Specifications
| Description | Specifications | Limit | ||
|---|---|---|---|---|
| General | ||||
| Type | V-type, DOHC | |||
| Number of cylinders | 6 | |||
| Bore | 92mm (3.6220in.) | |||
| Stroke | 87.0mm (3.4252in.) | |||
| Total displacement | 3, 470cc (211.75cu.in.) | |||
| Compression ratio | 10.6 | |||
| Firing order | 1-2-3-4-5-6 | |||
| Valve timing | ||||
| Intake | Opens (ATDC) | 10° | ||
| Closes (ABDC) | 74° | |||
| Exhaust | Opens (BBDC) | 52° | ||
| Closes (ATDC) | 0° | |||
| Cylinder head | ||||
| Flatness of gasket surface | Less than 0.05mm (0.0019in.) [Less than 0.02mm (0.0008in.)/150x150] | |||
| Flatness of manifold mounting | Intake | Less than 0.1mm (0.0039in.) [Less than 0.03mm (0.001in.)/110x110] | ||
| Exhaust | Less than 0.1mm (0.0039in.) [Less than 0.03mm (0.001in.)/110x110] | |||
| Camshaft | ||||
| Cam height | LH Camshaft | Intake | 47.2mm (1.8582in.) | |
| Exhaust | 45.8mm (1.8031in.) | |||
| RH Camshaft | Intake | 47.2mm (1.8582in.) | ||
| Exhaust | 45.8mm (1.8031in.) | |||
| Journal outer diameter | LH, RHcamshaft | Intake | No. 1: 27.964 ~ 27.978mm (1.1009 ~ 1.1015in.) No. 2, 3, 4: 23.954 ~ 23.970mm (0.9430 ~ 0.9437in.) | |
| Exhaust | No. 1: 27.964 ~ 27.978mm (1.1009 ~ 1.1015in.) No. 2, 3, 4: 23.954 ~ 23.970mm (0.9430 ~ 0.9437in.) | |||
| Bearing oil clearance | LH, RHcamshaft | Intake | No. 1: 0.027 ~ 0.057mm (0.0011 ~ 0.0022in.) No. 2, 3, 4: 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.) | |
| Exhaust | No. 1: 0.027 ~ 0.057mm (0.0011 ~ 0.0022in.) No. 2, 3, 4: 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.) | |||
| End play | 0.02 ~ 0.18mm (0.0008 ~ 0.0071in.) | |||
| Valve | ||||
| Valve length | Intake | 105.27mm (4.1445in.) | ||
| Exhaust | 105.50mm (4.1535in.) | |||
| Stem outer diameter | Intake | 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.) | ||
| Exhaust | 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.) | |||
| Face angle | 45.25° ~ 45.75° | |||
| Thickness of valve head (margin) | Intake | 1.56 ~ 1.86mm (0.06142 ~ 0.07323in.) | ||
| Exhaust | 1.73 ~ 2.03mm (0.06811 ~ 0.07992in.) | |||
| Valve stem to valve guide clearance | Intake | 0.020 ~ 0.047mm (0.00078 ~ 0.00185in.) | 0.07mm (0.00275in.) | |
| Exhaust | 0.030 ~ 0.054mm (0.00118 ~ 0.00212in.) | 0.09mm (0.00354in.) | ||
| Valve guide | ||||
| Inner diameter | Intake | 5.500 ~ 5.512mm (0.2165 ~ 0.2170in.) | ||
| Exhaust | 5.500 ~ 5.512mm (0.2165 ~ 0.2170in.) | |||
| Length | Intake | 41.8 ~ 42.2mm (1.6457 ~ 1.6614in.) | ||
| Exhaust | 41.8 ~ 42.2mm (1.6457 ~ 1.6614in.) | |||
| Valve seat | ||||
| Width of seat contact | Intake | 1.15 ~ 1.45mm (0.05118 ~ 0.05709in.) | ||
| Exhaust | 1.35 ~ 1.65mm (0.05315 ~ 0.06496in.) | |||
| Seat angle | Intake | 44.75° ~ 45.20° | ||
| Exhaust | 44.75° ~ 45.20° | |||
| Valve spring | ||||
| Free length | 45.5mm (1.7913in.) | |||
| Load | 19.3±0.8kg/34.0mm (42.7±1.8 lb/1.3386in.) | |||
| 42.3±1.3kg/23.8mm (93.3±2.9 lb/0.9370in.) | ||||
| Out of squareness | Less than 1.5° | |||
| MLA | ||||
| MLA outer diameter | Intake | 34.964 ~ 34.980mm (1.3765 ~ 1.3772in.) | ||
| Exhaust | 34.964 ~ 34.980mm (1.3765 ~ 1.3772in.) | |||
| Cylinder head tappet bore inner diameter | Intake | 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.) | ||
| Exhaust | 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.) | |||
| MLA to tappet bore clearance | Intake | 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) | 0.07mm (0.0027in.) | |
| Exhaust | 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) | 0.07mm (0.0027in.) | ||
| Valve clearance (At 20°C [68°F]) | ||||
| Intake | 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.) | 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.) | ||
| Exhaust | 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.) | 0.20 ~ 0.40mm (0.0078 ~ 0.0157in.) | ||
| Cylinder block | ||||
| Cylinder bore | 92.00 ~ 92.03mm (3.6220 ~ 3.6232in.) | |||
| Flatness of gasket surface | Less than 0.05mm (0.0019in.) [Less than 0.02mm (0.0008in.)/150x150] | |||
| Piston | ||||
| Piston outer diameter | 91.96 ~ 91.99mm (3.6204 ~ 3.6216in.) | |||
| Piston to cylinder clearance | 0.03 ~ 0.05mm (0.0012 ~ 0.0020in.) | |||
| Ring groove width | No. 1 ring groove | 1.23 ~ 1.25mm (0.0484 ~ 0.0492in.) | ||
| No. 2 ring groove | 1.23 ~ 1.25mm (0.0484 ~ 0.0492in.) | |||
| Oil ring groove | 2.01 ~ 2.03mm (0.0791 ~ 0.0799in.) | |||
| Piston ring | ||||
| Side clearance | No. 1 ring | 0.04 ~ 0.08mm (0.0015 ~ 0.0031in.) | 0.1mm (0.004in.) | |
| No. 2 ring | 0.04 ~ 0.08mm (0.0015 ~ 0.0031in.) | 0.1mm (0.004in.) | ||
| Oil ring | 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.) | 0.2mm (0.008in.) | ||
| End gap | No. 1 ring | 0.17 ~ 0.32mm (0.0067 ~ 0.0126in.) | 0.6mm (0.0236in.) | |
| No. 2 ring | 0.37 ~ 0.52mm (0.0145 ~ 0.0204in.) | 0.7mm (0.0275in.) | ||
| Oil ring | 0.20 ~ 0.50mm (0.0078 ~ 0.0196in.) | 0.8mm (0.0315in.) | ||
| Piston pin | ||||
| Piston pin outer diameter | 21.097 ~ 22.000mm (0.8305 ~ 0.8661in.) | |||
| Piston pin hole inner diameter | 22.004 ~ 22.010mm (0.8662 ~ 0.8665in.) | |||
| Piston pin hole clearance | 0.004 ~ 0.013mm (0.00015 ~ 0.00051in.) | |||
| Connecting rod small end inner diameter | 22.005 ~ 22.016mm (0.8663 ~ 0.8667in.) | |||
| Connecting rod small end hole clearance | 0.005 ~ 0.019mm (0.00019 ~ 0.00074in.) | |||
| Connecting rod | ||||
| Connecting rod big end inner diameter | 58.000 ~ 58.018mm (2.2834 ~2.2842in.) | |||
| Connecting rod bearing oil clearance | 0.038 ~ 0.056mm (0.0014 ~ 0.0022in.) | |||
| Side clearance | 0.1 ~ 0.25mm (0.0039 ~ 0.0098in.) | |||
| Crankshaft | ||||
| Main journal outer diameter | 68.942 ~ 68.960mm (2.7142 ~ 2.7149in.) | |||
| Pin journal outer diameter | 54.954 ~ 54.972mm (2.1635 ~ 2.1642in.) | |||
| Main bearing oil clearance | 0.022 ~ 0.040mm (0.0008 ~ 0.0016in.) | |||
| End play | 0.10 ~ 0.28mm (0.0039 ~ 0.0110in.) | |||
| Oil pump | ||||
| Regulating pressure | 400 ~ 450kPa (4.08 ~ 4.59kgf/cm 2 , 58.01 ~ 65.27psi) | |||
| Engine oil | ||||
| Oil quantity | Total | 6.0 L (6.34 US qt, 5.28 lmp.qt) | ||
| Oil pan | 5.5 L (5.81 US qt, 4.84 lmp.qt) | |||
| Drain and refill | 5.2 L (5.49 US qt, 4.58 lmp.qt) | Including oil filter | ||
| Oil grade | Recommendation | 5W-20/GF4&SM | If not available, refer to the recommended API or ILSAC classification and SAE viscosity number. | |
| Classification | API SL, SM or above ILSAC GF3, GF4 or above | Satisfy the requirement of the API or ILSAC classification. | ||
| SAE viscosity grade | Recommended SAE viscosity number | Refer to the LUBRICATION SYSTEM . | ||
| Oil pressure (at 1000rpm) | 130kPa (1.32kgf/cm 2 , 18.77psi) [at 1000rpm, 110°C (230°F)] | Oil temperature (oil pan): 110±2°C (230±35.6°F) | ||
| Cooling system | ||||
| Cooling method | Forced circulation with water pump | |||
| Coolant quantity | 8.3 L (8.8 us.qts, 7.3 lmp.qts) | |||
| Thermostat | Type | Wax pellet type | ||
| Opening temperature | 82±2°C (179.6±35.6°F) | |||
| Fully opened temperature | 95°C (203°F) | |||
| Full lift | 10mm (0.3937in.) MIN | |||
| Radiator cap | Main valve opening pressure | 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm 2 , 13.51 ~ 17.78psi) | ||
| Vacuum valve opening pressure | 0 ~ 6.86 kpa (0 ~ 0.07kg/cm 2 , 0 ~ 0.99psi) | |||
| Water temperature sensor | ||||
| Type | Thermister type | |||
| Resistance | 20°C (68°F) | 2.31 ~ 2.59Kohms | ||
| 80°C (176°F) | 0.3222 Kohms | |||
ENGINE MECHANICAL SYSTEM SPECIFICATIONS
Tightening Torques
| Item | Quantity | Nm | Kgf.m |
|---|---|---|---|
| Crankshaft pulley bolt | 1 | 284.4 ~ 304.0 | 29.0 ~ 31.0 |
| Timing chain cover bolt B | 17 | 18.6 ~ 21.6 | 1.9 ~ 2.2 |
| Timing chain cover bolt C | 4 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Timing chain cover bolt D | 2 | 58.8 ~ 68.6 | 6.0 ~ 7.0 |
| Timing chain cover bolt F | 2 | 24.5 ~ 26.5 | 2.5 ~ 2.7 |
| Timing chain cover bolt G | 4 | 21.6 ~ 23.5 | 2.2 ~ 2.4 |
| Timing chain cover bolt H | 1 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Timing chain cover bolt I | 1 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Timing chain cover bolt J | 1 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Timing chain cover bolt K | 4 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Timing chain cover bolt L | 1 | 21.6 ~ 26.5 | 2.2 ~ 2.7 |
| Timing chain auto tensioner bolt | 2 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Timing chain auto tensioner nut | 2 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Timing chain auto tensioner arm bolt | 2 | 18.6 ~ 21.6 | 1.9 ~ 2.2 |
| Timing chain guide bolt | 4 | 19.6 ~ 24.5 | 2.0 ~ 2.5 |
| Oil pump chain cover bolt | 2 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Oil pump chain tensioner bolt | 1 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Oil pump chain guide bolt | 2 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Oil pump chain sprocket bolt | 1 | 18.6 ~ 21.6 | 1.9 ~ 2.2 |
| Lower oil pan bolt | 13 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Drive belt auto tensioner bolt (M12) | 1 | 81.4 ~ 85.3 | 8.3 ~ 8.7 |
| Drive belt auto tensioner bolt (M8) | 1 | 17.7 ~ 21.6 | 1.8 ~ 2.2 |
| Drive belt idler bolt | 1 | 53.9 ~ 57.9 | 5.5 ~ 5.9 |
| OCV (oil control valve) bolt | 2 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Cylinder head bolt | 16 | (37.3~41.2) + (118~122°) + (88~92°) | (3.8~4.2) + (118~122°) + (88~92°) |
| Cylinder head bolt | 1 | 18.6 ~ 23.5 | 1.9 ~ 2.4 |
| CVVT bolt | 4 | 64.7 ~ 76.5 | 6.6 ~ 7.8 |
| Camshaft bearing cap bolt | 32 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Cylinder head cover bolt | 38 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Connecting rod bolt | 12 | (17.7~21.6) + (88~92°) | (1.8~2.2) + (88~92°) |
| Main bearing cap inner bolt (M11) | 8 | 49.0 + 90° | 5.0 + 90° |
| Main bearing cap outer bolt (M8) | 8 | 19.6 + 120° | 2.0 + 120° |
| Main bearing cap side bolt (M8) | 8 | 29.4 ~ 31.4 | 3.0 ~ 3.2 |
| Oil drain cover bolt | 6 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Oil jet bolt | 3 | 27.5 ~ 31.3 | 2.8 ~ 3.2 |
| Rear oil seal case bolt | 6 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Baffle plate bolt | 6 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Upper oil pan bolt | 16 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Knock sensor bolt | 2 | 15.7 ~ 23.5 | 1.6 ~ 2.4 |
| Drive plate bolt | 8 | 71.54 ~ 75.46 | 7.3 ~ 7.7 |
| Oil filter cap | 24.5 | 2.5 | |
| Oil drain bolt | 1 | 34.3 ~ 44.1 | 3.5 ~ 4.5 |
| Oil pump bolt | 3 | 20.6 ~ 22.6 | 2.1 ~ 2.3 |
| Oil filter body bolt | 4 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Oil cover bolt | 4 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Water pump bolt (Timing chain cover bolt L) | 1 | 21.6 ~ 26.5 | 2.2 ~ 2.7 |
| Water pump bolt (Timing chain cover bolt K) | 4 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Water pump bolt (Timing chain cover bolt G) | 4 | 21.6 ~ 23.5 | 2.2 ~ 2.4 |
| Water pump pulley bolt | 4 | 7.8 ~ 9.8 | 0.8 ~ 1.0 |
| Water temp. control nut | 4 | 18.6 ~ 23.5 | 1.9 ~ 2.4 |
| Water temp. control bolt | 2 | 18.6 ~ 23.5 | 1.9 ~ 2.4 |
| Water inlet pipe bolt | 3 | 16.7 ~ 19.6 | 1.7 ~ 2.0 |
| Intake manifold bolt | 6 | 26.5 ~ 31.4 | 2.7 ~ 3.2 |
| Intake manifold nut | 2 | 18.6 ~ 23.5 | 1.9 ~ 2.4 |
| Surge tank bolt (M6 x 36) | 3 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Surge tank bolt (M6 x 128) | 2 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Surge tank nut | 2 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Surge tank stay bolt (M10 x 20) | 2 | 27.5 ~ 31.4 | 2.8 ~ 3.2 |
| Exhaust manifold nut | 16 | 39.2 ~ 44.1 | 4.0 ~ 4.5 |
| Exhaust manifold stay bolt | 4 | 24.5 ~ 35.3 | 2.5 ~ 3.6 |
| Heat protector bolt | 4 | 9.8 ~ 11.8 | 1.0 ~ 1.2 |
| Front muffler bolt | 2 | 39.2 ~ 53.9 | 4.0 ~ 5.5 |
| Front muffler nut | 4 | 39.2 ~ 53.9 | 4.0 ~ 5.5 |
| Center muffler nut | 2 | 39.2 ~ 58.8 | 4.0 ~ 6.0 |
| Main muffler nut | 2 | 39.2 ~ 58.8 | 4.0 ~ 6.0 |
| Air cleaner assembly bolt | 2 | 7.8 ~ 9.8 | 0.8 ~ 1.0 |
| Intake air hose clamp bolt | 1 | 2.9 ~ 4.9 | 0.3 ~ 0.5 |
TIGHTENING TORQUE SPECIFICATIONS
Compression Pressure
Note. If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
Scheme 191
Scheme 192
- Warm up engine until the normal operating temperature (80~95°C (176-203°F)).
- Remove the surge tank. (Refer to «INTAKE AND EXHAUST SYSTEM»(/hyundai/santa-fe/ii-2010-2012/remont/exhaust/#intake-and-exhaust-system-g35-dohc) .)
- Remove the ignition coil connectors (A) and ignition coils (B).
- Remove the spark plugs. Using a 16mm plug wrench, remove the 6 spark plugs.
- Check cylinder compression pressure. Insert a compression gauge into the spark plug hole. Fully open the throttle. Crank the engine over 7 times to measure compression pressure. NOTE: Always use a fully charged battery to obtain engine speed of 250 rpm or more. Repeat step 1 ) though 3 ) for each cylinder. NOTE: This measurement must be done in as short a time as possible. Compression pressure : 1, 029kPa (10.5kgf/cm 2 , 149psi) (250~400 rpm) Minimum pressure : 882kPa (9.0kgf/cm 2 , 128psi) 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 step 1 ) through 3 ) 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.
- Reinstall the spark plugs.
- Install the ignition coils and ignition connectors.
- Install the surge tank. (Refer to «INTAKE AND EXHAUST SYSTEM»(/hyundai/santa-fe/ii-2010-2012/remont/exhaust/#intake-and-exhaust-system-g35-dohc) .)
Valve Clearance Inspection And Adjustment
Note. Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C (68°F)) and cylinder head is installed on the cylinder block.
Scheme 193
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Scheme 201
Scheme 202
Scheme 203
Scheme 204
Scheme 205
Scheme 206
Scheme 207
Scheme 208
Scheme 209
Scheme 210
- Remove the engine cover.
- Remove the engine side cover.
- Remove air cleaner assembly.
- Remove the surge tank. (Refer to «INTAKE AND EXHAUST SYSTEM»(/hyundai/santa-fe/ii-2010-2012/remont/exhaust/#intake-and-exhaust-system-g35-dohc) .)
- Remove the cylinder head cover. (Refer to «TIMING SYSTEM»(/hyundai/santa-fe/ii-2010-2012/remont/mechanical/#timing-system-g35-dohc) .)
- Set No. 1 cylinder to TDC/compression. Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the lower timing chain cover. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft clockwise one revolution (360°). NOTE: Do not rotate engine counterclockwise.
- Inspect the valve clearance. With No. 1 cylinder at TDC inspect clearances only on the valves shown in diagram below. Measurement method. Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting tappet. Valve clearance Specification Engine coolant temperature : 20°C [68°F] Limit Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.) Exhaust : 0.20 ~ 0.40mm (0.0078 ~ 0.0157in.) Turn the crankshaft pulley clockwise one revolution (360°) and align the groove with timing mark "T" of the lower timing chain cover. With No. 4 cylinder at TDC inspect clearances only the valves shown in diagram below. (Refer to procedure step 1 .)
- Adjust the intake and exhaust valve clearance. Set the No. 1 cylinder to the TDC/compression. Remove the timing chain. NOTE: Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased. Remove the LH/RH exhaust camshaft OCV (A). Remove the LH/RH camshaft bearing cap (A) and thrust bearing cap (B). Remove the LH/RH camshaft assembly (A). Remove the MLA. Measure the thickness of the removed tappet using a micrometer. Calculate the thickness of a new tappet so that the valve clearance comes within the specified value. T : Thickness of removed tappet A : Measured valve clearance N : Thickness of new tappet Intake : N = T + [A - 0.20mm (0.0079in.)] Exhaust : N = T + [A - 0.30mm (0.0118in.)] Select a new tappet with a thickness as close as possible to the calculated value. NOTE: Shims are available in 41size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.600mm (0.1417in.) Place a new tappet on the cylinder head. NOTE: Apply engine oil at the selected tappet on the periphery and top surface. Install the intake and exhaust camshaft. Install the bearing caps. (Refer to «CYLINDER HEAD ASSEMBLY»(/hyundai/santa-fe/ii-2010-2012/remont/mechanical/#cylinder-head-assembly-g35-dohc) .) Install the timing chain. (Refer to «TIMING SYSTEM»(/hyundai/santa-fe/ii-2010-2012/remont/mechanical/#timing-system-g35-dohc) .) Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and camshaft sprocket timing marks (A). Recheck the valve clearance. Valve clearance (Engine coolant temperature : 20°C [68°F]) [Specification] Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.) Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)
Troubleshooting
| Symptom | Suspect area | Remedy |
|---|---|---|
| Engine misfire with abnormal internal lower engine noises. | Worn crankshaft bearings. Loose or damaged engine drive plate. | Replace the crankshaft and bearings as required. Repair or replace the drive plate as required. |
| Worn piston rings. (Oil consumption may or may not cause the engine to misfire.) | Inspect the cylinder for a loss of compression. Repair or replace as required. | |
| Worn crankshaft thrust bearings | Replace the crankshaft and bearings as required. | |
| Engine misfire with abnormal valve train noise. | Stuck valves. (Carbon buildup on the valve stem) | Repair or replace as required. |
| Excessive worn or mis-aligned timing chain. | Replace the timing chain and sprocket as required. | |
| Worn camshaft lobes. | Replace the camshaft and valve lifters. | |
| Engine misfire with coolant consumption. | Faulty cylinder head gasket and/or cranking or other damage to the cylinder head and engine block cooling system Coolant consumption may or may not cause the engine to overheat. | Inspect the cylinder head and engine block for damage to the coolant passages and/or a faulty head gasket. Repair or replace as required. |
| Engine misfire with excessive oil consumption. | Worn valves, guides and/or valve stem oil seals. | Repair or replace as required. |
| Worn piston rings. (Oil consumption may or may not cause the engine to misfire) | Inspect the cylinder for a loss of compression. Repair or replace as required. | |
| Engine noise on start-up, but only lasting a few seconds. | Incorrect oil viscosity. | Drain the oil. Install the correct viscosity oil. |
| Worn crankshaft thrust bearing. | Inspect the thrust bearing and crankshaft. Repair or replace as required. | |
| Upper engine noise, regardless of engine speed. | Low oil pressure. | Repair or replace as required. |
| Broken valve spring. | Replace the valve spring. | |
| Worn or dirty valve lifters. | Replace the valve lifters. | |
| Stretched or broken timing chain and/or damaged sprocket teeth. | Replace the timing chain and sprockets. | |
| Worn timing chain tensioner, if applicable. | Replace the timing chain tensioner 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 stem or valve seat may cause the valve to stay open. | Inspect the valves and valve guides, then repair as required. | |
| Worn drive belt, idler, tensioner and bearing. | Replace as required. | |
| Lower engine noise, regardless of engine speed. | Low oil pressure. | Repair as required. |
| Loose or damaged drive plate. | Repair or replace the drive plate. | |
| Damaged oil pan, contacting the oil pump screen. | Inspect the oil pan. Inspect the oil pump screen. Repair or replace as required. | |
| Oil pump screen loose, damaged or restricted. | Inspect the oil pump screen. Repair or replace as required. | |
| Excessive piston-to-cylinder bore clearance. | Inspect the piston, piston pin and cylinder bore. Repair as required. | |
| Excessive piston pin-to-piston clearance. | Inspect the piston, piston pin and the connecting rod. Repair or replace as required. | |
| Excessive connecting rod bearing clearance | Inspect the following components and repair as required. The connecting rod bearings. The connecting rods. The crankshaft pin journals. | |
| Excessive crankshaft bearing clearance. | Inspect the following components, and repair as required. The crankshaft bearings. The crankshaft main journals. The cylinder block. | |
| Incorrect piston, piston pin and connecting rod installation | Verify the piston pins and connecting rods are installed correctly. Repair as required. | |
| Engine noise under load. | Low oil pressure | Repair or replace as required. |
| Excessive connecting rod bearing clearance. | Inspect the following components and repair as required: The connecting rod bearings. The connecting rods. The crankshaft. | |
| Excessive crankshaft bearing clearance. | Inspect the following components, and repair as required. The crankshaft bearings. The crankshaft main journals. The cylinder block. | |
| Engine will not crank-crankshaft will not rotate. | Hydraulically locked cylinder. Coolant/antifreeze in cylinder. Oil in cylinder. Fuel in cylinder. | Remove spark plugs and check for fluid. Inspect for broken head gasket. Inspect for cracked engine block or cylinder head. Inspect for a sticking fuel injector and/or leaking fuel regulator. |
| Broken timing chain and/or timing chain and/or timing chain gears. | Inspect timing chain and gears. Repair as required. | |
| Material in cylinder. Broken valve Piston material Foreign material | Inspect cylinder for damaged components and/or foreign materials. Repair or replace as required. | |
| Seized crankshaft or connecting rod bearings. | Inspect crankshaft and connecting rod bearing. Repair as required. | |
| Bent or broken connecting rod. | Inspect connecting rods. Repair as required. | |
| Broken crankshaft. | Inspect crankshaft. Repair as required. |
ENGINE MECHANICAL SYSTEM TROUBLESHOOTING
Special Service Tools
SPECIAL SERVICE TOOLS Tool (Number and name) Illustration Use Crankshaft front oil seal installer (09231-3C100) Installation of the front oil seal Ring gear stopper (09231-2B100) Removal and installation of crankshaft pulley bolt Ring gear stopper (09231-3D100) Removal and installation of crankshaft pulley bolt. Torque angle adapter (09221-4A000) Installation of bolts & nuts needing an angular method Valve stem seal remover (09222-29000) Removal of the valve stem seal Valve stem seal installer (09222-3C100) Installation of the valve stem seal Valve spring compressor & holder (09222-3K000) (09222-3K100) Removal and installation of the intake or exhaust valves 09222-3K000 09222-3K100 (holder) Crankshaft rear oil seal installer (09231-3C200) (09231-H1100) Installation of the crankshaft rear oil seal 09231-3C200 09231-H1100 Oil pan remover (09215-3C000) Removal of oil pan
