2014 Chevrolet Sonic 1.4L Motor LUV

2014 Chevrolet Sonic LT
2014 ENGINE Engine Mechanical - 1.4L (LUV) - Sonic
2014 ENGINE
Engine Mechanical - 1.4L (LUV) - Sonic
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications

Specification
Application Metric English
Air Conditioning Compressor Bracket Bolts 22 N.m 16 lb ft
Camshaft Actuator 50 N.m + 60 degrees 37 lb ft + 60 degrees
Camshaft Bearing Cap Bolts 8 N.m 71 lb in
Camshaft Cover Bolts 8 N.m 71 lb in
Camshaft Position Actuator Solenoid Valve 8 N.m 71 lb in
Camshaft Position Sensor Bolt 6 N.m 53 lb in
50 N.m + 60 degrees 37 lb ft + 60 degrees
Camshaft Sprocket Bolt
(1) (1)
Catalytic Converter Bracket to Cylinder Block 22 N.m 16 lb ft
Catalytic Converter to Bracket 22 N.m 16 lb ft
Catalytic Converter to Turbocharger (V-clamp) 13 N.m 115 lb in
Connecting Rod Bearing Cap
(1) (1)
150 N.m + 45
111 lb ft + 45 degrees
Crankshaft Balancer Bolt degrees + 15 degrees
+ 15 degrees (1)
(1)
10 N.m + 60 degrees 89 lb in + 60 degrees
Crankshaft Bearing Tie Plate Bolts (M6)
+ 15 degrees (1) + 15 degrees (1)
Crankshaft Bearing Tie Plate Bolts (M8)
Crankshaft Position Sensor Bolt 8 N.m 71 lb in
35 N.m + 180 26 lb ft + 180 degrees
Cylinder Head Bolts
degrees (1) (1)
Drive Belt Tensioner Bolt M8 22 N.m 16 lb ft
Drive Belt Tensioner Bolt M10 55 N.m 41 lb ft
Engine Cooling Thermostat Housing Bolts 8 N.m 71 lb in
Engine Front Cover Bolts M10 35 N.m 26 lb ft
Engine Front Cover Bolts M6 8 N.m 71 lb in
60 N.m + 45-60 44 lb ft + 45-60
Engine Mount Bracket Bolts
degrees (1) degrees (1)
Engine Mount Right Side to Body 62 N.m 46 lb ft
50 N.m + 60-75 37 lb ft + 60-75
Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69
10:32:52 a. m.
domingo, 25 de junio de 2017 10:32:13 Page 1 © 2011 Mitchell Repair Information Company, LLC.
Engine Mount Right Side to Engine Mount Bracket degrees (1) degrees (1)
Engine Oil Filter Cap 25 N.m 18 lb ft
Exhaust Manifold Heat Shield Bolts 8 N.m 71 lb in
Flywheel Bolts (Two-Mass)
Fuel Injection Rail to Intake Manifold 6 N.m 53 lb in
Generator to Cylinder Block and Engine Cover 35 N.m 26 lb ft
Ignition Coil Bolts 8 N.m 71 lb in
Intake Manifold Bolt 20 N.m 15 lb ft
Knock Sensor 20 N.m 15 lb ft
Oil Cooler Coolant Inlet Pipe to Oil Cooler 10 N.m 89 lb in
Oil Cooler to Engine Block 20 N.m 15 lb ft
Oil Cooler to Oil Filter Assembly (only bolts serviceable) 10 N.m 89 lb in
Oil Filler Plug to Engine Front Cover (M18) 30 N.m 22 lb ft
Oil Filter Assembly to Block 20 N.m 15 lb ft
Oil Gallery Plug in Engine Front Cover (M22) 60 N.m 44 lb ft
Oil Pan Bolt 10 N.m 89 lb in
Oil Pan Drain Plug 14 N.m 124 lb in
Oil Pressure Indicator 20 N.m 15 lb ft
Oil Pressure Relief Valve 50 N.m 37 lb ft
Oil Pump Cover Bolts 8 N.m 71 lb in
Oil Pump Housing Plug (M10) 10 N.m 89 lb in
Oxygen Sensor to Exhaust Manifold 42 N.m 31 lb ft
Oxygen Sensor to Exhaust Front Pipe 42 N.m 31 lb ft
Piston Oil Nozzles to Block 25 N.m 18 lb ft
Spark Plugs 25 N.m 18 lb ft
Starter Bolts 25 N.m 18 lb ft
Throttle Body Bolts 9 N.m 80 lb in
Timing Chain Guide 8 N.m 71 lb in
Timing Chain Tensioner 8 N.m 71 lb in
Timing Chain Tensioner Plug 35 N.m 26 lb ft
Timing Chain Tensioner Shoe 20 N.m 15 lb ft
Turbocharger Coolant Feed Pipe to Engine Block 30 N.m 22 lb ft
Turbocharger Coolant Feed Pipe to Turbocharger (Quick
20 N.m 15 lb ft
Fitting)
Turbocharger Coolant Return Pipe to Turbocharger (Quick
20 N.m 15 lb ft
Fitting)
Turbocharger Oil Feed Pipe to Oil Cooler/Filter 8 N.m 71 lb in
Turbocharger Oil Feed Pipe to Turbocharger 20 N.m 15 lb ft
Turbocharger Oil Return Pipe to Turbocharger 8 N.m 71 lb in
Turbocharger to Cylinder Head 8 N.m (1) 71 lb in (1)
domingo, 25 de junio de 2017 10:32:13 a. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
Water Outlet 8 N.m 71 lb in

Water Pump Housing Bolts
First Pass 8 N.m 71 lb in
Final Pass 30 Degrees (2)
Water Pump Drain Plug 15 N.m 11 lb ft
Water Pump Pulley Bolts 22 N.m 16 lb ft
1 = Use NEW Fastener.
2 = Tighten only 2 bolts to a final pass, see water pump documents.
ENGINE MECHANICAL SPECIFICATIONS
Engine Mechanical Specifications

Specification
Application Metric English
General Data
Engine Type 4-Cylinder Inline
Displacement 1364 ccm 83.24 cu in
Bore 72.5 mm 2.854 in
Stroke 82.6 mm 3.3 in
Compression Ratio 9.5:1
Number of Valves 16
Maximum Power @ engine speed KW/RPM 105 KW /4900
Maximum Torque @ engine speed / RPM / lb ft / 200 N.m / 1850 148 lb ft / 4000
RPM
Engine Block
72.492 mm - 72.508
Cylinder Bore Diameter Standard 2.8540 in - 2.8546 in
mm
72.992 mm - 73.008
Cylinder Bore Diameter Oversize 0.5 2.8737 in - 2.8743 in
mm
Piston, Piston Rings and Piston Pins
72.453 mm - 72.467
Piston Diameter Standard 2.8525 in - 2.8530 in
mm
72.953 mm - 72.967
Piston Diameter Oversize 0.5 2.8722 in - 2.8727 in
mm
Piston Clearance to Bore 0.025 mm -0.055 mm 0.001 in - 0.0022 in
Piston - Upper Compression Ring Thickness 1.17 mm - 1.195 mm 0.0461 in 0.047 in
Piston - Upper Compression Ring Ring Gap 0.25 mm - 0.4 mm 0.0098 in - 0.0157 in
Piston - Upper Compression Ring Side Clearance 0.025 mm - 0.07 mm 0.001 in - 0.0028 in

Piston - Lower Compression Ring Thickness 1.17 mm - 1.195 mm 0.0461 in 0.047 in

Piston - Lower Compression Ring Ring Gap 0.4 mm - 0.6 mm 0.0157 in - 0.0236 in
Piston - Lower Compression Ring Side Clearance 0.025 mm - 0.07 mm 0.001 in - 0.0028 in
Piston - Oil Ring Thickness 1.92 mm - 2 mm 0.0756 in - 0.0787 in
Piston - Oil Ring Ring Gap 0.25 mm - 0.75 mm 0.0098 in - 0.0295 in
Piston - Oil Ring Side Clearance 0.04 mm - 0.12 mm 0.0016 in - 0.0047 in
18.006 mm - 18.012
Piston Pin Bore Diameter 0.7089 in - 0.7091 in
mm
Piston Pin Outer Diameter 17.995 mm - 18 mm 0.7085 in - 0.7087 in
Piston Pin Length 48 mm 1.8898 in
0.005 mm - 0.010 0.0002 in - 0.00039
Piston Pin Clearance to Piston Bore mm in
0.010 mm - 0.018 0.0039 in - 0.00070
Piston Pin Clearance to Conrod Bore mm in
Crankshaft
Crankshaft Bearing Journal Standard Diameter 50.004 mm -50.017
1.9687 in - 1.9692 in
(brown or green) mm
Crankshaft Bearing Journal Undersize 0.25 Diameter 49.754 mm -49.767
1.9588 in - 1.9593 in
(brown/blue or green/blue) mm
Crankshaft Bearing Journal Undersize 0.5 Diameter 49.504 mm -49.517
1.949 in - 1.9495 in
(brown/white or green/white) mm
23.000 mm -23.052
Crankshaft Bearing Journal Width Standard 0.9055 in - 0.9076 in
mm
23.200 mm -23.252
Crankshaft Bearing Journal Width Undersize 0.25 0.9134 in - 0.9154 in
mm
23.400 mm -23.452
Crankshaft Bearing Journal Width Undersize 0.4 0.9213 in - 0.9233 in
mm
Crankshaft Bearing Mark 328N (brown) - Thickness 1.989 mm -1.995 mm 0.0783 in - 0.0785 in
Crankshaft Bearing Mark 329N (green) - Thickness 1.995 mm -2.001 mm 0.0785 in - 0.0788 in
Crankshaft Bearing Mark 330N - Thickness 2.114 mm - 2.120
0.0832 in - 0.0835 in
Undersize 0.25 (brown/blue) mm
Crankshaft Bearing Mark 331 - Thickness Undersize 2.120 mm - 2.126
0.0835 in - 0.0837 in
0.25 (green/blue) mm
0.0881 in - 0.0884 in
0.5 (brown/white) mm
0.0884 in - 0.0886 in
0.5 (green/white) mm
0.007 mm - 0.031
Crankshaft Bearing Clearance 0.0003 in - 0.0012 in
mm
0.100 mm - 0.202
Crankshaft Bearing Clearance Axial 0.0039 in - 0.008 in
mm
Crankshaft Bearing Out Of Round 0.03 mm 0.0012 in
42.971 mm - 42.987
Connecting Rod Bearing Journal Diameter Standard 1.6918 in - 1.6924 in
mm
Connecting Rod Bearing Journal Diameter Undersize 42.721 mm -42.737 1.6819 in - 1.6826 in
0.25 (blue) mm
Connecting Rod Bearing Journal Diameter Undersize 42.471 mm -42.487
1.6721 in - 1.6727 in
0.5 (white) mm
1.490 mm - 1.500
Connecting Rod Bearing Thickness Standard 0.0587 in - 0.0591 in
mm
1.615 mm - 1.625
Connecting Rod Bearing Thickness Undersize 0.25 0.0636 in - 0.064 in
mm
1.740 mm - 1.750
Connecting Rod Bearing Thickness Undersize 0.5 0.0685 in - 0.0689 in
mm
Connecting Rod Bearing Diameter Standard (upper 1.490 mm - 1.500
0.0587 in - 0.0591 in
and lower) mm
Connecting Rod Bearing Diameter Undersize 0.25 1.615 mm - 1.625
0.0636 in - 0.064 in
(upper and lower) mm
Connecting Rod Bearing Diameter Undersize 0.5 1.740 mm - 1.750
0.0685 in - 0.0689 in
(upper and lower) mm
0.013 mm - 0.061
Connecting Rod Bearing Clearance 0.0005 in - 0.0024 in
mm
Cylinder Head
Cylinder Head - Intake Valve Seat Width 1.4 mm - 1.8 mm 0.0551 in - 0.0709 in
Cylinder Head - Exhaust Valve Seat Width 1 mm -1.4 mm 0.0394 in - 0.0551 in
Cylinder Head - Valve Seat Angle 90° 30`
Cylinder Head - Valve Seat Angle Adjustment Upper 110°
Cylinder Head - Valve Seat Angle Adjustment Lower 60°
Cylinder Head - Intake Valve Guide Inner Diameter 4.991 mm - 5.007
0.1965 in - 0.1971 in
Standard mm
Cylinder Head - Intake Valve Guide Inner Diameter + 5.066 mm - 5.082
0.1994 in - 0.2001 in
0.075 mm
Cylinder Head - Intake Valve Guide Inner Diameter 5.141 mm -5.157 mm 0.2024 in - 0.203 in
0.150
Cylinder Head - Exhaust Valve Guide Inner Diameter 4.991 mm - 5.007
0.1965 in - 0.1971 in
Standard mm
0.1994 in - 0.2001 in
+ 0.075 mm


0.2024 in - 0.203 in
+ 0.150 mm
Cylinder Head - Valve Guide Length 38.7 mm - 39.3 mm 1.5236 in - 1.5472 in
Cylinder Head - Surface Flatness (max) - Block Deck 0.05 mm 0.00197 in
- longitude
Cylinder Head - Surface Flatness (max) - Block Deck 0.03 mm 0.00118 in
- transverse
Valve Train
Intake Valve Length Standard 92.9 mm 3.6575 in
Exhaust Valve Length Standard 92.7 mm 3.6496 in
4.950 mm - 4.965
Intake Valve Stem Diameter Standard 0.1949 in - 0.1955 in
mm
4.930 mm - 4.945
Exhaust Valve Stem Diameter Standard 0.1941 in - 0.1947 in
mm
5.025 mm - 5.040
Intake Valve Stem Diameter + 0.075 0.1978 in - 0.1984 in
mm
5.005 mm - 5.020
Exhaust Valve Stem Diameter + 0.075 0.197 in - 0.1976 in
mm
5.100 mm - 5.115
Intake Valve Stem Diameter + 0.150 0.2008 in - 0.2014 in
mm
5.080 mm - 5.095
Exhaust Valve Stem Diameter + 0.150 0.2 in - 0.2006 in
mm
Intake Valve Disc Diameter 27.9 mm - 28.1 mm 1.0984 in - 1.1063 in
Exhaust Valve Disc Diameter 24.9 mm - 25.1 0.9803 in - 0.9882 in
Valve Spring Height Free 40 mm 1.5748 in
Valve Spring Height Under Load - Valve open 21.5 mm 0.8465 in
Valve Spring Height Under Load - Valve closed 30 mm 1.1811 in
0.026 mm - 0.057
Valve Clearance to Guide Intake 0.001 in - 0.0022 in
mm
0.046 mm - 0.077
Valve Clearance to Guide Exhaust 0.0015 in - 0.003 in
mm
Engine Oil
Quality Dexos I
Filling - With New Oil Filter 4L 4.25 Quarts
Viscosity 0W30 / 0W40 / 5W30 / 5W40
Oil Pressure @ Idle Speed 150 kpa 22 psi
Oil Pressure @ 3000 rpm - 3500 rpm 380 kpa - 650 kpa 55 psi - 94 psi
Oil Pump

Axial Clearance Vane Rotor to Cover 0.01 mm 0.0004 in

Axial Clearance Vane to Cover 0.09 mm 0.0036 in
Axial Clearance Vane Ring to Cover 0.04 mm 0.0016 in
Axial Clearance Slide to Cover 0.08 mm 0.0031 in
Axial Clearance Slide Seal to Cover 0.09 mm 0.0036 in
Radial Clearance Vane to Vane Rotor 0.05 mm 0.002 in
Radial Clearance Vane to Slide 0.2 mm 0.008 in
ADHESIVES, FLUIDS, LUBRICANTS AND SEALERS
Adhesives, Fluids, Lubricants and Sealers

Application Type of Material GM Part Number
Bolt Connections Screw Locking Compound Refer to electronic parts catalog
DEXOS II, 0-W30, 0-W40, 5-
Engine Oil Refer to electronic parts catalog
W30 and 5-W40
First Camshaft Bearing Cap Surface Sealant Refer to electronic parts catalog
Oil Pan Oil Pan Sealant Refer to electronic parts catalog
Oxygen Sensor Assembly Paste Refer to electronic parts catalog
Seal Rings Silicon Grease Refer to electronic parts catalog
COMPONENT LOCATOR
DISASSEMBLED VIEWS
Accessory Drive Components

Fig. 1: Locating Accessory Drive Components

Courtesy of GENERAL MOTORS COMPANY
Callout Component Name

1 Generator And Air Conditioning Compressor Belt
2 Drive Belt Tensioner Bolt (short)
3 Drive Belt Tensioner Bolt (long)
4 Drive Belt Tensioner
5 Upper Generator Bolt
6 Water Pump Pulley Bolt
7 Water Pump Pulley
8 Water Pump Bolt (Long)
9 Water Pump Bolt (Short)
10 Water Pump
11 Generator
12 Air Conditioning Compressor Bolt
13 Air Conditioning Compressor

14 Air Conditioning Compressor Bracket Bolt
15 Air Conditioning Compressor Bracket
16 Lower Generator Bolt
17 Crankshaft Balancer
18 Crankshaft Balancer Bolt
Engine Front Cover And Oil Pump Assembly (1 of 2)
Fig. 2: Locating Engine Front Cover And Oil Pump Assembly Components (1 Of 2)

1 Camshaft Position Actuator Solenoid Valve Bolt
2 Intake Camshaft Position Actuator Solenoid Valve
3 Exhaust Camshaft Position Actuator Solenoid Valve

4 Intake Camshaft Position Sensor Bolt

5 Intake Camshaft Position Sensor
6 Intake Camshaft Position Sensor Seal Ring
7 Engine Front Cover
8 Engine Front Cover Gasket
9 Exhaust Camshaft Position Sensor Seal Ring
10 Exhaust Camshaft Position Sensor
11 Exhaust Camshaft Position Sensor Bolt
12 Engine Front Cover Oil Gallery Plug
13 Engine Front Cover Oil Gallery Plug Seal Ring
14 Oil Pressure Relief Valve Piston
15 Oil Pressure Relief Valve Spring
16 Oil Pressure Relief Valve Plug
17 Engine Front Cover Bolt (M10)
18 Crankshaft Front Oil Seal
19 Engine Front Cover Bolt (M6)
20 Water Drain Plug Seal Ring
21 Water Drain Plug
22 Exhaust Camshaft Position Actuator Solenoid Valve Bolt
Engine Front Cover And Oil Pump Assembly (2 of 2)

Fig. 3: Locating Engine Front Cover And Oil Pump Assembly Components (2 Of 2)

1 Oil Pump Cover Bolt
2 Oil Pump Cover
3 Oil Pump Vane Ring
4 Oil Pump Vane Rotor
5 Oil Pump Vane
6 Oil Pump Slide Spring Pin
7 Oil Pump Slide Spring
8 Oil Pump Slide Pivot Pin
9 Oil Pump Slide Seal
10 Oil Pump Slide Seal Spring
11 Oil Pump Slide
12 Oil Pump Vane Ring
Timing Chain Components
Fig. 4: Timing Chain Components


1 Timing Chain Tensioner Bolt
2 Timing Chain Tensioner
3 Timing Chain Tensioner Shoe
4 Camshaft Timing Chain
5 Intake Camshaft Sprocket Bolt (With Actuator)
6 Intake Camshaft Position Sensor Exciter Wheel
7 Intake Camshaft Sprocket (With Position Actuator)
8 Upper Timing Chain Guide Bolt
9 Upper Timing Chain Guide
10 Exhaust Camshaft Sprocket (With Position Actuator)

11 Exhaust Camshaft Position Sensor Exciter Wheel

12 Exhaust Camshaft Sprocket Bolt (With Actuator)
13 Timing Chain Guide Pivot Pin
14 Crankshaft Sprocket
15 Timing Chain Guide Right Side
16 Timing Chain Guide Bolt
17 Timing Chain Tensioner Shoe Bolt
Intake Manifold Assembly- 1.4L LDD
Fig. 5: Locating Intake Manifold Assembly Components - 1.4L LDD


1 Intake Manifold Sealings
2 Intake Manifold (With Intake Manifold Runner and Intake Manifold Runner Valve)

3 Throttle Body Bolt

4 Throttle Body
5 Throttle Body Seal Ring
6 Fuel Injection Fuel Rail Bolt
7 Evaporative Emission Canister Purge Solenoid Valve
8 Evaporative Emission Canister Purge Solenoid Valve Rubber
9 Evaporative Emission Canister Purge Solenoid Valve Bracket Bolt
10 Evaporative Emission Canister Purge Solenoid Valve Bracket
11 Fuel Injection Fuel Rail
12 Fuel Injector Retainer Clamp
13 Fuel Injector
14 Manifold Absolute Pressure Sensor Bolt
15 Manifold Absolute Pressure Sensor
16 Manifold Absolute Pressure Sensor Seal Ring
Cylinder Head Assembly

Fig. 6: Identifying Cylinder Head Assembly Components


1 Camshaft Cover
2 Oil Level Indicator
3 Camshaft Cover Bolt
4 Oil Filler Cap
5 Oil Filler Cap Seal Ring
6 Camshaft Cover Gasket
7 Camshaft Bearing Cap Bolt
8 Camshaft Bearing Cap
9 Cylinder Head Bolt
10 Valve Keys
11 Valve Spring Retainer
12 Valve Spring
13 Engine Lift Bracket Left Side

14 Engine Lift Bracket Bolt
15 Cylinder Head
16 Intake Valve
17 Exhaust Valve
18 Engine Lift Bracket
20 Engine Lift Bracket
22 Oil Pressure Indicator Switch (only for 1.4L LDD)
23 Oil Pressure Indicator Switch Seal Ring (only for 1.4L LDD)
24 Hydraulic Valve Lash Adjuster
25 Hydraulic Valve Lash Adjuster Arm
26 Exhaust Camshaft
27 Intake Camshaft
Engine Block Assembly- 1.4L LDD

Fig. 7: Identifying Engine Block Assembly Components - 1.4L LDD


1 Transmission Guide Sleeve
3 Cylinder Head Guide Sleeve
4 Engine Block
6 Knock Sensor
7 Knock Sensor Bolt
8 Upper Crankshaft Thrust Bearing
9 Upper Crankshaft Bearing
10 Crankshaft
11 Lower Crankshaft Bearing
12 Lower Crankshaft Thrust Bearing
13 Crankshaft Bearing Cap Tie Plate

14 Crankshaft Bearing Cap Tie Plate Bolt (M10)
15 Oil Pan
16 Oil Pan Bolt
17 Oil Pan Drain Plug Seal Ring
18 Oil Pan Drain Plug
19 Crankshaft Position Sensor Bolt
20 Crankshaft Position Sensor
21 Crankshaft Position Sensor Seal Ring
23 Crankshaft Position Sensor Reluctor Ring
24 Flywheel Bolt
25 Engine Flywheel
26 Crankshaft Rear Oil Seal
27 Crankshaft Position Sensor Reluctor Ring Bolt
28 Connecting Rod Bearing Cap Bolt
29 Connecting Rod Bearing Cap
30 Lower Connecting Rod Bearing
31 Upper Connecting Rod Bearing
32 Connecting Rod
33 Piston Pin
34 Piston
35 Piston Oil Ring (With oil Ring Spacer)
36 Lower Compression Ring
37 Upper Compression Ring
Engine Block Assembly- 1.4L LUH and LUJ

Fig. 8: Identifying Engine Block Assembly Components - 1.4L LUH and LUJ

4 Cylinder Head
6 Knock Sensor
7 Knock Sensor Bolt
8 Upper Crankshaft Thrust Bearing
9 Upper Crankshaft Bearing
10 Crankshaft
11 Lower Crankshaft Bearing
12 Lower Crankshaft Thrust Bearing
13 Crankshaft Bearing Cap Tie Plate

15 Oil Pan Baffle
16 Oil Pan Baffle Bolt
17 Oil Pan
18 Oil Pan Bolt
19 Oil Pan Drain Plug
20 Crankshaft Position Sensor Bolt
21 Crankshaft Position Sensor
22 Crankshaft Position Sensor Seal Ring
24 Piston Oil Nozzle
25 Crankshaft Position Sensor Reluctor Ring
26 Crankshaft Position Sensor Reluctor Ring Bolt
27 Crankshaft Rear Oil Seal
28 Engine Flywheel (Two-Mass)
29 Engine Flywheel Bolt
30 Connecting Rod Bearing Cap Bolt
31 Connecting Rod Bearing Cap
32 Lower Connecting Rod Bearing
33 Upper Connecting Rod Bearing
34 Connecting Rod
35 Piston Pin
36 Piston Pin Retainer
37 Piston Pin Retainer
38 Piston
39 Piston Oil Ring (With Oil Ring Spacer)
40 Lower Compression Ring
41 Upper Compression Ring
Intake Manifold Assembly - 1.4L LUH and LUJ

Fig. 9: Intake Manifold Assembly - 1.4L LUH and LUJ


1 Fuel Injector Fuel Rail
2 Fuel Injector Fuel Rail Bolt
3 Manifold Absolute Pressure Sensor
4 Manifold Absolute Pressure Sensor Bolt
5 Evaporative Emission Canister Purge Solenoid Valve
6 Intake Manifold
7 Throttle Body Seal Ring
8 Throttle Body
9 Throttle Body Bolt
10 Intake Manifold Gasket
Exhaust Side - 1.4L LUH and LUJ

Fig. 10: Identifying Exhaust Side Components - 1.4L LUH and LUJ

1 Positive Crankcase Ventilation Pipe Assembly
2 Exhaust Manifold Gasket
3 Turbo Charger Oil Feed Pipe Hollow Screw
4 Turbo Charger Oil Feed Pipe
5 Turbo Charger Oil Feed Pipe Bolt
6 Oil Cooler Coolant Outlet Hose
7 Oil Cooler Coolant Outlet Hose Clamp
8 Oil Cooler Coolant Feed Pipe Bolt
9 Oil Cooler Coolant Feed Pipe
10 Engine Oil Cooler Assembly
11 Catalytic Converter Bracket
12 Catalytic Converter to Catalytic Converter Bracket Nut
13 Turbocharger Coolant Return Pipe

14 Turbocharger Coolant Feed Pipe
15 Turbocharger Coolant Feed Pipe Hollow Screw
16 Heated Oxygen Sensor 1
17 Catalytic Converter
18 Catalytic Converter Heat Shield
19 Catalytic Converter Heat Shield Bolt
20 Catalytic Converter Seal
21 Catalytic Converter V-Clamp
22 Turbocharger Oil Return Pipe
23 Turbocharger Oil Return Pipe Bolt
24 Exhaust Manifold Heat Shield
25 Exhaust Manifold Heat Shield Bolt
26 Turbocharger (with Exhaust Manifold)
27 Engine Oil Pressure Switch
ENGINE IDENTIFICATION
Engine Number

Fig. 11: Locating Engine Number

NOTE: The engine identification number must be stamped to the cylinder block in case
of engine replacement.
The engine number is stamped to the engine block (1).
DIAGNOSTIC INFORMATION AND PROCEDURES

SYMPTOMS - ENGINE MECHANICAL
Strategy Based Diagnostics
Perform a Diagnostic System Check - Vehicle .
All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for
repairing all systems. The diagnostic flow may always be used in order to resolve a system condition. The
diagnostic flow is the place to start when repairs are necessary.
Visual/Physical Inspection
Inspect for aftermarket devices which could affect the operation of the engine.
Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
Inspect for the correct oil level, proper oil viscosity and correct filter application.
Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM,
ambient temperature, engine temperature, amount of engine warm-up time and other specifics.
Compare the engine sounds, if applicable, to a known good engine and make sure you are not trying to
correct a normal condition.
Intermittent
Test the vehicle under the same conditions that the customer reported in order to verify the system is operating
properly.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Noise on Start-Up, but Only Lasting a Few Seconds

Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank - Crankshaft Will Not Rotate
Engine Compression Test
Oil Consumption Diagnosis
Oil Pressure Diagnosis and Testing
Drive Belt Chirping, Squeal and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
OIL PRESSURE DIAGNOSIS AND TESTING
Special Tools
EN-498-B Oil Pressure Gauge

EN-498-3 Adapter
For equivalent regional tools, refer to Special Tools.
Removal Procedure
1. Disconnect the oil pressure indicator switch wiring harness plug.

Fig. 12: Engine Oil Pressure Indicator Switch

2. Remove the oil pressure indicator switch (1) and the oil pressure indicator switch seal ring (2).
Measuring Procedure

Fig. 13: Gauge And Adapter

1. Install EN-498-B gauge (1) along with EN-498-3 adapter (2).

2. Start Engine.
NOTE: The oil temperature should be between 80°C (176°F) and 100°C (212°).
3. Measure the oil pressure:

The oil pressure at idle speed should be 150 kpa (22 psi).
The oil pressure between 3000 - 3500 rpm should be 380 - 650 kpa (55 - 94 psi).
4. Stop engine.
5. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following
conditions:
Oil pump worn or dirty. Refer to Oil Pump Replacement and Engine Front Cover and Oil
Pump Cleaning and Inspection.
Oil suction gallery clogged or dirty. Refer to Oil Pan Cleaning and Inspection
Cracked, porous or restricted oil galleries.
Oil pressure relief valve malfunction.

6. Remove EN-498-B gauge and EN-498-3 adapter.
Installation Procedure
Fig. 14: Engine Oil Pressure Indicator Switch

1. Install the oil pressure indicator switch (1) and a NEW oil pressure indicator switch seal ring (2).
2. Tighten the oil pressure indicator switch to 20 N.m (15 lb ft).
CAUTION: Refer to Fastener Caution .
OIL LEAK DIAGNOSIS
Oil Leak Diagnosis

Step Action Yes No
DEFINITION: You can repair most fluid leaks by first, visually locating the leak, repairing or replacing
the component or by resealing the gasket surface. Once the leak is identified, determine the cause of the
leak. Repair the leak and the cause of the leak.

1. Operate the vehicle until it reaches normal

operating temperature. Refer to Engine
Mechanical Specifications.
2. Park the vehicle on a level surface over a large
1 sheet of paper or other clean surface.
3. Wait 15 minutes.
4. Inspect for drippings.
Are drippings present? Go to Step 2 System OK

Can you identify the type of fluid and the approximate
2
location of the leak? Go to Step 10 Go to Step 3
1. Visually inspect the suspected area. Use a small
mirror to assist in looking at hard to see areas.
2. Inspect for leaks at the following locations:
Sealing surfaces
3 Fittings
Cracked or damaged components

1. Completely clean the entire engine and surrounding
components.
2. Operate the vehicle for several miles at normal
operating temperature and at varying speeds.
3. Park the vehicle on a level surface over a large
4 sheet of paper or other clean surface.
4. Wait 15 minutes.
5. Identify the type of fluid and the approximate
location of the leak.

Sealing surfaces
5 Fittings

1. Completely clean the entire engine and surrounding

components.
2. Apply an aerosol-type powder, for example, baby
powder or foot powder, to the suspected area.
3. Operate the vehicle for several miles at normal
6 operating temperature and at varying speeds.
4. Identify the type of fluid and the approximate
location of the leak from the discolorations in the
powder surface.

Sealing surfaces
7 Fittings

Identify the type of fluid and the approximate location of
the leak.
8
Sealing surfaces
9 Fittings

location of the leak? Go to Step 10 System OK
1. Inspect the engine for mechanical damage. Special
interest should be shown to the following areas:
Higher than recommended fluid levels
Higher than recommended fluid pressures
Plugged or malfunctioning fluid filters or
pressure bypass valves
Plugged or malfunctioning engine ventilation

system
Improperly tightened or damaged fasteners
Cracked or porous components
Improper sealants or gaskets, where required
Improper sealant or gasket installation
10 Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
2. Inspect the engine for customer modifications.
Is there mechanical damage or customer modifications to

the engine? Go to Step 11 System OK
Repair or replace all damaged or modified components.
11 -
Did you complete the repair? Go to Step 1
OIL CONSUMPTION DIAGNOSIS
Oil Consumption Diagnosis

Checks Causes
The causes of excessive oil consumption may include the following conditions:
Preliminary External oil leaks.
Incorrect oil level or improper reading of the oil level indicator.
With the vehicle on a level surface, run the engine for a few
minutes, allow adequate drain down time (2-3 minutes) and
check for the correct engine oil level.
Improper oil viscosity.
Refer to the vehicle owners manual and use the recommended

SAE grade and viscosity for the prevailing temperatures.
Continuous high speed driving and/or severe usage.

Crankcase ventilation system restrictions or malfunctioning
components.
Worn valve guides and/or valve stems.
Worn, missing or improperly installed valve stem oil seals.
Piston rings broken, worn, not seated properly.
Allow adequate time for the rings to seat.
Replace worn piston rings as necessary.

Piston and rings improperly installed or miss-fitted to the

cylinder bore.
ENGINE NOISE UNDER LOAD
Engine Noise Under Load

Cause Correction
Insufficient or poor oil supply to components.
Low oil pressure 1. Perform oil pressure test.
2. Repair or replace all damaged components.
1. Inspect the torque converter bolts and flywheel.
Loose torque converter bolts
1. Inspect the flywheel and flywheel attaching bolts.
Loose and/or damaged flywheel
1. Inspect the piston rings for low ring tension, broken or worn
Excessive piston-to-cylinder
rings, inspect cylinder bore.
bore clearance
Excessive crankshaft thrust 1. Inspect the crankshaft end play and crankshaft thrust bearings.
bearing clearance 2. Repair or replace all damaged components.
Excessive crankshaft bearing 1. Inspect the crankshaft bearings and crankshaft journals.
clearance 2. Repair or replace all damaged components.
ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS
Engine Noise on Start-Up, but Only Lasting a Few Seconds

Cause Correction
Incorrect oil filter without anti-drainback feature Install the correct oil filter.
Incorrect oil viscosity Drain the engine oil and replace with the correct
viscosity oil.
High stationary hydraulic lash adjuster (SHLA), Replace the SHLAs, valve lifters, as required.
valve lifter, leak down rate
Worn crankshaft thrust bearing Inspect the thrust bearing and crankshaft.
Repair or replace as required.
Damaged or faulty oil filter by-pass valve Inspect the oil filter by-pass valve for proper
operation.
Repair or replace as required.
BASE ENGINE MISFIRE WITHOUT INTERNAL ENGINE NOISES

Base Engine Misfire without Internal Engine Noises

Condition Action
Abnormalities in the accessory drive belt and/or components may
Abnormalities (severe cracking, cause engine RPM variations, noises similar to a faulty lower engine
bumps or missing areas) in the and also lead to a misfire condition. A misfire code may be present
accessory drive belt. Also worn, without an actual misfire condition.
damaged or misaligned accessory
drive components or excessive 1. Inspect the accessory drive components.
pulley runout.
A misfire code may be present without an actual misfire condition.
Loose and/or damaged crankshaft
pulley 1. Inspect crankshaft pulley and pulley bolt.
Loose torque converter bolts 1. Inspect torque converter bolts and flywheel.
Loose and/or damaged flywheel 1. Inspect flywheel and flywheel attaching bolts.
A severe restriction in the exhaust flow can cause significant loss of
engine performance and may set a misfire code. Possible causes of
Restricted exhaust system
restrictions include collapsed or dented pipes, plugged mufflers and/or
catalytic converters. Repair or replace all damaged components.
1. Inspect fuel filter, fuel system for leaks and/or restrictions.
Air in fuel system
Bent and/or worn valve bridge 1. Inspect valve bridge and valve finger-follower.
and finger-follower 2. Repair or replace all damaged components.
Carbon on the valve stem or valve seat may cause the valve to stick.
Sticking valve 1. Inspect valves and valve guides.
Damaged or misaligned timing 1. Inspect timing gears.
gears 2. Replace all damaged components.
1. Inspect camshaft lobes.
Worn or faulty camshaft lobes
1. Perform compression tests.
Excessive piston-to-cylinder bore
clearance 2. Inspect the piston, piston rings and cylinder bore.
Faulty cylinder head gaskets
and/or cracking or other damage

to the cylinder heads and engine 1. Perform compression tests.
block cooling system passages.
(Coolant consumption may or 2. Inspect the piston, piston rings and cylinder bore.
may not cause the engine to 3. Repair or replace all damaged components.
overheat.)
BASE ENGINE MISFIRE WITH ABNORMAL INTERNAL LOWER ENGINE NOISES
Base Engine Misfire with Abnormal Internal Lower Engine Noises

Condition Actions
Abnormalities (server cracking, Abnormalities in the accessory drive belt and/or components may
bumps or missing areas) in the cause engine RPM variations, noises similar to faulty lower engine and
accessory drive belt also lead to a misfire condition. A misfire code may be present without
an actual misfire condition.
1. Inspect the accessory drive components.

Worn, damaged or misaligned
accessory drive components or 1. Inspect the accessory drive components.
excessive pulley runout
2. Repair or replace all damage components.
Loose and/or damaged crankshaft
pulley 1. Repair or replace all damaged components.
2. Inspect crankshaft pulley and pulley bolt.
Loose torque converter bolts 1. Inspect torque converter bolts and flywheel.
Loose and/or damaged flywheel 1. Inspect flywheel and flywheel attaching bolts.
1. Perform cylinder leak down and compression tests.
Excessive piston-to-cylinder bore
clearance 2. Inspect the piston, piston rings and cylinder bore.
Severely worn thrust surfaces on the crankshaft and/or thrust bearing
may permit for and aft movement of the crankshaft and create a
Excessive crankshaft thrust misfire code without an actual misfire condition.
bearing clearance
1. Inspect the crankshaft end play and crankshaft thrust bearings.
2. Repair or replace all damaged.
BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE
Base Engine Misfire with Abnormal Valve Train Noise

Condition Action
Loose, worn or damaged valve 1. Inspect valve bridge and finger-follower.
bridge and finger-follower 2. Repair or replace all damaged components.
1. Inspect valve springs.
Broken valve springs
BASE ENGINE MISFIRE WITH COOLANT CONSUMPTION
Base Engine Misfire with Coolant Consumption

Inspection Action
DEFINITION: Base engine misfire with coolant consumption
Preliminary Inspection Verify that there are no external coolant leaks.
Cylinder balance test with scan tool
Cooling system pressurization
Isolate Affected Cylinders
Inspection of glow plugs
Compression test
Inspect EGR valve and intake system for evidence of coolant
EGR System Inspection leakage.
Replace the EGR cooler if any problem is found.
Remove cylinder heads of the affected cylinder bank and inspect
Cylinder Head Gasket Leakage for damage.
Replace components as necessary.
Inspect the cylinder head for cracks.
Inspect the cylinder block for damage.
Cylinder Head or Engine Block
Damage Inspect the cylinder block to head mating surface for
straightness.
Replace components as necessary.
BASE ENGINE MISFIRE WITH EXCESSIVE OIL CONSUMPTION
Base Engine Misfire with Excessive Oil Consumption

Condition Action
1. Inspect the valves and valve guides.
Worn valve guides
1. Inspect the valve stem oil seals.
Worn valve stem oil seals
1. Perform compression tests to determine the cause.
2. Inspect the piston rings for low ring tension, broken or worn
Excessive piston-to-cylinder
rings.
bore clearance
3. Inspect cylinder bore.
UPPER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
Upper Engine Noise, Regardless of Engine Speed

Condition Action
Insufficient or poor oil supply to valve train.
Low oil pressure 1. Perform oil pressure test.
1. Inspect valve finger-follower, valve bridge, valve finger follower
Improper lubrication to the valve
lifter, oil pump and engine block oil galleries.
finger-follower
Worn or damaged valve finger- 1. Inspect valve bridge and finger-follower.
follower 2. Repair or replace all damaged components.
2. If damaged replace camshaft and all valve finger-followers.
Damaged or misaligned timing 1. Inspect timing gears.
gears 2. Replace all damaged components.
LOWER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
Lower Engine Noise, Regardless of Engine Speed

Condition Action
Worn accessory drive
components (abnormalities such
as severe cracking, bumps or 1. Inspect the accessory drive components.
missing areas in the accessory 2. Repair or replace all damaged components.

drive belt and/or misalignment of
the system components.)
Insufficient or poor oil supply to crankshaft and connecting rod
bearings.
Low oil pressure
1. Perform oil pressure test.
1. Inspect the cylinder balance with scan tool to help locate the
Leaking and/or sticking fuel cylinder that is the source of the noise.
injection nozzle (A stuck fuel
injection nozzle can cause a noise 2. If you cannot locate the cylinder that is the source of the noise,
similar to a damaged piston, rod diagnose the engine for mechanical damage.
or rod bearing.) 3. If it has been determined that the fuel injection nozzle is causing
the noise, replace the fuel injection nozzle.
Loose and/or damaged crankshaft 1. Inspect crankshaft pulley and pulley bolt.
pulley 2. Repair or replace all damaged components.
1. Inspect torque converter bolts and flywheel.
Loose torque converter bolts
1. Inspect flywheel and flywheel attaching bolts.
Loose and/or damaged flywheel
Excessive piston pin-to-bore 1. Inspect the piston, piston pin and the connecting rod.
Misaligned or bent connecting 1. Inspect connecting rod and connecting rod bearings.
rod 2. Repair or replace all damaged components.
1. Inspect the connecting rod bearings, connecting rods, crankshaft
Excessive connecting rod bearing
and crankshaft journals.
clearance
Excessive crankshaft bearing 1. Inspect the crankshaft bearings and crankshaft journals.
ENGINE WILL NOT CRANK - CRANKSHAFT WILL NOT ROTATE
Engine Will Not Crank - Crankshaft Will Not Rotate

Cause Correction
Seized accessory drive system 1. Inspect the accessory drive system components.
component 2. Repair or replace all damaged components.
Hydraulically locked cylinder

1. Inspect for broken head gasket(s).
Coolant/antifreeze in cylinder 2. Inspect for cracked engine block or cylinder head.
Oil in cylinder 3. Inspect for a sticking fuel injector.

Fuel in cylinder
1. Remove the engine assembly. The torque converter bolts are
Seized automatic transmission
not accessible with the engine installed to the transmission.
torque converter
2. Rotate the crankshaft at the pulley.
1. Disengage the clutch.
Seized manual transmission
2. Rotate crankshaft at the pulley.
Material in cylinder
1. Inspect the cylinder for damaged components and/or foreign
Broken valve materials.
Piston material 2. Repair or replace as required.
Foreign material
Seized crankshaft or connecting rod 1. Inspect the crankshaft and connecting rod bearings.
bearing 2. Repair as required.
1. Inspect the connecting rods.
Bent or broken connecting rod
2. Repair as required.
1. Inspect the crankshaft.
Broken crankshaft
2. Repair as required.
ENGINE COMPRESSION TEST
Special Tools
EN-48248 Cylinder Compression Pressure Gauge
Removal Procedure
1. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement .
2. Remove the spark plugs. Refer to Spark Plug Replacement .
3. Remove the relay holder cover.
4. Remove the fuel pump relay.
5. Crank the engine with the starter motor for 5 seconds to remove any foreign substances from the
cylinders.
NOTE: The engine cranking time for the compression test should be less then 10
seconds and at 30 second intervals.
6. Prior to taking a compression reading, verify the cranking speed is greater than 300 RPM. If the cranking
speed is below 300 RPM, repair the slow cranking speed condition before continuing with the
compression test.
7. Install EN-48248 gauge in the spark plug bore for the cylinder that is being checked.
8. Using the vehicle's starter motor, rotate or crank the engine for 4 compression strokes, puffs, for the
cylinder being tested.
9. Observe the compression gauge and note the reading as the compression test is being performed. A
normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified
level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts
increasing on the following compression strokes but does not reach the specified level.
10. Record the compression reading for the cylinder just tested.
11. Repeat steps for all remaining cylinders. All 4 cylinders must be tested to obtain valid test results. Record
the readings.
12. The maximum pressure differential should not exceed 100 kPa (14.5 psi).
13. The nominal cylinder compression value is
for natural aspirated engines 1300 kPa - 1500 kPa (188.5 psi - 217.6 psi).
for turbo engines 1200 kPa - 1400 kPa (174 psi - 203.1 psi).
1. Install the fuel pump relay.

2. Install the relay holder cover.
3. Install the spark plugs. Refer to Spark Plug Replacement .
4. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement .
DRIVE BELT CHIRPING, SQUEAL AND WHINE DIAGNOSIS
Diagnostic Aids
A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be
necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern.
If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable
solution.
If the noise is intermittent, verify the accessory drive components by varying their loads making sure they
are operated to their maximum capacity. An overcharged A/C system, power steering system with a
pinched hose or wrong fluid or a generator failing are suggested items to inspect.
A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or
suspension component. Other items of the vehicle may also cause the noise.
The drive belts will not cause a whine noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table.

The noise may not be engine related. This step is to verify that the engine is making the noise. If the
engine is not making the noise do not proceed further with this table.
The noise may be an internal engine noise. Removing the drive belts one at a time and operating the
engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the
water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is
operating with the drive belts removed.
Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive
belt grooves from the accumulation of rubber dust.
Misalignment of the pulleys may be caused from improper mounting of the accessory drive component,
incorrect installation of the accessory drive component pulley or the pulley bent inward or outward from a
previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or
three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper
installation procedure for that pulley.
10
Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer or washer was
installed.
12
Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys
that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth
surface of a pulley when the back side of the belt is used to drive the pulley.
14
This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not
operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which
could cause a squeal noise.
15
This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from
working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and
may be turning an accessory drive component in the wrong direction.
16
installation procedure for that pulley.
17
This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle
compare the pulley sizes.
19
Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary
repair.
Drive Belt Chirping, Squeal and Whine Diagnosis

Step Action Yes No
CAUTION:
Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition
of the drive belt. Failure to follow this recommendation will damage the drive belt.
DEFINITION: The following items are indications of chirping:
A high pitched noise that is heard once per revolution of the drive belt or a pulley.
Chirping may occur on cold damp start-ups and will subside once the vehicle reaches normal
operating temp.
DEFINITION: The following items are indications of drive belt squeal:
A loud screeching noise that is caused by a slipping drive belt. This is unusual for a drive belt with
multiple ribs.
The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning
compressor engagement snapping the throttle or slipping on a seized pulley or a faulty accessory
drive component.
DEFINITION: The following items are indications of drive belt whine:
A high pitched continuous noise.

The noise may be caused by an accessory drive component failed bearing.
Did you review the Drive Belt Symptom operation and Go to Symptoms -
1
perform the necessary inspections? Go to Step 2 Engine Mechanical
Verify that there is a chirping, squeal or whine noise.
2 Does the engine make the chirping squeal or whine Go to Diagnostic
noise? Go to Step 3 Aids

1. Remove the drive belt.
If the engine has multiple drive belts, remove

the belts one at a time and perform the test
below each time a belt is removed.
3
2. Operate the engine for no longer than 30-40
seconds.
3. Repeat this test if necessary by removing the
remaining belt(s).
Go to Symptoms -
Does the chirping, squeal or whine noise still exist? Engine Mechanical Go to Step 4
If diagnosing a chirping noise, inspect for severe
pilling exceeding 1/3 of the belt groove depth.
4 If diagnosing a squeal or whine noise, proceed to Step
13 .
Do the belt grooves have pilling? Go to Step 5 Go to Step 6
Clean the drive belt pulleys with a suitable wire brush.
5
Did you complete the repair? Go to Step 20 Go to Step 6
Inspect for misalignment of the pulleys.
6
Are any of the pulleys misaligned? Go to Step 7 Go to Step 8
Replace or repair any misaligned pulleys.
7
Inspect for bent or cracked brackets.
8
Did you find any bent or cracked brackets? Go to Step 9 Go to Step 10
Replace any bent or cracked brackets.
9
Inspect for improper, loose or missing fasteners.
10
Did you find the condition? Go to Step 11 Go to Step 12
1. Tighten any loose fasteners. Refer to Fastener
Tightening Specifications.
CAUTION:
11 Refer to Fastener Caution .
2. Replace any improper or missing fasteners.

Inspect for a bent pulley.
12
Inspect for an accessory drive component seized
bearing or a faulty accessory drive component.
13 Did you find and correct the condition?
If diagnosing a whine noise and the condition still

exist, proceed to Diagnostic Aids. Go to Step 20 Go to Step 14

Test the drive belt tensioner for proper operation.
14
Did you find and correct the condition? Go to Step 20 Go to Step 15
Inspect for the correct drive belt length.
15
Inspect for misalignment of a pulley.
16
Inspect for the correct pulley size. Go to Diagnostic
17
Did you find and correct the condition? Go to Step 20 Aids
Replace the bent pulley.
18
Replace the drive belt. Refer to Symptoms - Engine
19 Mechanical. Go to Diagnostic
Did you complete the repair? Go to Step 20 Aids
Operate the system in order to verify the repair.
20
Did you correct the condition? System OK Go to Step 3
DRIVE BELT RUMBLING AND VIBRATION DIAGNOSIS
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the engine operating
may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused
by, but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid or
an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the
accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt
may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table and the noise is only heard when the drive belts are
installed, there might be an accessory drive component with a failure. Varying the load on the different
accessory drive components may aid in identifying which component is causing the rumbling noise.
Test Description
This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause
a similar symptom.
This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise
may be confused with an internal engine noise due to the similarity in the description. Remove only one
drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump
may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with
the drive belts removed.
Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of
the drive belt will not cause the noise. Belt separation can be recognized at the edge of the belt or felt as a
lump in the belt.
Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt
does not have a smooth surface for proper operation.
Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer or washer was
installed.
11
This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump
shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play.
Compare the water pump with a known good water pump.
12
Accessory drive component brackets that are bent, cracked or loose may put extra strain on that accessory
component causing it to vibrate.
Drive Belt Rumbling and Vibration Diagnosis

Step Action Yes No
DEFINITION: The following items are indications of drive belt rumbling:
A low pitch tapping, knocking or thumping noise heard at or just above idle.
Heard once per revolution of the drive belt or a pulley.
Rumbling may be caused from:
Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive
belt pulley groove
The separation of the drive belt
A damaged drive belt.

DEFINITION: The following items are indications of drive belt vibration:
The vibration is engine-speed related.

The vibration may be sensitive to accessory load.
Did you review the Drive Belt Symptom operation Go to Symptoms -
1
and perform the necessary inspections? Go to Step 2 Engine Mechanical
Verify that there is a rumbling noise or that the
vibration is engine related.
2
Does the engine make the rumbling noise or Go to Diagnostic
vibration? Go to Step 3 Aids
If the engine has multiple drive belts, remove

the belts one at a time and perform the test
below each time a belt is removed.
3
2. Operate the engine for no longer than 30-40
seconds.
3. Repeat this test if necessary by removing the
remaining belt(s).
Go to Symptoms -
Does the rumbling or vibration still exist? Engine Mechanical Go to Step 4
Inspect the drive belts for wear, damage, separation,
4 sections of missing ribs and debris build-up.
Did you find any of these conditions? Go to Step 7 Go to Step 5
Inspect for severe pilling of more than 1/3 of the
5 drive belt pulley grooves.
Did you find severe pilling? Go to Step 6 Go to Step 7
1. Clean the drive belt pulleys using a suitable
wire brush.
6 2. Reinstall the drive belts.
Did you correct the condition? Go to Step 8 Go to Step 7

Install a new drive belt.
7
Did you complete the replacement? Go to Step 8 Go to Step 9
8
9
Did you find any of these conditions? Go to Step 10 Go to Step 11
1. Tighten any loose fasteners. Refer to
Fastener Tightening Specifications.
10
CAUTION:

Refer to Fastener Caution .
2. Replace improper or missing fasteners.

Inspect for bent or cracked brackets. Go to Diagnostic
11
Did you find and correct the condition? Go to Step 12 Aids
12
DRIVE BELT FALLS OFF AND EXCESSIVE WEAR DIAGNOSIS
Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to
fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the
application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive
belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall
off.
Test Description
This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when
the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect
the belt for cuts, tears or sections of ribs missing.
installation procedure of that pulley.
Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys
that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth
surface of a pulley when the back side of the belt is used to drive the pulley.
Accessory drive component brackets that are bent or cracked will let the drive belt fall off.
Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer or washer was
installed. Missing. loose or the wrong fasteners may cause pulley misalignment from the bracket moving
under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.
13
The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the
drive belt may be caused by mis-positioning the drive belt by one groove on a pulley.
14
The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive
belt ribs should match all of the grooves on all of the pulleys.
15
This inspection is to verify the drive belt is not contacting any parts of the engine or body while the
engine is operating. There should be sufficient clearance when the drive belt accessory drive components
load varies. The drive belt should not come in contact with an engine or a body component when
snapping the throttle.
Drive Belt Falls Off and Excessive Wear Diagnosis

Step Action Yes No
DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys.
DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt.
Did you review the Drive Belt Symptom operation and Go to Symptoms -
1
perform the necessary inspections? Go to Step 2 Engine Mechanical
If diagnosing high wear, proceed to Step 13 .
If diagnosing a drive belt that falls off, inspect for a
2
damaged drive belt.
Install a new drive belt. Refer to Drive Belt
Replacement.
3
Does the drive belt continue to fall off? Go to Step 4 System OK
Inspect for misalignment of the pulleys.
4
Did you find and repair the condition? Go to Step 12 Go to Step 5
Inspect for a bent or dented pulley.
5
Inspect for a bent or a cracked bracket.
6
7
Did you find loose or missing fasteners? Go to Step 8 Go to Step 9
1. Tighten any loose fasteners. Refer to Fastener
Tightening Specifications.
CAUTION:
2. Replace improper or missing fasteners.

Test the drive belt tensioner for operating correctly.
9
Does the drive belt tensioner operate correctly? Go to Step 11 Go to Step 10
Replace the drive belt tensioner. Refer to Drive Belt
10 Tensioner Replacement.
Inspect for failed drive belt idler and drive belt
11 tensioner pulley bearings. Go to Diagnostic
Did you find and repair the condition? Go to Step 12 Aids
12
Inspect the drive belt for the proper installation. Refer
13 to Drive Belt Replacement.
Did you find this condition? Go to Step 16 Go to Step 14
Inspect for the proper drive belt.
14
Did you find this condition? Go to Step 16 Go to Step 15
Inspect for the drive belt rubbing against a bracket,
15 hose or wiring harness. Go to Diagnostic
Did you find and repair the condition? Go to Step 17 Aids
Replace the drive belt. Refer to Drive Belt
16 Replacement.
Did you complete the replacement? Go to Step 17 -
17
Did you correct the condition? System OK -
DRIVE BELT TENSIONER DIAGNOSIS

Special Tools
EN-48488 Holding Wrench
1. Diagnosis consists of a function check on the automatic belt tensioner and a visual check on the belt and
the components linked to the belt.
Fig. 15: Drive Belt Tensioner Spring, Drive Belt Tensioner Pulley Bolt And Wrench
2. Install the EN-48488 wrench (2) to the drive belt tensioner pulley bolt (1).
3. Apply tension to the drive belt tensioner spring (3) by moving the drive belt tensioner pulley clockwise.
4. Allow the drive belt tensioner to slide back slowly and thereby inspect the drive belt tensioner mechanism
for practicability.
REPAIR INSTRUCTIONS - ON VEHICLE

DRIVE BELT REPLACEMENT

Special Tools

EN-955 Locking Pin
Removal Procedure
1. Remove the right front wheelhouse liner extension. Refer to Front Wheelhouse Liner Inner Front
Extension Replacement (Left Side) , Front Wheelhouse Liner Inner Front Extension Replacement
(Right Side, LUV) , Front Wheelhouse Liner Inner Front Extension Replacement (Right Side,
LWE, LUW) .
2. Install the engine support fixture. Refer to Engine Support Fixture.
3. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
Fig. 16: Holding Wrench And Drive Belt Tensioner

4. Install EN-48488 holding wrench (2) to the drive belt tensioner (1).

Fig. 17: Locking Pin

5. Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with EN-955 locking
pin (1).
6. Remove the EN-48488 holding wrench.

Fig. 18: Drive Belt Routing

7. Remove the drive belt (1).

Fig. 19: Drive Belt Routing

1. Install the drive belt (1).


2. Install the EN-48488 holding wrench (2) to the drive belt tensioner (1).


3. Move the drive belt tensioner clockwise until EN-955 locking pin (1) can be removed.
4. Allow the tensioner to slide back slowly.
6. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
7. Install the right front wheelhouse liner extension. Refer to Front Wheelhouse Liner Inner Front
LWE, LUW) .
8. Remove the engine support fixture. Refer to Engine Support Fixture.
DRIVE BELT TENSIONER REPLACEMENT
Special Tools
EN-955 Locking Pin


Removal Procedure
LWE, LUW)

4. Install the EN-48488 holding wrench (2) to the drive belt tensioner (1).


pin (1).
8. Repeat steps 4 and 5 in order to remove the EN-955 locking pin from the drive belt tensioner.

Fig. 24: Drive Belt Tensioner And Bolts

9. Remove the lower drive belt tensioner bolt (1).

10. Remove the upper drive belt tensioner bolt (2).
11. Remove the drive belt tensioner (3).


1. Install the drive belt tensioner (3).

2. Install the lower drive belt tensioner bolt (1).
3. Install the upper drive belt tensioner bolt (2).
4. Tighten the lower drive belt tensioner bolt (1) to 22 N.m (16 lb ft).
5. Tighten the upper drive belt tensioner bolt (2) to 55 N.m (41 lb ft).


NOTE: Engine mount bracket is removed.
6. Install the EN-48488 holding wrench (2) to drive belt tensioner (1).


pin (1).
8. Install the drive belt.
9. Move the drive belt tensioner clockwise until EN-955 locking pin can be removed.
10. Allow the tensioner to slide back slowly.
LWE, LUW) .
ENGINE MOUNT REPLACEMENT - RIGHT SIDE

Fig. 28: Engine Mount & Components

Engine Mount Replacement - Right Side

Preliminary Procedures
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
3. Prior to removing the mount, mark the mount location using spray paint or a marker for correct
positioning during installation.
Engine Mount Bolt (Qty: 1)
CAUTION:
1
Tighten
62 N.m (46 lb ft)
Engine Mount Nut (Qty: 2)
2 Tighten
62 N.m (46 lb ft)
Engine Mount Bracket to Mount Bolt (Qty: 3)
Procedure
Ensure to use a NEW bolt whenever the mount is removed..

Tighten
50 N.m + 60° to 75° (37 lb ft + 60° to 75°)
3
Special Tools
EN-470-B Angular Torque Wrench
For equivalent regional tools, refer to Special Tools
4 Engine Mount
ENGINE MOUNT BRACKET REPLACEMENT - RIGHT SIDE
Fig. 29: Engine Mount Bracket - Right Side

Engine Mount Bracket Replacement - Right Side

1. Remove the engine mount. Refer to Engine Mount Replacement - Right Side.
2. Remove the front wheelhouse front liner if necessary. Refer to Front Wheelhouse Liner
Replacement (Rear) , Front Wheelhouse Liner Replacement (Front) , Front Wheelhouse
Liner Replacement (with WFK) .
Engine Mount Bracket Fastener (Qty: 3)
CAUTION:

This component uses torque-to-yield bolts. When servicing this component do not
reuse the bolts, New torque-to-yield bolts must be installed. Reusing used torque-to-
yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW
torque-to-yield bolts may lead to engine damage.
CAUTION:
Procedure
Raise and lower the engine as needed to access the bolts.
Tighten
62 N.m (46 lb ft)
2 Engine Mount Bracket
ENGINE COVER REPLACEMENT
Fig. 30: Engine Cover And Oil Cap

Engine Cover Replacement

1 Engine Cover
Procedure
Use a suitable tool to first unclip the front of the cover, then rotate the cover backward and
pull upward to remove.
INTAKE MANIFOLD REPLACEMENT
Special Tools
EN-34730-91 Pressure Tester

EN-6015 Closure Plugs
For equivalent regional tools, refer to Special Tools
Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Remove the engine sight shield.
Fig. 31: Heater Outlet Hose And ECM Wiring Harness Retainer Clips
3. Unclip the heater outlet hose from retainer clip (1).

4. Unclip the engine control module wiring harness from 2 retainer clips (2).
5. Lower the vehicle.
6. Remove the charge air cooler outlet air hose from the throttle body. Refer to Charge Air Cooler Outlet
Air Hose Replacement .
Fig. 32: Throttle Body Wiring Harness Plug

7. Disconnect the throttle body wiring harness plug (1).

Fig. 33: PCV Hose And Wiring Harness Plugs

8. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (2).
9. Disconnect the manifold absolute pressure sensor wiring harness plug (1).
10. Disconnect the 4 fuel injector wiring harness plugs (4).
11. Unclip the engine control module wiring harness from the camshaft cover.
12. Disconnect the PCV hose (3).

Fig. 34: Turbocharger Wastegate Regulator Solenoid Valve Wiring Harness Plug, Intake Manifold
And Fuel Injection Rail Retainer Clips
13. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).
14. Unclip the engine control module wiring harness from 2 intake manifold retainer clips (2) and from 2 fuel
injection rail retainer clips (1).
15. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

Fig. 35: Fuel Feed Pipe And Fuel Injector Rail

16. Remove the fuel feed pipe (4) from fuel injector rail.
17. Unclip the fuel feed pipe from retainer clip (1).
18. Remove the fuel ventilation pipe (2) from evaporative emission canister purge solenoid valve.
19. Unclip the fuel ventilation pipe from retainer clip (1).
20. Close the vents with the EN-6015 closure plugs.
21. Disconnect the brake booster vacuum pipe (3) from the intake manifold.

Fig. 36: Intake Manifold Bolts

NOTE: The intake manifold bolts remain in intake manifold.
22. Remove the 6 intake manifold bolts (1).

Fig. 37: Intake Manifold

23. Remove the intake manifold (1) and the intake manifold gasket.
24. Transfer parts from intake manifold as necessary. Refer to Intake Manifold Disassemble and Intake
Manifold Assemble.
1. Clean the sealing surfaces.


2. Install the intake manifold (1) along with a NEW intake manifold gasket.


3. Install the 6 intake manifold bolts (1) and tighten to 20 N.m (15 lb ft).

Fig. 40: Fuel Feed Pipe And Fuel Injector Rail

4. Connect the fuel ventilation pipe (2) to the evaporative emission canister purge solenoid valve.
5. Clip in the fuel ventilation pipe to the retainer clip (1).
6. Connect the fuel feed pipe (4) to the injector rail.
7. Clip in the fuel feed pipe to the retainer clip (1).
8. Connect the brake booster vacuum pipe (3) to the intake manifold.

Fig. 41: Turbocharger Wastegate Regulator Solenoid Valve Wiring Harness Plug, Intake Manifold
And Fuel Injection Rail Retainer Clips
9. Connect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).
10. Clip in the engine control module wiring harness to 2 intake manifold retainer clips (2) and from 2 fuel
injection rail retainer clips (1).

Fig. 42: PCV Hose And Wiring Harness Plugs

11. Clip in the engine control module wiring harness to the camshaft cover.
12. Connect the 4 fuel injector wiring harness plugs (4).
13. Connect the manifold absolute pressure sensor wiring harness plug (1).
14. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (2).
15. Connect the PCV hose (3).

Fig. 43: Throttle Body Wiring Harness Plug

16. Connect the throttle body wiring harness plug (1).

17. Install the charge air cooler outlet air hose to the throttle body. Refer to Charge Air Cooler Outlet Air
Hose Replacement .
18. Raise and support the vehicle.

Fig. 44: Heater Outlet Hose And ECM Wiring Harness Retainer Clips
19. Clip in the heater outlet hose to retainer clip (1).

20. Clip in the engine control module wiring harness to 2 retainer clips (2).
21. Install the engine sight shield.
22. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
CAMSHAFT TIMING CHAIN REPLACEMENT
Special Tools
EN-955 Locking Pin
For equivalent regional tools. Refer to Special Tools.
Removal Procedure
1. Remove the engine front cover. Refer to Engine Front Cover with Oil Pump Replacement.

Fig. 45: Timing Chain And Timing Chain Tensioner

NOTE: If EN-955 fixing pin can not be inserted, compress the timing chain
tensioner further with the aid of a flat bladed tool to allow complete
insertion of the pin.
2. Push the timing chain (2) in direction to the timing chain tensioner (1) and install the EN-955 pin (3).

Fig. 46: Upper Timing Chain Guide And Bolts

3. Remove the two upper timing chain guide bolts (1).

4. Remove the upper timing chain guide (2).

Fig. 47: Timing Chain Guide Right Side

5. Remove the two timing chain guide right side bolts (2).
6. Remove the timing chain guide right side (1).

Fig. 48: Timing Chain Tensioner Shoe And Bolt

7. Remove the timing chain tensioner shoe bolt (2).

8. Remove the timing chain tensioner shoe (1).

Fig. 49: Timing Chain And Crankshaft Sprocket

9. Remove the timing chain (1) and crankshaft sprocket (2) together as a unit.

Fig. 50: Engine Front Cover Gasket

10. Remove the engine front cover gasket (1).
1. Clean the engine front cover sealing surfaces on engine block and cylinder head.

Fig. 51: Sealing Compound Application Areas

2. Apply a 2 mm (0.0787 in) bead of RTV sealant the areas shown above (1, 2).


3. Install the engine front cover gasket (1).


4. Install the two upper timing chain guide bolts (1) and tighten to 8 N.m (71 lb in).
5. Install the upper timing chain guide (2).


6. Install the timing chain (1) and crankshaft sprocket (2) together as a unit.


7. Install the timing chain tensioner shoe (1).

8. Install the timing chain tensioner shoe bolt (2) and tighten to 20 N.m (15 lb ft).


9. Install the timing chain guide right side (1).

10. Install the timing chain guide right side bolts (2) and tighten to 8 N.m (71 lb in).


11. Push the timing chain (2) in direction of the timing chain tensioner (1) and remove EN-955 pin (3).
12. Install the engine front cover. Refer to Engine Front Cover with Oil Pump Replacement.
TIMING CHAIN TENSIONER REPLACEMENT

Fig. 58: Timing Chain Tensioner

Timing Chain Tensioner Replacement

Preliminary Procedure
Remove the camshaft timing chain. Refer to Camshaft Timing Chain Replacement.
Timing Chain Tensioner Fastener (Qty: 2)
CAUTION:
1
Tighten
8 N.m (71 lb in)
2 Timing Chain Tensioner
HYDRAULIC VALVE LASH ADJUSTER ARM REPLACEMENT

Fig. 59: Hydraulic Valve Lash Adjuster Arms

Hydraulic Valve Lash Adjuster Arm Replacement

1. Remove the intake camshaft. Refer to Intake Camshaft Replacement.

2. Remove the exhaust camshaft. Refer to Exhaust Camshaft Replacement.
Hydraulic Valve Lash Adjuster Arms
Procedure
1 1. Mark the hydraulic valve lash adjuster arms upon removal to ensure installation is in
the correct position.
2. Lubricate the hydraulic valve lash adjuster arms with engine oil before installing the
arms.
HYDRAULIC VALVE LASH ADJUSTER REPLACEMENT

Fig. 60: Hydraulic Valve Lash Adjuster

Hydraulic Valve Lash Adjuster Replacement

Remove the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm
Replacement.
Hydraulic Valve Lash Adjuster
Procedure
1
1. Mark the hydraulic valve lash adjuster upon removal to ensure installation is in the
correct position.
2. Lubricate the hydraulic valve lash adjuster with engine oil before installation.
CAMSHAFT INTAKE AND EXHAUST SPROCKET REPLACEMENT
Special Tools
EN-955-A Locking Pin
Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
2. Remove the camshaft cover. Refer to Camshaft Cover Replacement.
3. Remove both camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid
Valve Replacement .
4. Adjust the engine to TDC. Refer to Camshaft Timing Chain Adjustment.
Fig. 61: Timing Chain Tensioner Plug

5. Remove the timing chain tensioner plug (1) from the engine front cover.

Fig. 62: Hexagonal Wrench Rotation Direction

6. Install a wrench (1) on the cast hexagonal portion of the intake camshaft, rotate the camshaft toward the
exhaust camshaft in order to apply tension.

Fig. 63: Timing Chain Tensioner Bore And Pin

7. Install EN-955-A pin (2) to the timing chain tensioner bore (1) to secure it in place.
8. Remove the wrench from intake camshaft.


9. Remove the upper timing chain guide bolts (1).


Fig. 65: Intake Camshaft Sprocket Bolt And Hexagonal Wrench

11. Loosen the intake camshaft sprocket bolt (2) while holding up the hexagon of the intake camshaft with a
wrench (1).
12. Loosen the exhaust camshaft sprocket bolt while holding up the hexagon of the exhaust camshaft with a
wrench.

Fig. 66: Camshaft Position Exciter Wheels And Camshaft Sprocket Bolts
13. Remove and DISCARD the camshaft sprocket bolts (2) and the camshaft position exciter wheels (1).

Fig. 67: Timing Chain And Camshaft Sprockets

14. Remove the camshaft sprockets (2) and timing chain (1) as one unit.
15. Remove the intake and exhaust camshaft sprocket.
16. Allow the chain to rest on the front cover.


1. Install the camshaft sprockets (2) and timing chain (1) as one unit.

2. Install the camshaft position exciter wheels (1).

3. Install the NEW camshaft sprocket bolts (2) hand tight only.
4. Remove the EN-955-A pin to apply tension to the timing chain.
5. Adjust the camshaft timing chain. Refer to Camshaft Timing Chain Adjustment.
NOTE: Engine must be adjusted to TDC.



7. Install the upper timing chain guide bolts (1) and tighten to 8 N.m (71 lb in).


8. Install the timing chain tensioner plug (1) and tighten to 50 N.m (37 lb ft).
9. Install both camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid
Valve Replacement .
10. Install the camshaft cover. Refer to Camshaft Cover Replacement.
11. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
12. Check and correct engine oil level.
CYLINDER HEAD REPLACEMENT
Special Tools

EN-955 Fixing Pin
EN-953-A Fixing Tool
Removal Procedure
1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the exhaust manifold and turbocharger as an assembly. Refer to Turbocharger Replacement.
3. Remove the intake manifold. Refer to Intake Manifold Replacement.
4. Remove the water outlet. Refer to Water Outlet Replacement (LUV) .
5. Remove the camshaft position actuator solenoid valve intake and exhaust. Refer to Camshaft Position
Actuator Solenoid Valve Replacement .
6. Adjust the engine to TDC. Refer to Camshaft Timing Chain Inspection.

7. Remove the timing chain tensioner plug (1) from the engine front cover.

Fig. 73: Hexagonal Wrench Rotation Direction

NOTE: Remove and reinstall the EN-953-A fixing tool for this step.
8. Install a wrench (1) on the cast hexagonal portion of the intake camshaft, rotate the camshaft toward the
exhaust camshaft in order to apply tension.

Fig. 74: Timing Chain Tensioner Bore And Pin

9. Install EN-955-10 pin (2) to the timing chain tensioner bore (1) to secure it in place.
10. Remove the wrench from intake camshaft.


11. Remove the upper timing chain guide bolts (1).


Fig. 76: Intake Camshaft Sprocket Bolt And Hexagonal Wrench

13. Loosen the intake camshaft sprocket bolt (2) while holding up the hexagon of the intake camshaft with a
wrench (1).
14. Loosen the exhaust camshaft sprocket bolt while holding up the hexagon of the exhaust camshaft with a
wrench.

16. Remove the both camshaft position sensors. Refer to Camshaft Position Sensor Replacement .


17. Remove the camshaft sprockets (2) and timing chain (1) as one unit.
18. Allow the camshaft sprockets (2) and timing chain (1) rest on the front cover. Do NOT remove sprockets
or chain.
20. Remove the engine mount bracket. Refer Engine Mount Bracket Replacement - Right Side.
21. Remove the drive belt. Refer to Drive Belt Replacement.
22. Remove the water pump pulley. Refer to Water Pump Pulley Replacement (LUV) , Water Pump
Pulley Replacement (LUW) .

Fig. 79: Engine Front Cover Bolts And Water Pump Bolts
23. Remove 5 engine front cover bolts (1, 2).

24. Remove 3 water pump bolts (3).
25. Install engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
26. Install engine mount. Refer to Engine Mount Replacement - Right Side.
27. Remove engine support fixture. Refer Engine Support Fixture.

Fig. 80: Cylinder Head Bolts Loosening Sequence

28. Loosen the 12 cylinder head bolts in the sequence as shown above. Use the following procedure:
First pass: Loosen the cylinder head bolts 90 degrees.
Final pass: Loosen the cylinder head bolts 180 degrees.

Fig. 81: Cylinder Head, Gasket, Bolts And Guide Sleeves

NOTE: Do not damage the guide sleeves (4, 5).
29. Remove and DISCARD the 12 cylinder head bolts (1).

30. With the aid of an assistant, lift the timing chain side of the cylinder head assembly slightly in direction of
the transmission.
31. Remove the cylinder head (2).
32. Remove the cylinder head gasket (3) and discard the gasket.

Fig. 82: Top Third Of Engine Front Cover Gasket

33. With the cylinder head out of vehicle, bend the top third of the engine front cover gasket (1) back and
forth until snaps off at the breaking point.
34. Remove the assembly parts from cylinder head:
Remove the EN-953-A fixing tool
Remove the intake camshaft. Refer to Intake Camshaft Removal.
Remove the exhaust camshaft. Refer to Exhaust Camshaft Removal.
Remove the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm
Removal.
Remove the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Removal.
Remove the spark plug. Refer to Spark Plug Replacement .
Remove the engine oil pressure indicator switch.
Remove the timing chain tensioner. Refer to Timing Chain Tensioner Removal.
Remove the 3 engine lift brackets.
35. For disassembly of the cylinder head. Refer to Cylinder Head Disassemble.
36. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection.
37. Transfer parts as necessary.
1. For assembly of the cylinder head. Refer to Cylinder Head Assemble.

2. Install the cylinder head assembly parts:
Install the 3 engine lift bracket bolts and tighten to 22 N.m (16 lb ft).
Install the timing chain tensioner. Refer to Timing Chain Tensioner Installation.
Install the engine oil pressure indicator switch and tighten to 20 N.m (15 lb ft)
Install the spark plug. Refer to Spark Plug Replacement .
Install the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Installation.
Install the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm
Installation.
Install the exhaust camshaft. Refer to Exhaust Camshaft Installation.
Install the intake camshaft. Refer to Intake Camshaft Installation.
Install the EN-953-A fixing tool.
3. Clean sealing surfaces of engine front cover and engine block from grease and old gasket material.
NOTE: Adjust the camshafts by means of the hexagon and a spanner.

Fig. 83: engine front cover gasket

NOTE: The engine front cover gasket comes as a complete unit.
4. Before installation the of the new front cover gasket, bend the top third of the engine front cover gasket
(1) back and forth until snaps off at the breaking point.

Fig. 84: Sealing Compound Application Area

5. Apply a 2 mm (0.0787 in) bead of RTV sealant to the areas shown (1).
6. Install a NEW cylinder head gasket. The marking "Top" should point to the cylinder head.

Fig. 85: Engine Front Cover Bolts And Sealing Compound Application Areas
7. Install engine front cover bolts (1) in order to guide the NEW upper engine front cover gasket.
8. Apply a 2 mm (0.0787 in) bead of RTV sealant to the areas shown (2).

Fig. 86: Timing Chain Tensioner, Guide Pin And Cylinder Head
NOTE: A second mechanic is required.
9. Guide the timing chain guide pin (2) to the timing chain guide and the timing chain tensioner (1) with the
installed fixing pin through the timing chain tensioner plug bore in engine front cover.


10. Install the cylinder head (2).

11. Loosely install 12 NEW cylinder head bolts (1).

Fig. 88: Engine Front Cover Bolts

12. Adjust the cylinder head to the engine front cover. Use a rubber mallet.
13. Position the engine front cover to cylinder head by installing 3 bolts (1).
14. Tighten the 3 bolts (1) to 8 N.m (71 lb in).

Fig. 89: Cylinder Head Bolts Tightening Sequence

15. Tighten the cylinder head bolts in the sequence as shown and in the following order.
Tighten the cylinder head bolts to 35 N.m (26 lb ft).
Tighten the cylinder head bolts an additional 180°. Use EN-470-B wrench.

Fig. 90: Engine Front Cover Bolts

16. Loosen the bolts from engine front cover (1).

Fig. 91: Engine Front Cover Bolts And Water Pump Bolts
17. Install the remaining bolts to engine front cover and water pump.
18. Tighten the engine front cover bolts (1, 2) to 8 N.m (71 lb in).
19. Tighten the water pump bolts (3) to 8 N.m (71 lb in).
22. Install the water pump pulley. Refer to Water Pump Pulley Replacement (LUV) , Water Pump Pulley
Replacement (LUW) .
23. Install the drive belt. Refer to Drive Belt Replacement.
24. Install engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
25. Install the engine mount. Refer to Engine Mount Replacement - Right Side.


27. Install the camshaft sprockets (2) and timing chain (1) as one unit.

28. Install the camshaft position exciter wheels (1).

29. Install the NEW camshaft sprocket bolts (2) and tighten to 50 N.m (37 lb ft) plus 60 degrees.
30. Install the both camshaft position sensors. Refer to Camshaft Position Sensor Replacement .
31. Remove the EN-955-10 pin to apply tension to the timing chain.
32. Adjust the camshaft timing chain. Refer to Camshaft Timing Chain Inspection.



34. Install the upper timing chain guide bolts (1) and tighten to 8 N.m (71 lb in).


CAUTION: Refer to Component Fastener Tightening Caution .
35. Install the timing chain tensioner plug and tighten to 50 N.m (37 lb ft).
36. Install the camshaft position actuator solenoid valve intake and exhaust. Refer to Camshaft Position
Actuator Solenoid Valve Replacement .
37. Install the exhaust manifold and turbocharger as an assembly. Refer to Turbocharger Replacement.
38. Install the Intake manifold. Refer to Intake Manifold Replacement.
39. Fill coolant fluid. Refer to Cooling System Draining and Filling .
40. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
41. Check and correct the engine oil.
42. Test the vehicle using the following procedure:
1. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
2. Start the engine and listen for unusual noises.
3. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil
pressure.
4. Run the engine speed at about 1, 000 RPM until the engine has reached normal operating
temperature.
5. Listen for sticking lifter and other unusual noises.
6. Inspect for fuel, oil and/or coolant leaks while the engine is running.
43. Inspect for coolant, oil, gas or exhaust leaks.
OIL PAN REPLACEMENT
Special Tools
EN-49980 Guidance Pins
Removal Procedure
LWE, LUW) .
2. Remove the oil filter and drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
3. Remove the front insulator cover. Refer to Front Compartment Front Insulator Cover Replacement .
4. Remove the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV, LUW) .

Fig. 96: Automatic Transmission Converter Cover And Bolts

NOTE: The intermediate shaft is shown removed for visual purposes only.
5. If equipped with an automatic transmission, remove the oil pan to automatic transmission bolts (1, 3) and
automatic transmission converter cover (2).

Fig. 97: Oil Pan To Automatic Transmission Bolts

6. Remove the oil pan to automatic transmission bolts (1).

Fig. 98: Transmission-To-Oil Pan Bolts

7. If equipped with manual transmission, remove the 3 manual transmission to oil pan bolts (1).

Fig. 99: Oil Pan And Bolts

8. Remove the oil pan bolts (1) and oil pan.
1. Clean the sealing surface of crankshaft bearing cap tie plate and the groove in the engine front cover from
old gasket material, oil, dirt and grease.

Fig. 100: Oil Pan Guidance Pins

2. Install the 2 EN-49980 guidance pins (1) to the shown oil pan screw bores.

Fig. 101: Engine Front Cover, Oil Suction Gallery And Screw Bore
NOTE: The sealing bead should be applied close to the inner edge of the oil pan.
Take care that the oil suction gallery (4) will not get contaminated with
sealing compound or dirt.
3. Apply 2 mm (0.0787 in) thickness of sealing compound (3, 2, 1).

Fig. 102: Oil Pan And Bolts

NOTE: The complete installation procedure of the oil pan should be done in 10
minutes.
4. Loosely install the oil pan bolts (1) in all but the guidance pin locations.
5. Remove the EN-49980 guidance pins and install the remaining oil pan bolts.
6. Tighten the oil pan bolts to 10 N.m (89 lb in).

Fig. 103: Transmission-To-Oil Pan Bolts

7. If equipped with manual transmission, install the 3 manual transmission to oil pan bolts (1) and tighten to
40 N.m (30 lb ft).

Fig. 104: Automatic Transmission Converter Cover And Bolts

8. If equipped with an automatic transmission, install and the automatic transmission converter cover (2)
and tighten the cover to automatic transmission bolt (1) to 40 N.m (30 lb ft) and automatic transmission
bolt (3) to 60 N.m (44 lb ft).

Fig. 105: Oil Pan To Automatic Transmission Bolts

9. Install the oil pan to automatic transmission bolts (1) and tighten to 40 N.m (30 lb ft).
10. Install a NEW oil filter and fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
11. Install the exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV, LUW) .
12. Install the front insulator cover. Refer to Front Compartment Front Insulator Cover Replacement .
LWE, LUW) .
AUTOMATIC TRANSMISSION FLEX PLATE REPLACEMENT

Fig. 106: Automatic Transmission Flex Plate And Bolts

Automatic Transmission Flex Plate Replacement

Remove the transmission. Refer to Transmission Replacement (With 1.2L or 1.4L Engine) ,
Transmission Replacement (With 1.6L or 1.8L Engine) .
Special Tools

EN-49979 Crankshaft Shock Mount Retainer
Automatic Transmission Flex Plate Fastener (Qty: 6)
CAUTION:
Procedure
Ensure to use a NEW fastener whenever the automatic transmission flex plate is removed.
Tighten
35 N.m (26 lb ft)

Tighten the bolt an additional 30 degrees and one more pass at 15 degrees using EN-
470-B wrench.
2 Flex Plate
Automatic Transmission Flex Plate
Procedure
Inspect the automatic transmission flex plate for the following:
3 1. Stress cracks around the flex plate.

2. Cracks at welded areas that retain the ring gear onto the flex plate.
3. Damaged or missing ring gear teeth.
4. Do not attempt to repair the welded areas that retain the ring gear to the automatic
transmission flex plate. Install a new flex plate.
ENGINE FLYWHEEL REPLACEMENT
Fig. 107: Engine Flywheel And Fasteners

Engine Flywheel Replacement


1. Remove the transmission. Refer to Transmission Replacement .

2. Remove the clutch pressure and driven plate. Refer to Clutch Pressure and Driven Plate
Replacement (1.4L) , Clutch Pressure and Driven Plate Replacement (1.8L) .
Special Tools
EN-652 Flywheel Holder.

EN-470-B Angular Torque Wrench.
For equivalent regional tools, refer to Special Tools .

Flywheel Fastener (Qty: 6)
CAUTION:
Procedure
1 Ensure to use a NEW fastener whenever the flywheel is removed.
Tighten
First pass tighten bolts to 35 N.m (26 lb ft)

Second pass 30 degrees.
Final pass 15 degrees.
Flywheel
Procedure
Inspect the engine flywheel for the following:
2 1. Stress cracks around the engine flywheel.

2. Cracks at welded areas that retain the ring gear onto the engine flywheel.
3. Damaged or missing ring gear teeth.
4. Do not attempt to repair the welded areas that retain the ring gear to the engine
flywheel plate. Install a new engine flywheel.
CRANKSHAFT BALANCER REPLACEMENT
Special Tools


Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove front wheelhouse liner extension right side. Refer to Front Wheelhouse Liner Inner Front
LWE, LUW) .
3. Remove the drive belt. Refer to Drive Belt Replacement.
4. Place collecting basin underneath.
Fig. 108: Bore And Mark

NOTE: The crankshaft balancer can be incorrectly installed 180° from the required
position. Be sure to note the location of the alignment hole on the
crankshaft balancer prior to removing the crankshaft balancer from the
engine.
5. Rotate the engine clockwise until the bore (2) in the crankshaft balancer aligns with the mark (1) on the
engine front cover.

Fig. 109: Crankshaft Components And Tools

6. Install EN-49979 crankshaft shock mount retainer (1) to suitable tool (2).
7. Loosen the crankshaft balancer bolt (4) while holding the crankshaft balancer (3).

Fig. 110: Crankshaft Balancer And Bolt

8. Remove and DISCARD the crankshaft balancer bolt (2).

9. Remove the crankshaft balancer (1).

Fig. 111: Engine Oil Pump Rotor And Crankshaft

NOTE: The crankshaft balancer flange must fit to the hexagon of the oil pump
rotor (2) and to the two-flats of the crankshaft (1). The TDC markings on
crankshaft balancer and engine front cover must match.
1. Install the crankshaft balancer carefully by pressing into position.

Fig. 112: Engine Front Cover And Crankshaft Balancer

2. Measure the distance (a) between the crankshaft balancer (2) and the mark on the engine front cover (1).
The distance (a) should be 5.5 mm (0.21654 in).
3. Install a NEW crankshaft balancer bolt.
NOTE: Never re-use the crankshaft balancer bolt.

Fig. 113: Crankshaft Components And Tools

CAUTION: Refer to Torque-to-Yield Fastener Caution .
4. Tighten the crankshaft balancer bolt (4) to 150 N.m (111 lb ft) while holding the crankshaft balancer (3)
with EN-49979 crankshaft shock mount retainer (1) and suitable tool (2). Use EN-470-B wrench.
5. Tighten the crankshaft balancer bolt to an additional 60°.
7. Install the front wheelhouse liner extension right side. Refer to Front Wheelhouse Liner Inner Front
LWE, LUW) .
CRANKSHAFT FRONT OIL SEAL REPLACEMENT
Special Tools
EN-960 Installer
EN-45000 Remover Oil seal
Removal Procedure
1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.

2. Place a drain pan underneath the front crankshaft seal area.
Fig. 114: Crankshaft Front Oil Seal And Remover

3. Remove crankshaft front oil seal (2) from engine front cover. Use EN-45000 remover (1).

Fig. 115: Crankshaft Front Oil Seal And Installer

1. Install NEW crankshaft front oil seal (1) to EN-960 installer (2).

Fig. 116: Crankshaft Front Oil Seal Installer And Engine Front Cover
2. Install crankshaft front oil seal by means of EN-960 installer (1) to engine front cover (2).

Fig. 117: Engine Front Cover And Crankshaft Front Oil Seal
3. Ensure that crankshaft front oil seal (2) is flush with engine front cover (1).
4. Install crankshaft balancer. Refer to Crankshaft Balancer Replacement.
5. Remove the drain pan.
CRANKSHAFT REAR OIL SEAL REPLACEMENT
Special Tools
EN-658 Rear Main Seal Installer
Removal Procedure
1. If equipped with automatic transmission, remove the flex plate. Refer to Automatic Transmission Flex
Plate Replacement.
2. If equipped with a manual transmission, remove the flywheel. Refer to Engine Flywheel Replacement.

Fig. 118: Rear Crankshaft Oil Seal

NOTE: Do not damage the outside diameter of the crankshaft or chamber with any
tool.
3. Using a flat-bladed tool, remove the rear crankshaft oil seal (1).

Fig. 119: Crankshaft Rear Oil Seal And Installer

1. Install the crankshaft rear oil seal (1) with EN-658 installer (2).

Fig. 120: Crankshaft Real Oil Seal Installer

2. Using the EN-658 installer (2), install a NEW crankshaft real oil seal (1).
3. If equipped with a manual transmission, install the flywheel. Refer to Engine Flywheel Replacement.
4. If equipped with automatic transmission, install the flex plate. Refer to Automatic Transmission Flex
Plate Replacement.
POSITIVE CRANKCASE VENTILATION HOSE/PIPE/TUBE REPLACEMENT
Removal Procedure
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

Fig. 121: Positive Crankcase Ventilation Pipe Retainer Clips And Clamp
2. Open the 2 positive crankcase ventilation pipe retainer clips (2) and (3).
3. Remove the positive crankcase ventilation pipe from the intake manifold.
NOTE: Move retainer clamp (1) in direction of the arrow.

Fig. 122: Positive Crankcase Ventilation Pipe, Charger Air Bypass Valve Pipe And Clamp
4. Loosen the charger air bypass valve pipe clamp (3).

5. Remove the charger air bypass valve pipe from turbocharger.
6. Remove the charger air bypass valve pipe (2) from turbo charger wastegate regulator solenoid valve.
7. Disconnect the positive crankcase ventilation pipe from turbocharger.
8. Unclip and remove the positive crankcase ventilation pipe assembly (1) from the camshaft cover retainer
clips.

Fig. 123: Positive Crankcase Ventilation Pipe, Charger Air Bypass Valve Pipe And Clamp
1. Install the positive crankcase ventilation pipe assembly (1) to the camshaft cover retainer clips.
2. Connect the positive crankcase ventilation pipe to turbocharger.
3. Install the charger air bypass valve pipe (2) to turbo charger wastegate regulator solenoid valve.
4. Install the charger air bypass valve pipe to turbocharger.
5. Fasten the charger air bypass valve pipe clamp (3).

Fig. 124: Positive Crankcase Ventilation Pipe Retainer Clips And Clamp
6. Install the positive crankcase ventilation pipe to the intake manifold and fix with retainer clamp (1).
7. Clip in the positive crankcase ventilation pipe to the 2 retainer clips (2) and (3).
8. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
ENGINE OIL HEATER REPLACEMENT

Fig. 125: Engine Oil Heater And Bolt

Engine Oil Heater Replacement

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
2. If equipped, remove the front insulator cover. Refer to Front Compartment Front Insulator
Cover Replacement .
Engine Oil Heater Bolt
CAUTION:
1
Tighten
40 N.m (30 lb ft)
Engine Oil Heater
2 Procedure
Disconnect the electrical connector.
ENGINE FRONT COVER WITH OIL PUMP REPLACEMENT

Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Set the engine to TDC. Refer to Camshaft Timing Chain Inspection.
4. Remove the front wheelhouse liner extension, right side. Refer to Front Wheelhouse Liner Inner Front
LWE, LUW) .
5. Remove the air conditioning compressor. Refer to Air Conditioning Compressor Replacement (LDE,
LUW, LWE) , Air Conditioning Compressor Replacement (LUV) .
6. Remove the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket
Removal.
7. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
8. Remove the oil pan. Refer to Oil Pan Replacement.
9. Lower vehicle.
10. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
11. Remove the generator from above. Refer to Generator Replacement (LUV) , Generator Replacement
(LUW) .
12. Remove the water pump pulley and the water pump. Refer to Water Pump Replacement (LUW) ,
Water Pump Replacement (LUV) .
13. Remove the camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid
Valve Removal.
14. Loosen the camshaft sprocket bolts until the camshaft position exciter wheels are free to rotate. Refer to
Camshaft Timing Chain Adjustment.

Fig. 126: M6, M10 Front Cover Bolts And Engine Front Cover
15. Remove the 13 engine front cover bolts M6 (1).

17. Remove the engine front cover (3).
18. Remove the camshaft timing chain. Refer to Camshaft Timing Chain Replacement.
NOTE: Removal of timing chain is necessary to get access to engine front cover
gasket.


19. Remove the engine front cover gasket (1).

20. Remove the intake and exhaust camshaft position sensors from the engine front cover. Refer to Camshaft
Position Sensor Replacement .
1. Install the intake and exhaust camshaft position sensors to the engine front cover. Refer to Camshaft
Position Sensor Replacement .
2. Clean the engine front cover sealing surfaces on engine block and cylinder head.


NOTE: The thickness of the sealing bead should be 2 mm (0.0787 in).
3. Apply sealing compound to the shown areas (1) and (2). Refer to Adhesives, Fluids, Lubricants and
Sealers.


NOTE: Mind the guide sleeves.
4. Install a NEW engine front cover gasket (1).

5. Install the timing chain. Refer to Camshaft Timing Chain Replacement.

NOTE: Mind the guide sleeves when installing the engine front cover. The
complete installation procedure of the engine front cover should not take
longer than 10 minutes.
6. Install the engine front cover (3).

7. Install the 13 engine front cover bolts M6 (1).
9. Tighten the 13 engine front cover bolts M6 to 8 N.m (71 lb in).
10. Tighten the 2 engine front cover bolts M10 to 35 N.m (26 lb ft).
11. Tighten the camshaft sprockets, install the upper timing chain guide and remove all special tools. Refer to
NOTE: Engine should be adjusted and fixed in TDC position.

12. Install the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid
Valve Replacement .
13. Install the water pump and the water pump pulley. Refer to Water Pump Replacement (LUW) , Water
Pump Replacement (LUV) .
14. Install the generator from above. Refer to Generator Replacement (LUV) , Generator Replacement
(LUW) .
15. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
16. Install the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket
Installation.
17. Install the air conditioning compressor. Refer to Air Conditioning Compressor Replacement (LDE,
LUW, LWE) , Air Conditioning Compressor Replacement (LUV) .
18. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
21. Install the engine mount. Refer to Engine Mount Replacement - Right Side.
23. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
24. Raise the vehicle.
25. Install the oil pan. Refer to Oil Pan Replacement.
26. Install the front wheelhouse liner extension, right side. Refer to Front Wheelhouse Liner Inner Front
LWE, LUW) .
28. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
29. Fill up engine oil. Refer to Engine Oil and Oil Filter Replacement.
OIL PUMP REPLACEMENT
Removal Procedure
1. Remove the engine front cover. Refer to Engine Front Cover with Oil Pump Replacement.

Fig. 131: Engine Oil Pump Cover And Bolts

2. Remove the 8 oil pump cover bolts (1).

3. Remove the oil pump cover (2).

Fig. 132: Oil Pump Slide Spring Windings And Engine Front Cover Edge
WARNING: Before removing the spring, cover the spring with a towel to prevent
the spring from flying and possibly causing damage or personal
injury.
NOTE: Insert the screw driver between the oil pump slide spring windings (2).
4. Protect the engine front cover edge (1) with a suitable piece of plastic.
5. Compress the oil pump slide spring with a screw driver and remove the oil pump slide spring in
conjunction with the oil pump slide spring pin.

Fig. 133: Locating Engine Oil Pump Components

NOTE: Keep the oil pump components in order to aid in installation.
6. Remove the oil pump components in the following order:

1. Outer oil pump vane ring (1).
2. Oil pump vane rotor (3) and the 7 oil pump vanes (2).
3. Inner oil pump vane ring (6).
4. Oil pump slide (4) and the 2 oil pump slide seals with the 2 oil pump slide seal springs (5).
Cleaning And Inspection Procedure
1. Inspect the engine front cover for cracks, scratches and damage.
2. Inspect the oil pump cover and the engine front cover for flatness.
3. Inspect the oil pump vanes, the oil pump vane rotor, the oil pump vane rings and the oil pump slide for
localized flatting.
4. Inspect the oil pump slide pivot pin for firm seat.

Fig. 134: Oil Gallery Bores

WARNING: Wear safety glasses when using compressed air in order to prevent
eye injury.
CAUTION: To ensure proper engine lubrication, clean clogged or contaminated

oil galleries in an approved solvent and with compressed air. Failure
to clean oil galleries may cause engine damage.
5. Clean the oil galleries with solvent and compressed air. Blow compressed air from bore (2) to bore (1).

Fig. 135: Oil Pump Components

NOTE: Oil pump slide spring pin, oil pump slide spring and slide seal and slide
seal spring can be ordered as single parts. All other oil pump components
can only be ordered as a replacement kit.
1. Install the oil pump components in the following order:

1. Install the oil pump slide (6).
NOTE: The bore (8) in the oil pump slide must fit smooth-running and
without clearance to the oil pump slide pivot pin (7).
2. Install the inner oil pump vane ring (5).

3. Install the oil pump vane rotor (4).
NOTE: Ensure the mark (9) of the oil pump vane rotor (4) points to the oil
pump cover.
4. Install the 7 oil pump vanes (2).

NOTE: Ensure the flats (3) on the oil pump vanes (2) point to the oil pump
vane rotor.
5. Install the outer oil pump vane ring (1).
Fig. 136: Oil Pump Slide Seal Springs And Grooves

2. Install the 2 oil pump slide seals and the 2 oil pump slide seal springs (2) in the position as shown to the 2
grooves (1) of the oil pump slide.

Fig. 137: Oil Pump Slide Spring, Pin, Chambers And Front Cover Edge
4. Install the oil pump slide spring pin (1) in conjunction with the oil pump slide spring (4). Use a
screwdriver to compress the oil pump slide spring. The flat side of oil pump slide spring pin must face
upwards.
NOTE: The length of the removed oil pump slide spring (2) should be 76.5 mm
(3.0118 in) for naturally aspirated engines and 61 mm (2.4016 in) for turbo
engines.
5. Lubricate the oil pump vanes, the oil pump vane rotor, the oil pump slide spring and the chambers (3)
with engine oil.
6. Inspect the oil pump slide spring mechanism for proper function.
7. Measure the oil pump axial and radial clearances and compare with the specified values. Refer to Engine
Front Cover and Oil Pump Cleaning and Inspection.


8. Install the oil pump cover (2) and the 8 oil pump cover bolts (1).

Fig. 139: Oil Pump Cover Bolts Tightening Sequence

CAUTION: Refer to Fastener Caution
9. Tighten the oil pump cover bolts in a sequence as shown to 8 N.m (71 lb in).

Fig. 140: Crankshaft Balancer

10. Install the crankshaft balancer (1) and rotate in shown direction (2) in order to inspect the function of the
oil pump mechanism. Crankshaft balancer should rotate easily.
11. Remove the timing chain and replace the engine front cover gasket. Refer to Camshaft Timing Chain
Replacement.
12. Install the timing chain. Refer to Camshaft Timing Chain Replacement.
13. Install the engine front cover. Refer to Engine Front Cover with Oil Pump Replacement.
14. Measure the oil pressure and compare with the specified values. Refer to Oil Pressure Diagnosis and
Testing.
ENGINE REPLACEMENT
Special Tools
EN-48244 Engine Assembly Remove/Install Pallet Supporter
Removal Procedure
1. Remove the battery and battery tray. Refer to Battery Tray Replacement .

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
4. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
5. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
6. Drain the cooling system. Refer to Cooling System Draining and Filling .
Fig. 141: Intermediate Steering Shaft And Bolt

7. Remove the lower intermediate steering shaft bolt (1) and slide the shaft away from steering column.
Refer to Intermediate Steering Shaft Replacement .

Fig. 142: Air Cleaner Assembly & Components

8. Remove the air cleaner assembly (1). Refer to Air Cleaner Assembly Replacement .

Fig. 143: Junction Block And Cover

9. Remove the junction block cover (1).

Fig. 144: Positive Battery Cable And Nut

10. Remove the positive battery cable nut (1) from the junction block.
11. Remove the positive battery cable (2) from the junction block.

Fig. 145: Body Wiring Harness Connector And Positive Cable Nut
12. Remove the positive cable nut (1) and battery positive cable, from the battery positive cable junction
block.
13. Disconnect the body wiring master harness connector (2), from the battery positive cable junction block.

Fig. 146: Junction Block

14. Remove the junction block nut (1).

15. Remove the junction block bolts (2).
16. Disconnect the wiring harness from the junction block base.
17. Remove the junction block (3) from the base.
18. Disconnect the wiring harness plug from the front compartment fuse block.

Fig. 147: Wiring Harness - Top Of Engine

19. Reposition the wiring harness (1) on top of the engine.

Fig. 148: Wiring Harness And Ground Nuts

20. Remove the ground nuts (1) and reposition the wiring harness (2) aside.

Fig. 149: Electrical Vacuum Pump

21. Disconnect the electrical connector and remove the brake booster hose (1).

Fig. 150: Heater Inlet Hose

22. Disconnect the heater inlet hose (1) from the heater core. Refer to Heater Inlet Hose Replacement
(LDE, LUW) , Heater Inlet Hose Replacement (LUV) .

Fig. 151: Heater Outlet Hose

23. Disconnect the heater outlet hose (1) from the heater core. Refer to Heater Outlet Hose Replacement
(LUV) , Heater Outlet Hose Replacement (LDE, LUW) .

Fig. 152: Automatic Transmission Range Selector Lever Cable Terminal And Shift Lever Pin
24. If equipped with an automatic transmission, disconnect the transmission range selector lever cable
terminal (1) from the transmission manual shift lever pin.
25. Remove the transmission range selector lever cable (2) from the cable bracket.

Fig. 153: Selector Level Cable Components

26. If equipped with manual transmission, disconnect the shift lever and selector lever cable end (1) from the
transmission shift lever and selector lever.
27. Pull the cable retainers (2) to release the shift lever and selector lever cable from the shift lever and
selector lever cable bracket.
28. Disconnect the shift lever and selector lever cable from the shift lever and selector lever cable bracket.

Fig. 154: Radiator Surge Tank And Mounting Bolts

29. Remove the radiator surge tank (2) and position aside. Refer to Radiator Surge Tank Replacement .
30. Disconnect the fan connector.

Fig. 155: A/C Compressor And Condenser Hose

31. Remove air conditioning compressor and condenser hose nut (1).
32. Remove air conditioning compressor and condenser hose (2) from refrigerant hose.

Fig. 156: Fuel Feed Pipe And Plastic Collars

33. Disconnect the fuel feed pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .

Fig. 157: Evaporative Emission Pipe

34. Disconnect the evaporative emission pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .

Fig. 158: Wheel Drive Shaft

35. Remove the wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement .
36. Remove the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV, LUW) .

Fig. 159: Lower Transmission Nut And Bolts

37. If equipped with an automatic transmission, remove the lower transmission nut (1) and the lower
transmission bolts (2, 3, 4).

Fig. 160: Lower Transmission Bolts

38. If equipped with manual transmission, remove the lower transmission bolt (3) and nut (4).
39. Remove the lower transmission bolts (1, 2).

Fig. 161: Front Frame Bolts

40. Remove the frame front bolts (1).

41. Position the EN-48244 engine assembly remove/install pallet supporter under the powertrain and support
with blocks of wood.

Fig. 162: Frame Suspension Retaining Bolts

42. Remove the upper frame suspension retaining bolts (1) on both sides.

Fig. 163: Right Side Engine Mount & Components

43. Remove the right side engine mount (4). Refer to Engine Mount Replacement - Right Side.

Fig. 164: Left Transmission Mount & Components

44. Remove and DISCARD the transmission mount bolts (1) - left side. Refer to Transmission Mount
Replacement - Left Side .
45. Disconnect any additional electrical connections as necessary.
46. Raise the vehicle until the powertrain is clear for removal.

Fig. 165: Torque Converter To Flywheel Bolt

47. If equipped with an automatic transmission, remove the starter. Refer to Starter Replacement (LUW) ,
Starter Replacement (LUV) .
48. Mark the relationship of the flex plate to the torque converter for reassembly.
49. Remove and DISCARD the flex plate to torque converter bolts (1).

Fig. 166: Upper Transmission To Engine Bolts

50. If equipped with an automatic transmission, remove the upper transmission to engine bolts (1) and
separate the engine and transmission.

Fig. 167: Upper Transmission-To-Engine Bolts

51. If equipped with manual transmission, remove the upper transmission to engine bolts (1). And separate
the engine and transmission.
52. Disconnect any electrical connectors as needed.
53. Transfer parts as necessary.
1. Install the transmission to the engine.

Fig. 168: Upper Transmission-To-Engine Bolts

2. If equipped with a manual transmission, install the upper transmission to engine bolts (1) to 60 (44 lb ft).

Fig. 169: Upper Transmission To Engine Bolts

3. If equipped with automatic transmission, install the upper transmission to engine bolts (1) and tighten to
60 (44 lb ft).

Fig. 170: Torque Converter To Flywheel Bolt

4. If equipped with an automatic transmission, install the torque converter to flex plate bolts (1) and tighten
to 60 (44 lb ft).
5. Install the starter. Refer to Starter Replacement (LUW) , Starter Replacement (LUV) .
6. Position the powertrain under the vehicle and slowly lower the body onto the powertrain.

Fig. 171: Left Transmission Mount & Components

7. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 (37 lb ft) plus 70
degrees.

Fig. 172: Right Side Engine Mount & Components

8. Install the right side engine mount (4). Refer to Engine Mount Replacement - Right Side.
9. Connect all previously disconnected electrical connections.

Fig. 173: Frame And Bolts

10. Install the frame (3) rear bolts (2) and front bolts (1), tighten a little bit.
11. Install the frame (3) rear bolts (2) and tighten to 135 (100 lb ft).
12. Install the frame (3) front bolts (1) and tighten to 58 (43 lb ft).

Fig. 174: Frame Suspension Retaining Bolts

13. Install the upper frame suspension retaining bolts (1) on both sides and tighten to 135 (100 lb ft).
14. Remove the lift table.

Fig. 175: Lower Transmission Bolts

15. If equipped with manual transmission, install the lower transmission bolts (1) and tighten to 60 (44 lb ft).
16. Install the lower transmission bolts (2) and tighten 40 (30 lb ft).
17. Install the lower transmission bolt (3) and nut (4) and tighten to 40 (30 lb ft).

Fig. 176: Lower Transmission Nut And Bolts

18. If equipped with an automatic transmission, install the lower transmission bolts (2, 4) and tighten to 60
(44 lb ft).
19. Install the lower transmission bolts (3) and the lower transmission nut (1) and tighten to 40 (30 lb ft).
20. Install the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV, LUW) .

Fig. 177: Wheel Drive Shaft

21. Install the wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement .

Fig. 178: Evaporative Emission Pipe

22. Connect the evaporative emission pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .

Fig. 179: Fuel Feed Pipe And Plastic Collars

23. Connect the fuel feed pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .

Fig. 180: A/C Compressor And Condenser Hose

24. Install air conditioning compressor and condenser hose to the refrigerant hose.
25. Install air conditioning compressor and condenser hose nut (1) tighten nut to 22 (16 lb ft).

Fig. 181: Radiator Surge Tank And Mounting Bolts

26. Install the radiator surge tank (2). Refer to Radiator Surge Tank Replacement .
27. Connect the fan connector.

Fig. 182: Selector Level Cable Components

28. If equipped with manual transmission, Connect the shift lever and selector lever cable end (1) to the
transmission shift lever and selector lever.
29. Connect the shift lever and selector lever cable to the shift lever and selector lever cable bracket.
30. Install the cable retainers (2) to the shift lever and selector lever cable bracket.

Fig. 183: Automatic Transmission Range Selector Lever Cable Terminal And Shift Lever Pin
31. If equipped with automatic transmission, install the transmission range selector lever cable (2) to the
cable bracket.
32. Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever
pin.
33. Adjust the automatic transmission range selector lever cable. Refer to Range Selector Lever Cable
Adjustment .

Fig. 184: Heater Inlet Hose

34. Connect the heater inlet hose (2) from the heater core. Refer to Heater Inlet Hose Replacement (LDE,
LUW) , Heater Inlet Hose Replacement (LUV) .

Fig. 185: Heater Outlet Hose

35. Connect the heater outlet hose (2) from the heater core. Refer to Heater Outlet Hose Replacement
(LUV) , Heater Outlet Hose Replacement (LDE, LUW) .

Fig. 186: Electrical Vacuum Pump

36. Connect the electrical connector and install the brake booster hose (1).

Fig. 187: Wiring Harness And Ground Nuts

37. Install the ground nuts (1) and wiring harness (2).

Fig. 188: Wiring Harness - Top Of Engine

38. Clip in the wiring harness plugs (1).

Fig. 189: Junction Block

39. Install the junction block to the base (3).

40. Install the junction block bolts (2) and tighten to 5 (44 lb in).
41. Install the junction block nut (1) and tighten to 5 (44 lb in).

Fig. 190: Body Wiring Harness Connector And Positive Cable Nut
42. Install the battery positive cable to the battery positive cable junction block and tighten nut (1) to 5 (44 lb
in).
43. Connect the body wiring master harness connector (2), to the battery positive cable junction block.

Fig. 191: Positive Battery Cable And Nut

44. Position the positive battery cable (2) to the junction block.
45. Install the positive battery cable nut (1) and tighten to 7 (62 lb in).

Fig. 192: Junction Block And Cover

46. Install the junction block cover (1).

Fig. 193: Air Cleaner Assembly & Components

47. Install the air cleaner assembly (1). Refer to Air Cleaner Assembly Replacement .

Fig. 194: Intermediate Steering Shaft And Bolt

48. Install the lower intermediate steering shaft bolt (1). Refer to Intermediate Steering Shaft
Replacement .
49. Install the battery and battery tray. Refer Battery Tray Replacement .
50. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
51. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
52. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
53. Fill the cooling system. Refer to Cooling System Draining and Filling .
ENGINE OIL AND OIL FILTER REPLACEMENT
Removal Procedure
1. Open hood.
2. Place a drain pan below the vehicle.
3. Using a 24 mm socket or closed end wrench loosen oil filter cap. Unscrew filter cap 3 turns and let oil
filter and cap assembly drain in housing for 30 seconds.

CAUTION: To prevent damage to oil filter cap ensure proper tool is used. Do not
use an open end wrench which may cause damage to filter cap.
Fig. 195: Engine Oil Filter Cap, Cap Seal Ring And Oil Filter Element
NOTE: Use care when removing engine oil filter cap and filter to minimize fluid
spillage. If fluid spillage occurs it must be cleaned with appropriate
cleaner.
NOTE: Inspect oil filter cap for any cracks or damage. If oil filter cap is damaged it
must be replaced.
4. Remove the engine oil filter cap (2) with the engine oil filter cap seal ring (3) and the oil filter element
(1).
6. Remove the oil pan drain plug and allow the oil to drain into the drain pan.

1. Clean the oil pan drain plug thread in the oil pan.
2. Install a NEW seal ring, if necessary to the oil pan drain plug.
NOTE: Inspect oil drain plug seal ring for damage, replace if damaged.
3. Install the oil pan drain plug and tighten to 14 N.m (10 lb ft).
CAUTION: Refer to Component Fastener Tightening Caution .
Fig. 196: Oil Filter Cap Seal Ring

5. Clean oil filter cap and lubricate the NEW oil filter cap seal ring (1) with clean engine oil. Ensure oil filter
cap seal ring is in proper position as shown.

Fig. 197: Engine Oil Filter Cap, Cap Seal Ring And Oil Filter Element
6. Install the engine oil filter cap (2) with NEW engine oil filter cap seal ring (3) and NEW oil filter element
(1) hand tight.
Fig. 198: Oil Filter Cap Seal Ring

CAUTION: Ensure oil filter cap is completely seated on oil filter housing. If not
completely seated an oil leak may occur.
CAUTION: Over torquing the oil filter cap may cause damage to the oil filter cap
resulting in an oil leak.
7. Using a 24 mm socket or closed end wrench tighten the engine oil filter cap to 25 N.m (18 lb ft).
8. Fill engine with NEW oil using Dexos™ 5W-30 specification.
CAUTION: Using engine oils of any viscosity other than those viscosities
recommended could result in engine damage.
NOTE: Do not overfill the engine with engine oil.
NOTE: Anytime engine oil is added (top off or oil changes) ensure all engine
surfaces are completely free of residual oil. If there is oil on any engine
surface clean as necessary.
Fig. 199: Proper Oil Filler Cap Seating

NOTE: Oil fill cap must be properly seated and tightened during installation.
9. Install oil fill cap.

10. Start the engine and allow it to run until the oil pressure control indicator goes off. Inspect for any oil
leaks around the drain plug, oil filter and oil fill cap.
Fig. 200: Engine Oil Level Indicator

11. Inspect the engine oil level. The oil level should be in the cross-hatched section of the oil level indicator
as shown.
12. Close hood.
13. Reset the engine oil life system monitor.
TURBOCHARGER REPLACEMENT
Special Tools

Removal Procedure
2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
4. Disconnect the positive crankcase ventilation pipe from turbocharger.
5. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement
(LUV) , Exhaust Manifold Heat Shield Replacement (LUW) .
Fig. 201: Turbocharger Wastegate Regulator Solenoid Valve Wiring Harness Connector And
Retaining Clip
6. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness connector (1) and unclip
wiring harness from retainer clip (2).

Fig. 202: Turbocharger Oil Feed Pipe Components

7. Remove the turbocharger oil feed pipe hollow screw (4).

8. Remove and DISCARD the 2 seal rings (1) and (3).
9. Remove the turbocharger oil feed pipe bolt (5).
10. Remove the turbocharger oil feed pipe (2).
NOTE: Close the screw bore in the turbocharger in order to avoid contamination.
11. Loosen the turbocharger coolant return hose clamp and remove the turbocharger coolant return hose (6)
from the oil cooler inlet pipe.
12. Remove the turbocharger coolant return pipe bolt (7).
13. Remove the charge air cooler inlet air hose from the turbocharger. Refer to Charge Air Cooler Inlet Air
Hose Replacement .
14. Remove the air conditioning bracket. Refer to Air Conditioning Compressor Bracket Removal.

Fig. 203: Ratchet Wrench And Holding Wrench

15. Install the EN-49942 holding wrench (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench
(1) along with an extension through EN-49942 holding wrench to the turbocharger coolant feed pipe
hollow screw.

Fig. 204: Ratchet Wrench, Holding Wrench And Coolant Feed Pipe
NOTE: EN-49942 holding wrench (2) should be installed to turbocharger coolant

feed pipe as shown. The holding wrench should be installed to avoid twist
of the turbocharger coolant feed pipe during the loosening procedure.
16. Loosen the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1).
17. Remove the turbocharger coolant feed pipe hollow screw.
18. Remove and DISCARD the 2 seal rings.
19. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LUV) .

Fig. 205: Turbocharger Oil Return Pipe Bolts

20. Remove the 2 turbocharger oil return pipe bolts (1) from turbocharger.
21. Remove the turbocharger oil return pipe from the turbocharger.
22. Remove and DISCARD the gasket.
23. Remove the wastegate actuator nuts and set aside.
NOTE: It is only necessary to move the wastegate actuator aside enough to

access the manifold nuts.

Fig. 206: Turbocharger Nuts

24. Remove and DISCARD the 8 turbocharger nuts (1).

Fig. 207: Turbocharger Assembly And Gasket

25. Remove the turbocharger assembly (1).

26. Remove and DISCARD the turbocharger gasket (2).
27. Remove the assembly parts from the turbocharger as necessary. Refer to Turbocharger Disassemble.
28. If the turbocharger is being reused, refer to Turbocharger Cleaning and Inspection.
1. Install the assembly parts to the turbocharger as necessary. Refer to Turbocharger Assemble.

Fig. 208: Turbocharger Assembly And Gasket

3. Install a NEW turbocharger gasket.

4. Install the turbocharger assembly (1).


5. Install the 8 NEW turbocharger nuts (1).

Fig. 210: Turbocharger Nuts Tightening Sequence

6. Tighten the 8 turbocharger nuts in a sequence as shown to 8 N.m (71 lb in).

7. Repeat the tightening procedure to ensure a proper fastening of the turbocharger nuts.
8. Install the wastegate actuator and nuts and tighten to 7 N.m (62 lb in).
NOTE: It is only necessary to move the wastegate actuator aside enough to

access the manifold nuts.

Fig. 211: Turbocharger Oil Return Pipe Bolts

9. Install a NEW gasket and the 2 turbocharger oil return pipe bolts (1) and tighten to 8 N.m (71 lb in).
10. Install the catalytic converter. Refer to Catalytic Converter Replacement (LUV) .

Fig. 212: Turbocharger Coolant Feed Pipe Components

11. Install the turbocharger coolant feed pipe to the engine block. Use the following procedure:
Install a NEW seal ring (3) to the turbocharger coolant feed pipe hollow screw (4).
Install the turbocharger coolant feed pipe hollow screw along with the seal ring to the turbocharger
coolant feed pipe (2).
Install a NEW seal ring (1) to the turbocharger coolant feed pipe hollow screw.
Install the turbocharger coolant feed pipe hollow screw along with the turbocharger coolant feed
pipe and the 2 seal rings to the engine.

Fig. 213: Ratchet Wrench And Holding Wrench

NOTE: The EN-49942 holding wrench should be installed in a perpendicular

position as shown to ensure a proper installation position of the
turbocharger coolant feed pipe.
hollow screw.
13. Install the air conditioning bracket. Refer to Air Conditioning Compressor Bracket Installation.

NOTE: EN-49942 holding wrench (2) should be installed to the turbocharger

coolant feed pipe as shown. The holding wrench should be installed to
avoid twist of the turbocharger coolant feed pipe during the fastening
procedure.
14. Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to 30 N.m
(22 lb ft).
15. Install the charge air cooler inlet air hose to the turbocharger. Refer to Charge Air Cooler Inlet Air
Hose Replacement .


16. Install the turbocharger coolant return pipe bolt (7) and tighten to 8 N.m (71 lb in).
17. Install the turbocharger coolant return hose (6) to the oil cooler inlet pipe.
18. Install the turbocharger coolant return hose clamp.
19. Install the turbocharger oil feed pipe (2) to the oil cooler and the turbocharger.
20. Install the turbocharger oil feed pipe bolt (5).
21. Install the turbocharger oil feed pipe hollow screw (4) along with the 2 NEW seal rings (1) and (3) and
tighten to 30 N.m (22 lb ft).
22. Tighten the turbocharger oil feed pipe bolt to 10 N.m (89 lb in).

Fig. 216: Turbocharger Wastegate Regulator Solenoid Valve Wiring Harness Connector And
Retaining Clip
23. Connect the turbocharger wastegate regulator solenoid valve wiring harness connector (1) and clip in
wiring harness to retainer clip (2).
24. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LUV) ,
Exhaust Manifold Heat Shield Replacement (LUW) .
25. Connect the positive crankcase ventilation pipe to the turbocharger.
26. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
28. Fill the cooling system. Refer to Cooling System Draining and Filling .
29. Use a scan tool to perform the Engine Control Module Setup for Component Replacement. Refer to
Control Module References .
TURBOCHARGER OIL FEED PIPE REPLACEMENT
Removal Procedure
2. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement
(LUV) , Exhaust Manifold Heat Shield Replacement (LUW) .

3. Remove the turbocharger oil feed pipe bolt (5).

4. Remove the turbocharger oil feed pipe hollow screw (4) and the 2 seal rings (1) and (3).
5. Remove the turbocharger oil feed pipe (2) and the rubber seal ring.


2. Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring.
3. Install the turbocharger oil feed pipe hollow screw (4) and 2 NEW seal rings (1) and (3).
4. Install the turbocharger oil feed pipe bolt (5) and tighten to 8 N.m (71 lb in).
5. Tighten the turbocharger oil feed pipe hollow screw to 20 N.m (15 lb ft).
6. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LUV) ,
Exhaust Manifold Heat Shield Replacement (LUW) .
TURBOCHARGER OIL RETURN PIPE REPLACEMENT
Removal Procedure
1. Remove the drivetrain and front suspension frame skid plate, if equipped. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement .
Fig. 219: Turbocharger Oil Return Pipe Components

NOTE: Simplified Graphic. DO NOT remove the warm up three way catalytic
converter.
2. Remove the 2 turbocharger oil return pipe bolts (1).

3. Place a drain pan below the vehicle.
4. Release the turbocharger oil return pipe connector (4) and disconnect the turbocharger oil return pipe
from the engine block.
5. Remove the turbocharger oil return pipe (2) and the gasket (3).

Fig. 220: Turbocharger Oil Return Pipe Components

2. Install the turbocharger oil return pipe (2) in compound with a NEW gasket (3) and connect to the engine
block.
3. Install the 2 turbocharger oil return pipe bolts (1) and tighten to 8 N.m (71 lb in).

5. Check engine oil level.
6. Install the drivetrain and front suspension frame skid plate, if equipped. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement .
CAMSHAFT COVER REPLACEMENT

Fig. 221: Camshaft Cover, Fasteners And Oil Level Indicator

Camshaft Cover Replacement

Remove the ignition coil. Refer to Ignition Coil Replacement .
Camshaft Cover Fastener (Qty: 15)
CAUTION:
1
Procedure
Ensure to follow the tighten sequence shown.
Tighten
8 N.m (71 lb in)
Oil Level Indicator
2
TIP: Remove the oil level indicator from camshaft cover.
Camshaft Cover
3 Procedure
1. Remove or reposition the clips as necessary.

2. Do not reuse the camshaft gasket. Also use a new gasket whenever removing or
replacing camshaft cover.
3. Disconnect electrical connector as necessary.
4. Transfer components as necessary.
INTAKE CAMSHAFT REPLACEMENT
Removal Procedure
1. Remove the camshaft intake and exhaust sprocket. Refer to Camshaft Intake and Exhaust Sprocket
Replacement.
Fig. 222: Intake Camshaft Bearing Cap Bolts Removal Sequence

2. Remove the camshaft bearing cap bolts in sequence shown. Ensure to remove the bolts one turn at a time
until there is no spring tension pushing on the camshaft.

Fig. 223: Camshaft Bearing Caps And Bolts

NOTE: Mark the camshafts bearing caps and the camshaft upon removal to
ensure installation is in the correct position.
3. Remove the camshaft bearing cap bolts (1).

4. Remove the camshaft bearing caps (2).
5. Remove the intake camshaft (3).


NOTE: Ensure that the camshaft sealing rings are in place in the camshaft
grooves. Camshaft sealing rings must be in place below the surface of the
camshaft journal in order to avoid being pinched between the cylinder
head and the camshaft caps.
1. Lubricate the camshaft and camshaft bearing caps with engine oil.
2. Install the intake camshaft (3).
3. Install the camshaft bearing caps (2).
4. Install the camshaft bearing cap bolts and tighten the bolts hand tight (1).

Fig. 225: Intake Camshaft Bearing Cap Bolts Tightening Sequence

5. Install and tighten the camshaft bearing cap bolts one turn at a time in sequence as shown to 8 N.m (71 lb
in).
6. Install the camshaft intake and exhaust sprocket. Refer to Camshaft Intake and Exhaust Sprocket
Replacement.
EXHAUST CAMSHAFT REPLACEMENT
Removal Procedure
1. Remove the camshaft intake and exhaust sprocket. Refer to Camshaft Intake and Exhaust Sprocket
Replacement.

3. Allow the both camshaft sprockets with the timing chain to rest on the engine front cover.

Fig. 227: Exhaust Camshaft Bearing Cap Bolts Removal Sequence

4. Remove the camshaft bearing cap bolts in sequence shown. Ensure to remove the bolts one turn at a time
until there is no spring tension pushing on the camshaft.


NOTE: Mark the camshafts upon removal to ensure installation is in the correct
position.
5. Remove the camshaft bearing cap bolts (1).

6. Remove the camshaft bearing caps (2).
7. Remove the exhaust camshaft (3).


NOTE: Ensure that the camshaft sealing rings are in place in the camshaft
grooves. Camshaft sealing rings must be in place below the surface of the
camshaft journal in order to avoid being pinched between the cylinder
head and the camshaft caps.
1. Lubricate camshaft and camshaft bearing caps with engine oil.

2. Install the exhaust camshaft (3).
3. Install the camshaft bearing caps (2).
4. Install the camshaft bearing cap and hand tighten the bolts (1).

Fig. 230: Exhaust Camshaft Bearing Cap Bolts Tightening Sequence

5. Install and tighten the camshaft bearing cap bolts one turn at a time in sequence as shown 8 N.m (71 lb
in).
6. Install the camshaft intake and exhaust sprocket. Refer to Camshaft Intake and Exhaust Sprocket
Replacement.
REPAIR INSTRUCTIONS - OFF VEHICLE

ENGINE SUPPORT FIXTURE

Fig. 231: Engine Support Fixture Components

Engine Support Fixture

Remove the radiator opening upper cover. Refer to Front Opening Upper Cover Replacement
Special Tools
EN-28467-300 Engine Support Fixture Adapter

J-28467-518 Main Support Beam
J-28467-1A Cross Bracket
J-28467-5A Strut Tower Support Assembly
J-28467-2A Radiator Tube Shelf Assembly
J-36857 Engine Lift Bracket
J-28467-8A Hook Assembly

Engine Support Fixture Adapter Leg (Qty: 2)
1 Procedure
Install the bracket to fender frame. Do not install on top of fender lip.

2 Main Support Beam

3 Cross Bracket
Strut Tower Support Assembly
4 Procedure
Adjust the length of the strut tower support assembly.
5 Radiator Tube Shelf Assembly
Hook Assembly
Procedure
6
Use a grade 10.9 bolt to install the engine lift bracket.
TIP: If the engine is not equipped with engine lift bracket, install J-36857 in place.
ENGINE MOUNT BRACKET REMOVAL
Fig. 232: Engine Mount Bracket And Bolts

1. Remove the 3 engine mount bracket bolts (1).

2. Remove the engine mount bracket (2).
CAMSHAFT TIMING CHAIN INSPECTION

Special Tools
EN-952 Fixing Pin

EN-49977-100 Transmitter Disc Fixation
1. Remove the ignition coil. Refer to Ignition Coil Replacement .


3. Remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (Rear) ,
Front Wheelhouse Liner Replacement (Front) , Front Wheelhouse Liner Replacement (with WFK)
engine front cover.

Fig. 234: Camshaft Grooves

5. Examine that the camshaft grooves (1) are visible as shown. If the camshaft grooves are not visible rotate
the crankshaft 360°.

Fig. 235: Crankshaft Bearing Cap Tie Plate Hole Plug And Seal Ring
6. Remove the crankshaft bearing cap tie plate hole plug (2) and the seal ring (1).

Fig. 236: Fixing Pin

CAUTION: To ensure proper crankshaft top dead center (TDC) alignment, the
retention pin should fit easily through the bore in the crankshaft tie
plate and into the crankshaft. Binding of the retention pin could affect
proper engine timing.
7. Install EN-952 fixing pin (1) to hold the crankshaft in TDC position.

Fig. 237: Fixing Tool

NOTE: The fixing tool should be installed completely to both camshaft grooves
without high effort.
8. Install EN-953-A fixing tool (1) to the camshafts.

Fig. 238: Transmitter Disc Fixation Tool And Bolts

NOTE: A wrong installation position is possible. Make sure that the fixation tool is
installed without clearance to the cylinder head in areas (3) and (4).
9. Install EN-49977-100 transmitter disc fixation (1) to inspect the correct position of the camshaft position
exciter wheels.
10. Tighten the bolts (2) of EN-49977-100 transmitter disc fixation.
11. If EN-953-A fixing tool or EN-49977-100 transmitter disc fixation can not be installed, refer to
12. Remove EN-49977-100 transmitter disc fixation.
13. Remove EN-953-A fixing tool.
14. Remove EN-952 fixing pin.
15. Install crankshaft bearing cap tie plate hole plug and seal ring and tighten to 40 N.m (30 lb ft).
16. Install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (Rear) , Front
Wheelhouse Liner Replacement (Front) , Front Wheelhouse Liner Replacement (with WFK)
17. Install the camshaft cover. Refer to Camshaft Cover Installation.
18. Install the ignition coil. Refer to Ignition Coil Installation.
CAMSHAFT TIMING CHAIN ADJUSTMENT
Special Tools
EN-952 Fixing Pin

EN-49977-100 Fixation Sensor Discs
1. Remove the ignition coil. Refer to Ignition Coil Replacement .

3. Remove the camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid
Valve Replacement .
4. Remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (Rear) ,
Front Wheelhouse Liner Replacement (Front) , Front Wheelhouse Liner Replacement (with
WFK) .


engine front cover.

Fig. 240: Crankshaft Bearing Cap Tie Plate Hole Plug And Seal Ring
6. Remove the crankshaft bearing cap tie plate hole plug (2) and the seal ring (1).

Fig. 241: Fixing Pin

CAUTION: To ensure proper crankshaft top dead center (TDC) alignment, the
retention pin should fit easily through the bore in the crankshaft tie
plate and into the crankshaft. Binding of the retention pin could affect
proper engine timing.
7. Install the EN-952 fixing pin (1) to hold the crankshaft in TDC position.

Fig. 242: Intake Camshaft Sprocket Bolt And Wrench

8. Loosen the intake camshaft sprocket bolt (2) while holding the hexagon of the intake camshaft with a
wrench (1) until the camshaft position exciter wheel is clearly rotatable.
9. Loosen the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft with a
wrench until the camshaft position exciter wheel is clearly rotatable.

Fig. 243: Fixing Tool

NOTE: The fixing tool should be installed completely to both camshaft grooves
without high effort.
10. Adjust the camshafts so that the EN-953-A fixing tool (1) can be installed.


11. Remove the 2 upper timing chain guide bolts (1).


Fig. 245: Intake Camshaft Sprocket Gearing And Special Tool

NOTE: Push the fixing tool in the direction of the arrow to ensure it engages
without clearance.
13. Install the EN-49977-200 fixing tool (2) and adjust the gearing of the fixing tool so it engages with the
intake camshaft sprocket gearing (1).

Fig. 246: Adjuster Bolt And Fastening Bolts

14. Tighten the 2 fastening bolts (1) of the EN-49977-200 fixing tool while pushing the fixing tool in
direction of the arrow.
15. Tighten the adjuster bolt (2).

Fig. 247: Fastening Bolts And Fixation Tool

NOTE: A wrong installation position is possible. Make sure that the fixation tool is
installed without clearance to the cylinder head in areas (3) and (5).
16. Install the EN-49977-100 fixation (2) to find and hold the camshaft position exciter wheels in the correct
position.
17. Tighten the 2 fastening bolts (6) of the EN-49977-100 fixation.
18. Tighten the intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft to 50
N.m (37 lb ft).
19. Tighten the intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft an
additional 60°.
20. Tighten the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft to 50 N.m
(37 lb ft).
21. Tighten the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft an
additional 60°.
22. Remove the EN-49977-100 fixation and the EN-49977-200 fixing tool.


24. Install the 2 upper timing chain guide bolts (1) and tighten to 8 N.m (71 lb in).
25. Remove the EN-953-A fixing tool.
26. Remove the EN-952 fixing pin.
27. Rotate the crankshaft for 720° and check the engine timing again. Repeat the adjustment procedure if
necessary.
28. Install the crankshaft bearing cap tie plate hole plug and seal ring and tighten to 40 N.m (30 lb ft).
29. Install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (Rear) , Front
Wheelhouse Liner Replacement (Front) , Front Wheelhouse Liner Replacement (with WFK)
30. Install the camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid
Valve Replacement .
32. Install the ignition coil. Refer to Ignition Coil Replacement .

DRAINING FLUIDS AND OIL FILTER REMOVAL
Fig. 249: Engine Oil Filter Element, Cap And Seal Ring
1. Remove the engine oil filter cap (2) along with the engine oil filter cap seal ring (3) and the oil filter
element (1).
2. Remove the oil pan drain plug and allow the oil to drain out.
3. Install the oil pan drain plug and a NEW seal ring and tighten to 14 N.m (124 lb in).
4. Install the engine oil filter cap along with a NEW engine oil filter cap seal ring and a NEW oil filter
element.
5. Tighten the engine oil filter cap to 25 N.m (18 lb ft).

Fig. 250: Water Pump Drain Plug And Seal Ring

6. Remove the water pump drain plug (1) and the water pump drain plug seal ring (2) and allow the
remaining coolant to drain out.
7. Install the water pump drain plug and a NEW seal ring and tighten to 15 N.m (11 lb ft).
POSITIVE CRANKCASE VENTILATION PIPE REMOVAL

Fig. 251: Positive Crankcase Ventilation Pipe Retainer Clips And Retainer Clamp
1. Open the 2 positive crankcase ventilation pipe retainer clips (2) and (3).
2. Remove the positive crankcase ventilation pipe from the intake manifold.
NOTE: Move retainer clamp (1) in direction of the arrow.

Fig. 252: Turbocharger, Positive Crankcase Ventilation Pipe Assembly And Charger Air Bypass
Valve Pipe
3. Loosen the charger air bypass valve pipe clamp (4).

4. Remove the charger air bypass valve pipe from turbocharger.
5. Remove the charger air bypass valve pipe (2) from turbo charger waste regulator solenoid valve.
6. Disconnect the positive crankcase ventilation pipe from turbocharger (3).
7. Unclip and remove the positive crankcase ventilation pipe assembly (1) from the camshaft cover retainer
clips.
EXHAUST MANIFOLD HEAT SHIELD REMOVAL

Fig. 253: Exhaust Manifold Heat Shield

1. Remove the 3 exhaust manifold heat shield bolts (1) and the washers.
2. Remove the exhaust manifold heat shield (2).
WARM UP THREE-WAY CATALYTIC CONVERTER REMOVAL

Fig. 254: Locating Catalytic Converter Components

1. Disconnect the heated oxygen sensor wiring harness (3) from retainer clip.
2. Remove the 2 catalytic converter to catalytic converter bracket nuts (4) and (6).
3. Loosen the three way warm up catalytic converter V-clamp (1).
4. Remove the three way warm up catalytic converter (5) and the catalytic converter seal (2).
TURBOCHARGER REMOVAL
Special Tool

Fig. 255: Holding Wrench And Ratchet Wrench

hollow screw.


of the turbocharger coolant feed pipe during the loosening procedure.
2. Loosen the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1).

Fig. 257: Turbocharger Oil Return Pipe

3. Remove the turbocharger coolant feed pipe hollow screw (3) and the 2 seal rings (1) and (2).
4. Disconnect the turbocharger oil return pipe (4) from the engine block.


5. Remove the turbocharger oil feed pipe bolt (5) from the oil cooler.
6. Remove the turbocharger oil feed pipe hollow screw (4) and the 2 seal rings (1) and (3) and close the
screw bore in the turbocharger.
7. Remove the turbocharger oil feed pipe (2) and the rubber seal ring.
8. Disconnect the turbocharger coolant return hose (6) from the oil cooler coolant inlet pipe and remove the
turbocharger coolant return pipe bolt (7) from the oil cooler.


9. Remove the 8 turbocharger nuts (1).

Fig. 260: Turbocharger Assembly And Turbocharger Gasket

10. Remove the turbocharger assembly (1) and the turbocharger gasket (2).
ENGINE OIL COOLER REMOVAL

Fig. 261: Locating Engine Oil Cooler Components

1. Remove the oil cooler coolant outlet hose clamp (1).

2. Remove the oil cooler coolant outlet hose (2) from engine coolant thermostat housing.
3. Remove the oil cooler coolant inlet hose clamp (3).
4. Remove the oil cooler coolant inlet hose (4) from water outlet.
5. Remove the oil cooler coolant outlet pipe bolt (7).
6. Remove the 3 oil cooler bolts (5).
7. Remove the engine oil cooler assembly (6) and the 2 oil cooler sealings (8) and (9).
ENGINE COOLANT THERMOSTAT HOUSING REMOVAL

Fig. 262: Engine Coolant Thermostat Housing

1. Remove the 3 engine coolant thermostat housing bolts (1).

2. Remove the engine coolant thermostat housing (2) and the engine coolant thermostat housing seal ring
(3).
WATER OUTLET REMOVAL

Fig. 263: Water Outlet, Bolts And Seal Ring

1. Remove the 3 water outlet bolts (3).

2. Remove the water outlet (2) and the water outlet seal ring (1).
DRIVE BELT TENSIONER REMOVAL


CAUTION: The drive belt tensioner must always be in a pre-tensioned state and
must never be free from tension. If the drive belt tensioner is free
from the belt tension, it must always stay fixed with an appropriate
locking pin. Failure to follow this instruction will lead to a damage of
the drive belt tensioner.
1. Remove the upper drive belt tensioner bolt (2).

2. Remove the lower drive belt tensioner bolt (3).
3. Remove the drive belt tensioner (1).
AIR CONDITIONING COMPRESSOR BRACKET REMOVAL

Fig. 265: Power Steering Pump Bracket/Air Conditioning Compressor Bracket And Bolts
1. Remove the 3 air conditioning compressor bracket bolts (1).

2. Remove the air conditioning compressor bracket (2).
WATER PUMP PULLEY REMOVAL

Fig. 266: Water Pump Pulley

1. Loosen the 3 water pump pulley bolts (2) while holding up the water pump pulley hub with a wrench.
2. Remove the 3 water pump pulley bolts (2).
3. Remove the water pump pulley (1).
CRANKSHAFT BALANCER REMOVAL
Special Tools
EN-956-1 Extension
1. Install EN-49979 retainer to EN-956-1 extension.

Fig. 267: Crankshaft Balancer, Retainer And Extension

NOTE: The crankshaft balancer can be incorrectly installed 180° from the required
position. Be sure to note the location of the alignment hole on the
crankshaft balancer prior to removing the crankshaft balancer from the
engine.
2. Loosen the crankshaft balancer bolt (4) while fixing the crankshaft balancer (3) with EN-49979 retainer
(1) and EN-956-1 extension (2).

Fig. 268: Crankshaft Balancer And Bolt

3. Remove and DISCARD the crankshaft balancer bolt (2).

4. Remove the crankshaft balancer (1).
WATER PUMP REMOVAL
1. Remove and DISCARD the 2 front cover bolts (1).

Fig. 269: Front Cover Bolts


Fig. 270: Water Pump, Gasket And Bolts

2. Remove the 5 short water pump bolts (4) and the 3 long water pump bolts (3).
3. Remove the water pump (2).
4. Remove and DISCARD the water pump gasket (1).
THROTTLE BODY REMOVAL

Fig. 271: Throttle Body And Bolts

1. Remove the 4 throttle body bolts (3).

2. Remove the throttle body (2) and the throttle body seal ring (1).
INTAKE MANIFOLD REMOVAL


NOTE: Intake manifold bolts remain in intake manifold screw bores.
1. Remove the 6 intake manifold bolts (1).


2. Remove the intake manifold (1) along with the intake manifold gasket.
GENERATOR REMOVAL

Fig. 274: Generator And Bolts

1. Remove the 2 generator bolts (2).

2. Remove the generator (1).
STARTER REMOVAL

Fig. 275: Starter, Bolt, Stud And Washer

1. Remove the upper starter bolt (2) and if equipped the washer (1).
2. Remove the lower starter bolt stud (3) and if equipped the washer.
3. Remove the starter (4).
ENGINE FLYWHEEL REMOVAL
Special Tools
EN-652 Flywheel Holder

Fig. 276: Engine Flywheel And Holder

1. Install EN-652 holder (1) to hold the engine flywheel (2).

Fig. 277: Engine Flywheel And Bolts

2. Remove and DISCARD the 6 engine flywheel bolts (2).

3. Remove the engine flywheel (1).
IGNITION COIL REMOVAL
Special Tools
EN-6009 Remover and Installer Ignition Module

Fig. 278: Ignition Coil Bolts

1. Remove the 2 ignition coil bolts (1).

Fig. 279: Ignition Coil And Remover/Installer

2. Install EN-6009 remover and installer (2) and remove the ignition coil (1).
CAMSHAFT COVER REMOVAL


1. Remove the oil level indicator (1).

Fig. 281: Camshaft Cover And Gasket

2. Remove the 15 camshaft cover bolts (1).

3. Remove the camshaft cover (2) and the camshaft cover gasket (3).
CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REMOVAL

Fig. 282: Camshaft Position Actuator Solenoid Valve Bolts

1. Remove the 4 camshaft position actuator solenoid valve bolts (1).

Fig. 283: Intake Camshaft Position Actuator Solenoid Valve And Exhaust Camshaft Position
Actuator Solenoid Valve
2. Move the intake camshaft position actuator solenoid valve (1) carefully counter clockwise in the position
shown.
3. Move the exhaust camshaft position actuator solenoid valve (2) carefully clockwise in the position
shown.

Fig. 284: Camshaft Position Actuator Solenoid Valves And Seal Rings
CAUTION: The camshaft position actuator solenoid valves must be kept parallel
to the engine front cover during removal and installation. The
camshaft position actuator solenoid valves can be damaged if they
become wedged or stuck during this process.
4. Carefully remove the 2 camshaft position actuator solenoid valves (2) and the seal rings (1).
OIL PAN REMOVAL

Fig. 285: Oil Pan Bolts

1. Remove the 16 oil pan bolts (1).

Fig. 286: Oil Pan Prying Area

CAUTION: Pry the oil pan carefully in order to prevent damage to the transaxle
case or the oil pan sealing surfaces.
2. Place a suitable prying tool to the area shown (1) and carefully pry the oil pan loose.

Fig. 287: Oil Pan

3. Remove the oil pan (1).
ENGINE FRONT COVER AND OIL PUMP REMOVAL
1. Set engine to TDC. Refer to Camshaft Timing Chain Inspection.


4. Remove the engine front cover.
CAMSHAFT TIMING CHAIN REMOVAL
Special Tools
EN-952 Fixing Pin

EN-955-10 Fixing Pin from EN-955 Kit
1. The engine should be adjusted to TDC.

2. The crankshaft should be fixed with EN-952 fixing pin.
3. The camshaft should be fixed with EN-953-A fixing tool.


4. Push the timing chain (2) in direction to the timing chain tensioner (1) and fix the tensioner with EN-955-
10 fixing pin (3).


5. Remove the 2 upper timing chain guide bolts (1).



7. Remove the 2 timing chain guide right side bolts (2).

8. Remove the timing chain guide right side (1).


9. Remove the timing chain tensioner shoe bolt (2).

10. Remove the timing chain tensioner shoe (1).


11. Remove the timing chain (1) in compound with the crankshaft sprocket (2).
TIMING CHAIN TENSIONER REMOVAL

Fig. 294: Timing Chain Tensioner And Bolts

1. Remove the 2 timing chain tensioner bolts (1).

2. Remove the timing chain tensioner (2).
ENGINE FRONT COVER GASKET REMOVAL


Remove and DISCARD the engine front cover gasket (1).
CAMSHAFT SPROCKET REMOVAL

Fig. 296: Intake Camshaft And Intake Camshaft Sprocket Bolt

1. Loosen the intake camshaft sprocket bolt (1) while holding the hexagon of intake camshaft (2) with a
wrench.

Fig. 297: Intake Camshaft Sprocket, Bolt And Intake Camshaft Position Exciter Wheel
2. Remove the intake camshaft sprocket bolt (1) and the intake camshaft position exciter wheel (2).
3. Remove the intake camshaft sprocket (3).
4. Loosen the exhaust camshaft sprocket bolt while holding the hexagon of exhaust camshaft with a wrench.
5. Remove the exhaust camshaft sprocket bolt and the exhaust camshaft position exciter wheel.
6. Remove the exhaust camshaft sprocket.
INTAKE CAMSHAFT REMOVAL

Fig. 298: Intake Camshaft Bearing Cap Bolts Removal Sequence

1. Remove the camshaft bearing cap bolts in a spiral sequence as shown one turn at a time until there is no
spring tension pushing on the camshaft.

Fig. 299: Intake Camshaft, Camshaft Bearing Caps And Bolts

NOTE: Mind the markings on the camshaft bearing caps to ensure they will be
installed in the same position.
2. Remove the 10 camshaft bearing cap bolts (1).

3. Remove the 5 camshaft bearing caps (2).
4. Remove the intake camshaft (3).
EXHAUST CAMSHAFT REMOVAL

Fig. 300: Exhaust Camshaft Bearing Cap Bolts Removal Sequence

1. Remove the camshaft bearing cap bolts in a spiral sequence as shown one turn at a time until there is no
spring tension pushing on the camshaft.

Fig. 301: Exhaust Camshaft, Camshaft Bearing Caps And Bolts

NOTE: Mind the markings on the camshaft bearing caps to ensure they will be
installed in the same position.
2. Remove the 10 camshaft bearing cap bolts (1).

3. Remove the 5 camshaft bearing caps (2).
4. Remove the exhaust camshaft (3).
HYDRAULIC VALVE LASH ADJUSTER ARM REMOVAL


NOTE: Mind the installation position of the hydraulic valve lash adjuster arms.
Remove the 16 hydraulic valve lash adjuster arms (1).
HYDRAULIC VALVE LASH ADJUSTER REMOVAL

Fig. 303: Hydraulic Valve Lash Adjusters

NOTE: Mind the installation position of the hydraulic valve lash adjusters.
Remove the 16 hydraulic valve lash adjusters (1).
CYLINDER HEAD REMOVAL

Fig. 304: Cylinder Head Bolts Loosening Sequence

1. Loosen the 12 cylinder head bolts in the sequence as shown. Use the following procedure:
1. Loosen the cylinder head bolts 90°.
2. Loosen the cylinder head bolts 180°.


NOTE: Do not damage the guide sleeves (4) and (5).
2. Remove the 12 cylinder head bolts (1).

3. Remove the cylinder head (2).
4. Remove the cylinder head gasket (3).
PISTON, CONNECTING ROD AND BEARING REMOVAL

Fig. 306: Rod Bearing Caps And Bolts

NOTE: Mark the installation position of the connecting rod bearing caps. The
connecting rod bearings and bearing caps must not be interchanged with
other connecting rods.
1. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 2 and 3.
2. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 2 and 3.
3. Rotate the crankshaft 180 degrees.


4. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 1 and 4.
5. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 1 and 4.

Fig. 308: Pistons, Connecting Rods And Bearings

6. Remove the 4 pistons (1) and connecting rods (2) and the 4 upper connecting rod bearings (3) from the
cylinder block.
CRANKSHAFT AND BEARING REMOVAL

Fig. 309: Crankshaft Position Sensor, Bolt And Seal Ring

1. Remove the crankshaft position sensor bolt (3).

2. Remove the crankshaft position sensor (1) and the crankshaft position sensor seal ring (2).

Fig. 310: Outer Crankshaft Bearing Cap Tie Plate Bolts

3. Remove and DISCARD the 12 outer crankshaft bearing cap tie plate bolts (1).

Fig. 311: Inner Crankshaft Bearing Cap Tie Plate Bolts Loosening Sequence
4. Loosen the 10 inner crankshaft bearing cap tie plate bolts in a sequence as shown.

Fig. 312: Crankshaft Bearing Cap Tie Plate, Bolts, Lower Crankshaft Bearings, Lower Crankshaft
Thrust Bearing And Crankshaft Rear Oil Seal
5. Remove and DISCARD the 10 crankshaft bearing cap tie plate bolts (1)
Remove the crankshaft bearing cap tie plate (2).
6. Remove the 4 lower crankshaft bearings (3) an the lower crankshaft thrust bearing (4).
7. Remove the crankshaft rear oil seal (5).

Fig. 313: Crankshaft, Upper Crankshaft Bearings And Upper Crankshaft Thrust Bearing
8. Remove the crankshaft (1), the 4 upper crankshaft bearings (2) and the upper crankshaft thrust bearing
(3).

Fig. 314: Crankshaft Position Sensor Reluctor Ring And Bolts

9. Remove the 3 bolts (2) and the crankshaft position sensor reluctor ring (1).
CYLINDER HEAD DISASSEMBLE
Special Tools
EN-840 Pliers/Remover
EN-8062 Valve Spring Compressor
EN-8062-5 Adapter
EN-50717-2 Compressor Assembly of EN-50717 Kit

Fig. 315: Valve Spring Compressor And Adapter Assembly

1. Install the EN-50717-2 assembly (1) to the EN-8062 compressor (4).

2. Install the EN-8062-5 adapter (3) to the EN-8062 compressor.
3. Install the compressor assembly to the cylinder head, so that the adapter (5) of the EN-50717-2 assembly
(1) contacts the valve spring retainer properly and the EN-8062-5 adapter (3) contacts the valve disc (2).
Prefix the EN-8062 compressor (4).

Fig. 316: Valve Spring Retainer And Valve Spring

WARNING: Valve springs can be tightly compressed. Use care when removing
the retainers and plugs. Personal injury could result.
4. Apply pressure to the EN-50717-2 assembly to push down the vale spring retainer (1) and compress the
valve spring (3) until the valve keys (2) are free from tension. Carefully remove the valve keys.

Fig. 317: Spring Compressor

5. Slowly and carefully loosen the EN-50717-2 assembly until the valve spring is entirely expanded.
6. Remove the compressor assembly from the cylinder head.
7. Remove the valve spring retainer (1) and the valve spring (3).
8. Remove and DISCARD the valve stem oil seal (4), using the EN-840 pliers (2).
9. Remove the valve (5).
10. Repeat the procedure with the remaining valves.
NOTE: Ensure that the valve train components are kept together and identified in
order for proper installation in their original position.
11. In case of re-using the cylinder head, refer to Cylinder Head Cleaning and Inspection.
CYLINDER HEAD CLEANING AND INSPECTION
Special Tools
EN-6216 Gauge

EN-6216-200/300/400 Gauge Instruments
For equivalent regional tools refer to Special Tools.
Cleaning Procedure
1. Remove any old thread sealant, gasket material or sealant.

2. Clean all cylinder head surfaces with non-corrosive sealant.
3. Blow out all the oil galleries using compressed air.
WARNING: Refer to Safety Glasses Warning .
4. Remove any carbon deposits from the combustion chamber.
Visual Inspection
1. Inspect the cylinder head camshaft bearing surfaces for the following conditions:
Excessive scoring or pitting
Discoloration from overheating
Deformation from excessive wear
If the camshaft bearing journals appear to be scored or damaged, you must replace the cylinder
head. DO NOT machine the camshaft bearing journals.
2. If any of the above conditions exist on the camshaft bearing surfaces, replace the cylinder head.
3. Inspect the cylinder head for the following:
Cracks, damage or pitting in the combustion chambers.
Debris in the oil galleries - Continue to clean the galleries until all debris is removed.
Coolant leaks or damage to the deck face sealing surface - If coolant leaks are present, measure the
surface war page as described under cylinder head measurement - deck flatness inspection.
Damage to any gasket surfaces.
Burnt or eroded areas in the combustion chamber.
Cracks in the exhaust ports and combustion chambers.
External cracks in the water passages.
Restrictions in the intake or exhaust passages.
Restrictions in the cooling system passages.
Rusted, damaged or leaking core plugs.
4. If the cylinder head is cracked or damaged, it must be replaced. No welding or patching of the cylinder
head is allowed.
Valve Inspection And Measurement

Fig. 318: Valve Inspection And Measurement

1. Clean the valves of carbon and oil. Carbon can be removed with a wire brush.
2. Inspect the valves for the following conditions:
1. Inspect the valve faces for burning and cracking (1). If pieces are broken, replace the valve and
inspect the corresponding piston and cylinder head area for damage.
2. Inspect the valve for straightness and distortion (2). Distorted valve must be replaced.
3. Inspect the valve stem for wear (3).
4. Inspect the valve key grooves for chipping and wear (5). Replace the valve if chipped or worn.

Fig. 319: Measuring Valve Length Using Slide Gauge

3. Measure the valve length (2). Use a slide gauge (1). Refer to Engine Mechanical Specifications to find
the permitted values.

Fig. 320: Measuring Valve Stem Diameter Using Micrometer Gauge

4. Measure the valve stem diameter. Use a micrometer gauge (2). Refer to Engine Mechanical
Specifications to find the permitted values. Note the measurement results.
Cylinder Head Measurement

Fig. 321: Using Straightedge To Inspect Cylinder Head Sealing Surface For Flatness
1. Inspect the cylinder head sealing surface for flatness. Use a straightedge (1). Refer to Engine Mechanical
Specifications to find the permitted values. If the measurement does not show the permitted values,
replace the cylinder head. Machining is NOT allowed.

Fig. 322: Checking Valve Stem To Guide Clearance Measurement

2. Prepare the gauge for valve stem to guide clearance measurement. Assemble the EN-6216 gauge and the
EN-6216-200/300/400 gauge instruments as followed:
1. Install the extension (5) to the support (4).
2. Install the inside caliper (2) to the extension (5).
3. Install the gauge (3) to the support (4) and pretension to 1 mm (0.0394 in).
4. Install the calibration washer (1) as shown to justify the gauge.
5. Adjust the gauge to 0 mm (0 in) by rotating the instrument dial.
6. Cautious remove the calibration washer (1).

Fig. 323: Measuring Valve Guide Inner Diameter

3. Measure the valve guide inner diameter (2) as shown in different areas (3). Use EN-6216 gauge (1) and
gauge instruments. Note the measurement results. Refer to Engine Mechanical Specifications to find the
permitted values.
4. Substract the valve stem diameter from valve guide inner diameter to calculate the valve stem to guide
clearance. Refer to Engine Mechanical Specifications to find the permitted values.
5. Turn the cylinder head upside down.
CYLINDER HEAD ASSEMBLE
Special Tools
EN-958 Valve Stem Seal Installer

EN-8062 Valve Spring Compressor
EN-8062-5 Adapter
EN-50717-2 Compressor Assembly of EN-50717 Kit

Fig. 324: Valve Stem Oil Seal And Installer

1. Lubricate the valve stem and the valve guide with clean engine oil.
2. Install the valve (5).
NOTE: Ensure all valve train components will be installed in their original
position.
3. Install the NEW valve stem oil seal (4), using the EN-958 installer (2).
4. Loosely install the valve spring (3) and the valve spring retainer (1).

Fig. 325: Valve Spring Compressor And Adapter Assembly

5. Install the EN-50717-2 assembly (1) to the EN-8062 compressor (4).

6. Install the EN-8062-5 adapter (3) to the EN-8062 compressor.
7. Install the compressor assembly to the cylinder head, so that the adapter (5) of the EN-50717-2 assembly
(1) contacts the valve spring retainer properly and the EN-8062-5 adapter (3) contacts the valve disc (2).
Prefix the EN-8062 compressor (4).

Fig. 326: Valve Spring Retainer And Valve Spring

CAUTION: The valve stem keys must correctly seat in the valve spring cap.
Engine damage may occur by not installing properly.
8. Apply pressure to the EN-50717-2 assembly to push down the vale spring retainer (1) and compress the
valve spring (3) until the valve keys (2) can be inserted. Carefully insert the valve keys then, so that they
are proper installed to the valve stem grooves.
9. Carefully release the tension from the EN-50717-2 assembly.
10. Inspect the valve keys and valve spring retainers for proper seat.
11. Remove the compressor assembly from the cylinder head.
12. Repeat the procedure with the remaining valves.
ENGINE BLOCK DISASSEMBLE

Fig. 327: Knock Sensor, Bolt, Cylinder Head Guide Sleeves And Transmission Guide Sleeves
1. Remove the knock sensor bolt (3).

2. Remove the knock sensor (2).
3. Remove the 2 cylinder head guide sleeves (1). Use suitable pliers.
4. Remove the 2 transmission guide sleeves (4) and (5). Use suitable pliers.

Fig. 328: Piston Oil Nozzles And Bolts

5. Remove the 4 piston oil nozzle bolts (2).

6. Remove the 4 piston oil nozzles (1).
ENGINE BLOCK ASSEMBLE

Fig. 329: Piston Oil Nozzles And Bolts

1. Install the 4 piston oil nozzles (1).

2. Install the 4 piston oil nozzle bolts (2) and tighten to 25 N.m (18 lb ft).

Fig. 330: Knock Sensor, Bolt, Cylinder Head Guide Sleeves And Transmission Guide Sleeves
3. Install the knock sensor (2).

4. Install the knock sensor bolt (3) and tighten to 20 N.m (15 lb ft).
5. Install the 2 cylinder head guide sleeves (1). Use a rubber mallet.
6. Install the 2 transmission guide sleeves (4) and (5). Use a rubber mallet.
PISTON AND CONNECTING ROD DISASSEMBLE
Special Tool
EN-49941 Remover / Installer Piston Retainer Ring

Fig. 331: Using Piston Ring Pliers

WARNING: Handle the piston carefully. Worn piston rings are sharp and may
cause bodily injury.
1. Remove the piston rings. Use piston ring pliers (1)

Fig. 332: Upper Compression Ring, Lower Compression Ring, Oil Rings And Oil Ring Spacer
2. The piston rings are ordered as followed:

Upper compression ring (1)
Lower compression ring (2)
Oil rings and oil ring spacer (3) and (4)
3. Install the piston and connecting rod assembly to a bench vise. Use aluminum braces

Fig. 333: Piston Pin Retainer, Remover And Notch

WARNING: Use extreme care when removing snap rings. Always wear adequate
eye protection in order to avoid personal injury.
4. Apply the EN-49941 remover (1) in the notch (3) to the piston pin retainer (2) and remove it.

Fig. 334: Connecting Rod, Piston And Piston Pin

5. Remove the piston pin (2) and the connecting rod (3) from the piston (1).
PISTON, CONNECTING ROD AND BEARING CLEANING AND INSPECTION
Special Tools
Visual Inspection And Cleaning Procedure
Connecting Rod
1. Clean the connecting rods in solvent and dry with compressed air.
eye injury.

2. Inspect the connecting rod for the following:

Signs of being twisted, bent, nicked or cracked
Scratches or abrasion on the connecting rod bearing seating surfaces
Piston
Fig. 335: Identifying Piston Damage Inspection Areas

1. Clean the piston with a cleaning solvent. DO NOT wire brush any parts of the piston.
2. Clean the piston ring grooves.
3. Inspect the piston on the following:
Cracked ring lands, skirts or pin bosses
Ring grooves for nicks
Eroded areas on the top of the piston (1)
Scuffed or damaged skirts (2)

Worn piston pin bores (3)
4. If there is any excessive wear, replace the piston.
5. Measure the clearance between piston pin and piston bore.
Piston And Connecting Rod Measurement Procedure
Piston Ring Clearance
Fig. 336: Measuring Piston Ring End Clearance

1. Install the piston rings to the cylinder as shown (1) and measure the piston ring end gap. Compare the
measurements with those provided below:
The upper compression ring end gap should be 0.4-0.6 mm (0.0157-0.0236 in).
The lower compression ring end gap should be 0.4-0.6 mm (0.0157-0.0236 in).
The oil ring end gap should be 0.2-0.9 mm (0.0079-0.0354 in).
2. If the clearance is greater than the provided specifications, the piston rings must be replaced.

Fig. 337: Measuring Piston Ring Side Clearance

3. Measure the piston ring side clearance as shown (1). Compare the measurements with those provided
below:
The upper compression ring side clearance should be 0.025-0.07 mm (0.001-0.0028 in).
The lower compression ring side clearance should be 0.025-0.07 mm (0.001-0.0028 in).
The oil ring side clearance should be 0.04-0.12 mm (0.0016-0.0047 in).
4. If the clearance is greater than the provided specifications, replace the piston rings.
5. If the clearance is still to great, replace the pistons.
Connecting Rod Bearing Clearance (With Micrometer Gauge Internal Measuring Device)
1. Install the connecting bearings and the connecting rod bearing caps.
2. Tighten the connecting rod bearing cap bolts in the following sequence:
1. Tighten the connecting rod bearing cap bolts to 10 N.m (89 lb in).

NOTE: The old bolts can be reused for the measuring procedure.
2. Tighten the bolts to an additional 60 degrees using EN-470-B wrench.

3. Tighten the bolts to an additional 15 degrees using EN-470-B wrench.
Fig. 338: Measuring Connecting Rod Bearing Diameters

3. Measure the connecting rod bearing diameters at 3 points as shown (1). Use a internal measuring device.
4. Calculate the average connecting rod inner diameter.
Formula: 1. result + 2. result + 3. result / 3

Fig. 339: Connecting Rod Journal Diameter Points

5. Measure the connecting rod journal diameter at 2 points between (1) and (3) and between (2) and (4). Use
a micrometer gauge.
6. Calculate the average connecting rod journal diameter.
Formula: 1. result + 2. result / 2.
7. Substract the average connecting rod journal diameter from the average connecting rod bearing diameter
in order to determine the connecting rod bearing clearance.
The clearance should be 0.013-0.061 mm (0.0005-0.0024 in).
PISTON AND CONNECTING ROD ASSEMBLE
Special Tools
EN-49941 Remover / Installer Piston Retainer Ring

Fig. 340: Connecting Rod, Piston And Piston Pin

NOTE: Lubricate the piston pin with clean engine oil.
1. Install the connecting rod (3) and the piston pin (2) to the piston (1).
2. Install the piston and connecting rod assembly to a bench vise. Use aluminum braces.

Fig. 341: Pushing Piston Pin Retainer Down With Thumb

WARNING: Use extreme care when removing snap rings. Always wear adequate
eye protection in order to avoid personal injury.
WARNING: Use care when removing or installing the piston retainer ring.
Ensure the EN-49941 remover/installer is installed properly onto the
retainer ring and that hands and fingers are kept clear from the front
of the tool. Otherwise, bodily injury may occur.
NOTE: Notch (2) on right side.
3. Place the piston pin retainer in the piston pin retainer groove so that the ring gap lays on the notch (2).
4. Push the piston pin retainer down with the thumb in the shown position (1) and hold.
5. Apply the EN-49941 installer (4) to the piston pin retainer in the position shown (3) and push in direction
of the arrow while pushing down with the thumb.
NOTE: The EN-49941 installer should be applied in a perpendicular position to the

piston pin retainer.
Fig. 342: Pushing Piston Pin Retainer Down

NOTE: Push the piston pin retainer down in the position shown (2).
6. Move the EN-49941 installer (1) carefully to the position shown while pushing in direction of the arrow
until the piston pin retainer engages in the piston pin retainer groove.
7. Push down the piston ring retainer to get a proper seat in the groove.

Fig. 343: Pushing Piston Pin Retainer Down With Thumb

NOTE: Notch (4) on left side. EN-49941 installer should be used with left hand.
8. Place the piston pin retainer in the piston pin retainer groove so that the ring gap lays on the notch (4).
9. Push the piston pin retainer down with the thumb in the position shown (1) and hold.
10. Apply the EN-49941 installer (3) to the piston pin retainer in the position shown (2) and push in direction
of the arrow while pushing down with the thumb.
NOTE: The EN-49941 installer should be applied in a perpendicular position to the

piston pin retainer.

Fig. 344: Pushing Piston Pin Retainer Down

NOTE: Push the piston pin retainer down in the position shown (1).
11. Move the EN-49941 installer (2) carefully to the position shown while pushing in direction of the arrow
until the piston pin retainer engages in the piston pin retainer groove.
12. Push down the piston ring retainer to get a proper seat in the groove.
13. Remove the piston and connecting rod assembly from the bench vise.

Fig. 345: Using Piston Ring Pliers

14. Install the piston rings. Use piston ring pliers (1).

Fig. 346: Upper Compression Ring, Lower Compression Ring, Oil Rings And Oil Ring Spacer
NOTE: Mind the TOP marking on the piston rings.
15. The piston rings must be ordered as followed:

Upper compression ring (1)
Lower compression ring (2)
Piston oil ring with spacer (3), (4)

Fig. 347: Oil Ring Joints, Lower Compression Ring Joint, Upper Compression Ring Joint And Oil
Ring Spacer Joint
16. The piston ring joints must be positioned 90 degrees to each other.
Upper compression ring joint (2)
Lower compression ring joint (5)
Oil ring joint, upper part (1)
Oil ring joint, lower part (4)
Oil ring spacer joint (3)
INTAKE MANIFOLD DISASSEMBLE

Fig. 348: Fuel Injection Fuel Rail Assembly And Intake Manifold Gasket
1. Remove the fuel injection rail ground cable nut (1).

2. Remove the 2 fuel injection rail bolts (2).
3. Remove the fuel injection fuel rail assembly (3).
4. Remove the intake manifold gasket (4).

Fig. 349: Evaporative Emission Canister Purge Solenoid Valve And Manifold Absolute Pressure
Sensors
5. Remove the 2 manifold absolute pressure sensor bolts (1).

6. Remove the 2 manifold absolute pressure sensors (2).
7. Remove the evaporative emission canister purge solenoid valve (3).
INTAKE MANIFOLD CLEANING AND INSPECTION

Fig. 350: Sealing Surfaces

1. Clean the sealing surfaces (1) and (2).

2. Inspect the intake manifold for cracks and fractures.
INTAKE MANIFOLD ASSEMBLE

Fig. 351: Evaporative Emission Canister Purge Solenoid Valve And Manifold Absolute Pressure
Sensors
1. Install the evaporative emission canister purge solenoid valve (3).

2. Install the 2 manifold absolute pressure sensors (2).
3. Install the 2 manifold absolute pressure sensor bolts (1) and tighten.

Fig. 352: Fuel Injection Fuel Rail Assembly And Intake Manifold Gasket
4. Install the fuel injection fuel rail assembly (3).

5. Install the 2 fuel injection rail bolts (2) and tighten to 8 N.m (71 lb in).
6. Install the fuel injection rail ground cable nut (1) and tighten.
7. Install a NEW intake manifold gasket (4).
CRANKSHAFT AND BEARING CLEANING AND INSPECTION
Special Tools

GE-571-B Dial Gauge

Crankshaft End Play, Check
Fig. 353: Gauge Tool

NOTE: Crankshaft attached with crankshaft bearing caps.
1. Install the GE-571-B gauge (1).

Install the holder on the front of the engine block.
Place the dial gauge plunger against the crankshaft and adjust.
2. Measure the longitudinal play of the crankshaft.
Move the crankshaft in the longitudinal direction.
Permissible crankshaft end play 0.100-0.202 mm (0.0039-0.0080 in).
3. Remove the GE-571-B gauge.
Crankshaft Out-of-Round, Check

Fig. 354: Gauge Tool

NOTE: Crankshaft removed.
1. Insert the crankshaft in the engine block.

2. Install the GE-571-B gauge (1).
Attach holder to the engine block.
Place the dial gauge plunger against the crankshaft bearing journal and adjust.
3. Check the rotational play of the crankshaft.
Turn the crankshaft evenly.
Maximum permissible rotational play 0.03 mm (0.001 in).
4. Remove the GE-571-B gauge.
Check Crankshaft Bearing Clearance (With Plastigage)

Fig. 355: Plastigage On Bearing Journal

NOTE: Crankshaft removed.

Do not rotate the crankshaft.
1. Lay out plastigage.
Lay out plastigage (flexible plastic thread) around the entire width of the crankshaft bearing journal (1).

Fig. 356: Crankshaft Bearing Cap Tie Plate

NOTE: The bolts can be reused for checking the crankshaft bearing play.
2. Install the 4 lower crankshaft bearings (3) and the lower crankshaft thrust bearing (4).
3. Install the crankshaft bearing cap tie plate (2).
4. Install the 10 inner crankshaft bearing cap tie plate bolts (1).

Fig. 357: Inner Crankshaft Bearing Cap Tie Plate Bolts Tightening Sequence
5. Tighten the 10 inner crankshaft bearing cap tie plate bolts in a sequence as shown and in the following
order:
1. Tighten the inner crankshaft bearing cap tie plate bolts to 25 N.m (18 lb ft).
2. Tighten the inner crankshaft bearing cap tie plate bolts an additional 60°. Use EN-470-B wrench.
3. Tighten the inner crankshaft bearing cap tie plate bolts an additional 15°. Use EN-470-B wrench.
6. Remove the crankshaft bearing cap tie plate bolts and the crankshaft bearing cap tie plate.

Fig. 358: Measuring Crankshaft Bearing Play Using Measuring Scale

NOTE: When reading the value, do not confuse millimeters and inches on the
measuring scale.
7. Measure the crankshaft bearing play.

Compare the width of the flattened plastic thread (arrow) to the measuring scale (1).
The crankshaft bearing play should be 0.007-0.031 mm (0.00028-0.00122 in).
Check Crankshaft Bearing Clearance (With Micrometer Gauge Internal Measuring Device)
1. Install and tighten the crankshaft bearing cap tie plate and the crankshaft bearings as shown above.
NOTE: The bolts can be reused for checking the crankshaft bearing play.

Fig. 359: Crankshaft Bearing Diameter Measuring Points

2. Measure the crankshaft bearing diameter at 3 points.
Measure in areas as shown (1) with an internal measuring device.
Calculate the average crankshaft bearing diameter.
Formula: 1. result + 2. result + 3. result / 3.

Fig. 360: Connecting Rod Journal Diameter Points

3. Measure the crankshaft bearing journal diameter at 2 points between (1) and (3) and between (2) and (4)
with the micrometer gauge.
4. Calculate the average crankshaft bearing journal diameter.
Formula: 1. result + 2. result / 2.
5. Determine the crankshaft bearing play.
Calculation formula: average crankshaft bearing diameter minus average crankshaft bearing journal
diameter.
6. The crankshaft bearing play should be 0.007-0.031 mm (0.00028-0.00122 in).
ENGINE FRONT COVER AND OIL PUMP CLEANING AND INSPECTION
Engine Front Cover Cleaning Procedure
1. Clean the engine front cover sealing surface.

Fig. 361: Oil Gallery Bores

eye injury.

2. Clean the shown oil gallery with solvent and compressed air. Blow compressed air from bore (2) to bore
(1).
Engine Front Cover Visual Inspection
Inspect the engine front cover for cracks, scratches and damage.
Oil Pump Visual Inspection and Measurement
1. Inspect the oil pump cover and the engine front cover for flatness.
2. Inspect the oil pump vanes, the oil pump vane rotor, the oil pump vane rings and the oil pump slide for
localized flatting.
3. Inspect the oil pump slide pivot pin for firm seat.
Fig. 362: Straight Edge Tool

NOTE: Oil pump components are installed.
4. Measure the oil pump axial clearances. Use a straight edge (1) and a feeler gauge.
1. The maximal axial clearance between engine front cover and oil pump vane rotor should be 0.1 mm
(0.004 in).
2. The maximal axial clearance between engine front cover and oil pump vane should be 0.09 mm
(0.0035 in).
3. The maximal axial clearance between engine front cover and oil pump vane ring should be 0.4 mm
(0.016 in).
4. The maximal axial clearance between engine front cover and oil pump slide should be 0.08 mm
(0.0031 in).
5. The maximal axial clearance between engine front cover and oil pump slide seal should be 0.09
mm (0.0035 in).

Fig. 363: Feeler Gauge, Oil Pump Slide And Oil Pump Vane
5. Measure the oil pump radial clearance. Use a feeler gauge (1). Measure the clearance between oil pump
vane rotor and oil pump vane (3).
The maximal clearance should be 0.05 mm (0.002 in).
6. Measure the clearance between oil pump vane and oil pump slide (2).
The maximal clearance should be 0.2 mm (0.008 in).
ENGINE FRONT COVER AND OIL PUMP DISASSEMBLE
Engine Front Cover Disassemble

Fig. 364: Locating Engine Front Cover Components

1. Remove the intake camshaft position sensor bolt (1).

2. Remove the intake camshaft position sensor (2) and the seal ring (3).
3. Remove the exhaust camshaft position sensor bolt (6).
4. Remove the exhaust camshaft position sensor (5) and the seal ring (4).
5. Remove the oil pressure relief valve (7, 8 and 9)
6. Remove the crankshaft front oil seal (10).
Oil Pump Removal


1. Remove the 8 oil pump cover bolts (1).

2. Remove the oil pump cover (2).

Fig. 366: Oil Pump Slide Spring Windings And Engine Front Cover Edge
WARNING: Before removing the spring, cover the spring with a towel to prevent
the spring from flying and possibly causing damage or personal
injury.
NOTE: Position a screw driver between the oil pump slide spring windings (2).
4. Compress the oil pump slide spring with a screw driver and remove the oil pump slide spring along with
the oil pump slide spring pin.

Fig. 367: Locating Engine Oil Pump Components

NOTE: Mind the installation position of the oil pump components.
5. Remove the oil pump components in the following order:

1. Outer oil pump vane ring (1).
2. Oil pump vane rotor (3) and the 7 oil pump vanes (2).
3. Inner oil pump vane ring (6).
4. Oil pump slide (4) and the 2 oil pump slide seals with the 2 oil pump slide seal springs (5).
TURBOCHARGER DISASSEMBLE
Special Tool
EN-49940 Remover Quick Connector


1. Remove the 2 turbocharger oil return pipe bolts (2).

2. Remove the turbocharger oil return pipe (1) and the sealing (3) from the turbocharger.

Fig. 369: Turbocharger Coolant Feed Pipe

NOTE: The quick fitting connectors should be always replaced when the
turbocharger coolant pipes are removed
3. Install the EN-49940 remover (2) to the turbocharger coolant feed pipe (1) and the quick fitting connector
as shown.
4. Compress the EN-49940 remover and remove the turbocharger coolant feed pipe direction of the arrow.

Fig. 370: Quick Fitting Connector And Seal Ring

5. Remove the quick fitting connector (2) and the seal ring (1).
6. Use the same procedure for the turbocharger coolant return pipe and the turbocharger coolant return pipe
quick fitting connector.

Fig. 371: Turbocharger Wastegate Actuator Components

7. Remove the clamp. (1)

8. Turbocharger Wastegate Actuator Hose (6) @ Turbocharger Wastegate Actuator (2) » Remove
9. Retainer (4) @ Turbocharger Wastegate Actuator » Remove
10. Nut (5) @ Turbocharger Wastegate Actuator » Remove [2x]
11. Turbocharger Wastegate Actuator (2) @ Turbocharger (3) » Remove
Fig. 372: Turbocharger Wastegate Actuator

12. Measure the removed turbocharger wastegate actuator (1) with caliper as shown.
13. Notice the value (a).
TURBOCHARGER CLEANING AND INSPECTION
Cleaning Procedure
1. Clean all sealing surfaces.

2. Clean all threads if necessary.
Inspection Procedure

Fig. 373: Wastegate Regulator Mechanism

1. Inspect the wastegate regulator mechanism (1) for functionality.

2. Inspect the turbine blades for damage or foreign material.
3. Inspect the turbocharger wastegate regulator vacuum hoses for damage.
4. Inspect the exhaust manifold and the turbocharger for cracks or other damage.
5. Inspect the exhaust manifold mating surface for flatness.
TURBOCHARGER ASSEMBLE

Fig. 374: Turbocharger Wastegate Actuator

1. Nut (2) @ Turbocharger Wastegate Actuator (1) Loosen

2. Transfer the measured value (a) from the OLD turbocharger wastegate actuator to the NEW by turning
the rod (3).
3. Tighten the nut (2) to 5.6 - 6.8 N.m (49-60 lb in).
4. Measure the turbocharger wastegate actuator again to check the adjusted value.
5. If the adjusted value does not match repeat step 1-4.

Fig. 375: Turbocharger Wastegate Actuator Components

6. Turbocharger Wastegate Actuator (2) @ Turbocharger (3) » Install

7. Nut (5) @ Turbocharger Wastegate Actuator » Install and tighten [2x] 5.6 - 6.8 N.m (49-60 lb in).
8. Retainer (4) @ Turbocharger Wastegate Actuator » Install
9. Turbocharger Wastegate Actuator Hose (6) @ Turbocharger Wastegate Actuator (2) » Install
10. Install the clamp. (1)
Fig. 376: Quick Fitting Connector And Seal Ring

11. Install the NEW quick fitting connector (2) and a NEW seal ring (1) to the turbocharger and tighten to 20
N.m (15 lb ft).

Fig. 377: Turbocharger Coolant Feed Pipe And Quick Fitting Connector
12. Inspect the turbocharger coolant pipes for ridges and damage.
13. Install the turbocharger coolant feed pipe (1) to the quick fitting connector (2) by pushing in direction of
the arrow until an audible click is heard.
14. Use the same procedure for the turbocharger coolant return pipe and the turbocharger coolant return pipe
quick fitting connector.


15. Install the turbocharger oil return pipe (1) and a NEW sealing (3) to the turbocharger.
16. Install the 2 turbocharger oil return pipe bolts (2) and tighten to 8 N.m (71 lb in).
ENGINE OIL COOLER DISASSEMBLE


1. Remove the oil cooler coolant inlet hose clamp (2).

2. Remove the oil cooler coolant inlet hose (1).
3. Remove the oil cooler coolant inlet pipe bolt (7)
4. Remove the oil cooler coolant inlet pipe (3) and the seal ring (6).
5. Remove the oil cooler coolant outlet hose clamp (4).
6. Remove the oil cooler coolant outlet hose (5).

Fig. 380: Engine Oil Pressure Indicator Switch, Oil Filter Cap And Oil Filter Element
7. Remove the engine oil pressure indicator switch (5) and the seal ring (4).
8. Remove the engine oil filter cap (1) along with the seal ring (2) and the oil filter element (3).
ENGINE OIL COOLER ASSEMBLE

Fig. 381: Engine Oil Pressure Indicator Switch, Oil Filter Cap And Oil Filter Element
1. Install the engine oil filter cap (1) along with a NEW seal ring (2) and a NEW oil filter element (3) and
tighten to 25 N.m (18 lb ft).
2. Install the engine oil pressure indicator switch (5) and NEW seal ring (4) and tighten to 20 N.m (15 lb ft).


3. Install the oil cooler coolant outlet hose (5)

4. Install the oil cooler coolant outlet hose clamp (4).
5. Install the oil cooler coolant inlet pipe (3) and a NEW seal ring (6).
6. Install the oil cooler coolant inlet pipe bolt (7) and tighten to 10 N.m (89 lb in).
7. Install the oil cooler coolant inlet hose (1).
8. Install oil cooler coolant inlet hose clamp (2).
OIL PAN CLEANING AND INSPECTION

Fig. 383: Oil Suction Gallery, Sealing Surface And Screw Bores
eye injury.

1. Clean the oil suction gallery (2) with compressed air. Be sure to remove all dirt and old gasket material
from the suction gallery (2).
2. Remove all remaining old gasket material from sealing surface (1) and screw bores (3).
3. Clean the sealing surfaces from dirt and grease.
4. Inspect the sealing surface for cracks and damage.
CRANKSHAFT AND BEARING INSTALLATION
Special Tools

EN-235-6 Installer from EN-235-D Kit.

EN-658-1 Installer from EN-658 Kit.
1. Lubricate crankshaft, crankshaft bearings and crankshaft bearing cap tie plate with engine oil.
Fig. 384: Crankshaft, Upper Crankshaft Bearings And Upper Crankshaft Thrust Bearing
2. Install the 4 upper crankshaft bearings (2) and the crankshaft thrust bearing (3).
3. Install the crankshaft (1).

Fig. 385: Sealing Compound Application Area

4. Apply sealing compound (1) to the outer rim of the groove on the crankshaft bearing cap tie plate. Refer
to Adhesives, Fluids, Lubricants and Sealers.

Fig. 386: Crankshaft Bearing Cap Tie Plate

NOTE: The complete installation procedure should not take longer than 10
minutes.
5. Install the 4 lower crankshaft bearings (3) and the lower crankshaft thrust bearing (4).
6. Install the crankshaft bearing cap tie plate (2).
7. Install the 10 NEW inner crankshaft bearing cap tie plate bolts (1).
NOTE: Do not reuse the old bolts.

Fig. 387: Inner Crankshaft Bearing Cap Tie Plate Bolts Tightening Sequence
8. Tighten the 10 inner crankshaft bearing cap tie plate bolts in the sequence shown and to the following
specifications:
1. Tighten the inner crankshaft bearing cap tie plate bolts to 25 N.m (18 lb ft).
2. Tighten the inner crankshaft bearing cap tie plate bolts an additional 60 degrees. Use EN-470-B
wrench.
3. Tighten the inner crankshaft bearing cap tie plate bolts an additional 15 degrees. Use EN-470-B
wrench.

Fig. 388: Outer Crankshaft Bearing Cap Tie Plate Bolts

9. Install the 12 NEW outer crankshaft bearing cap tie plate bolts (1) and tighten to the following
specification:
1. Tighten the outer crankshaft bearing cap tie plate bolts to 10 N.m (89 lb in).
2. Tighten the outer crankshaft bearing cap tie plate bolts an additional 60 degrees. Use EN-470-B
wrench.
3. Tighten the outer crankshaft bearing cap tie plate bolts an additional 15 degrees. Use EN-470-B
wrench.

Fig. 389: Crankshaft Position Sensor, Bolt And Seal Ring

10. Install the crankshaft position sensor (1) and a NEW crankshaft position sensor seal ring (2).
11. Install the crankshaft position sensor bolt (3) and tighten to 8 N.m (71 lb in).

Fig. 390: Crankshaft Rear Oil Seal

12. Slide the crankshaft rear oil seal (2) across the EN-235-6 installer (1) contained in EN-235-D kit.

Fig. 391: Crankshaft Rear Oil Seal And Installer

13. Install the crankshaft rear oil seal (1) with EN-235-6 installer (2) to the crankshaft.

Fig. 392: Oil Seal Installer

NOTE: Ensure that the crankshaft rear oil seal fits proper.
14. Use EN-658-1 installer (2) to strike the crankshaft rear oil seal (1)
PISTON, CONNECTING ROD AND BEARING INSTALLATION
Special Tools

Fig. 393: Piston Ring Joint Adjustment Points

1. Adjust the piston ring joints as follows:

1. Upper compression ring (1).
2. Lower compression ring (4).
3. Oil rings (2) or (3).
4. Oil ring spacer (5).

Fig. 394: Rods And Arrow On Piston Head

2. The arrow (1) on the piston head must point to the timing side.
3. The markings on the connecting rods (2) must point to the transmission side.

Fig. 395: Pistons, Connecting Rods And Bearings

4. Install a piston ring compressor to compress the piston rings.

5. Install the pistons (1) in along with connecting rods (2) and upper connecting rod bearings (3) to the
engine block and to the crankshaft.


NOTE: The flarings (arrows) on the connecting rod bearing caps must point to the
transmission side. The connecting rod bearing caps must be installed in
their original position.
6. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 1 and 4.
7. Install the 4 NEW connecting rod bearing cap bolts (1) and tighten in the following sequence:
1. Tighten the connecting rod bearing cap bolts to 25 N.m (18 lb ft).
2. Tighten the connecting rod bearing cap bolts an additional 45 degrees. Use EN-470 B wrench.
8. Rotate the crankshaft 180 degrees.

NOTE: The flarings (arrows) on the connecting rod bearing caps must point to the
transmission side. The connecting rod bearing caps must be installed in
their original position.
9. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 3 and 2.
10. Install the 4 NEW connecting rod bearing cap bolts (1) and tighten in the following sequence:
1. Tighten the connecting rod bearing cap bolts to 25 N.m (18 lb ft).
2. Tighten the connecting rod bearing cap bolts an additional 45 degrees. Use EN-470-B wrench.
CYLINDER HEAD INSTALLATION
Special Tools

EN-470-B Angular Torque Wrench.
1. Clean the sealing surfaces and remove dirt and old gasket material from thread bores, water galleries and
oil galleries.
eye injury.

NOTE: Mind the guide sleeves (4) and (5).
2. Install a NEW cylinder head gasket (3). The marking "Top" should point to the cylinder head.
3. Install the cylinder head (2).
4. Install 12 NEW cylinder head bolts (1) and hand tighten.


5. Lay a straight edge (1) against the engine block and cylinder head. Adjust the transition in area (2) until
there is no clearance between cylinder head and straight edge, using a rubber mallet.

Fig. 400: Cylinder Head Bolts Tightening Sequence

6. Tighten the cylinder head bolts in the sequence shown and to the following specifications:
1. Tighten the cylinder head bolts to 35 N.m (26 lb ft).
2. Tighten the cylinder head bolts an additional 180 degrees. Use EN-470-B wrench.
HYDRAULIC VALVE LASH ADJUSTER INSTALLATION

Fig. 401: Hydraulic Valve Lash Adjusters

NOTE: Mind the installation position of the hydraulic valve lash adjusters.
1. Lubricate the hydraulic valve lash adjusters with engine oil.

2. Install the 16 hydraulic valve lash adjusters (1).
HYDRAULIC VALVE LASH ADJUSTER ARM INSTALLATION


NOTE: Hydraulic valve lash adjuster arms should be installed in their original
position.
1. Lubricate the hydraulic valve lash adjuster arms with engine oil.
2. Install the 16 hydraulic valve lash adjuster arms (1).
INTAKE CAMSHAFT INSTALLATION

Fig. 403: Intake Camshaft, Camshaft Bearing Caps And Bolts

NOTE: Mind the markings on the camshaft bearing caps. Camshaft bearing caps
should be installed in their original position.

2. Install the intake camshaft (3).
3. Install the 5 camshaft bearing caps (2).
4. Install the 10 camshaft bearing cap bolts (1) and hand tighten.

Fig. 404: Intake Camshaft Bearing Cap Bolts Tightening Sequence

NOTE: Tighten the camshaft bearing cap bolts one turn at a time in order to avoid
shape distortion of the camshaft.
5. Tighten the camshaft bearing cap bolts one turn at a time and in a spiral sequence as shown to 8 N.m (71
lb in).
EXHAUST CAMSHAFT INSTALLATION

Fig. 405: Exhaust Camshaft, Camshaft Bearing Caps And Bolts

NOTE: Mind the markings on the camshaft bearing caps. Camshaft bearing caps
should be installed in their original position.

2. Install the exhaust camshaft (3).
3. Install the 5 camshaft bearing caps (2).
4. Install the 10 camshaft bearing cap bolts (1) and hand tighten.

Fig. 406: Exhaust Camshaft Bearing Cap Bolts Tightening Sequence

NOTE: Tighten the camshaft bearing cap bolts one turn at a time in order to avoid
shape distortion of the camshaft.
5. Tighten the camshaft bearing cap bolts one turn at a time and in a spiral sequence as shown to 8 N.m (71
lb in).
CAMSHAFT SPROCKET INSTALLATION

Fig. 407: Intake Camshaft Sprocket, Bolt And Intake Camshaft Position Exciter Wheel
1. Install the intake camshaft sprocket (3).

2. Install the intake camshaft position sensor exciter wheel (2) and the intake camshaft sprocket bolt (1), but
do not tighten yet.
3. Install the exhaust camshaft sprocket.
4. Install the exhaust camshaft position sensor exciter wheel and the exhaust camshaft sprocket bolt, but do
not tighten yet.
NOTE: Tightening of camshaft sprocket bolts will be done after the engine front
cover installation.
TIMING CHAIN TENSIONER INSTALLATION

Fig. 408: Timing Chain Tensioner And Bolts

1. Install the timing chain tensioner (2).

2. Install the 2 timing chain tensioner bolts (1) and tighten to 8 N.m (71 lb in).
ENGINE FRONT COVER GASKET INSTALLATION
1. Clean the sealing surfaces and remove all remains of old sealing compound material.


2. Apply sealing compound to the shown areas (1) and (2). Refer to Adhesives, Fluids, Lubricants and
Sealers.


NOTE: Mind the guide sleeves.
3. Install the NEW engine front cover gasket (1).

4. Install the timing chain. Refer to Camshaft Timing Chain Installation.
5. Install the engine front cover. Refer to Engine Front Cover and Oil Pump Installation.
NOTE: The complete installation procedure should not take longer than 10
minutes.
CAMSHAFT TIMING CHAIN INSTALLATION
Special Tools
EN-952 Fixing Pin

EN-955-10 Fixing Pin from EN-955 Kit

1. The engine should be adjusted to TDC.

2. The crankshaft should be locked with EN-952 fixing pin.
3. The camshaft should be locked with EN-953-A fixing tool.

4. Install the timing chain (1) along with the crankshaft sprocket (2).


5. Install the timing chain tensioner shoe (1).

6. Install the timing chain tensioner shoe bolt (2) and tighten to 20 N.m (15 lb ft).


7. Install the timing chain guide right side (1).

8. Install the 2 timing chain guide right side bolts (2) and tighten to 8 N.m (71 lb in).


9. Push the timing chain (2) in direction to the timing chain tensioner (1) and remove the EN-955-10 fixing
pin (3).
The upper timing chain guide will be installed after the installation of the engine front cover and the fastening
of the camshaft sprockets.
ENGINE FRONT COVER AND OIL PUMP INSTALLATION
Special Tools
EN-952 Fixing Pin

EN-49977-100 Transmitter Disc Fixation
EN-49977-200 Fixing Tool

NOTE: Mind the guide sleeves when installing engine front cover.
1. Install the engine front cover (3).

4. Tighten the 13 engine front cover bolts M6 to 8 N.m (71 lb in).
5. Tighten the 2 engine front cover bolts M10 to 35 N.m (26 lb ft).
Camshaft Sprocket Fastening

Fig. 416: Intake Camshaft Sprocket Gearing And Special Tool

NOTE: Push the fixing tool in the direction of the arrow to ensure it fully engages.
1. Install EN-49977-200 fixing tool (2) and ensure that the gearing of the fixing tool engages with the intake
camshaft sprocket gearing (1).

Fig. 417: Adjuster Bolt And Fastening Bolts

2. Tighten the 2 fastening bolts (1) of EN-49977-200 fixing tool while pushing the fixing tool in direction of
the arrow.
3. Tighten the adjuster bolt (2).

Fig. 418: Fastening Bolts And Fixation Tool

NOTE: A wrong installation position is possible. Make sure that the holding tool is
fully installed to the cylinder head in areas (3) and (5).
4. Install EN-49977-100 transmitter disc holder (2) to find and hold the correct position of the camshaft
position exciter wheels.
5. Tighten the fastening bolts (6) of EN-49977-100 transmitter disc holder.
6. Tighten the NEW intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft
to 50 N.m (37 lb ft).
7. Tighten the intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft to an
additional 60 degrees.
8. Tighten the NEW exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft to
50 N.m (37 lb ft).
9. Tighten the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft to an
additional 60 degrees.
10. Remove EN-49977-100 transmitter disc holder and EN-49977-200 fixing tool.
Upper Timing Chain Guide Installation


2. Install the 2 upper timing chain guide bolts (1) and tighten to 8 N.m (71 lb in).
3. Remove EN-953-A fixing tool and EN-952 fixing pin.
4. Install crankshaft bearing cap tie plate hole plug and seal ring and tighten to 50 N.m (37 lb ft).
OIL PAN INSTALLATION
Special Tools
EN-49980 Guidance Pins

1. Clean the sealing surfaces from old sealing material, dirt, oil and grease.
Fig. 420: Engine Front Cover, Oil Suction Gallery And Screw Bore
NOTE: The sealing bead should be applied close to the inner edge of the oil pan.
Take care that the oil suction gallery (4) will not get contaminated with
sealing compound or dirt. The thickness of the sealing bead (3) should be
2 mm (0.0787 in).
2. Apply sealing compound to the oil pan. Refer to Adhesives, Fluids, Lubricants and Sealers.
3. Apply sealing compound to the groove of the engine front cover (1). Refer to Adhesives, Fluids,
Lubricants and Sealers.
4. Apply sealing compound around the screw bore (2) of the crankshaft bearing cap tie plate.

Fig. 421: Engine Oil Pan Pins

NOTE: The complete installation procedure of the oil pan should not take longer
than 10 minutes.
5. Install the 2 EN-49980 pins (1) and (2) to the shown oil pan screw bores.

Fig. 422: Engine Oil Pan Pins And Screw Bores

CAUTION: Use care when installing the oil pan to prevent disruption of the
sealing bead. The sealing bead should remain consistent until the oil
pan is mated with the engine. An inconsistent sealing bead can
cause an insufficient seal and result in engine damage.
6. Carefully install the oil pan. Guide the oil pan with EN-49980 pins (2) and the equivalent screw bores (1).
7. Hold the oil pan with 4 oil pan bolts.
8. Remove EN-49980 pins.
9. Install the remaining 12 oil pan bolts and hand tighten.


10. Lay a straight edge (1) against the oil pan and engine block. Using a rubber mallet, adjust the transition in
area (2) until there is no clearance between oil pan and the straight edge.
11. Tighten the 16 oil pan bolts to 10 N.m (89 lb in).
CAMSHAFT POSITION ACTUATOR SOLENOID VALVE INSTALLATION

Fig. 424: Camshaft Position Actuator Solenoid Valves And Seal Rings
CAUTION: The camshaft position actuator solenoid valves must be kept parallel
to the engine front cover during removal and installation. The
camshaft position actuator solenoid valves can be damaged if they
become wedged or stuck during this process.
1. Install the 2 camshaft position actuator solenoid valves (2) and the 2 seal rings (1) by carefully and evenly
pressing.

Fig. 425: Camshaft Position Actuator Solenoid Valve Bolts

2. Install the 4 camshaft position actuator solenoid valve bolts (1) and tighten to 8 N.m (71 lb in).

Fig. 426: Camshaft Position Actuator Solenoid Valves Proper Position

3. The 2 camshaft position actuator solenoid valves should be installed in the position as shown (1) and (2).
CAMSHAFT COVER INSTALLATION


2. Apply sealing compound to areas (1) and (2). Refer to Adhesives, Fluids, Lubricants and Sealers.

Fig. 428: Camshaft Cover And Gasket

NOTE: The installation procedure should not take longer than 10 minutes.
3. Install the camshaft cover (2) and a NEW gasket (3).

4. Install the 15 camshaft cover bolts (1).

Fig. 429: Camshaft Cover Bolts Tightening Sequence

5. Tighten the 15 camshaft cover bolts in a sequence as shown to 8 N.m (71 lb in).


6. Install the oil level indicator (1).
IGNITION COIL INSTALLATION
Special Tools
EN-6009 Remover and Installer Ignition Module

Fig. 431: Ignition Coil And Remover/Installer

1. Install the ignition coil (1) and remove EN-6009 remover and installer (2).

Fig. 432: Ignition Coil Bolts

2. Install the 2 ignition coil bolts (1) and tighten to 8 N.m (71 lb in).
ENGINE FLYWHEEL INSTALLATION
Special Tools


Fig. 433: Engine Flywheel And Bolts

1. Install the engine flywheel (1).

2. Install the 6 NEW engine flywheel bolts (2).

Fig. 434: Engine Flywheel And Holder

3. Install EN-652 holder (1) to hold the engine flywheel (2).

4. Tighten the 6 engine flywheel bolts in a cross sequence to 60 N.m (44 lb ft).
1. Tighten the 6 engine flywheel bolts in a cross sequence to an additional 45 degrees. Use EN-470-B
wrench.
2. Tighten the 6 engine flywheel bolts in a cross sequence to an additional 15 degrees. Use EN-470-B
wrench.
5. Remove EN-652 holder.
GENERATOR INSTALLATION

Fig. 435: Generator And Bolts

1. Install the generator (1).

2. Install the 2 generator bolts (2) and tighten to 35 N.m (26 lb ft).
STARTER INSTALLATION

Fig. 436: Starter, Bolt, Stud And Washer

1. Install the starter (4).

2. Install the lower starter bolt stud (3) and if equipped the washer.
3. Install the upper starter bolt (2) and if equipped the washer (1).
4. Tighten the starter bolt and starter bolt stud to 25 N.m (18 lb ft).
INTAKE MANIFOLD INSTALLATION


2. Install the intake manifold (1) along with a NEW intake manifold gasket.


3. Install the 6 intake manifold bolts (1) and tighten to 20 N.m (15 lb ft).
THROTTLE BODY INSTALLATION

Fig. 439: Throttle Body And Bolts

1. Install the throttle body (2) and a NEW throttle body seal ring (1).
2. Install the 4 throttle body bolts (3) and tighten to 8 N.m (71 lb in).
WATER PUMP INSTALLATION
Special Tools
EN-45059 Angle Meter

Fig. 440: Water Pump And Engine Front Cover Bolts

2. The water pump and engine front cover bolts are located as followed:
Engine front cover special bolt without cone end 60 mm (2.362 in) (1).
Engine front cover standard bolt with cone end 52 mm (2.047 in) (2).
Water pump bolt 25 mm (0.984 in) (3).

Fig. 441: Front Cover Bolts

3. Install the 2 NEW front cover bolts (1).

Fig. 442: Water Pump, Bolts And Gasket

4. Install the water pump (2) and a NEW water pump gasket (1).
5. Install the 5 water pump bolts (4) and the 5 long engine front cover bolts (3) and tighten in a cross
sequence to 8 N.m (71 lb in).

Fig. 443: Identifying Water Pump Bolts

6. Tighten the 2 water pump bolts (1) to an additional 30 degrees, using the EN-45059 meter
CRANKSHAFT BALANCER INSTALLATION
Special Tools

EN-956-1 Extension

Fig. 444: Engine Oil Pump Rotor And Crankshaft

NOTE: The crankshaft balancer flange must fit to the hexagon of the oil pump
rotor (2) and to the two-flat of the crankshaft (1).
1. Install the crankshaft balancer by carefully pressing into position.

Fig. 445: Engine Front Cover And Crankshaft Balancer

2. Measure the distance a between the crankshaft balancer (2) and the engine front cover (1). The distance a
should be 5.5 mm (0.21654 in).
3. Install a NEW crankshaft balancer bolt.
NOTE: Never re-use the crankshaft balancer bolt.

Fig. 446: Crankshaft Balancer, Retainer And Extension

4. Tighten the crankshaft balancer bolt (4) while holding the crankshaft balancer (3) with EN-49979 retainer
(1) and EN-956-1 extension (2) in the following order:
1. Tighten the crankshaft balancer bolt to 150 N.m (111 lb ft).
2. Tighten the crankshaft balancer bolt to an additional 45 degrees, using EN-470-B wrench.
WATER PUMP PULLEY INSTALLATION

Fig. 447: Water Pump Pulley

1. Install the water pump pulley (1).

2. Install the 3 water pump pulley bolts (2).
3. Tighten the 3 water pump pulley bolts (2) to 22 N.m (16 lb ft) while holding up the water pump pulley
hub with a wrench.
AIR CONDITIONING COMPRESSOR BRACKET INSTALLATION

Fig. 448: Power Steering Pump Bracket/Air Conditioning Compressor Bracket And Bolts
1. Install the air conditioning compressor bracket (2).

2. Install the 3 air conditioning compressor bracket bolts (1) and tighten to 22 N.m (16 lb ft).
DRIVE BELT TENSIONER INSTALLATION


1. Install the drive belt tensioner (1).

2. Install the upper drive belt tensioner bolt (2).
3. Install the lower drive belt tensioner bolt (3).
4. Tighten the lower drive belt tensioner bolt (M8) to 22 N.m (16 lb ft).
5. Tighten the upper drive belt tensioner bolt to 55 N.m (41 lb ft).
DRIVE BELT INSTALLATION
Special Tools
EN-955 Locking Pins


1. Install the drive belt.
NOTE: Ensure that the drive belt tensioner is held with EN-955-2 locking pin.
Fig. 450: Locking Pin And Wrench

2. Move the drive belt tensioner clockwise until EN-955-20 locking pin (2) can be removed. Use EN-48488
wrench (1).
3. Remove EN-955-20 locking pin (2) from the drive belt tensioner while holding with EN-48488 wrench
(1).
4. Release tension from drive belt tensioner and remove EN-48488 wrench (1).
ENGINE OIL COOLER INSTALLATION


NOTE: Lubricate the oil cooler seal (8) with clean engine oil.
1. Install the engine oil cooler assembly (6) along with 2 NEW sealings (8) and (9).
2. Install the 3 oil cooler bolts (5) and tighten to 10 N.m (89 lb in).
3. Install the oil cooler coolant outlet pipe bolt (7) and tighten to 10 N.m (89 lb in).
4. Install the oil cooler coolant outlet hose (2) to the engine coolant thermostat housing.
5. Install the oil cooler coolant outlet hose clamp (1).
6. Install the oil cooler coolant inlet hose (4) to the water outlet.
7. Install the oil cooler coolant inlet hose clamp (3).
WATER OUTLET INSTALLATION

Fig. 452: Water Outlet, Bolts And Seal Ring

2. Install the water outlet (2) and a NEW water outlet seal ring (1).
3. Install the 3 water outlet bolts (3) and tighten to 8 N.m (71 lb in).
ENGINE COOLANT THERMOSTAT HOUSING INSTALLATION

Fig. 453: Engine Coolant Thermostat Housing

2. Install the engine coolant thermostat housing (2) and a NEW engine coolant thermostat housing seal ring
(3).
3. Install the 3 engine coolant thermostat housing bolts (1) and tighten to 8 N.m (71 lb in).
TURBOCHARGER INSTALLATION
Special Tool

2. Replace the connect fittings on the turbocharger coolant feed pipe and the turbocharger coolant return
pipe. Refer to Turbocharger Disassemble and Turbocharger Assemble.
Fig. 454: Turbocharger Assembly And Turbocharger Gasket

NOTE: Mind the turbocharger oil return pipe.
3. Install the turbocharger assembly (1) and a NEW turbocharger gasket (2).


4. Connect the turbocharger oil return pipe to the engine while installing the turbocharger.
5. Install the turbocharger coolant feed pipe hollow screw along with 2 NEW seal rings (1) and (2).


6. Install the 8 NEW turbocharger nuts (1).

Fig. 457: Turbocharger Nuts Tightening Sequence

7. Tighten the 8 turbocharger nuts in a sequence as shown to 8 N.m (71 lb in).

8. Repeat the tightening procedure to ensure a proper fastening of the turbocharger nuts.


9. Connect the turbocharger coolant return hose (6) to the oil cooler coolant inlet pipe and install the
turbocharger coolant return pipe bolt (7) to the oil cooler. Tighten the turbocharger coolant return pipe
bolt to 8 N.m (71 lb in).
10. Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring.
11. Install the turbocharger oil feed pipe hollow screw (4) in compound with 2 NEW seal rings (1) and (3).
12. Install the turbocharger oil feed pipe bolt (5) to the oil cooler and tighten to 8 N.m (71 lb in).
13. Tighten the turbocharger oil feed pipe hollow screw to 20 N.m (15 lb ft).

Fig. 459: Holding Wrench And Ratchet Wrench

NOTE: The EN-49942 holding wrench (2) should be installed to turbocharger

coolant feed pipe as shown. The holding wrench should be installed to
avoid twisting of the turbocharger coolant feed pipe during the fastening
procedure.
hollow screw.


of the turbocharger coolant feed pipe while the fastening procedure.
15. Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to 30 N.m
(22 lb ft).
EXHAUST MANIFOLD HEAT SHIELD INSTALLATION

Fig. 461: Exhaust Manifold Heat Shield

1. Install the exhaust manifold heat shield (2).

2. Install the 3 exhaust manifold heat shield bolts (1) and the washers and tighten to 8 N.m (71 lb in).
WARM UP THREE-WAY CATALYTIC CONVERTER INSTALLATION

Fig. 462: Locating Catalytic Converter Components

1. Install the warm up three way catalytic converter (5) to the brackets and the turbocharger. Use a NEW
warm up three way catalytic converter seal (2).
2. Install a NEW warm up three way catalytic converter V-clamp (1).
NOTE: Never re-use the V-clamp.
3. Install the 2 catalytic converter to catalytic converter bracket nuts (4) and (6) and hand tighten.
4. Hand tighten the catalytic converter V-clamp.
5. Connect the heated oxygen sensor wiring harness (3) to retainer clip.

Fig. 463: Catalytic Converter V-Clamp

6. The catalytic converter V-clamp (1) should be installed in the shown position.
7. Tighten the catalytic converter to catalytic converter bracket nuts to 22 N.m (16 lb ft).
8. Tighten the catalytic converter V-clamp to 13 N.m (115 lb in).
POSITIVE CRANKCASE VENTILATION PIPE INSTALLATION

Fig. 464: Turbocharger, Positive Crankcase Ventilation Pipe Assembly And Charger Air Bypass
Valve Pipe
1. Install the positive crankcase ventilation pipe assembly (1) to the camshaft cover retainer clips.
2. Connect the positive crankcase ventilation pipe to turbocharger (3).
3. Install the charger air bypass valve pipe (2) to turbo charger waste regulator solenoid valve.
4. Install the charger air bypass valve pipe to turbocharger.
5. Fasten the charger air bypass valve pipe clamp (4).

Fig. 465: Positive Crankcase Ventilation Pipe Retainer Clips And Retainer Clamp
6. Install the positive crankcase ventilation pipe to the intake manifold and fix with retainer clamp (1).
7. Clip in the positive crankcase ventilation pipe to the 2 retainer clips (2) and (3).
ENGINE MOUNT BRACKET INSTALLATION

Fig. 466: Engine Mount Bracket And Bolts

1. Install the engine mount bracket (2).

2. Install the 3 engine mount bracket bolts and tighten to 60 N.m (45 lb ft) + 45-60°.
ENGINE FRONT COVER AND OIL PUMP ASSEMBLE
Oil Pump Installation

Fig. 467: Oil Pump Components

NOTE: The oil pump slide spring and pin, as well as the slide seal and slide seal
spring can be ordered as single parts. All other oil pump components can
only be ordered as a replacement kit.
1. Install the oil pump components in the following order:

1. Install the oil pump slide (6).
NOTE: The bore (8) in the oil pump slide must fit smooth-running and
without clearance to the oil pump slide pivot pin (7).
2. Install the inner oil pump vane ring (5).

3. Install the oil pump vane rotor (4).
NOTE: Mind the installation position of the oil pump vane rotor (4). The mark
(9) must point to direction of the oil pump cover.
4. Install the 6 oil pump vanes (2).

NOTE: Mind the localized flats (3) on the oil pump vanes (2) caused by the
oil pump vane rings. The localized flats must point to the oil pump
vane rotor.
5. Install the outer oil pump vane ring (1).
Fig. 468: Oil Pump Slide Seal Springs And Grooves

2. Install the 2 oil pump slide seals and the 2 oil pump slide seal springs (2) in the position as shown to the 2
grooves (1) of the oil pump slide.

Fig. 469: Oil Pump Slide Spring, Pin, Chambers And Front Cover Edge
4. Install the oil pump slide spring pin along with the oil pump slide spring (4). Use a screwdriver to
compress the oil pump slide spring. The flat side of oil pump slide spring pin must face upwards.
NOTE: The length of the removed oil pump slide spring (2) should be 76.5 mm
(3.0118 in) for suction engines and 61 mm (2.4016 in) for turbo engines.
5. Measure the oil pump clearances to ensure a correct installation of the oil pump components. Refer to
Engine Front Cover and Oil Pump Cleaning and Inspection.
6. Lubricate the oil pump vanes, the oil pump vane rotor, the oil pump slide spring and the area (3) with
engine oil.
7. Inspect the oil pump slide spring mechanism for functionality.


8. Install the oil pump cover (2) and the 8 oil pump cover bolts (1).

Fig. 471: Oil Pump Cover Bolts Tightening Sequence

9. Tighten the oil pump cover bolts in a sequence as shown to 8 N.m (71 lb in).

Fig. 472: Crankshaft Balancer

10. Install the crankshaft balancer (1) and rotate in the direction shown (2) in order to inspect the function of
the oil pump mechanism. The crankshaft balancer should rotate easily.
Engine Front Cover Assemble

Fig. 473: Locating Engine Front Cover Components

1. Install the crankshaft front oil seal (10).

2. Install the oil pressure relief valve (7), (8) and (9) and tighten to 50 N.m (37 lb ft).
3. Install the exhaust camshaft position sensor (5) and the seal ring (4).
4. Install the exhaust camshaft sensor bolt (6) and tighten to 6 N.m (53 lb in).
5. Install the intake camshaft position sensor (2) and the seal ring (3).
6. Install the intake camshaft sensor bolt (1) and tighten to 6 N.m (53 lb in).
DRIVE BELT REMOVAL
Special Tools
EN-955 Locking Pins


Fig. 474: Locking Pin And Wrench

1. Install EN-48488 wrench (1) to the drive belt tensioner.

2. Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with the EN-955-20
locking pin (2).
NOTE: The drive belt tensioner must always be in a pre-tensioned state.
AUTOMATIC TRANSMISSION FLEX PLATE REMOVAL
Special Tools

Fig. 475: Automatic Transmission Flex Plate

1. Install the EN-652 flywheel holder (1) in order to fix the automatic transmission flex plate (2).


2. Remove and DISCARD the 6 automatic transmission flex plate bolts (2).
3. Remove the automatic transmission flex plate (1).
ENGINE BLOCK CLEANING AND INSPECTION
Special Tools
EN-8087 Cylinder Bore Gauge
For equivalent regional tool, refer to Special Tools.
Cleaning Procedure
1. Remove any old thread sealant, gasket material or sealant.

2. Clean all the following areas with solvent:
Sealing surfaces
Cooling passages
Oil passages
3. Clean all threaded and through holes with solvent.

4. Dry the engine block with compressed air.
eye injury.
Visual Inspection
1. Inspect the crankshaft bearings journals for damage or spun bearings. The crankshaft bearing journals are
not repairable, if the crankshaft bearing journals are damaged the engine block assembly must be
replaced.
2. Inspect all sealing and mating surfaces for damage, repair or replace the engine block assembly if
necessary.
3. Inspect all threaded and through holes for damage or excessive debris.
4. Inspect all bolts for damage, if damaged replace with NEW bolts only.
5. Inspect the cylinder walls for cracks or damage. The cylinder sleeves are not serviced separately, if the
cylinders are damaged the cylinder block assembly must be replaced.
6. Inspect the engine block for cracks. Do not repair any cracks. If cracks are found, the cylinder block
assembly must be replaced.
Measuring Procedure
Engine Block Flatness Inspection

Fig. 477: Inspecting Engine Block For Distortion Using Straight Edge
1. Inspect the engine block as shown for distortion. Use a straightedge (1).

Fig. 478: Inspecting Engine Block For Deflection Using Straight Edge
2. Inspect the engine block as shown for deflection. Use a straightedge (1).
Cylinder bore and crankshaft bearing bore
1. Install the crankshaft bearing cap tie plate and tighten.
NOTE: Old bolts can be used for the measuring procedure.

Fig. 479: Measuring Bearing Bore Concentricity And Alignment Using Gauge Tool
2. Inspect the crankshaft main bearing bores. Use the EN-8087 gauge (1) to measure the bearing bore
concentricity and alignment. Refer to Engine Mechanical Specifications to find the permitted values.
3. Replace the engine block and crankshaft bearing cap tie plate if the crankshaft bearing bores are out of
specification.

Fig. 480: Inspecting Cylinder Bore

4. Inspect the cylinder bores using the EN-8087 gauge (1). Inspect for the following items:
Wear
Taper
Runout
Ridging
5. Refer to Engine Mechanical Specifications to find the permitted values.
6. If the cylinder bores are out of specification, replace the engine block.
7. Remove the crankshaft bearing cap tie plate.
AUTOMATIC TRANSMISSION FLEX PLATE INSTALLATION
Special Tools

1. Clean the 6 screw bores. Rework if necessary.

2. Install the automatic transmission flex plate (1).

3. Install 6 NEW automatic transmission flex plate bolts (2).

Fig. 482: Automatic Transmission Flex Plate

4. Install EN-652 flywheel holder (1) in order to fix the automatic transmission flex plate (2).
5. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to 35 N.m (26 lb ft).
6. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to an additional 30°.
7. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to an additional 15°.
DESCRIPTION AND OPERATION

ENGINE COMPONENT DESCRIPTION
Cylinder Block

The cylinder hollow frame structured in-line 4 cylinder. The block has 5 crankshaft bearings with the thrust
bearing located on the third bearing from the front of the engine.
Crankshaft
The crankshaft is a steel crankshaft. It is supported in 5 main journals with main bearings which have oil
clearance for lubrication. The 3rd bearing is the thrust bearing which controls the proper axial end play of the
crankshaft. A harmonic damper is used to control torsional vibration.
Oil Pump
The engine is equipped with a variable oil pump. The oil pump is integrated into the engine front cover and
provides different oil pressure values depending on the engine speed.
Oil Pan
The oil pan is a structural aluminum oil pan with transmission attachment points. The oil suction gallery for the
oil pump is integrated into the oil pan.
Piston and Connecting Rod
The pistons are aluminum pistons. The connecting rods are made of fractured steel. The piston pin is floating in
piston bore and shrinked in connecting rod.
Cylinder Head
This cylinder head is a double over head camshaft (DOHC) type and has 2 camshafts that open 4 valves per
cylinder with hydraulic valve lash adjusters and hydraulic valve lash adjuster arms. The cylinder head is made
of cast aluminum alloy for better strength and hardness while remaining light weight. The combustion chamber
of the cylinder head is designed for increasing of squish and swirl efficiency to help maximize gasoline
combustion efficiency.
Camshaft Drive with Variable Camshaft Timing
A timing chain is used for camshaft drive. There is a tensioner to control the tension of the chain. The engine is
equipped with a variable camshaft timing system. The camshaft adjuster will readjust itself depending on the
engine speed. The valve timing readjusts to reduce fuel consumption and provide optimal power and torque.
Intake Manifold
The intake manifold provides the air flow passage to the combustion chambers through the throttle body. The
intake manifold along with the throttle body have an effect on engine torque, power, noise, driveability,
emission, fuel economy and performance. The intake manifold is made of plastic for better strength with
maintaining a light weight.
Turbocharger
The turbocharger consists of turbine and compressor on a common shaft. The shaft bearing is constructed to
higher rotation speed and lubricated by engine oil. The turbocharger is water cooled for improved durability.
The turbine wheel is driven by exhaust emissions. The compressor wheel compresses the intake air. A bypass
valve (Wastegate) regulates the charging pressure for generating a high pressure at low speed as well. At a
defined charging pressure it regulates the way of the exhaust emission on bypassing the turbine wheel. The
Wastegate valve is controlled pneumatic and electric from the pressure in the intake manifold. The pressure of
exhaust emission is reduced by opening the Wastegate thereby reducing the intake pressure.
LUBRICATION DESCRIPTION
General Lubrication Description
Fig. 483: Lubrication System Components

Oil is applied under pressure to the crankshaft bearings (6), connecting rod bearings (7), camshaft bearings (2)
and hydraulic lash adjusters (3). In addition the variable oil pump (9), variable camshaft phaser (1) and
hydraulic chain tensioner (14) are supplied with pressurized oil. Oil is sucked from the oil pan through the fixed
screen into the variable vane type oil pump. The pump is integrated in the front cover and directly driven by the
crankshaft. Also integrated into the front cover is a pressure relieve valve (8) that opens when the oil pressure is
too high at a cold start. When that valve is open some oil flows directly into the oil pan. Normally the
pressurized oil passes into the engine oil gallery leading through the oil cooler (5) to the oil filter assembly (4).
The oil is cleaned by passing the filter from the outer to the inner side of the filter. Then the oil flows into the
main oil gallery. A filter by-pass valve in the oil filter ensures continues oil flow in case the oil filter should be
restricted by more than 1.7 bar. From the oil filter the oil is distributed to the crankshaft bearings, oil pump
displacement control chamber (10) and cylinder head feed (11). The connecting rod bearings are supplied by oil
flow passages through the crankshaft connecting the main journals to the rod journals. A groove around each
upper main bearing furnishes oil to the drilled crankshaft passages. In the cylinder head the oil is distributed to
the variable camshaft phasers, chain tensioner, oil pressure switch (12) and through the restrictor orifice (13)
into the camshaft feed oil gallery. From there the hydraulic valve lifters and camshaft bearings are supplied with
oil.
Variable Oil Pump Description
The engine is equipped with a variable displacement vane oil pump. It is indirect regulated by the oil pressure
out of the main oil gallery. The purpose of this indirect regulation is to keep a defined maximum pressure in the
main oil gallery independent of the individual pressure drop between the pump outlet, the main gallery inlet and
the various engine components. The purpose of the variable displacement is to reduce the power consumption
of the pump to reduce the overall fuel consumption of the engine. The oil flow of a static displacement oil pump
is linear to the speed of the pump. This would lead to a too high oil pressure after a certain engine speed (ca.
1000 rpm at cold oil temperature, ca. 3000 rpm at hot oil temperatures). To reduce that high oil pressure normal
pumps have a relieve valve: a portion of the pressurized, already pumped oil is fed back to the intake of the
pump. This is waste of power. The oil flow of a Variable Displacement Vane Pump (VDVP) as used in Fam 0
Gen 3 is linear to the speed and to the excentricity of the rotor to the slide. The slide is moveable, so it is
possible to reduce the oil flow for a given speed by reducing the excentricity. With a lower flow the oil pressure
is reduced; pump oil flow equals now engine oil flow.
CLEANLINESS AND CARE
An automobile engine is a combination of many of the following surfaces:
Machined
Honed
Polished
Lapped
The tolerances of these surfaces are measured in the ten-thousandths of an inch. When you service any internal
engine part, cleanliness and care are important. Apply a liberal coating of engine oil to the friction areas during
assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, practice
proper cleaning and protection procedures to the machined surfaces and to the friction areas.
Whenever you remove the valve train components, keep the components in order. Follow this procedure in
order to install the components in the same locations and with the same mating surfaces as when removed.
WARNING: Refer to Battery Disconnect Warning .

Disconnect the negative battery cables before you perform any major work on the engine.
USE OF ROOM TEMPERATURE VULCANIZING (RTV) AND ANAEROBIC SEALANT
Pipe Joint Compound
NOTE: Three types of sealer are commonly used in engines. These are RTV sealer,
anaerobic gasket eliminator sealer and pipe joint compound. The correct sealer
and amount must be used in the proper location to prevent oil leaks. DO NOT
interchange the 3 types of sealers. Use only the specific sealer or the equivalent
as recommended in the service procedure.
Pipe joint compound is a pliable sealer that does not completely harden. This type sealer is used where 2
non-rigid parts, such as the oil pan and the engine block, are assembled together.
Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include:
exhaust manifold, head gasket or other surfaces where gasket eliminator is specified.
Follow all safety recommendations and directions that are on the container. To remove the sealant or the
gasket material.
Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the
procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind
threaded holes, as it may prevent the bolt from clamping properly.
Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed
must be clean and dry.
Tighten the bolts to specifications. Do not overtighten.
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS
Tool
Illustration Number/Description

EN-194-E
KM-194-E
Spark Plug Key

EN-235-D
KM-235-D
Seal Installer Kit

EN-301
KM-301
Measuring Bridge

EN-470-B
KM-470-B
J-45059
Angular Torque
Wrench

EN-498-B
KM-498-B
Pressure Gauge

GE-571-B
MKM-571-B
Dial Gauge

EN-652
DT-652
KM-652
Flywheel Holder

EN-658
KM-658
J-35264
Installer

EN-663
KM-663
Installer

EN-796-A
KM-796-A
Remover Quick
Fitting

CH-807
KM-807
Plugs

EN-840
KM-840
Pliers / Remover

EN-849
KM-849
Assembly Tray

EN-952
KM-952
Fixing Tool
Crankshaft

EN-953-A
KM-953-A
Fixing Tool
Camshaft

EN-955
KM-955
Locking Pins

EN-956-1
KM-956-1
Extension

EN-960
KM-960
Installer

EN-6015
KM-6015
Closure Plugs

EN-45000
KM-J45000
J-45000
Remover Oil Seal

EN-45059
Angle Meter

EN-6009
KM-6009
Remover / Installer

EN-6086
MKM-6086
Basic Kit, Spring and
Wedge Replacer

EN-6167
KM-6167
Adapter Kit

EN-6171
KM-6171
Release Tool

EN-6179
KM-6179
Installer / Remover

EN-6215
KM-6215
Mounting Equipment

EN-34730-91
KM-34730-91
J-34730-91
Pressure Tester

EN-48248
Cylinder
Compression
Pressure Gauge

CH-904
Base Frame

CH-49289
Centering Frame

CH-49290
Engine Support Tool

EN-48488
KM-956
Holding Wrench

EN-49940
Remover Quick
Connector

EN-49941
Remover / Installer
Piston Retainer Ring

EN-49942
Holding Wrench

EN-49977-100
Fixation Sensor
Disks and Camshafts

EN-49977-200
Fixing Tool

EN-49979
Retainer Shock
Mount Crankshaft

EN-49980
Guidance Pins Oil
Pan

EN-47649
Engine Bridge

EN-47650
Retainer Frame

EN-47650-300
Adapter

EN-47650-200
Front Adapter


2014 Chevrolet Sonic 1.4L Motor LUV

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2014 Chevrolet Sonic LT

2014 ENGINE Engine Mechanical - 1.4L (LUV) - Sonic

Engine Mechanical - 1.4L (LUV) - Sonic

Fastener Tightening Specifications

Water Outlet 8 N.m 71 lb in

ENGINE MECHANICAL SPECIFICATIONS

Engine Mechanical Specifications

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Piston - Lower Compression Ring Thickness 1.17 mm - 1.195 mm 0.0461 in 0.047 in

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Cylinder Head - Exhaust Valve Guide Inner Diameter 5.141 mm - 5.157

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Axial Clearance Vane Rotor to Cover 0.01 mm 0.0004 in

ADHESIVES, FLUIDS, LUBRICANTS AND SEALERS

Adhesives, Fluids, Lubricants and Sealers

Accessory Drive Components

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 1: Locating Accessory Drive Components

Callout Component Name

13 Air Conditioning Compressor

Engine Front Cover And Oil Pump Assembly (1 of 2)

Callout Component Name

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

4 Intake Camshaft Position Sensor Bolt

Engine Front Cover And Oil Pump Assembly (2 of 2)

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Callout Component Name

Timing Chain Components

Fig. 4: Timing Chain Components

Callout Component Name

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

11 Exhaust Camshaft Position Sensor Exciter Wheel

Intake Manifold Assembly- 1.4L LDD

Fig. 5: Locating Intake Manifold Assembly Components - 1.4L LDD

Callout Component Name

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

3 Throttle Body Bolt

Cylinder Head Assembly

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 6: Identifying Cylinder Head Assembly Components

Callout Component Name

13 Engine Lift Bracket Left Side

Engine Block Assembly- 1.4L LDD

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 7: Identifying Engine Block Assembly Components - 1.4L LDD

Callout Component Name

13 Crankshaft Bearing Cap Tie Plate

Engine Block Assembly- 1.4L LUH and LUJ

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Callout Component Name

13 Crankshaft Bearing Cap Tie Plate

Intake Manifold Assembly - 1.4L LUH and LUJ

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Fig. 9: Intake Manifold Assembly - 1.4L LUH and LUJ

Callout Component Name

Exhaust Side - 1.4L LUH and LUJ

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Callout Component Name

13 Turbocharger Coolant Return Pipe