter in both the axial and thrust directions. Each
cylinder block. Be very careful not to allow any measurement should be made at six points.
material to accidentally drop into the cylinder block.
Be very careful not to scratch the cylinder block. CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
2. Carefully remove the oil pump, rear oil seal
cylinder block. Be very careful not to scratch the
retainer, and crankcase assembly installation upper surface of the cylinder block.
surface seal.
3. Wipe the cylinder block clean. Cylinder Bore Inside Diameter
4. Visually inspect the cylinder block. If necessary, Limit : 93.530 mm (3.6823 in)
use a flaw detector to perform a dye penetrate and If the measurement exceed the specified limit, the
hydraulic (or air pressure) test. If cracking or other cylinder block must be replaced.
damage is discovered, the cylinder block must Diameter
either be repaired or replaced. Grade A : 93.400 mm- -93.410 mm
(3.6772 in--3.6776 in)
Flatness Grade B : 93.411 mm- -93.420 mm
1. Using a straight-edge and feeler gauge, check (3.6776 in--3.6779 in)
that the upper surface of the cylinder block is not Grade C : 93.421 mm- -93.430 mm
warped. (3.6780 in--3.6783 in)
NOTE: Be very careful not to allow any material to
accidentally drop into the upper surface of the cylinder
block. Be very careful not to scratch the upper surface
of the cylinder block.
2. The cylinder block must be reground or replaced if
the warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)
012RS005 015RS012
NOTE: For information on piston diameter, please refer Legend
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to the section "Inspection of the Piston and Connecting (1) Number 1 and 4 main bearing upper and lower.
Rod Assembly" in this manual.
(2) Number 2 and 3 main bearing upper.
· The "Grade" mark (1) is stamped at the
(3) Number 2 and 3 main bearing lower.
position illustrated.
· Carefully mount the crankshaft.

· Apply engine oil to the thrust washer.
· Assemble the thrust washer to the No. 3
bearing journal. The oil grooves must face the
crankshaft.
012RS006
Reassembly
1. Install cylinder block.
2. Install crankshaft.
· Install the main bearings to the cylinder block
015RS013
and the main bearing caps. 3. Install rear oil seal retainer.
· Be sure that they are positioned correctly. · Remove oil on cylinder block and retainer fitting
· Apply new engine oil to the upper and lower surface.
main bearing faces. · Apply sealant (TB1207B or equivalent) to
NOTE: Do not apply engine oil to the bearing back retainer fitting surface as shown in illustration.
faces. · The oil seal retainer must be installed within 5
minutes after sealant application before the
sealant hardens.

NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
015RW002
Legend
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(2) Around Dowel Pin 015RS018
5. Install piston and connecting rod assembly.

· Apply engine oil to oil seal lip and align a dowel · Apply engine oil to the cylinder bores, the
pin hole in the cylinder block with that in the connecting rod bearings and the crankshaft
retainer. pins.
· Tighten retainer fixing bolts to the specified NOTE: Do not apply engine oil to the bearing back
torque. faces.
Torque: 25 N××m (2.5 kg××m/18.4 lb ft) · Check to see that the piston ring end gaps are
correctly positioned.
015RW001
4. Install flywheel 015RS019
1. Thoroughly clean and remove the oil from the Legend

threads of crankshaft. (1) No.1 Compression Ring
2. Remove the oil from the crankshaft and (2) No.2 Compression Ring
flywheel mounting faces. (3) Oil Ring Side Rail Upper
3. Mount the flywheel on the crankshaft and then (4) Oil Ring Side Rail Lower
install the washer. (5) Piston Front Mark
4. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown.
· Insert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor.
· The front marks (1) must be facing the front of
the engine.
012RW005
8. Install oil pump assembly. Refer to “Oil Pump" in
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this manual.
9. Install oil strainer and O-ring.
015RS020 10. Install oil pipe and O-ring.
6. Install oil gallery and tighten the bolts in 2 steps in 11. Install crankcase with oil pan.
the order shown. 1. Completely remove all residual sealant,
1st step : 29 N××m (3.0 kg××m/22 lb ft) lubricant and moisture from the sealing
2nd step : 55°° ~ 65° surfaces. The surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB-
1207C or its equivalent) to the contact surfaces
of the crankcase. There must be no gaps in the
bead.
3. The oil pan must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
012RS007
7. Install cylinder block side bolts (1) and tighten

crankcase bolts in sequence shown in the
illustration.
4. Tighten the bolts and nuts to the specified

torque.
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013RW010
Legend
(1) Portion Between Both Holes
(2) Bolt Hole Portions
12. Install cylinder head gasket.

13. Install cylinder head assembly. Refer to “Cylinder
Head" in this manual.
Main Data and Specification
General Specification
Item Specifications
Engine type, number of cylinders and arrangement Water cooled, four cycle V6
Form of combustion chamber Pent-roof type
Valve mechanism 4-Cams, 4-Valves, DOHC Gear & Belt Drive
Cylinder liner type Casted in cylinder block
Total piston displacement 3494 cc
Cylinder bore x stroke 93.4mm x 85.0mm
(3.6772 in ´ 3.3465 in)
Compression ratio 8.6
2
Compression pressure at 300rpm 1.37 MPa (14.0 Kg/cm )
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Engine idling speed rpm Non adjustable (750)
Valve clearance Intake: 0.28 mm (0.11 in)
Exhaust: 0.30mm (0.12 in)
Oil capacity 5.3 liters
Ignition timing Non adjustable (12° BTDC at idle rpm)
Spark plug PK16PR11, RC10PYP4, K16PR-P11
Plug gap 1.0 mm – 1.1 mm (0.0394 in – 0.0433 in)
Torque Specifications
Ignition coil, Spark plug, Crankshaft angle sensor and Under cover
N××m (kg××m/ lb ft)
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RTW460LF000101
Cylinder head cover, Cylinder head, Camshaft bracket, Common chamber, ECM
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RTW46ALF000601
Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, timing belt
cover, Oil pump, Oil gallery, Oil strainer and water pump
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RTW46ALF000701
Connecting rod and Water pump

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E06RW042
Engine mount
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RTW36ALF000101
Special Tool
PART NO. PART NO.
ILLUSTRATION ILLUSTRATION
PART NAME PART NAME
5-8840-2445-0
5-8840-0011-0
(J-42985)
(J-21687-02)
Installer; Camshaft
Remover; tie rod end
oil seal
5-8840-0203-0 5-8840-2545-0
(J-36390) (J-39206)
Wrench; Oil filter (79f) Installer; Pilot bearing
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5-8840-2446-0
(J-8062)
Compressor;
Valve spring (1) 5-8840-0133-0
(J-8614-01)
5-8840-2547-0
(J-42898) Holder; Crankshaft
Adapter; Compressor,
Valve spring (2)
5-8840-0623-0 5-8840-2153-0
(J-37281) (J-37228)
Remover; Oil controller Seal cutter
5-8840-0624-0 5-8840-2286-0
(J-38537) (J-39201)
Installer; Oil controller Installer; Real oil seal
5-8840-2005-0 5-8840-2287-0
(J-29107) (J-39202)
Universal pitman arm Installer; Oil pump
remover oil seal
PART NO.
ILLUSTRATION
PART NAME
9-8511-4209-0
(J-24239-1)
Cylinder head bolt wrench
5-8840-2442-0
(J-42899)
Replacer; Valve guide (1,2)
5-8840-2548-0
(J-42687)
Installer; Valve guide (1)
5-8840-2549-0
(J-37985-1)
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Remover; Valve guide (2)
5-8840-2444-0
(J-42689)
Adjusting Tool; Valve
clearance
5-8840-2443-0
(J-42686)
Lever; Gear spring
5-8840-2447-1
(J-43041)
Holder; Universal

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ENGINE MECHANICAL (6VE1 3.

ENGINE MECHANICAL (6VE1 3.5L)

Crankshaft ............................................................... 6A-71

General Description Cylinder Block

General Information on Engine Service Exhaust Manifold

Symptom Possible Cause Action

2. Ignition Trouble - Starting Motor Turns Over But

Symptom Possible Cause Action

3. Trouble In Fuel System

4. Engine Lacks Compression

9. Repeat the test with each cylinder.

Rough Engine Idling or Engine Stalling

Rough Engine Running

Symptom Possible Cause Action

Engine Lacks Power

Symptom Possible Cause Action

Symptom Possible Cause Action

Symptom Possible Cause Action

Symptom Possible Cause Action

Symptom Possible Cause Action

Symptom Possible Cause Action

Symptom Possible Cause Action

Engine Oil Consumption Excessive

Fuel Consumption Excessive

Engine Oil Pressure Check

Malfunction Indicator Lamp

Symptom Possible Cause Action

Cylinder Head Cover LH

6. Remove fixing bolt for fuel injector harness

2. Install fuel injection harness bracket and tighten

4. Connect ground cable and tighten bolts to the

Cylinder Head Cover RH

2. Install exhaust gas recirculation pipe and tighten to

13. Remove the four throttle body fixing bolts.

5. Remove heat protector two fixing bolts then the

3. Remove steering shaft. Refer to removal

5. Remove cooling fan assembly four fixing nuts,

1. Install timing belt.

NOTE: When timing marks are aligned, No.2 piston will

4. Align the alignment mark on the LH bank

2. Align the alignment mark on the RH bank

6. Install crankshaft pulley temporarily and tighten

3. Remove double clips or equivalent clips, from

4. Install camshaft assembly and camshaft brackets, Legend

3. Tighten twenty bolts on numerical order an one 8. Install crankshaft pulley.

5. Install cylinder head cover RH.

2. Align dowel pin hole to dowel pin on the

NOTE: Do not reuse cylinder head bolts. 6. Install crankshaft pulley.

2. Install common chamber.

Valve Stem Oil Controller, Valve Spring and Valve Guide

4. Install tappet with shim.

Piston, Piston Ring and Connecting Rod

Legend (4) Oil Strainer

1. Remove cylinder head assembly.

3. Remove oil strainer fixing bolts, remove oil strainer

6. Install cylinder head assembly.

Crankshaft and Main Bearings