Specifications: 2005 Hyundai Tiburon GT 2005 Hyundai Tiburon GT

2005 Hyundai Tiburon GT
2005 ENGINE Engine Mechanical System (G6BA-GSL 2.7L) - Tiburon
2005 ENGINE
Engine Mechanical System (G6BA-GSL 2.7L) - Tiburon
SPECIFICATIONS
ENGINE GENERAL SPECIFICATIONS (G6BA - GSL 2.7L)
Description Specifications Limit
General
Type V-type, DOHC
Number of cylinder 6
Bore 86.7mm (3.4133in.)
Stroke 75mm (2.9528in.)
Total displacement 2,656cc
Compression ratio 10:1
Firing order 1-2-3-4-5-6
Valve timing
Intake valve
Opens (BTDC) 6°
Closes (ABDC) 46°
Exhaust valve
Opens (BBDC) 44°
Closes (ATDC) 8
Camshaft
Drive mechanism Cogged type belt
Cam height
Intake 43.95 ~ 44.15mm (1.7303 ~ 43.45mm (1.7106in.)
1.7382in.)
Exhaust 43.95 ~ 44.15mm (1.7303 ~ 43.45mm (1.7106in.)
1.7382in.)
Journal diameter 25.964 ~ 25.980mm (1.0222 ~ 25.914mm (1.0202in.)
1.0228in.)
Bearing oil clearance 0.02 ~ 0.061mm (0.0007 ~ 0.1mm (0.0039in.)
0.0024in.)
End play 0.1 ~ 0.15mm (0.0039 ~ 0.0059in.)
Cylinder head
Flatness of cylinder head surface Max. 0.03mm (0.0012in.) 0.05mm (0.0020in.)
Flatness of manifold mounting
surface
Intake Max. 0.15mm (0.0059in.) 0.15mm (0.0059in.)
Exhaust Max. 0.15mm (0.0059in.) 0.15mm (0.0059in.)
Valve guides hole diameter
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0.05 (0.002) O.S. 11.05 ~ 11.068mm (0.435 ~

0.436in.)
0.25 (0.010) O.S. 11.25 ~ 11.268mm (0.443 ~
0.444in.)
0.50 (0.020) O.S. 11.50 ~ 11.518mm (0.453 ~
0.453in.)
Intake valve seat ring hole
diameter
0.3 (0.012) O.S. 33.300 ~ 33.325mm (1.311 ~
1.312in.)
Exhaust valve seat ring hole
diameter
0.3 (0.012) O.S. 28.600 ~ 28.621mm (1.126 ~
1.127in.)
Valve
Overall length
Intake 96.1mm (3.783in.)
Exhaust 97.15mm (3.825in.)
Stem diameter
Intake 5.965 ~ 5.98mm (0.235 ~
0.2354in.)
Exhaust 5.95 ~ 5.965mm (0.234 ~ 0.235in.)
Face angle 45° ~ 45.5°
Margin
Intake 1.0mm (0.0394in.) 0.5mm (0.0197in.)
Exhaust 1.3mm (0.0512in.) 0.8mm (0.0315in.)
Clearance (Stem-to-guide)
Intake 0.02 ~ 0.05mm (0.008 ~ 0.0020in.) 0.10mm (0.0039in.)
Exhaust 0.030 ~ 0.065mm (0.0012 ~ 0.13mm (0.0051 in.)
0.0026in.)
Valve spring
Free length 42.5mm (1.6732in.) 41.5mm (1.6339in.)
Load 21kg/35mm (48.4lb/1.3780in.) 21.9kg/34mm
(48.4lb/1.3386in.)
Out of squareness Max. 1.5° Max. 3°
Piston
Diameter (Standard) 86.68 ~ 86.71mm (3.413 ~
3.414in.)
Clearance (Piston-to-cylinder) 0.01 ~ 0.03mm (0.0004 ~
0.0012in.)
Ring groove width
No.1 1.230 ~ 1.250mm (0.0484 ~
0.0492in.)
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No.2 1.220 ~ 1.240mm (0.0480 ~

0.0488in.)
Oil 2.515 ~ 2.535mm (0.0990 ~
0.0998in.)
Piston for service 0.25mm (0.010in.), 0.50mm
(0.020in.)
Piston ring
Number of rings per piston 3
Compression ring 2
Oil ring 1
Compression ring type
No.1 Inner bevel type
No.2 Taper type
Oil ring type 3-piece type
Ring end gap
No.1 0.20 ~ 0.35mm (0.0079 ~ 0.8mm (0.031 in.)
0.0138in.)
No.2 0.37 ~ 0.52mm (0.0146 ~ 0.8mm (0.031 in.)
0.0205in.)
Oil ring side rail 0.2 ~ 0.7mm (0.0079 ~ 0.0276in.) 1.0mm (0.039in.)
Ring side clearance
No.1 0.04 ~ 0.08mm (0.0016 ~ 0.0031 0.1mm (0.004in.)
in.)
No.2 0.03 ~ 0.07mm (0.0012 ~ 0.1mm (0.004in.)
0.0028in.)
Rings for service 0.25mm (0.010in.), 0.50mm
(0.020in.)
Connecting rod
Piston pin installation force 2,450 ~ 12.225N
(250 ~ 1,250kg, 551 ~ 2,755lb)
Side clearance (big end) 0.10 ~ 0.25mm (0.0039 ~ 0.4mm (0.016in.)
0.0098in.)
Bend 0.05mm or less/100mm
(0.0020in. or less/3.937in.)
Bearing oil clearance 0.018 ~ 0.036mm (0.0007 ~ 0.1mm (0.004in.)
0.0014in.)
Crankshaft
Journal O.D. 61.982 ~ 62.000mm (2.4402 ~
2.4409in.)
Pin O.D. 47.982 ~ 48.000mm (1.8891 ~
1.8898in.)
Out-of-round, taper of journal and Max. 0.003mm (0.0012in.)
pin
Taper of journal and pin Max. 0.005mm (0.00020in.)

End play 0.070 ~ 0.250mm (0.0028 ~ 0.4mm (0.016in.)
0.0098in.)
Main bearing clearance 0.004 ~ 0.022mm (0.0002 ~ 0.1mm (0.004in.)
0.0009in.)
Cylinder block 0.05mm (0.002in.)
Cylinder bore 86.7mm (3.4134in.)
Flatness of gasket surface Max. 0.03mm (0.0012in.)
Out-of-round of cylinder bore Max. 0.02mm (0.0008in.)
Oil pump
Body clearance 0.100 ~ 0.181mm (0.0039 ~
0.0071 in.)
Side clearance 0.040 ~ 0.095mm (0.0016 ~
0.0037in.)
Relief spring
Free height 43.8mm (1.724in.)
Load 4.6kg/39.3mm (10lb/1.548in.)
Oil filter
Type Cartridge, full flow
Engine oil pressure 50kPa (7.3psi) or more
[Conditions: Oil temperature is 75
to 90°C (167 to 194°F)]
Cooling method Engine coolant cooling, forced
circulation with electric fan
Cooling system quantity 7.0lit (7.4U.S.qts., 6.1lmp.qts)
Thermostat
Type Wax pellet type with jiggle valve
Normal opening temperature 82 +/-2.0°C (179.6 +/- 3.6°F)
Opening temperature range 80 ~ 84°C (176 ~ 183.2°F)
Wide open temperature 95°C (203°F)
Radiator cap
Main valve opening pressure 107.9 +/- 14.7kPa (1.1 +/-
0.15kg/cm2 ,
15.65 +/- 2.13psi)
Main valve closing pressure 83.4kPa (0.85kg/cm2 , 12.1 psi)
Vacuum valve opening pressure -6.86kPa (-0.07kg/cm2 , -1.00 psi)
Air cleaner
Type Dry
Element Paper type
Exhaust pipe
Muffler Expansion resonance type
Suspend system Rubber hangers
SERVICE STANDARDS
SERVICE STANDARDS
Standard value
Coolant concentration
Tropical areas 40%
Other areas 50%
COOLANT
COOLANT SPECIFICATION
Engine coolant Ethlylene glycol base for aluminum radiator
SEALANT
SEALANT SPECIFICATIONS
Engine coolant temperature sensor LOCTITE 262 or equivalent, Three bond No. 1324
or equivalent.
Oil pressure switch 3M ATD No.8660 or Three bond No.1141E
PCV valve LOCTITE 242 or equivalent
TIGHTENING TORQUE
TIGHTENING TORQUE SPECIFICATIONS

Item Nm kgf.cm lbf.ft
Camshaft sprocket bolt 90 ~ 110 900 ~ 1,100 65 ~ 85
Cylinder head cover bolt 8 ~ 10 80 ~ 100 5.8 ~ 7.2
Main bearing cap bolt
M10 27~33 + (90°~94°) 270~300 + (90°~94°) 19.5~24+ (90°~94°)
M8 13~19 + (90°~94°) 130~190 + (90°~94°) 10~14+ (90°~94°)
Connecting rod bolt 16~20+ (90°~94°) 160~200+ (90°~94°) 12~15+ (90°~94°)
Cylinder head bolt (Cold 25 + (58°~62°) + (43° 250 + (58°~62°) + (43° 18 + (58°~62°) + (43°
engine) ~47°) ~47°) ~47°)
Oil pan drain plug 35 ~ 45 350 ~ 450 25 ~ 33
Lower oil pan bolt 10 ~ 12 100 ~ 120 7~9
Upper oil pan bolt
[10 x 38mm (0.937 x 30 ~ 42 300 ~ 420 22 ~ 30
1.4961 in.)]
[8 x 22mm (0.3150 x 19 ~ 28 190 ~ 280 14 ~ 20
0.8661 in.)]
[161.5mm (6.3582in.)] 5~7 50 ~ 70 4~5
[152.5mm (6.0039in.)] 5~7 50 ~ 70 4~5
Oil screen bolt 15 ~ 22 150 ~ 220 11 ~ 16
Oil pump case bolt 12 ~ 15 120 ~ 150 9 ~ 11

Oil relief valve plug 40 ~ 50 400 ~ 500 29 ~ 36
Oil pressure switch 15 ~ 22 150 ~ 220 11 ~ 16
Oil pressure cover screw 8 ~ 12 80 ~ 120 6~9
Oil filter 12 ~ 16 120 ~ 160 9 ~ 12
Drive plate and adapt 73 ~ 77 730 ~ 770 53 ~ 56
Air cleaner body 8 ~ 12 80 ~ 120 6~9
installation bolt
Surge tank stay 15 ~ 20 150 ~ 200 11 ~ 14
Air intake surge tank to 15 ~ 20 150 ~ 200 11 ~ 14
intake manifold (bolt)
Air intake surge tank to 15 ~ 20 150 ~ 200 11 ~ 14
intake manifold (nut)
Intake manifold to 19 ~ 21 190 ~ 210 14 ~ 15
cylinder head
Heat protector exhaust 17 ~ 22 170 ~ 220 12 ~ 16
manifold
Exhaust manifold to 30 ~ 35 300 ~ 350 22 ~ 26
cylinder head (Self-
locking nut)
Oil level gauge guide to 12 ~ 15 120 ~ 150 9 ~ 11
engine
Water outlet fitting bolt 17 ~ 20 170 ~ 200 12 ~ 14
Power steering oil pump 17 ~ 26 170 ~ 260 12 ~ 19
bracket to cylinder head
Crank position sensor 5-6 50 ~ 60 3.6 ~ 4.3
wheel screw
Engine mounting 50 ~ 65 500 ~ 650 36 ~ 47
insulator bolt
Engine mounting bracket 60 ~ 80 600 ~ 800 43 ~ 58
nut
Engine mounting bracket 60 ~ 80 600 ~ 800 43 ~ 58
bolt
Engine support bracket 60 ~ 70 600 ~ 700 43 ~ 51
bolt
Front roll stopper bracket 50 ~ 65 500 ~ 650 36 ~ 47
sub frame bolt
Front roll stopper 50 ~ 65 500 ~ 650 36 ~ 47
insulator bolt and nut
Rear roll stopper bracket 50 ~ 65 500 ~ 650 36 ~ 47
to sub frame
Rear roll stopper insulator 50 ~ 65 500 ~ 650 36 ~ 47
bolt and nut
Transaxle mounting 50 ~ 65 500 ~ 650 36 ~ 47
bracket bolt
Transaxle mounting 90-110 900 ~ 1,100 65 ~ 80
insulator bolt
Fuel hose clamp to rear 12 ~ 15 120 ~ 150 9 ~ 11
cylinder head assembly
Transaxle mounting plate 10 ~ 12 100 ~ 120 7~9
Rear plate 10 ~ 12 100 ~ 120 7~9
Oil seal case 10 ~ 12 100 ~ 120 7~9
Crankshaft pulley bolt 180 ~ 190 1,800 ~ 1,900 130 ~ 138
Timing belt cover bolt 10 ~ 12 100 ~ 12 7~9
Engine hanger bracket to 20 ~ 27 200 ~ 270 14 ~ 20
engine
Alternator mounting 20 ~ 30 200 ~ 300 14 ~ 22
bracket to engine
Alternator mounting nut 20 ~ 30 200 ~ 300 14 ~ 22
(Engine front case side)
Alternator mounting bolt 20 ~ 30 200 ~ 300 14 ~ 22
(Alternator mounting
bracket side)
Starter to transmission 20 ~ 30 200 ~ 300 14 ~ 22
(nut)
Starter to transmission 27 ~ 34 270 ~ 340 20 ~ 25
(bolt)
Drive belt pulley bolt 35 ~ 55 350 ~ 550 25 ~ 40
Drive belt tensioner bolt 20 ~ 27 200 ~ 270 14 ~ 20
Engine coolant pump to 15 ~ 22 150 ~ 220 11 ~ 16
cylinder block bolt (Head
mark "7" mark)
Engine coolant 20 ~ 40 200 ~ 400 14 ~ 29
temperature sensor
Engine coolant inlet 17 ~ 20 170 ~ 200 12 ~ 14
fitting attaching bolt
Throttle body to surge 15 ~ 20 150 ~ 200 11 ~ 14
tank bolt
Oxygen sensor to exhaust 40 ~ 50 400 ~ 500 29 ~ 36
manifold
Front exhaust pipe to 30 ~ 40 300 ~ 400 22 ~ 29
exhaust manifold nut
Front exhaust pipe to 40 ~ 60 400 ~ 600 29 ~ 43
catalytic converter bolt
Catalytic converter to 40 ~ 60 400 ~ 600 29 ~ 43
center exhaust pipe nut
Center exhaust pipe to 40 ~ 60 400 ~ 600 29 ~ 43
main muffler nut
Main muffler hanger 10 ~ 15 100 ~ 150 7 ~ 11

support bracket bolt
Delivery pipe installation 10 ~ 15 100 ~ 150 7 ~ 11
bolt
Timing belt tensioner 43 ~ 55 430 ~ 550 31 ~ 40
pulley bolt
Timing belt idler pulley 50 ~ 60 500 ~ 600 36 ~ 43
bolt
Timing belt tensioner arm 35 ~ 55 350 ~ 550 25 ~ 40
fixed bolt
Auto tensioner fixed bolt 20 ~ 27 200 ~ 270 14 ~ 20
Accelerator cable bracket 4-6 40 ~ 60 3-4
Spark plug 20 ~ 30 200 ~ 300 14 ~ 22
COMPRESSION
NOTE: If the there is lack of power, excessive oil consumption or poor fuel economy,
measure the compression pressure.
1. Warm up and stop engine
Allow the engine to warm up to normal operating temperature.
2. Remove ignition coils. (See IGNITION SYSTEM )

3. Remove spark plugs.
Using a 16mm plug wrench, remove the 6 spark plugs.
4. Check cylinder compression pressure

a. Insert a compression gauge into the spark plug hole.
Fig. 1: Inserting Compression Gauge Into Spark Plug Hole

Courtesy of HYUNDAI MOTOR CO.
b. While cranking the engine, measure the compression pressure.
NOTE: Always use a fully charged battery to obtain engine speed of 250
RPM or more.
c. Repeat steps (a) through (b) for each cylinder.
NOTE: This measurement must be done in as short a time as possible.
Compression pressure:
1,420kPa (14.5kgf/cm2 , 206psi)
Minimum pressure:
1,270kPa (13kgf/cm2 , 184psi)
Difference between each cylinder:
100kPa (1.0kgf/cm2 , 15psi) or less
d. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat steps (a) through (b) for cylinders with low
compression.
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are
worn or damaged.
If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
5. Reinstall spark plugs. (See INSPECT SPARK PLUG AND SPARK PLUG CABLE )
6. Install ignition coils. (See IGNITION SYSTEM )
TROUBLESHOOTING
PROBLEM SYMPTOMS
Symptom Suspect area Remedy
Engine misfire with abnormal Loose or improperly installed Repair or replace the flywheel as
internal lower engine noises. engine flywheel. required.
Worn piston rings Inspect the cylinder for a loss of
(Oil consumption may or may not compression.
cause the engine to misfire.) Repair or replace as required.
Worn crankshaft thrust bearings Replace the crankshaft and
bearings as required
Engine misfire with abnormal Stuck valves. Repair or replace as required
valve train noise. (Carbon buildup on the valve stem)
Excessive worn or misaligned Replace the timing chain and
timing chain sprocket as required.
Worn camshaft lobes. Replace the camshaft and valve
lifters.
Engine misfire with coolant Faulty cylinder head gasket Inspect the cylinder head
consumption and/or cranking or other and engine block for
damage to the cylinder head damage to the coolant
and engine block cooling passages and/or a faulty
system. head gasket.
Coolant consumption may or Repair or replace as
may not cause the engine to required.
overheat.
Engine misfire with excessive oil Worn valves, guides and/or valve Repair or replace as required.
consumption stem oil seals.

Worn piston rings. Inspect the cylinder for a
(Oil consumption may or may not loss of compression.
cause the engine to misfire)
Repair or replace as
required.
Engine noise on start-up, but Incorrect oil viscosity Drain the oil.
only lasting a few seconds.
Install the correct viscosity
oil.
Worn crankshaft thrust bearing. Inspect the thrust bearing
and crankshaft.
required.
Upper engine noise, regardless of Low oil pressure Repair or replace as required.
engine speed. Broken valve spring. Replace the valve spring.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain Replace the timing chain and
and/or damaged sprocket teeth. sprockets.
Worn timing chain tensioner, if Replace the timing chain tensioner
applicable. as required.
Worn camshaft lobes. Inspect the camshaft lobes.
Replace the timing camshaft
and valve lifters as required.
Worn valve guides or valve stems. Inspect the valves and valve
guides, then repair as required.
Stuck valves. (Carbon on the valve Inspect the valves and valve
stem or valve seat may cause the guides, then repair as required.
valve to stay open.
Lower engine noise, regardless Low oil pressure. Repair or required.
of engine speed Loose or damaged flywheel. Repair or replace the flywheel.
Damaged oil pan, contacting the oil Inspect the oil pan.
pump screen.
Inspect the oil pump screen.
required.
Oil pump screen loose, damaged or Inspect the oil pump screen.
restricted.
required.
Excessive piston-to-cylinder bore Inspect the piston, piston pin
clearance. and cylinder bore.
Repair as required.
Excessive piston pin-to-connecting Inspect the piston, piston pin
rod clearance and the connecting rod.
required.
Excessive connecting bearing rod Inspect the following components
clearance and repair as required.
The connecting rod

bearings.
The connecting rods.
The crankshaft.
The crankshaft journal.
Excessive crankshaft bearing Inspect the following components,
The crankshaft bearing.

The crankshaft journals.
Incorrect piston, piston pin and Verify the piston pins and
connecting rod installation connecting rods are installed
correctly.
Repair as required.
Engine noise under load Low oil pressure Repair or replace as required.
Excessive connecting rod bearing Inspect the following components
clearance and repair as required:
The connecting rod

bearings.
The connecting rods.
The crankshaft
Excessive crankshaft bearing Inspect the following components,
The crankshaft bearings.

The crankshaft journals.
The cylinder block
crankshaft
Engine will not crank-crankshaft Hydraulically locked cylinder 1. Remove spark plugs and
will not rotate check for fluid.
Coolant/antifreeze in
2. Inspect for broken head
cylinder.
gasket.
Oil in cylinder.
3. Inspect for cracked engine
Fuel in cylinder block or cylinder head.
4. Inspect for a sticking fuel
injector and/or leaking fuel
regulator.
Broken timing chain and/or timing 1. Inspect timing chain and
chain gears. gears.
2. Repair as required.
Material in cylinder 1. Inspect cylinder for
damaged components and/or
Broken valve foreign materials.
Piston material 2. Repair or replace as
Foreign material required.
Seized crankshaft or connecting rod 1. Inspect crankshaft and
bearings. connecting rod bearing.
Bend or broken connecting rod. 1. Inspect connecting rods.
Broken crankshaft 1. Inspect crankshaft.
SPECIAL TOOLS
SPECIAL TOOLS DESCRIPTION
Tool (Number and name) Illustration Use
Crankshaft front oil seal installer Installation of the front oil seal
(09214-33000)
Camshaft oil seal installer Installation of the camshaft oil

(09214-21000) seal
Valve guide installer (09221- Remove and installation of the

3F100 A/B) valve guide
Valve stem oil seal installer Installation of the valve stem oil
(09222-22001) seal
Valve spring compressor & Removal and installation of the

adaptor (09222-28000, 09222- intake or exhaust valve
28100)
Crankshaft rear oil seal installer 1. Installation of the engine

(09231-33000) rear oil seal
2. Installation of the crankshaft
rear oil seal
TIMING SYSTEM
TIMING BELT
COMPONENT
Fig. 2: Identifying Timing System Components And Torque Specifications.

REMOVAL
Engine removal is not required for this procedure.
1. Remove the engine cover.

2. Remove RH front wheel.
3. Remove 2 bolts (B) and RH side cover (A).
Fig. 3: Removing 2 Bolts And RH Side Cover

4. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover.
Fig. 4: Aligning Crankshaft Pulley Groove With Timing Mark "T" Of Timing Belt Cover
NOTE: Always turn the crankshaft clockwise.
5. Remove drive belt (A) and belt tensioner (B).
Fig. 5: Removing Drive Belt And Belt Tensioner

6. Remove the engine mount bracket.

1. Set the jack to the engine oil pan.
Fig. 6: Setting Jack To Engine Oil Pan

NOTE: Place wooden block between the jack and engine oil pan.
2. Remove the 2 bolts, 2 nuts and engine mount bracket (A).
Fig. 7: Removing 2 Bolts, 2 Nuts And Engine Mount Bracket

7. Remove the power steering pump. (See MECHANICAL POWER STEERING SYSTEM )
8. Remove the 7 bolts (B) and timing belt upper cover (A).
Fig. 8: Removing 7 Bolts And Timing Belt Upper Cover

9. Remove the crankshaft pulley bolt and crankshaft pulley (A).
Fig. 9: Removing Crankshaft Pulley Bolt And Crankshaft Pulley

10. Remove the drive belt idler pulley (A).
Fig. 10: Removing Drive Belt Idler Pulley

11. Remove the 4 bolts (B) and timing belt lower cover (A).
Fig. 11: Removing 4 Bolts And Timing Belt Lower Cover

12. Remove the engine support bracket (A).
Fig. 12: Removing Engine Support Bracket

13. Check that timing marks of the camshaft timing pulleys and cylinder head covers are aligned. If not, turn
the crankshaft 1 revolution (360°).
14. Remove timing belt tensioner.
Alternately loosen the 2 bolts, and remove the tensioner (A).
Fig. 13: Loosening 2 Bolts And Removing Tensioner

15. Remove the timing belt (A).
Fig. 14: Removing Timing Belt

NOTE: If the timing belt is reused, make an arrow indicating the turning direction
to make sure that the belt is reinstalled in the same direction as before.
16. Remove the tensioner pulley (A) and timing belt idler pulley (B).
Fig. 15: Removing Tensioner Pulley And Timing Belt Idler Pulley
17. Remove the crankshaft sprocket.

18. Remove camshaft sprockets.
Hold the hexagonal head wrench portion of the camshaft with a wrench and remove the bolt and camshaft
sprocket.
CAUTION: Be careful not to damage the cylinder head and valve lifter with the
wrench.
INSPECTION
SPROCKETS, TENSIONER, IDLER
1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear,
cracks, or damage. Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise.
Replace as necessary.
Fig. 16: Inspecting Tensioner Pulley And Idler Pulley For Easy And Smooth Rotation And
Checking For Play Or Noise
3. Replace the pulley if there is a grease leak from its bearing.
TIMING BELT
1. Check the belt for oil or dust deposits.
Replace, if necessary.
Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of the following
flaws are evident, replace the belt.
NOTE: Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with oil, water and
steam.
INSTALLATION
1. Install the crankshaft sprocket.
Align the pulley set key with the key groove the crankshaft sprocket and slide on the crankshaft sprocket.
2. Install the camshaft sprockets and tighten the bolts to the specified torque.
1. Temporarily install the camshaft sprocket bolts.
2. Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft
sprocket bolts.
Tightening torque
Camshaft sprocket bolt
90 ~ 110Nm (900 ~ 1100kgf.cm, 65 ~ 80lbf.ft)
3. Install the idler pulley (B) and the tensioner pulley (A).
Tightening torque
Idler pulley bolt
50 ~ 60Nm (500 - 600kgf.cm, 36 - 43lbf.ft)
Tensioner arm fixed bolt
35 ~ 55Nm (350 ~ 550kgf.cm, 25 ~ 40lbf.ft)
NOTE: Insert and install the idler pulley to the roll pin that is pressed in the water
pump boss.
Fig. 17: Installing Idler Pulley And Tensioner Pulley

4. Align the timing marks of the camshaft sprocket and crankshaft sprocket with the No.1 piston placed at
top dead center and its compression stroke.
Fig. 18: Aligning Timing Marks Of Camshaft Sprocket And Crankshaft Sprocket With No 1 Piston
Placed At Top Dead Center
5. Set timing belt tensioner.

1. Using a press, slowly press in the push rod.
2. Align the holes of the push rod and housing pass a set pin through the holes to keep the setting
position of the push rod.
3. Release the press.
6. Install the timing belt tensioner.
1. Temporarily install the tensioner with the 2 bolts.
2. Alternately tighten the 2 bolts.
Tightening torque
20 ~ 27Nm (200 - 270kgf.cm, 14 - 20lbf.ft)
Fig. 19: Installing Timing Belt Tensioner

7. Install the timing belt.
1. Remove any oil or water on the sprockets, and keep them clean.
2. Install the timing belt in this order.
Crankshaft sprocket (A) --> Idler pulley (B) --> Camshaft sprocket LH side (C) --> Water pump pulley
(D) --> Camshaft sprocket RH side (E) --> Tensioner pulley (F).
Fig. 20: Installing Timing Belt

8. Remove the set pin (A) from the tensioner.
Fig. 21: Removing Set Pin From Tensioner

9. Timing belt tensioner checking.

1. Rotate the crankshaft 2 turns clockwise and measure the projected length of the auto tensioner at
TDC (#1 compression stroke) after 5 minutes.
2. The projected length should be 7 ~ 9mm (0.27 ~ 0.31 in.)
Fig. 22: Measuring Projected Length Of Auto Tensioner At TDC

10. Install the engine support bracket (A).
Tightening torque
B: 60 ~ 70Nm (600 ~ 700kgf.cm, 43 ~ 51 lbf.ft)
C: 15 ~ 22Nm (150 ~ 220kgf.cm, 11 ~ 16lbf.ft)
Fig. 23: Installing Engine Support Bracket

11. Install the timing belt lower cover (A) with 4 bolts (B).
Tightening torque
Timing belt cover bolt
10 ~ 12Nm (100 ~ 120kgf.cm, 7 ~ 9lbf.ft)
Fig. 24: Installing Timing Belt Lower Cover With 4 Bolts

12. Install the drive belt idler pulley (A).
Tightening torque
Idler pulley bolt
35 ~ 55Nm (350 ~ 550kgf.cm, 25 ~ 40lgf.ft)
Fig. 25: Installing Drive Belt Idler Pulley

13. Install the crankshaft pulley (A).
Make sure that crankshaft sprocket pin fits the small hole in the pulley.
Tightening torque
Crankshaft pulley bolt
180 ~ 190Nm (1800 ~ 1900kgf.cm, 130 ~ 138lbf.ft)
Fig. 26: Installing Crankshaft Pulley

14. Install the timing belt upper cover (A) with 7 bolts (B).
Fig. 27: Installing Timing Belt Upper Cover With 7 Bolts

15. Install the power steering pump. (See MECHANICAL POWER STEERING SYSTEM )
16. Install the drive belt tensioner (B) and drive belt (A).
Fig. 28: Installing Drive Belt Tensioner And Drive Belt

17. Install the engine mount bracket.
Install engine mount bracket with 2 nuts and 2 bolt.
Tightening torque
60 ~ 80Nm (600 ~ 800kgf.cm, 44 ~ 59lbf.ft)
Fig. 29: Installing Engine Mount Bracket

18. Install RH side cover (A) with 2 bolts (B).
Fig. 30: Installing RH Side Cover With 2 Bolts

19. Install RH front wheel.

20. Install engine cover.
CYLINDER HEAD ASSEMBLY

COMPONENTS
Fig. 31: Identifying Cylinder Head Assembly Components And Torque Specifications (1 Of 2)
Fig. 32: Identifying Cylinder Head Assembly Components Torque Specifications (2 Of 2)

REMOVAL
Engine removal is not required for this procedure.
CAUTION: Use fender covers to avoid damaging painted surfaces.

To avoid damaging the cylinder head, wait until the engine coolant
temperature drops below normal temperature before removing it.
When handling a metal gasket, take care not to fold the gasket or
damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.
NOTE: Mark all wiring and hoses to avoid misconnection.

Inspect the timing belt before removing the cylinder head.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
(See REMOVAL).
1. Disconnect the negative terminal from the battery.
Fig. 33: Removing Battery

3. Drain the engine coolant. (See ENGINE COOLANT REFILLING AND BLEEDING) Remove the
radiator cap to speed draining.
4. Remove the intake air hose and air cleaner assembly.
1. Disconnect the AFS connector.
2. Disconnect the breather hose from air cleaner hose.
5. Remove the upper radiator hose (A) and lower radiator hose (B).
Fig. 34: Removing Upper Radiator Hose And Lower Radiator Hose
6. Remove the heater hoses (A).
Fig. 35: Removing Heater Hoses

7. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the
intake manifold.
1. TPS (Throttle Position Sensor) connector (A).
2. ISA (Idle Speed Actuator) connector (B).
3. PCSV (Purge Control Solenoid Valve) connector (C).
4. Injector connector (E).
5. Knock sensor connectors (F).
6. CMP (Camshaft Position Sensor) connector (G).
Fig. 36: Removing Engine Wire Harness Connectors And Wire Harness Clamps From
Cylinder Head And Intake Manifold
7. ECT (Engine Coolant Temperature) sensor connector (A).

8. Ignition coil connector (B).
9. Crankshaft position sensor connector (C).
10. Oxygen sensor connector (D).
Fig. 37: Removing Crankshaft Position Sensor Connector, Oxygen Sensor Connector, ECT
And Ignition Coil Connector
11. Three fuel injector connectors (A).
Fig. 38: Removing Fuel Injector Connectors

8. Remove the fuel inlet hose (A) from delivery pipe.
Fig. 39: Removing Fuel Inlet Hose From Delivery Pipe

9. Remove the PCSV hose.

10. Remove the brake booster vacuum hose (A).
Fig. 40: Removing Brake Booster Vacuum Hose

11. Remove the accelerator cable by loosening the lock-nut, then slip the cable end out of the throttle linkage.
12. Remove the PCV hose (A).
Fig. 41: Removing PCV Hose

13. Remove the Intake Manifold. (See INTAKE MANIFOLD )

14. Remove the power steering pump. (See POWER STEERING OIL PUMP ).
15. Remove the Exhaust Manifold. (See EXHAUST MANIFOLD )
16. Remove the timing belt. (See REMOVAL)
17. Remove the spark plug cable. (See INSPECT SPARK PLUG AND SPARK PLUG CABLE )
18. Remove the cylinder head covers (A).
Fig. 42: Removing Cylinder Head Cover

19. Remove the camshaft sprocket.

20. Remove the camshaft bearing caps (A).
Fig. 43: Removing Camshaft Bearing Caps (1 Of 2)

Fig. 44: Removing Camshaft Bearing Caps (2 Of 2)

21. Remove the camshafts (A).
Fig. 45: Removing Camshafts (1 Of 2)

Fig. 46: Removing Camshafts (2 Of 2)

22. Remove the timing belt rear cover (A).
Fig. 47: Removing Timing Belt Rear Cover

23. Remove the water temperature control assembly (A) and water pipe.
Fig. 48: Removing Water Temperature Control Assembly And Water Pipe
24. Remove the cylinder head bolts, then remove the cylinder heads.
1. Uniformly loosen and remove the 8 cylinder head bolts on each cylinder head in several passes and
in the sequence shown, then repeat for the other side, as shown. Remove the 16 cylinder head bolts
and plate washer.
Fig. 49: Identifying Removal Sequence Of Cylinder Head Bolts

CAUTION: Head warpage or cracking could result from removing bolts in

an incorrect order.
2. Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden
blocks on a bench.
CAUTION: Be careful not to damage the contact surfaces of the cylinder
head and cylinder block.
DISASSEMBLY
NOTE: Identify HLA (Hydraulic Lash Adjuster), valves, valve springs as they are
removed so that each item can be reinstalled in its original position.
1. Remove HLAs (A).
Fig. 50: Removing Hydraulic Lash Adjuster

2. Remove valves.
1. Using SST (09222-28000, 09222-28100), compress the valve spring and remove retainer lock.
Fig. 51: Using SST (09222-28000, 09222-28100) To Compress Valve Spring And Remove
Retainer Lock
2. Remove the spring retainer.

3. Remove the valve spring.
4. Remove the valve.
5. Using needle-nose pliers, remove the oil seal.
6. Using a magnetic finger, remove the spring seat.
INSPECTION
CLEANING
1. Clean top surfaces of pistons and cylinder block.

1. Turn the crankshaft, and bring each piston to top dead center (TDC).
Using a gasket scraper, remove all the carbon from the piston top surface.
2. Using a gasket scraper, remove all the gasket material from the cylinder block surface.
3. Using compressed air, blow carbon and oil from the bolt holes.
2. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.
CAUTION: Be careful not to scratch the cylinder block contact surface.
3. Clean combustion cambers.
Using a wire brush, remove all the carbon from the combustion cambers.
CAUTION: Be careful not to scratch the cylinder block contact surface.
4. Clean cylinder heads.
Using a soft brush and solvent, thoroughly clean the cylinder head.
5. Clean valves.
1. Using a gasket scraper, chip off any carbon from the valve head.
2. Using a wire brush thoroughly clean the valve.
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface Contacting the cylinder block for
warpage.
Flatness of cylinder head gasket surface
Standard: Less than 0.03mm (0.0012 in.)
Limit: 0.05 mm (0.0020 in.)
Fig. 52: Using Precision Straight Edge And Feeler Gauge To Measure Surface Contacting Cylinder
Block For Warpage
2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If
cracked, replace the cylinder head.
VALVE AND VALVE SPRING
1. Inspect valve stems and valve guides.

1. Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide inside.
Fig. 53: Using Caliper Gauge To Measure Inside Diameter Of Valve Guide
2. Using a micrometer, measure the diameter of the valve stem.
Fig. 54: Using Micrometer To Measure Diameter Of Valve Stem

3. Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
[Standard]
Intake: 0.02 ~ 0.05mm (0.0008 ~ 0.0020 in.)
Exhaust: 0.030 ~ 0.065mm (0.0012 ~ 0.0026 in.)
[Limit]
Intake: 0.1mm (0.0040 in.)
Exhaust: 0.13mm (0.0051 in.)
If the clearance is greater than maximum, replace the valve and valve guide.
2. Inspect valves.
1. Check the valve is ground to the correct valve face angle.

2. Check that the surface of the valve for wear. If the valve face is worn, replace the valve.
3. Check the valve head margin thickness. If the margin thickness is less than minimum, replace the
valve.
Margin
[Standard]
Intake: 1.0mm (0.0394 in.)
Exhaust: 1.3mm (0.0512 in.)
[Limit]
Intake: 0.5mm (0.0197 in.)
Exhaust: 0.8mm (0.0315 in.)
Fig. 55: Checking Valve Head Margin Thickness

4. Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
3. Inspect valve seats
Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then
recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact
width should be within specifications and centered on the valve face.
4. Inspect valve springs.

1. Using a steel square, measure the out-of-square of the valve spring.
2. Using a vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height: 42.5mm (1.6732 in.)
Load: 21kg/35mm (48.4kg/1.378mm)
[Limit]
Free height: -1.0mm (-0.0394 in.)
Out-of-square: 3°
Fig. 56: Using Vernier Calipers To Measure Free Length Of Valve Spring
If the free length is not as specified, replace the valve spring.
CAMSHAFT
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake: 43.95 ~ 44.15mm (1.7303 ~ 1.7382 in.)
Exhaust: 43.95 ~ 44.15mm (1.7303 ~ 1.7382 in.)
Fig. 57: Using Micrometer To Measure Cam Lobe Height

If the cam lobe height is less than minimum, replace the camshaft.
2. Inspect cam journals.
Using a micrometer, measure the journal diameter.
Journal diameter
Standard value
25.964 ~ 25.980mm (1.0222 ~ 1.0228 in.)
If the journal diameter is not as specified, check the oil clearance.
3. Inspect camshaft bearings.
Check that bearing for flaking and scoring. If the bearings are damaged, replace the bearing caps and
cylinder head as a set.
4. Inspect camshaft journal oil clearance.

1. Clean the bearing caps and camshaft journals.
2. Place the camshafts on the cylinder head.
3. Lay a strip of plastigage across each of the camshaft journal.
Fig. 58: Laying Strip Of Plastigage Across Each Of Camshaft Journal

4. Install the bearing caps. (See step 3 )
CAUTION: Do not turn the camshaft.
5. Remove the bearing caps.

6. Measure the plastigage at its widest point.
Bearing oil clearance
Standard value: 0.02 ~ 0.061mm (0.0008 ~ 0.0024 in.)
Limit: 0.1mm (0.0039 in.)
Fig. 59: Measuring Plastigage At Its Widest Point

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.
7. Completely remove the plastigage.

8. Remove the camshafts.
5. Inspect camshaft end play.
1. Install the camshafts. (See step 6 )
2. Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
Standard value: 0.1 ~ 0.15mm (0.004 ~ 0.0059 in.)
Fig. 60: Using Dial Indicator To Measure End Play While Moving Camshaft Back And Forth
If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.
3. Remove the camshafts.
REPLACEMENT
VALVE GUIDE
1. Using the SST (09221-3F100A), withdraw the old valve guide toward the bottom of the cylinder head.
Fig. 61: Using SST (09221-3F100A) To Withdraw The Old Valve Guide Toward The Bottom Of
Cylinder Head
2. Recondition the valve guide hole so that it can match the newly press-fitted oversize valve guide.
3. Using the SST (09221-3F100A/B), press-fit the valve guide. The valve guide must be press-fitted from
the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guides are different in
length.
OVERSIZE VALVE GUIDE SPECIFICATIONS

Oversize valve guide hole size
Over size mm (in.) Size mark mm (in.)
0.05 (0.002) 5 11.05 ~ 11.068
(0.4350 ~ 0.4357)
0.25 (0.010) 25 11.25 ~ 11.268
(0.4429 ~ 0.4436)
0.50 (0.020) 50 11.50 ~ 11.518
(0.4528 ~ 0.4535)
Valve guide length
Intake: 39mm (1.535 in.)
Exhaust: 43mm (1.693 in.)
Fig. 62: Using SST (09221-3F100A/B) To Press-Fit Valve Guide

4. After the valve guide is press-fitted, insert a new valve and check for proper stem-to-guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as
necessary.
REASSEMBLY
NOTE: Thoroughly clean all parts to be assembled. Before installing the parts, apply
fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.
1. Install valves.
1. Install the spring seats.
2. Using SST (09222-22001), push in a new oil seal.
NOTE: Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage past the
valve guides.
Fig. 63: Using SST (09222-22001) To Push In A New Oil Seal

3. Install the valve, valve spring and spring retainer.
NOTE: Place valve springs so that the side coated with enamel faces toward
the valve spring retainer and then installs the retainer.
4. Using the SST (09222-28000, 09222-28100), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the
valve spring compressor.
Fig. 64: Using SST (09222-28000, 09222-28100) To Compress Spring And Install Retainer
Locks
5. Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to
ensure proper seating of the valve and retainer lock.
Fig. 65: Ensure Proper Seating Of Valve And Retainer Lock Using Wooden Handle Of A
Hammer
2. Install HLAs.
Check that the HLA rotates smoothly by hand.
Fig. 66: Installing Hydraulic Lash Adjuster

INSTALLATION
NOTE: Thoroughly clean all parts to be assembled.

Always use a new head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No. 1 piston at TDC. (See REMOVAL).
1. Install the cylinder head gaskets on the cylinder block.
Fig. 67: Installing Cylinder Head Gaskets On Cylinder Block

NOTE: Be careful of the installation direction.
2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts.
Tightening torque
25Nm (250kgf.cm, 18lbf.ft) + 60° + 45°
1. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
2. Install the plate washer to the cylinder head bolt.
3. Install and uniformly tighten the cylinder head bolts on each cylinder head in several passes and in
the sequence shown, then repeat for the other side, as shown.
Fig. 68: Identifying Tightening Sequence Of Cylinder Head Bolts

If only one of the cylinder head bolts dose not meet the torque specification, replace the cylinder
head bolt.
Torque: 25Nm (250kgf.cm, 18lbf.ft)
Fig. 69: Retightening Cylinder Head Bolts

4. Retighten the cylinder head bolts by 60° in the numerical order shown.
5. Retighten the cylinder head bolts by 45° in the numerical order shown.
4. Install the water pipe and water temperature control assembly (A).
Tightening torque
Water temperature control
15 - 20Nm (150 ~ 200kgf.cm, 11 ~ 14lbf.ft)
Fig. 70: Installing Water Temperature Control Assembly

5. Install the timing belt rear cover (A).
Tightening torque
Timing belt rear cover
10 ~ 12Nm (100 ~ 120kgf.cm, 7 ~ 9lbf.ft)
Fig. 71: Installing Timing Belt Rear Cover

6. Install the camshafts.

1. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain
sprocket as shown.
Fig. 72: Aligning Camshaft Timing Chain With Intake Timing Chain Sprocket And Exhaust
Timing Chain Sprocket
2. Install the camshaft (A).
Fig. 73: Installing Camshaft

3. Install the camshaft bearing caps (A).
Tightening torque
M6 (38mm): 10 ~ 12Nm (100 ~ 120kgf.cm, 7 ~ 9lbf.ft)
M6 (50mm): 14 ~ 16Nm (140 ~ 160kgf.cm, 10 ~ 12lbf.ft)
Fig. 74: Installing Camshaft Bearing Caps

NOTE: Apply new engine oil to the thrust portion and journal of the
camshafts.
Apply a light coat of engine oil on the threads and under the heads of
the bearing cap bolts.
7. Using the SST (09214-21000), install the camshaft bearing oil seal.
Fig. 75: Using SST (09214-21000) To Install Camshaft Bearing Oil Seal
8. Install the camshaft sprocket.

1. Temporarily install the camshaft sprocket bolts.
2. Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft
sprocket bolts.
Tightening torque
Camshaft sprocket bolt
90 ~ 110Nm (900 ~ 1100kgf.cm, 65 ~ 80lbf.ft)
9. Install semi-circular packing.

10. Install the cylinder head cover.
1. Install the cylinder head cover gasket (A) in the groove of the cylinder head cover (B).
Fig. 76: Installing Cylinder Head Cover Gasket In The Groove Of The Cylinder Head Cover
NOTE: Before installing the head cover gasket, thoroughly clean the
head cover gasket and the groove.
When installing, make sure the head cover gasket is seated
securely in the corners of the recesses with no gap.
2. Apply liquid gasket to the head cover gasket at the corners of the recess.
NOTE: Use liquid gasket, LOCTITE No.5699.

Check that the mating surfaces are clean and dry before
applying liquid gasket.
After assembly, wait at least 30 minutes before filling the engine
with oil.
3. Install the cylinder head covers (A) with the 16 bolts. Uniformly tighten the bolts in several passes.
Tightening torque
8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~ 7.4lbf.ft)
Fig. 77: Installing Cylinder Head Covers With 16 Bolts

Fig. 78: Identifying Tightening Sequence Of Cylinder Head Covers Bolts

11. Install the spark plug cable. (See INSPECT SPARK PLUG AND SPARK PLUG CABLE )
12. Install the timing belt. (See INSTALLATION).
13. Install the exhaust manifold. (See EXHAUST MANIFOLD )
14. Install the power steering pump. (See POWER STEERING OIL PUMP )
15. Install the intake manifold. (See INTAKE MANIFOLD )
16. Install the PCV hose (A).
Fig. 79: Installing PCV Hose

17. Install the accelerator cable.

18. Install the brake booster vacuum hose (A).
Fig. 80: Installing Brake Booster Vacuum Hose

19. Install the PCSV hose.

20. Install the fuel inlet hose (A).
Fig. 81: Installing Fuel Inlet Hose

21. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake
manifold.
Fig. 82: Installing Fuel Injector Connectors

2. Oxygen sensor connector (D).

5. ECT sensor connector (A).
Fig. 83: Installing Oxygen Sensor Connector, Crankshaft Position Sensor Connector, ECT
Sensor Connector And Ignition Coil Connector
6. CMP (Camshaft position sensor) connector (G).

7. Knock sensor connector (F).
10. ISA connector (B).
11. TPS connector (A).
Fig. 84: Installing ISA Connector, TPS Connector, PCSV Connector, Injector Connector,
Knock Sensor Connector & CMP Connector
22. Install the heater hoses (A).
Fig. 85: Installing Heater Hoses

23. Install the upper radiator hose (A) and lower radiator hose (B).
Fig. 86: Installing Upper Radiator Hose And Lower Radiator Hose
24. Install the intake air hose and air cleaner assembly.
1. Install the intake air hose and air cleaner assembly.
2. Connect the breather hose from air cleaner hose.
3. Connect the AFS connector.
25. Install the engine cover.
26. Connect the negative terminal to the battery.
Fig. 87: Connecting Negative Terminal To Battery

27. Fill with engine coolant.

28. Start the engine and check for leaks.
29. Recheck engine coolant level and oil level.
ENGINE AND TRANSAXLE ASSEMBLY

REMOVAL
CAUTION: Use fender covers to avoid damaging painted surfaces.

To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.
NOTE: Mark all wiring and hoses to avoid misconnection.

Inspection the timing belt before removing the cylinder head.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
(See REMOVAL)
1. Disconnect the negative terminal from the battery.
Fig. 88: Disconnecting Negative Terminal From Battery

3. Drain the engine coolant.
Remove the radiator cap to speed draining.

1. Disconnect the AFS connector.
2. Disconnect the breather hose from air cleaner hose.
5. Remove the upper radiator hose (A) and lower radiator hose (B).
Fig. 89: Removing Upper Radiator Hose And Lower Radiator Hose
6. Remove the heater hoses (A).
Fig. 90: Removing Heater Hoses

7. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the
intake manifold.
1. TPS (Throttle Position Sensor) connector (A).
2. ISA (Idle Speed Actuator) connector (B).
5. Knock sensor connector (F).
6. CMP (Camshaft Position Sensor) connector (G).
Fig. 91: Removing TPS, ISA, PCSV, CMP, Injector And Knock Sensor Connectors
7. ECT (Engine Coolant Temperature) sensor (A) connector.

10. Rear oxygen sensor connector (D).
Fig. 92: Removing ECT Sensor, Ignition Coil, Crankshaft Position Sensor And Rear Oxygen
Sensor Connectors
Fig. 93: Removing Fuel Injector Connectors

8. Disconnect front heated oxygen sensor (LH) connector (A), air compressor switch connector (B) and oil
pressure sensor connector (C).
Fig. 94: Disconnecting Front Heated Oxygen Sensor, Air Compressor Switch And Oil Pressure
Sensor Connectors
9. Disconnect rear heated oxygen sensor (RH) connector.

10. Remove the fuel inlet from delivery pipe (A).
Fig. 95: Removing Fuel Inlet From Delivery Pipe

11. Remove the PCSV hose.

12. Remove the brake booster vacuum hose (A).
Fig. 96: Removing Brake Booster Vacuum Hose

13. Remove the accelerator cable by loosening the lock-nut, then slip the cable end out of the throttle linkage.
14. Remove the power steering pump hose (A).
Fig. 97: Removing Power Steering Pump Hose (1 Of 2)

Fig. 98: Removing Power Steering Pump Hose (2 Of 2)

15. Remove the battery body bracket.

16. Disconnect the transaxle wire harness connector.
a. Disconnect the inhibitor switch connector (A).
b. Disconnect the transaxle range connector (B).
c. Disconnect the input shaft speed connector (C).
Fig. 99: Disconnecting Transaxle Range, Inhibitor Switch And Input Shaft Speed Connectors
d. Disconnect the output shaft speed connector (A).

e. Disconnect the vehicle speed sensor connector (B).
Fig. 100: Disconnecting Output Shaft Speed Connector And Vehicle Speed Sensor Connector
17. Remove the control cable (A) transaxle range switch.
Fig. 101: Removing Control Cable Transaxle Range Switch

18. Remove the transaxle oil cooler hoses (A/T) (A).
Fig. 102: Removing Transaxle Oil Cooler Hoses (A/T)

19. Remove the under cover.

20. Remove the front exhaust pipe (A).
Fig. 103: Removing Front Exhaust Pipe

21. Disconnect the ABS wheel speed sensor (A) from both front knuckles. (See FRONT AXLE ).
Fig. 104: Disconnecting ABS Wheel Speed Sensor From Both Front Knuckles
22. Remove the front strut lower mounting bolts and nuts. (See FRONT STRUT ASSEMBLY ).
Fig. 105: Removing Front Strut Lower Mounting Bolts And Nuts
23. Remove the caliper and hang the caliper assembly (A).
Fig. 106: Removing Caliper And Hanging Caliper Assembly

24. Remove the steering U-joint mounting bolt (A). (See STEERING COLUMN AND SHAFT )
Fig. 107: Removing Steering U-Joint Mounting Bolt

25. Install the jack for supporting engine and transaxle assembly.
26. Remove the engine mounting bracket (A).
Fig. 108: Removing Engine Mounting Bracket

27. Remove the transaxle mounting bracket (A).
Fig. 109: Removing Transaxle Mounting Bracket

28. Remove the sub frame mounting bolts and nuts.
Tightening torque
A: 160 ~ 180Nm (1600 ~ 1800kgf.cm, 118 ~ 133lbf.ft)
B: 70 ~ 90Nm (700 ~ 900kgf.cm, 52 ~ 66lbf.ft)
Fig. 110: Removing Sub Frame Mounting Bolts And Nuts (1 Of 2)

Fig. 111: Removing Sub Frame Mounting Bolts And Nuts (2 Of 2)

29. Jack up the vehicle.
INSTALLATION
Installation is in the reverse order of removal.
Perform the following:
Adjust the shift cable.

Adjust the throttle cable.
Refill the engine with engine oil.
Refill the transaxle with fluid.
Refill the radiator with engine coolant.
Bleed air from the cooling system with the heater valve open.
Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump
runs for approximately two seconds and fuel line pressurizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
ENGINE BLOCK
COMPONENT
Fig. 112: Identifying Engine Block Components And Torque Specifications (1 Of 2)

Fig. 113: Identifying Engine Block Components And Torque Specifications (2 Of 2)

DISASSEMBLY
1. A/T: remove drive plate.

2. Install engine to engine stand for disassembly (A).
3. Remove timing belt. (See REMOVAL)
4. Remove cylinder head. (See REMOVAL)

5. Remove oil level gauge assembly.
6. Remove the alternator. (See GENERATOR ).
7. Remove the air compressor. (See A/C COMPRESSOR CONTROLS (MANUAL) )
8. Remove the power steering pump bracket (A).
Fig. 114: Removing Power Steering Pump Bracket

9. Remove water pump. (See WATER PUMP )

10. Remove knock sensors (A).
Fig. 115: Removing Knock Sensors

11. Remove the lower oil pan (A).
Fig. 116: Removing Lower Oil Pan

12. Remove oil screen.
Remove the 2 bolts (B), oil screen (A) and gasket.
Fig. 117: Removing 2 Bolts, Oil Screen And Gasket

13. Remove the upper oil pan (A).
Fig. 118: Removing Upper Oil Pan

14. Check the connecting rod end play. (See INSPECTION)

15. Remove the connecting rod caps and check oil clearance. (See INSPECTION)
16. Remove piston and connecting rod assemblies.
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
NOTE: Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in the correct

order.
17. Remove front case. (See REMOVAL)

18. Remove oil seal case.
Remove the 3 bolts (B) and oil seal case (A).
Fig. 119: Removing 3 Bolts And Oil Seal Case

19. Check the crankshaft end play. (See step 4 )

20. Remove crankshaft bearing cap and check oil clearance. (See step 3 )
Fig. 120: Removing Bolts

21. Lift the crankshaft (A) out of the engine, being careful not to damage journals.
NOTE: Arrange the main bearings and trust washers in the correct order.
Fig. 121: Lifting Crankshaft Out Of Engine

22. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and
pin as a set.
23. Remove piston rings.

1. Using a piston ring expender, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.
NOTE: Arrange the piston rings in the correct order only.
24. Disconnect connecting rod from piston.
INSPECTION
CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod end play.
Using a dial indicator, measure the end play while moving the connecting rod back and forth.
Standard end play: 0.1 ~ 0.25mm (0.004 ~ 0.01 0 in.)
Maximum end play: 0.4mm (0.016 in.)
Fig. 122: Using Dial Indicator To Measure The End Play While Moving Connecting Rod Back And
Forth
If out-of-tolerance, replace the connecting rod assembly.

If still out-of-tolerance, replace the crankshaft.
2. Check the connecting road bearing oil clearance.
1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap bolts.

3. Remove the connecting rod cap and bearing half.
4. Clean the crank pin and bearing.
5. Place plastigage across the crank pin.
6. Reinstall the bearing half and cap, and torque the bolts.
Tightening torque
16 ~ 20Nm (160 ~ 200kgf.cm, 12 ~ 15lbf.ft) + 90°
NOTE: Do not turn the crankshaft.
7. Remove the 2 bolts, connecting rod cap and bearing half.

8. Measure the plastigage at its widest point.
Standard oil clearance
0.018 ~ 0.036mm (0.0007 ~ 0.0014 in.)
Fig. 123: Measuring Plastigage At Its Widest Point

9. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in the next column),
and recheck the clearance.
CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.
10. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.
NOTE: If the proper clearance cannot be obtained by using the appropriate

larger or smaller bearings, replace the crankshaft and start over.
CAUTION: If the marks are indecipherable because of an accumulation of

dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.
Fig. 124: Identifying Connecting Rod Mark Location

CONNECTING ROD INSIDE DIAMETER SPECIFICATIONS
CLASS MARK INSIDE DIAMETER

0 A 51.000 ~ 51.006mm
(2.0079 ~ 2.0081in.)
1 B 51.006 ~ 51.012mm
(2.0081 ~ 2.0083in.)
2 C 51.012 ~ 51.018mm
(2.0083 ~ 2.0086in.)
Fig. 125: Identifying Crankshaft Pin Mark Location

CRANKSHAFT PIN OUTSIDE DIAMETER SPECIFICATIONS
OUTSIDE DIAMETER OF
CLASS MARK PIN
I A 47.994 ~ 48.000mm
(1.8895 ~ 1.8898in.)
II B 47.988 ~ 47.994mm
(1.8893 ~ 1.8895in.)
III C 47.982 ~ 47.988mm
(1.8890 ~ 1.8893in.)
Fig. 126: Identifying Connecting Rod Bearing Identification Mark Location

CONNECTING ROD BEARING THICKNESS SPECIFICATIONS

CLASS MARK THICKNESS OF BEARING
A BLUE 1.500 ~ 1.503mm
(0.0590 ~ 0.0591in.)
B BLACK 1.497 ~ 1.500mm
(0.0589 ~ 0.0590in.)
C NONE 1.494 ~ 1.497mm
(0.0588 ~ 0.0589in.)
D GREEN 1.491 ~ 1.494mm
(0.0587 ~ 0.0588in.)
E YELLOW 1.488 ~ 1.491mm
(0.0586 ~ 0.0587in.)
11. Selection
CONNECTING ROD IDENTIFICATION MARK AND ASSEMBLING CLASSIFICATION OF

BEARING
ASSEMBLING
CRANKSHAFT CONNECTING ROD CLASSIFICATION OF
IDENTIFICATION MARK IDENTIFICATION MARK BEARING
I (A) 0 (A) E (YELLOW)
1 (B) D (GREEN)
2 (C) C (NONE)
II (B) 0 (A) D (GREEN)
1 (B) C (NONE)
2 (C) B (BLACK)
III (C) 0 (A) C (NONE)
1 (B) B (BLACK)
2 (C) A (BLUE)
3. Check the crankshaft bearing oil clearance.

1. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
2. Clean each main journal and bearing half with a clean shop tower.
3. Place one strip of plastigage across each main journal.
4. Reinstall the bearings and caps, then torque the bolts.
Tightening torque
M8
13 ~ 19Nm (130 ~ 190kgf.cm, 10 ~ 14lbf.ft) + 90°
M10
27 ~ 33Nm (270 ~ 330kgf.cm, 19.5 ~ 24lbf.ft) + 90°
NOTE: Do not turn the crankshaft.
5. Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance
0.004 ~ 0.022mm (0.00016 ~ 0.00087in.)
Fig. 127: Measuring Widest Part Of Plastigage

6. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in the next column),
and recheck the clearance.
CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.
7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.
NOTE: If the proper clearance cannot be obtained by using the appropriate larger
or smaller bearings, replace the crankshaft and start over.
CAUTION: If the marks are indecipherable because of an accumulation of dirt

and dust, do not scrub them with a wire brush or scraper. Clean them
only with solvent or detergent.
CONNECTING RODS
1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly
match. When a new connecting rod is installed, make sure that the notches for holding the bearing in
place are on the same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a
severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as
well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to
the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted
should be replaced.
Allowable bend of connecting rod
0.05mm/100mm (0.0020 in./3.94 in.) or less
Allowable twist of connecting rod
0.1mm/100mm (0.0039 in./3.94 in.) or less
Crankshaft bore mark location
Letters have been stamped on the end of the block as a mark for the size of each of the 4 main journal
bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the
correct bearings.
Fig. 128: Identifying Crankshaft Bore Mark Location

CRANKSHAFT BORE INSIDE DIAMETER SPECIFICATIONS

CLASS MARK INSIDE DIAMETER
a A 66.000 ~ 66.006mm
(2.5984 ~ 2.5986in.)
b B 66.006 ~ 66.012mm
(2.5986 ~ 2.5989in.)
c C 66.012 ~ 66.018mm
(2.5989~2.5991 in.)
Fig. 129: Identifying Crankshaft Journal Mark Location

CRANKSHAFT JOURNAL OUTSIDE DIAMETER SPECIFICATIONS
OUTSIDE DIAMETER OF
CLASS MARK JOURNAL
I A 61.994 ~ 62.000mm
(2.4407 ~ 2.4409in.)
II B 61.988 ~ 61.994mm
(2.4405 ~ 2.4407in.)
III C 61.982 ~ 61.988mm
(2.4402 ~ 2.4405in.)
Fig. 130: Identifying Crankshaft Bearing Identification Mark Location

CRANKSHAFT BEARING THICKNESS SPECIFICATIONS

CLASS MARK THICKNESS OF BEARING
A BLUE 2.007 ~ 2.010mm
(0.0790 ~ 0.0791in.)
B BLACK 2.004 ~ 2.007mm
(0.0789 ~ 0.0790in.)
C NONE 2.001 ~ 2.004mm
(0.0788 ~ 0.0789in.)
D GREEN 1.998 ~ 2.001mm
(0.0787 ~ 0.788in.)
E YELLOW 1.995 ~ 1.998mm
(0.0785 ~ 0.0787in.)
CRANKSHAFT BORE IDENTIFICATION MARK AND ASSEMBLING CLASSIFICATION OF

BEARING
ASSEMBLING
CRANKSHAFT CRANKSHAFT BORE CLASSIFICATION OF
IDENTIFICATION MARK IDENTIFICATION MARK BEARING
I (A) a (A) E (YELLOW)
b (B) D (GREEN)
c (C) C (NONE)
II (B) a (A) D (GREEN)
b (B) C (NONE)
c (C) B (BLACK)
III (C) a (A) C (NONE)
b (B) B (BLACK)
c (C) A (BLUE)
4. Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a
screwdriver.
Standard end play
0.07 ~ 0.25mm (0.0027 ~ 0.0098in.)
Limit: 0.30mm (0.0118in.)
Fig. 131: Using Dial Indicator To Measure Crankshaft End Play

If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness
1.925 ~ 1.965mm (0.076 ~ 0.077in.)
5. Inspect main journals and crank pins Using a micrometer, measure the diameter of each main journal and
crank pin.
Main journal diameter
61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)
Crank pin diameter
47.982 ~ 48.000mm (1.8890 ~ 1.8898in.)
Fig. 132: Measuring Diameter Of Each Main Journal And Crank Pin Using Micrometer
CYLINDER BLOCK
1. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge,
measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Standard: Less than 0.03mm (0.0012 in.)
Limit: 0.05 mm (0.0020 in.)
Fig. 133: Measuring Surface Contacting Cylinder Head Gasket For Warpage Using Precision
Straight Edge And Feeler Gauge
4. Inspect cylinder bore diameter
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder liner.
5. Inspect cylinder bore diameter
Using a cylinder bore gauge, measure the cylinder bore diameter at position A, B and C in the thrust and
axial directions.
Standard diameter
86.70 ~ 86.73mm (3.4134 ~ 3.4145in.)
Fig. 134: Measuring Cylinder Bore Diameter Using Cylinder Bore Gauge
6. Check the cylinder bore size code (A) on the cylinder block bottom face.
Fig. 135: Checking Cylinder Bore Size Code On Cylinder Block Bottom Face
CYLINDER BORE INNER DIAMETER SPECIFICATION

Class Cylinder bore inner diameter Size code
A 86.70 ~ 86.71mm (3.4133 ~ A
3.4137in.)
B 86.71 ~ 86.72mm (3.4137-3.4141 B
in.)
C 86.72 ~ 86.73mm (3.4141 ~ C
3.4145in.)
7. Check the piston size code (A) on the piston top face.
Fig. 136: Checking Piston Size Code On Piston Top Face

NOTE: Stamp the grade mark of basic diameter with rubber stamp.
PISTON DIAMETER SPECIFICATIONS

Class Piston diameter Size code
A 86.68 ~ 86.69mm (3.4126 ~ A

3.4130in.)
B 86.69 ~ 86.70mm (3.4130 ~ None
3.4133in.)
C 86.70 ~ 86.71 mm (3.4133 ~ C
3.4137in.)
8. Select the piston related to cylinder bore class.
Clearance: 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)
BORING CYLINDER
1. Oversize pistons should be selected according to the largest bore cylinder.
CYLINDER BORE SIZE SPECIFICATIONS

Identification Mark Size
0.25 0.25mm (0.010in.)
0.50 0.50mm (0.0250in.)
NOTE: The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.

3. According to the measured O.D., calculate the new bore size.
New bore size = Piston O.D + 0.01 to 0.03mm (0.0004 to 0.0012 in.) (clearance between piston and
cylinder) - 0.01 mm (0.0004 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size.
CAUTION: To prevent distortion that may result from temperature rise during
honing, bore the cylinder holes in the firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard: 0.01 ~ 0.03mm (0.0004 ~ 0.0012 in.)
NOTE: When boring the cylinders, finish all of the cylinders to the same oversize.
Do not bore only one cylinder to the oversize.
PISTON AND RINGS
1. Clean piston
1. Using a gasket scraper, remove the carbon from the piston top.
2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
3. Using solvent and a brush, thoroughly clean the piston.
NOTE: Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 38.5mm (1.516in.) from the top land of
the piston.
Standard diameter
86.68 ~ 86.71mm (3.4126 ~ 3.4138in.)
Fig. 137: Measuring Piston Outside Diameter

3. Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Piston ring side clearance
No. 1: 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.)
No. 2: 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)
Limit
No. 1: 0.1mm (0.004in.)
No. 2: 0.1mm (0.004in.)
Fig. 138: Using Feeler Gauge To Measure Clearance Between New Piston Ring And Wall Of Ring
Groove
If the clearance is greater than maximum, replace the piston.
5. Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge.
If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder
bore diameter against the wear limits on BORING CYLINDER, If the bore is over the service limit, the
cylinder block must be rebored. (See BORING CYLINDER).
Piston ring end gap
Standard
No.1: 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)
No.2: 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)
Limit
Oil ring: 0.2 ~ 0.7mm (0.0079 - 0.0276in.)
Fig. 139: Measuring Piston Ring End Gap

PISTON PINS
1. Measure the diameter of the piston pin.
Piston pin diameter
21.001 ~ 21.007mm (0.8268 ~ 0.8270in.)
Fig. 140: Measuring Diameter Of Piston Pin

2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance
0.011 ~ 0.018mm (0.00043 ~ 0.00071 in.)
3. Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod interference
0.016 ~ 0.033mm (0.00063 ~ 0.00130in.)
OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.
Fig. 141: Checking Continuity Between Terminal And Body With An Ohmmeter
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is
continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50kpa (7psi) vacuum is applied through the oil hole, the switch is
operating properly.
Check for air leakage. If air leaks, the diagram is broken. Replace it.
Fig. 142: Checking Continuity Between Terminal And Body When Fine Wire Is Pushed
REASSEMBLY
NOTE: Thoroughly clean all parts to assembled.

Before installing the parts, apply fresh engine oil to all sliding and rotating
surfaces.
Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble piston and connecting rod.

1. Use a hydraulic press for installation.
2. The piston front mark (A) and the connecting rod front mark (B) must face the timing belt side of
the engine.
Fig. 143: Identifying Piston Front Mark And Connecting Rod Front Mark
2. Install piston rings.

1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
3. Position the piston rings so that the ring ends are as shown.
Fig. 144: Identifying Piston Ring Ends Position

3. Install connecting rod bearings.

1. Align the bearing claw with the groove of the connecting rod or connecting rod cap.
2. Install the bearings in the connecting rod and connecting rod cap.
Fig. 145: Installing Connecting Rod Bearings

4. Install main bearings.
NOTE: Upper 1, 2, 3, 4 bearings have an oil groove of oil holes; Lower bearings do
not.
1. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings
(A).
Fig. 146: Pushing In 4 Upper Bearings

2. Align the bearing claw with the claw groove of the main bearing cap (A), and push in the 4 lower
bearings (B).
Fig. 147: Aligning Bearing Claw With The Claw Groove Of The Main Bearing Cap And Push
In 4 Lower Bearings
5. Install thrust bearings.
Install the 2 thrust bearings (A) under the No. 3 journal position of the cylinder block with the oil grooves
facing outward.
Fig. 148: Installing 2 Thrust Bearings Under No. 3 Journal Position Of Cylinder Block With Oil
Grooves Facing Outward
6. Place crankshaft (A) on the cylinder block.
Fig. 149: Placing Crankshaft On Cylinder Block

7. Place main bearing caps on cylinder block.

8. Install main bearing cap bolts.
NOTE: The main bearing cap bolts are tightened in 2 progressive steps.
If any of the bearing cap bolts in broken or deformed, replace it.
Tightening torque
Main bearing cap bolt
M8
13 ~ 19Nm (130 ~ 190kgf.cm, 10 ~ 14lbf.ft) + 90° ~ 94°
M10
27 ~ 33Nm (270 ~ 330kgf.cm, 19.5 ~ 24lbf.ft) + 90° - 94°
1. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
2. Install and uniformly tighten the 16 bearing cap bolts, in several passes, in the sequence shown.
Tightening torque
M8 (A): 13 ~ 19Nm (130 ~ 190kgf.cm, 10 ~ 14lbf.ft)
M10 (B): 27 ~ 33Nm (270 ~ 330kgf.cm, 19.5 ~ 24lbf.ft)
Fig. 150: Installing Bearing Cap Bolts

3. Retighten the bearing cap bolts by 90° - 94° in the numerical order shown.
Fig. 151: Identifying Retightening Sequence Of Bearing Cap Bolts

4. Check that the crankshaft turns smoothly.

9. Check crankshaft end play. (See 4 )
10. Install piston and connecting rod assemblies.
NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves
and cylinder bores.
1. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of
the connecting rod bolts.
2. Install the ring compressor, check that the bearing is securely in place, then position the piston in
the cylinder, and tap it in using the wooden handle of a hammer.
3. Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment
before pushing the piston into place.
4. Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque
16 ~ 20Nm (160 ~ 200kgf.cm, 12 ~ 15lbf.ft) + 90° ~ 94°
NOTE: Maintain downward force on the ring compressor to prevent the rings from
expanding before entering the cylinder bore.
Fig. 152: Installing Piston And Connecting Rod Assemblies

11. Apply liquid gasket to the oil seal case and install the oil seal case (A).
Tightening torque
10 ~ 12Nm (100 ~ 120kgf.cm, 7.3 ~ 8.8lbf.ft)
Fig. 153: Install The Oil Seal Case

NOTE: Use liquid gasket MS721-40A or equivalent

Check that the mating surfaces are clean and dry.
12. Install rear oil seal.

1. Apply engine oil to a new oil seal lip.
2. Using SST (09231 -33000) and a hammer, tap in the oil seal until its surface is flush with the rear
oil seal retainer edge.
Fig. 154: Using SST (09231 -33000) And Hammer To Tap In The Oil Seal Until Its Surface Is
Flush With Rear Oil Seal Retainer Edge
13. Install front case. (See INSTALLATION)

14. Install the upper oil pan.
1. Using a razor blade and gasket scraper, remove all the old packing material from the gasket
surfaces.
NOTE: Check that the mating surfaces are clean and dry before applying
liquid gasket.
2. Install the oil pan (A) with the 17 bolts.
Uniformly tighten the bolts in several passes.
Tightening torque
19 ~ 28Nm (190 ~ 280kgf.cm, 14 ~ 20lbf.ft): (bolts 1 ~ 15)
5 ~ 7Nm (50 ~ 70kgf.cm, 4 ~ 5lbf.ft): (bolts 16 & 17)
Fig. 155: Installing Upper Oil Pan

Fig. 156: Identifying Tightening Sequence Of Upper Oil Pan Bolts

NOTE: To prevent leakage of oil, apply liquid gasket to the inner threads of
the bolt holes.
Do not install the parts if five minutes or more have elapsed since
applying the liquid gasket. Instead, reapply liquid gasket after
removing the residue.
After assembly, wait at least 30 minutes before filling the engine with
oil.
15. Install oil screen.
Install a new gasket and oil screen (A) with 2 bolts (B).
Tightening torque
15 ~ 22Nm (150 ~ 220kgf.cm, 11 ~ 16lbf.ft)
Fig. 157: Installing New Gasket And Oil Screen With 2 Bolts
16. Install the lower oil pan.

1. Apply liquid gasket as an even bead, centered between the edges of the mating surface. Use liquid
gasket MS 721-40A or equivalent.
NOTE: To prevent leakage of oil, apply liquid gasket to the inner

threads of the bolt holes.
Do not install the parts if five minutes or more have elapsed
since applying the liquid gasket. Instead, reapply liquid gasket
after removing the residue.
with oil.
2. Install the lower oil pan 10 bolts.
Uniformly tighten the bolts several passes
Tightening torque
10 ~ 12Nm (100 ~ 120kgf.cm, 7.3 ~ 8.8lbf.ft)
Fig. 158: Identifying Tightening Sequence Of Lower Oil Pan Bolts

17. Install oil pressure sensor.

1. Apply adhesive to 2 or 3 threads.
Adhesive: THREE BOND TB2403 or equivalent.
2. Install the oil pressure sensor (A).
Tightening torque
15 ~ 22Nm (150 ~ 220kgf.cm, 11 ~ 16lbf.ft)
Fig. 159: Installing Oil Pressure Sensor

18. Install knock sensor (A).
Tightening torque
17 ~ 26Nm (170 ~ 260kgf.cm, 12.5 ~ 19lbf.ft)
Fig. 160: Installing Knock Sensor

19. Install water pump. (See WATER PUMP )

20. Install the power steering pump bracket (A).
Tightening torque
35 ~ 55Nm (350 ~ 550kgf.cm, 25.8 ~ 40.6lbf.ft)
Fig. 161: Installing Power Steering Pump Bracket

21. Install the air compressor. (See A/C COMPRESSOR CONTROLS (MANUAL) )
22. Install the alternator. (See ALTERNATOR BELT INSPECTION AND ADJUSTMENT )
23. Install oil level gauge assembly.
1. Install a new O-ring on the oil level gauge.
2. Apply engine oil on the O-ring.
3. Install the oil level gauge assembly (A) with the bolt.
Tightening torque
12 ~ 15Nm (120 ~ 150kgf.cm, 9 ~ 11lbf.ft)
24. Install cylinder head. (See INSTALLATION)

25. Install timing belt. (See INSTALLATION)
26. Remove engine stand.
27. Install drive plate.
Tightening torque
73 ~ 77 Nm (730 ~ 770kgf.cm, 53 ~ 56lbf.ft)
COOLING SYSTEM
COMPONENT
Fig. 162: Identifying Cooling System Components And Torque Specifications

ENGINE COOLANT REFILLING AND BLEEDING
WARNING: Never remove the radiator cap when the engine is hot. Serious scalding
could be caused by hot fluid under high pressure escaping from the
radiator.
CAUTION: When pouring engine coolant, be sure to shut the relay box lid and not to
let coolant spill on the electrical parts or the paint. If any coolant spills,
rinse it off immediately.
1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to
the touch.
2. Remove radiator cap.
3. Loosen the drain plug, and drain the coolant.
4. Tighten the radiator drain plug securely.
5. Remove, drain and reinstall the reservoir. Fill the tank halfway to the MAX mark with water, then up to
the MAX mark with antifreeze.
6. Fill fluid mixture with coolant and water slowly through the radiator cap. Gently squeeze the upper/lower
hoses of the radiator so as to bleed air easily.
NOTE: Use only genuine antifreeze/coolant.

For best corrosion protection, the coolant concentration must be
maintained year-round at 50% minimum. Coolant concentrations less
than 50% may not provide sufficient protection against corrosion or
freezing.
Coolant concentrations greater then 60% will impair cooling
efficiency and are not recommended.
CAUTION: Do not mix different brands of antifreeze/coolants.

Do not use additional rust inhibitors or anti-rust products; they
may not be compatible with the coolant.
7. Start the engine and allow coolant to circulates. When the cooling fan operates and coolant circulates,
refill coolant through the radiator cap.
8. Repeat 7 until the cooling fan 3 ~ 5 times and bleed air sufficiently out of the cooling system.
9. Install the radiator cap and fill the reservoir tank to the "MAX" line with coolant.
10. Run the vehicle under idle until the cooling fan operates 2-3 times.
11. Stop the engine and allow coolant to cool.
12. Repeat steps 6 to 11 until the coolant level stays constant and all air is bleed out of the cooling system.
NOTE: Recheck the coolant level in the reservoir tank for 2-3 days after replacing
coolant.
CAP TESTING
1. Remove the radiator cap, wet its seal with engine coolant, then install it on the pressure tester.
Fig. 163: Installing Radiator Cap On Pressure Tester

2. Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm2 , 14 ~ 19psi)

3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.
TESTING
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant,
then install it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm2 14 ~
19psi).
Fig. 164: Applying Pressure Tester To The Radiator And Applying Pressure
3. Inspect for engine coolant leaks and a drop in pressure.

4. Remove the tester and reinstall the radiator cap.
NOTE: Check for engine oil in the coolant and/or coolant in the engine oil.
REMOVAL
WATER PUMP
1. Drain the engine coolant.
WARNING: System is under high pressure when the engine is hot. To avoid
danger of releasing scalding engine coolant, remove the cap only
when the engine is cool.
2. Remove drive belts. (See REMOVAL)

4. Remove the timing belt idler. (See INSPECTION)
5. Remove the water pump.
Remove the water pump (A) and gasket (B).
Fig. 165: Removing Water Pump And Gasket

THERMOSTAT
NOTE: Removal of the thermostat would have an adverse effect, causing a lowering of
cooling efficiency. Do not remove the thermostat, even If the engine tends to
overheat.

2. Drain engine coolant so its level is below thermostat.
3. Remove the lower hose.
4. Remove water inlet (A) and thermostat (B).
Fig. 166: Removing Water Inlet And Thermostat

INSPECTION
WATER PUMP
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump
assembly if necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump
assembly
NOTE: A small amount of "weeping" from the bleed hole is normal.
THERMOSTAT
1. Immerse the thermostat in water and gradually heat the water.
Fig. 167: Immersing Thermostat In Water

2. Check the valve opening temperature.
Valve opening temperature: 82°C (177°F)
Full opening temperature: 95°C (205°F)
If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift.
Valve lift: 10mm (0.4in.) or more at 95°C (205°F)
If the valve lift is not as specified, replace the thermostat.
INSTALLATION
WATER PUMP
1. Install the water pump (A) and a new gasket (B) with the 8 bolts.
Tightening torque
15 ~ 22Nm (150 ~ 220kgf.cm, 11 ~ 16lbf.ft)
Fig. 168: Installing Water Pump And New Gasket

Fig. 169: Installing Water Pump Bolts

WATER PUMP BOLTS NUMBER AND SIZE SPECIFICATION

Bolt Size Number
A 8 x 25 4
B 8 x 30 2
C 8 x 32 1
D 8 x 40 1
2. Install the timing belt idler. (See INSTALLATION)

3. Install the timing belt. (See INSTALLATION)
4. Install drive belt.
5. Fill with engine coolant. (See ENGINE COOLANT REFILLING AND BLEEDING)
6. Start engine and check for leaks.
7. Recheck engine coolant level.
THERMOSTAT
1. Place thermostat in thermostat housing.

1. Install the thermostat with the jiggle valve upward.
2. Install a new to the thermostat (B).
Fig. 170: Installing Water Inlet And Thermostat

2. Install water inlet (A).
Tightening torque
17 ~ 20Nm (170 ~ 200kgf.cm, 12.5 ~ 14lbf.ft)
3. Install the lower hose.
4. Fill with engine coolant.

LUBRICATION SYSTEM
COMPONENT
Fig. 171: Identifying Lubrication System Components And Torque Specifications

OIL AND FILTER
CAUTION: Prolonged and repeated contact with mineral oil will result in the
removal of natural fats from the skin, leading to dryness, irritation
and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
Exercise caution in order to minimize the length and frequency of
contact of your skin to used oil. Wear protective clothing and gloves.
Wash your skin thoroughly with soap and water, or use waterless
hand cleaner, to remove any used engine oil. Do not use gasoline,
thinners, or solvents.
In order to preserve the environment, used oil and used oil filter must
be disposed of only at designated disposal sites.
1. Drain engine oil.

a. Remove the oil filter cap.
b. Remove the oil drain plug (A), and drain the oil into a container.
Fig. 172: Removing Oil Drain Plug And Oil Filter

2. Replace oil filter.

a. Remove the oil filter (B).
b. Check and clean the oil filter installation surface.
c. Check the part number of the new oil filter is as same as old one.
d. Apply clean engine oil to the gasket of a new oil filter.
e. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
f. Tighten it an additional 3/4 turn.
3. Refill with engine oil filter.
Clean and install the oil drain plug with a new gasket.
Tightening torque
35 ~ 45Nm (350 ~ 450kgf.cm, 26 ~ 33lbf.ft)
Fill with fresh engine oil
Capacity
Drain and refill
W/Oil filter change: 4.5I (4.74U.S.qts, 3.95lmp qts)
W/O Oil filter change: 4.2I (4.30U.S.qts, 3.65lmp qts)
Install the oil filter cap.

4. Start engine and check for oil leaks.
5. Recheck engine oil level.
INSPECTION
1. Check engine oil quality
Check the oil for deterioration, entry of water, discoloring or thinning.
If the quality is visibly poor, replace the oil.
2. Check engine oil level.
After warming up the engine and then 5 minutes after the engine stop, oil level should be between the "L"
and "F" marks on the dipstick.
If low, check for leakage and add oil up to the "F" mark.
NOTE: Do not fill with engine oil above the "F" mark.
SELECTION OF ENGINE OIL
Recommended API classification: SH OR ABOVE
Fig. 173: Recommended SAE Viscosity Grades Chart

NOTE: For best performance and maximum protection of all types of operation, select
only those lubricants which:
1. Satisfy the requirement of the API classification.

2. Have proper SAE grade number for expected ambient temperature range.
Lubricants that do not have both an SAE grade number and API service classification on the container should
not be used.
REMOVAL
1. Drain engine oil.

2. Remove RH front wheel.
3. Remove RH side cover.
4. Remove the front exhaust pipe. (See step 20 )
5. Remove the alternator from engine. (See ALTERNATOR BELT INSPECTION AND
ADJUSTMENT )
6. Remove the drive belt. (See REMOVAL)
7. Turn the crankshaft and align the white groove on the crankshaft pulley with the pointer on the lower
cover. (See step 4 )
9. Remove the oil pan and oil screen. (See DISASSEMBLY)
10. Remove the oil pump case (A).
Fig. 174: Removing Oil Pump Case

1. Remove the screws (B) from the pump housing, then separate the housing and cover (A).
Fig. 175: Removing Screws From Pump Housing And Separating Housing And Cover
2. Remove the inner and outer rotors.
DISASSEMBLY
1. Remove the relief plunger.
Remove the plug (A), spring (B) and relief plunger (C).
Fig. 176: Removing Plug, Spring And Relief Plunger

INSPECTION
1. Inspect relief plunger.
Coat the valve with engine oil and check that it falls smoothly into the plunger hole by its own weight. If
it does not, replace the relief plunger. If necessary, replace the front case.
2. Inspect relief valve spring.
Inspect for distorted or broken relief valve spring.
Standard value
Free height: 43.8mm (91.724in.)
Load: 4.6kg/39.1mm (10lb/1.547in.)
3. Inspect rotor side clearance.
Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision
straight edge.
Side clearance
0.040 ~ 0.095mm (0.0016 ~ 0.0037in.)
Fig. 177: Using Feeler Gauge And Precision Straight Edge To Measure The Clearance Between The
Rotors And Precision Straight Edge

If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front
case.
4. Inspect rotor body clearance.
Using a feeler gauge, measure the clearance between the outer rotor and body.
Body clearance
0.100 ~ 0.181mm (0.0039 ~ 0.0071 in.)
Fig. 178: Using Feeler Gauge To Measure The Clearance Between The Outer Rotor And Body
If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front
case.
REASSEMBLY
1. Install relief plunger.
Install relief plunger (C) and spring (B) into the front case hole, and install the plug (A).
Tightening torque
40 ~ 50Nm (400 ~ 500kgf.cm, 30 ~ 37lb.ft)
Fig. 179: Installing Relief Plunger, Spring And Plug

INSTALLATION
1. Install oil pump.

1. Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
2. Install the oil pump cover (A) to front case with the 8 screws (B).
Tightening torque
8 ~ 12Nm (80 ~ 120kgf.cm, 6 ~ 8.8lbf.ft)
Fig. 180: Installing Oil Pump Cover To Front Case With 8 Screws
2. Check that the oil pump turns freely.

3. Install the oil pump on the cylinder block.
1. Remove any old liquid gasket and be careful not to drop any oil on the contact surfaces of the oil
pump and cylinder block.
Using a razor blade and gasket scraper, remove all the old liquid gasket from the gasket
surfaces and sealing grooves.
Using a non-residue solvent, clean both sealing surfaces.

2. Apply liquid gasket to the oil pump as shown in the illustration.
Use liquid gasket MS 721-40A.
Fig. 181: Applying Liquid Gasket To Oil Pump

NOTE: To prevent leakage of oil, apply liquid gasket to the inner

threads of the bolt holes.
Do not install the parts if five minutes or more have elapsed
since applying the liquid gasket. Instead, reapply liquid gasket
after removing the residue.
with oil.
3. Place a new O-ring on the cylinder block.

4. Engage the spline teeth of the oil pump drive gear with large teeth of the crankshaft, and slide the
oil pump on the crankshaft.
5. Install the oil pump with 5 bolts.
Uniformly tighten the bolts in several passes.
Tightening torque
12 ~ 15Nm (120 ~ 150kgf.cm, 8.8 ~ 11lbf.ft)
Fig. 182: Installing Oil Pump Bolts

OIL PUMP BOLT SIZE AND NUMBER SPECIFICATIONS

Bolt Size Number
A 8 x 25 3
B 8 x 35 1
C 8 x 45 1
4. Apply a light coat of oil to the seal lip.

5. Using the special tool (09214-33000), install the oil seal.
Fig. 183: Installing Oil Seal Using Special Tool (09214-33000)

6. Install the oil pan and oil screen. (See step 15 for oil screen and 16 for oil pan )
7. Install the timing belt. (See INSTALLATION)
8. Install the drive belt.
9. Install the alternator. (See ALTERNATOR BELT INSPECTION AND ADJUSTMENT )
10. Install the front exhaust pipe. (See EXHAUST MANIFOLD)
11. Install the RH front wheel.
12. Fill engine with oil.
14. Recheck engine oil level.
INTAKE AND EXHAUST SYSTEM

COMPONENT
INTAKE MANIFOLD
Fig. 184: Identifying Intake Manifold Components And Torque Specifications

EXHAUST MANIFOLD
Fig. 185: Identifying Exhaust Manifold Components And Torque Specifications

MUFFLER
Fig. 186: Identifying Muffler Components And Torque Specifications

REMOVAL
INTAKE MANIFOLD

2. Remove air cleaner hose.
3. Remove surge tank assembly.
1. Disconnect the accelerator cable.
2. Disconnect the TPS connector.
3. Disconnect the ISA connector.

4. Disconnect the injector connector.
5. Disconnect the PCSV connector.
6. Disconnect the PCSV hose.
7. Disconnect the brake booster vacuum hose (A).
Fig. 187: Disconnecting Brake Booster Vacuum Hose

8. Disconnect the PCV hose.

9. Disconnect the IAT sensor connector.
10. Remove the surge tank stay.
11. Remove the surge tank assembly.
4. Remove the injector assembly (A).
Fig. 188: Removing Injector Assembly

5. Remove the intake manifold (A) and gasket.
Fig. 189: Removing Intake Manifold And Gasket

EXHAUST MANIFOLD
1. Remove the under cover.

2. Remove the front exhaust pipe (A).
Fig. 190: Removing Front Exhaust Pipe

3. Disconnect the oxygen sensor connector.

4. Remove the heat protector (A).
Fig. 191: Removing Heat Protector

5. Remove the exhaust manifold (A) and gasket (B).
Fig. 192: Removing Exhaust Manifold And Gasket

INSTALLATION
INTAKE MANIFOLD
1. Install the intake manifold and gasket.
Tightening torque
19 ~ 21 Nm (190 ~ 210kgf.cm, 14 ~ 15lbf.ft)
Fig. 193: Installing Intake Manifold And Gasket

2. Install the injector assembly. (See FUEL SYSTEM (G6BA-GSL 2.7) )

3. Install the surge tank assembly.
1. Install the surge tank assembly.
Tightening torque
15 ~ 20Nm (150 ~ 200kgf.cm, 11 ~ 15lbf.ft)
2. Install the surge tank stay.
Tightening torque
15 ~ 20Nm (150 ~ 200kgf.cm, 11 ~ 15lbf.ft)
3. Install the ground cable.

4. Connect the IAT sensor connector.
5. Connect the PCV hose.
6. Connect the brake booster vacuum hose.

7. Connect the PCSV hose.
8. Connect the PCSV connector.
9. Connect the injector connector.
10. Connector the ISA connector.
11. Connector the TPS connector.
12. Connector the actuator cable.
4. Install the air cleaner hose.
5. Install the engine cover.
EXHAUST MANIFOLD
1. Install the exhaust manifold (A) and gasket (B).
Tightening torque
30 ~ 35Nm (300 ~ 350kgf.cm, 22 ~ 26lbf.ft)
Fig. 194: Installing Exhaust Manifold And Gasket

2. Install the heat protector (A).
Tightening torque
17 ~ 22Nm (170 ~ 220kgf.cm, 12 ~ 16lbf.ft)
Fig. 195: Installing Heat Protector

3. Connect the oxygen sensor connector.

4. Install the front exhaust pipe (A).
Tightening torque
30 ~ 40Nm (300 ~ 400kgf.cm, 22 ~ 30lbf.ft)
Fig. 196: Installing Front Exhaust Pipe

5. Install the under cover.

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2005 Hyundai Tiburon GT

2005 ENGINE Engine Mechanical System (G6BA-GSL 2.7L) - Tiburon

Engine Mechanical System (G6BA-GSL 2.7L) - Tiburon

viernes, 19 de febrero de 2021 08:16:29

0.05 (0.002) O.S. 11.05 ~ 11.068mm (0.435 ~

No.2 1.220 ~ 1.240mm (0.0480 ~

Taper of journal and pin Max. 0.005mm (0.00020in.)

TIGHTENING TORQUE SPECIFICATIONS

Oil pump case bolt 12 ~ 15 120 ~ 150 9 ~ 11

Main muffler hanger 10 ~ 15 100 ~ 150 7 ~ 11

1. Warm up and stop engine

Allow the engine to warm up to normal operating temperature.

2. Remove ignition coils. (See IGNITION SYSTEM )

Using a 16mm plug wrench, remove the 6 spark plugs.

4. Check cylinder compression pressure

Fig. 1: Inserting Compression Gauge Into Spark Plug Hole

b. While cranking the engine, measure the compression pressure.

c. Repeat steps (a) through (b) for each cylinder.

NOTE: This measurement must be done in as short a time as possible.

1,420kPa (14.5kgf/cm2 , 206psi)

1,270kPa (13kgf/cm2 , 184psi)

Difference between each cylinder:

100kPa (1.0kgf/cm2 , 15psi) or less

consumption stem oil seals.

The connecting rod

The crankshaft bearing.

The connecting rod

The crankshaft bearings.

Camshaft oil seal installer Installation of the camshaft oil

Valve guide installer (09221- Remove and installation of the

Valve spring compressor & Removal and installation of the

Crankshaft rear oil seal installer 1. Installation of the engine

Fig. 2: Identifying Timing System Components And Torque Specifications.

Engine removal is not required for this procedure.

1. Remove the engine cover.

Fig. 3: Removing 2 Bolts And RH Side Cover

NOTE: Always turn the crankshaft clockwise.

5. Remove drive belt (A) and belt tensioner (B).

Fig. 5: Removing Drive Belt And Belt Tensioner

6. Remove the engine mount bracket.

Fig. 6: Setting Jack To Engine Oil Pan

2. Remove the 2 bolts, 2 nuts and engine mount bracket (A).

Fig. 7: Removing 2 Bolts, 2 Nuts And Engine Mount Bracket

Fig. 8: Removing 7 Bolts And Timing Belt Upper Cover

9. Remove the crankshaft pulley bolt and crankshaft pulley (A).

Fig. 9: Removing Crankshaft Pulley Bolt And Crankshaft Pulley

10. Remove the drive belt idler pulley (A).

Fig. 10: Removing Drive Belt Idler Pulley

Fig. 11: Removing 4 Bolts And Timing Belt Lower Cover

12. Remove the engine support bracket (A).

Fig. 12: Removing Engine Support Bracket

Alternately loosen the 2 bolts, and remove the tensioner (A).

Fig. 13: Loosening 2 Bolts And Removing Tensioner

15. Remove the timing belt (A).

Fig. 14: Removing Timing Belt

17. Remove the crankshaft sprocket.

SPROCKETS, TENSIONER, IDLER

3. Replace the pulley if there is a grease leak from its bearing.

1. Check the belt for oil or dust deposits.