2.7L V6 Engine: Other Kia Optima I рестайлинг

ADJUSTING VALVE CLEARANCE

As the intake and exhaust valves are equipped with auto-lash adjustment mechanisms, there is no need to adjust the valve clearance. The proper function of the auto-lash mechanism may be determined by checking for tappet noise. When there is tappet noise or any unusual noise, first check the engine oil pressure. If the engine oil pressure is okay, check the auto-lash by removing and bleeding or replacing it.

Scheme 279

1. First loosen slightly and then tighten to the specified torque. Tightening torque Cylinder head bolts Cold [Engine temperature approximately 20°C (68°F)]: 25 Nm (250 kg.cm, 18 lb.ft)+(58°~62°)+(43°~47°)
2. Be sure to follow the specific torque sequence as shown in the illustration. NOTE: Run the engine to normal operating temperature, let it cool, and then re-torque the bolts to specifications.

Scheme 280

Scheme 281

1. Before checking compression, check the engine oil level and that the starter motor and battery are all in normal operating condition.
2. Start the engine and wait until engine coolant temperature reaches 80°C~95°C (176°F~205°F).
3. Stop the engine and disconnect the spark plug cables.
4. Remove the spark plugs.
5. Crank the engine to remove any foreign material in the cylinders.
6. Attach the compression gauge to a spark plug hole.
7. Depress the accelerator pedal to fully open the throttle.
8. Crank the engine and read the gauge. Standard value: 12.2 kg/cm 2 (1220 kPa, 170 psi) Limit: 10.7 kg/cm 2 (1050 kPa, 149 psi)
9. Repeat steps 6 - 8 on all cylinders, ensuring that the pressure differential for each of the cylinders is within the specified limit. Limit: Max. 1.0 kg/cm 2 (100 kPa, 14 psi) between cylinders
10. If a cylinder's compression or pressure differential is below the specification, add a small amount of oil through the spark plug hole and repeat steps from 6 - 9 . 1) If the addition of oil brings the compression up, it is possible that there is wear between the piston ring and cylinder wall. If compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder head gasket are all possible causes. Tightening torque Spark plug: 20-30 Nm (200-300 kg.cm, 14-22 lb.ft)

Scheme 282

1. Position a vehicle on a level surface.
2. Stop the engine. NOTE: In the case of a vehicle that has been out of service for a prolonged period, run the engine for several minutes. Stop the engine and wait for 5 minutes at least, then check the oil level.
3. Check that the engine oil level is within the level range indicated on the oil dipstick. If the oil level is found to have fallen to the lower limit (the MIN mark), refill to the "MAX" mark. NOTE: When refilling, use the same type of engine oil as the one currently being used.
4. Check that the oil is not dirty or mixed with coolant or gasoline, and that it has the proper viscosity.

SELECTION OF ENGINE OIL

Note. For best performance and for maximum protection for all types of operation, select only those lubricants which: Confirm the requirements of the API classification. Have proper SAE grade number for expected ambient temperature range. Lubricants which do not have both a SAE grade number and an API service classification on the container should not be used.

Recommended API classification

SG or SG/CD, SH or SH/CD

Scheme 283

Scheme 284

1. Run the engine until it reaches normal operating temperature.
2. Stop the engine.
3. Remove the oil filler cap (on rocker cover) and the drain plug (on the oil pan). Drain the engine oil.
4. Re-install and tighten the drain plug to the specified torque. Tightening torque Drain plug : 35-45 Nm (350-450 kg. cm., 25-33 lb. ft.) CAUTION: Whenever tightening oil drain plug, use a new drain plug gasket.
5. Fill the crankcase with fresh engine oil through the oil filler cap opening. Refill Specifications Without oil filter; 4.5 lit (4.76 U.S.qts., 3.95 Imp.qts.) With oil filter; 4.8 lit (5.07 U.S.qts., 4.22 Imp.qts.) CAUTION: Do not overfill the crankcase. This will cause oil aeration and loss of oil pressure.
6. Install the oil filler cap.
7. Start and run the engine.
8. Stop the engine and then check the oil level. Add oil if necessary.

Filter Selection

All Kia engines are equipped with a high quality, throw-away oil filter. The filter is recommended as a replacement filter on all vehicles. The quality of replacement filters varies considerably. Only high quality filters should be used to assure the most efficient service. Make sure that the rubber gasket from the old oil filter is completely removed from the mating surface on the engine block, before installing the new filter.

Procedure for Replacing Oil Filter

1. Use a filter wrench to remove the oil filter.
2. Before installing the new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.
3. Tighten the oil filter to the specified torque. Tightening torque Oil filter: 17-25 Nm (170-250 kg.cm, 12-18 lb.ft)
4. Start and run the engine and check engine oil leaks.
5. After stopping the engine, check the oil level and add oil as necessary.

Scheme 285

Scheme 286

Scheme 287

Scheme 288

Scheme 289

1. Hang the belt on the pulley of the tensioner and install the tensioner. Tightening torque Tensioner assembly bolt : 20-27 Nm (200-270 kg.cm, 14-20lb.ft)
2. Install the belt in following order. [Alternator -> Power steering -> Crankshaft pulley -> Air conditioner pulley -> Idler pulley.]
3. Rotate the tensioner arm clockwise (about 14°) with spanner (16 mm) and hang the belt to the idler pulley.
4. When installing the belt on the hole of pulley, make sure there is no tooth gap of belt.
5. The tensioner mark should be between MIN. and MAX. position, if not, replace the belt.

Scheme 290

Scheme 291

1. Loosen the radiator cap.
2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and apply 150 kPa (21 psi, 1.53 kg/cm 2 ) pressure. Hold for two minutes in that condition, while checking for leakage from the radiator, hose or connections. WARNING: Radiator coolant may be extremely hot. Do not open the system while hot, or scalding Engine coolant could spray out causing severe burns and blindness. Allow the vehicle to cool to ambient air temperature before servicing this system. Be sure to completely clean away any moisture from the places checked. When the tester is removed, be careful not to spill any coolant from it. Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the radiator.
4. If there is leakage, repair or replace the appropriate part.

Scheme 292

1. Use an adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops moving. Main valve opening pressure : 93.2-122.6 kPa (0.95-1.25 kg/m 2 , 13.51-17.78 psi) Main valve closing pressure : 83.4kPa (0.85 kg/cm 2 ,12.1 psi)
3. Check that the pressure level is maintained at or above the limit.
4. Replace the radiator cap if the reading does not remain at or above the limit. NOTE: Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an improper indication.

RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY

Example

The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature of 20°C (68°F).

Scheme 293

Scheme 294

Engine Mounting

1. Remove the engine mount insulator bolts.
2. Remove the engine mount bracket from the engine.

Scheme 295

Transaxle Mounting

1. Remove the transaxle mounting bolt.
2. Remove the transaxle bracket.

Scheme 296

Front Roll Stopper

1. Remove the front roll stopper upper and lower bolts.
2. Remove the front roll rod assembly.

Scheme 297

Rear Roll Stopper

1. Remove the bolt from the rear roll stopper.
2. Remove the rear roll stopper from the sub-frame.

Scheme 298

Scheme 299

Scheme 300

Scheme 301

1. Remove the oil pressure switch, using 24 mm deep socket. NOTE: Since a sealant is used on the threaded area, be careful not to damage the oil pressure switch.
2. Remove the oil filter and the oil pan.
3. Remove the oil screen and gasket.
4. Remove the three bracket securing bolts and remove the oil filter bracket and gasket.
5. Remove the oil relief valve plug from the oil pump case.
6. Remove the oil pump case.

Oil Pump

1. Visually check the parts of the oil pump case for cracks and damage.
2. Assemble the rotor on the oil pump and then check the clearance with a thickness gauge. Oil pump side clearance Standard value Body clearance : 0.100-0.181 mm (0.0039-0.0071 in.) Side clearance : 0.040-0.095 mm (0.0016-0.0037 in.)

Scheme 302

Relief Plunger and Spring

1. Check the relief plunger for smooth operation.
2. Check the relief spring for a deformation or break.

Oil Filter Bracket

1. Make sure that there is no damage on the oil filter installation surface.
2. Check the oil filter bracket for oil leak or cracks.

Scheme 303

Scheme 304

1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wedge is pushed. If there is continuity even when the fine wedge is pushed, replace it.
3. Or, if there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch is operating properly. Check that air doesn't leak. If air leaks, the diaphragm is broken. Replace switch.

Scheme 305

Scheme 306

Scheme 307

Scheme 308

Scheme 309

1. Install the oil pump case with the gasket. Tightening torque Oil pump case bolt : 12-15 Nm (120-150 kg.cm, 9-10 lb.ft) Oil pump cover screw : 8-12 Nm (80-120 kg.cm, 5.8-8.6 lb.ft)
2. Install the oil seal into the oil pump case as far as possible, using special tool (09214-33000).
3. Install the relief plunger and spring, and tighten the oil relief valve plug to the specified torque. Tightening torque Oil relief valve plug : 40-50 Nm (400-500 kg.cm, 29-36 lb.ft)
4. Install the oil screen and a new gasket. Tightening torque Oil screen bolt : 15-22 Nm (150-220 kg.cm, 11-15 lb.ft)
5. Clean the gasket surfaces of the cylinder block and the oil pan.
6. Apply sealant to the groove of the oil pan flange. NOTE: Make the first cut from the end of the nozzle furnished with the sealant about 4 mm. After application of the sealant, do not exceed 15 minutes before installing the oil pan. Do not apply the sealant to the range A shown in the illustration on the oil pan flange.
7. Install the oil pan and tighten the bolts to the specified torque. Tightening torque Oil pan bolt : 19-28 Nm (190-280 kg.cm, 13.75-20.27 lb. ft.) 5-7 Nm (50-70 kg.cm, 3.7-5.0 lb.ft) 30-42 Nm (300-420 kg.cm, 21.70-30.40 lb.ft)
8. Tighten the oil pan bolt as shown in illustration.
9. Using 24 mm deep socket, install the oil pressure switch after applying sealant to the threaded area. Sealant: Threebond 1104 or equivalent NOTE: Do not torque the oil pressure switch too much. Tightening torque Oil pressure switch: 8-12 Nm (80-120 kg.cm, 5.8-8.6 lb.ft)

Scheme 310

Scheme 311

Scheme 312

Scheme 313

Scheme 314

Scheme 315

Scheme 316

Scheme 317

Scheme 318

Scheme 319

Scheme 320

Scheme 321

Scheme 322

Scheme 323

1. Reduce the internal pressure of the fuel lines and hoses. Disconnect the fuel pump harness connector in the trunk room. Start the engine and, after it stops, turn the ignition switch to OFF. Disconnect the battery negative (-) terminal. Connect the fuel pump harness connector.
2. Remove the battery and engine cover.
3. Detach the air cleaner.
4. Disconnect the connectors for the engine harness.
5. Disconnect the connectors for the alternator harness, the oil pressure switch and the oil pressure sensor.
6. Drain the engine coolant.
7. Disconnect the transaxle oil cooler hoses. NOTE: When disconnecting the hoses, make identification marks to avoid making any mistakes when installing them. CAUTION: Be careful not to spill any of the oil or fluid out of the hoses. Plug the openings to prevent the entry of foreign material.
8. Disconnect the radiator upper and lower hoses on the engine side, and then remove the radiator assembly.
9. Disconnect the high tension cable and all wires to the distributor from the ignition coil.
10. Disconnect the engine ground.
11. Disconnect the brake booster vacuum hose.
12. Remove the main fuel line, and the return and vapor hoses from the engine side.
13. Disconnect the heater hoses (inlet and outlet) on the engine side.
14. Disconnect the accelerator cable and cruise control cable at the engine side.
15. Remove the control cable from the transaxle.
16. Disconnect the speedometer cable from the transaxle.
17. Remove the power steering oil pump hose.
18. Raise the vehicle.
19. Remove the oil pan shield.
20. Drain the transaxle oil.
21. Disconnect the front exhaust pipe from the manifold. NOTE: Use a wire to suspend the exhaust pipe from the bottom of the vehicle.
22. Remove the lower arm ball joint bolts and upper arm bolt from the knuckle.
23. Remove the axle shafts from the transaxle housing. CAUTION: Plug up the holes of the transaxle case to prevent entry of foreign material. The circlips on the axle shafts should be replaced when installing again.
24. Attach a cable to the engine, and use a chain hoist to lift the engine only enough to pull the cable tight.
25. Remove the front roll stopper.
26. Remove the rear roll stopper.
27. Disconnect the connector of starter motor harness.
28. Remove the engine mount bolts.
29. Remove the bolts and nuts that fasten the engine mount bracket to the body.
30. Slowly raise the engine and transaxle and temporarily hold it in the raised condition. CAUTION: Confirm that all of the cables, hoses, harnesses, connectors etc., are disconnected from the engine.
31. Remove the transaxle mounting bracket bolts.
32. Remove the left mount insulator bolt.
33. While directing the transaxle side downward, lift the engine and transaxle assembly up out of the vehicle.

Scheme 324

Scheme 325

Scheme 326

1. Remove the engine cover and intake manifold.
2. Disconnect the breather hose and the engine harness.
3. Remove the coolant pump pulley, crankshaft pulley, idler pulley and tensioner pulley.
4. Remove the coolant pump pulley, crankshaft pulley, idler pulley and tensioner pulley.
5. Loosen the timing belt tensioner pulley, and temporarily secure it.
6. Remove the timing belt from the camshaft sprocket.
7. Remove the spark plug cables.
8. Loosen the cylinder head cover bolts and then remove it.
9. Remove the camshaft sprocket.
10. Remove the camshaft bearing caps.
11. Remove the camshaft.

Scheme 327

Scheme 328

1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or worn excessively, replace the camshaft. Cam height [Standard] Intake : 43.95-44.15 mm (1.7303-1.7382) in.) Exhaust: 43.95-44.15 mm (1.7303-1.7382) in.) [Limit] Intake : 43.45 mm (1.7106 in.) Exhaust : 43.45 mm (1.7106 in.)
3. Check the cam surface for abnormal wear or damage, and replace if necessary.
4. Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head assembly or camshaft bearing cap, as necessary. Camshaft end play : 0.1 - 0.15 mm (0.0039-0.0059 in.)

Oil Seal (Camshaft Front)

1. Check the lips for wear. If lip threads are worn, replace.
2. Check the oil seal lip contacting surface or camshaft. If it is worn in stages, replace the camshaft.

Hydraulic Lash Adjuster (HLA)

With the HLA filled with engine oil, hold A and Press B by hand. If B moves, replace the HLA.

Scheme 329

Scheme 330

Scheme 331

1. Check the chain guide for bend, cracks or damage. Replace if necessary.
2. Check the rubber part of chain guide for abnormal wear. Replace if necessary.

Camshaft Timing Chain

Check the bushing and plate of timing chain for wear. Replace if there is severe wear.

Scheme 332

Scheme 333

Scheme 334

Scheme 335

Scheme 336

Scheme 337

Scheme 338

Scheme 339

Scheme 340

Scheme 341

1. Install the HLA.
2. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown in illustration.
3. Install the camshaft after lubricating the journal of camshaft with engine oil.
4. Install the bearing caps. Check the markings on the caps for intake/exhaust identification symbol. I: Intake camshaft E: Exhaust camshaft
5. Tighten the bearing caps to the specified torque in two or three steps as shown in illustration. Tightening torque Bearing cap bolt: 14-15 Nm (140-150kg.cm, 10-11 lb.ft)
6. Using the special tool, camshaft oil seal installer (09221-21000), press fit the camshaft oil seal. Be sure to apply engine oil to the external surface of the oil seal. Insert the oil seal along the camshaft front end and install by driving the installer with a hammer until the oil seal pulley is seated.
7. Install the camshaft sprocket to the specified torque. Tightening torque Camshaft sprocket bolt: 90-110 Nm (900-1100 kg.cm, 65-80 lb.ft)
8. Install the cylinder head cover. Tightening torque Cylinder head cover bolts: 5-6 Nm (50-60 kg.cm, 3.6-4.4 lb.ft) Tightening procedure Tighten all bolts with temporary torque (half of the standard torque) in sequence. (Scheme 342) Tighten all bolts with standard torque.
9. Install the spark plug cables, center cover.
10. Install the timing belt and then tighten the timing belt tensioner pulley.
11. Install the timing belt cover.
12. Install the coolant pump pulley and crankshaft pulley, and tensioner pulley.
13. Install the intake manifold and engine cover.
14. Install the oil filler cap.
15. Connect the breather hose and engine harness.

Scheme 342

CONNECTING ROD CAP

1. Remove the connecting rod cap nuts and then remove the caps and the big end lower bearing.
2. Push each piston-connecting rod assembly toward the top of the cylinder.

Scheme 343

Scheme 344

Scheme 345

1. Use the special tools (09234-33001) to disassemble and re-assemble the piston and connecting rod.
2. Place the proper insert in the fork of the tool. Position the insert between the connecting rod and the piston.
3. Insert the proper removal tool through the hole in the arch of the tool. CAUTION: Center the piston, rod and pin assembly with the removal arbor.
4. Press the piston pin out of the connecting rod.
5. Install the proper pin guide (refer to application chart in illustration) through the piston and into the connecting rod. Hand tap the pin guide into the piston for proper retention. Drop the piston pin into the other side of the piston. CAUTION: The pin guide centers the connecting rod in the piston. When the piston, connecting rod, piston pin and pin guide assembly are positioned on the fork of the tool, the pin guide will also center this assembly in the tool. If a pin guide that is too small is used, the piston assembly will not be located centrally in the tool, and damage may occur to the fork and/or the insert of the tool.
6. Install piston assembly onto fork assembly of a tool. The tool will support connecting rod at the piston pin. Be sure that piston assembly is slid onto the fork until the pin guide contacts the fork insert.
7. Adjust the installing arbor to the proper length by turning the numbered sleeve on the lettered shaft until the specified alphanumeric setting from the application chart in illustration is obtained. Turn knurled nut to lock numbered sleeve on shaft.
8. Insert the installing arbor through the hole in the arch of the tool. Press piston pin into the connecting rod until the sleeve on the installing arbor contacts the top of the tool arch. The pin guide will fall out of the connecting rod as the piston pin is pressed in. CAUTION: Do not exceed 1250 kg of force when installing the arbor sleeve against the arch.

Connecting Rod

1. When the connecting rod cap is installed, make sure that cylinder numbers put on the rod end 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, and also if it has a step wear in, or severely rough surface of the inside diameter of the small end.

Piston and Piston Pins

1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
2. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. When the piston requires replacement, its rings should also be replaced.
3. Check that the piston pin fits in the piston pin hole. Replace any piston and pin assembly that is defective. The piston pin must be smoothly pressed by hand into the pin hole at room temperature.

Piston Rings

1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring in a ring groove to measure the side clearance. If the clearance still exceeds the service limit, replace the piston and rings together. If it is less than the service limit, replace the piston rings only. 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 : 0.1 mm (0.004 in.) No.2 : 0.1 mm (0.004 in.)
2. 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. Piston ring end gap [Standard dimension] No.1 : 0.20-0.35 mm (0.0079-0.0138 in.) No.2 : 0.37-0.52 mm (0.0146-0.0205 in.) Oil ring side rail : 0.20-0.7 mm (0.0079-0.0276 in.) [Limit] No.1, No.2 : 0.8 mm (0.031 in.) Oil ring side rail : 1.0 mm (0.039 in.)

When replacing the ring without correcting the cylinder bore, check the gap with the ring situated at the lower part of cylinder that is less worn.

When replacing a ring, be sure to use a ring of the same size.

Piston ring service size and mark

STD : None

0.25 mm (0.010 in.) O.S. : 25

0.50 mm (0.020 in.) O.S. : 50

Note. The mark can be found on the upper side of the ring next to the end.

Scheme 346

Scheme 347

Scheme 348

1. Install the upper main bearings in the cylinder block.
2. Install the lower main bearings in the main bearing caps. CAUTION: Install the bearing with the oil hole in the block.
3. Install the thrust washers in the No. 3 main bearing cap with the oil grooves facing outward.
4. Make sure that the front mark of the piston and the front mark (identification mark) of the connecting rod are directed toward the front of the engine.
5. When the connecting rod cap is installed, make sure that the cylinder numbers put on the rod and cap at disassembly match.
6. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
7. When assembling, bolts should be fastened by plastic region angle - controlled method as follows. Apply oil to the thread of nuts and spot areas. Tighten the connecting rod bolt. Tightening torque Connecting rod bolt : 16-20 Nm (160-200 kg.cm, 11.6-14 lb.ft) +(90°~94°) CAUTION: After removing the connecting rod bolt, do not use bolt again.
8. Check the bearing clearance as follows: Remove oil and dirt from the bearings and journals. Cut plastic gauge to the same length as the width of the bearing and place it in parallel with the journal, avoiding the oil holes. Install the bearing and cap. Tighten to the specified torque. During this operation, do NOT turn the crankshaft. Remove the cap, measure the width of the plastic gauge at the widest part by using the scale printed on the plastic gauge package. Connecting rod cap Bearing clearance Standard : 0.018-0.036 mm (0.0007-0.0014 in.) Limit : 0.1 mm (0.0039 in.)
9. Check the connecting rod side clearance. Side clearance : 0.10-0.25 mm (0.0039-0.0098 in.) Limit : 0.4 mm (0.016 in.)

Scheme 349

Scheme 350

Scheme 351

Scheme 352

Scheme 353

1. Install the spacer.
2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring groove and spacer, hold it down firmly, and then press down on the portion which is to be inserted into the groove with a finger as shown in illustration. CAUTION: Do not use a piston ring expander when installing side rail in order to protect side rail.
3. Install the lower side rail by the same procedure as Step 2 .
4. Apply engine oil around the piston and piston rings.
5. Using a piston ring expander, install the No. 2 piston ring.
6. Install the No. 1 piston ring.
7. Position each piston ring end gap as far away from neighboring gaps as possible. Make sure that the gaps are not positioned in the thrust and pin directions.
8. Hold piston rings firmly in a piston ring compressor as they are inserted into cylinder.

Scheme 354

Crankshaft

1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check the oil holes for restrictions. Repair or replace any defective part.
2. Inspect for out-of-roundness and taper of the crankshaft journal and pin. Standard value Crankshaft journal O.D. : 61.982-62.000 mm (2.4402-2.4409 in.) Crankshaft pin O.D. : 47.982-48.000 mm (1.8891-1.8898 in.)

Scheme 355

Main Bearings and Connecting Rod Bearings

Visually inspect each bearing for peeling, melt, seizure and improper contact. Replace any defective bearings.

Measuring Oil Clearance

Check for oil clearance by measuring the outside diameter of the crankshaft journal and the inside diameter of the bearing. The clearance can be obtained by calculating the difference between the measured outside and inside diameters.

Standard value

Oil clearance

Crankshaft main bearing

0.004-0.022 mm (0.0002-0.0009 in.)

Connecting rod bearing

0.018-0.036 mm (0.0007-0.0014 in.)

Scheme 356

Plastic gauge Method

Plastic gauge may be used to measure the clearance.

Scheme 357

1. Remove oil and grease and any other dirt from the bearings and journals.
2. Cut the plastic gauge to the same length as the width of the bearing and place it in parallel with the journal, avoiding the oil holes.
3. Install the crankshaft, bearings and caps and tighten them to the specified torques. During this operation, do not turn the crankshaft. Remove the caps. Measure the width of the plastic gauge at the widest part by using the scale printed on the gauge package. If the clearance exceeds the service limit, the bearing should be replaced or an undersize bearing should be used. When installing a new crankshaft, be sure to use standard size bearings. Should the standard clearance not be obtained even after replacing the bearing, the journal and pin should be ground to the undersize and a bearing of the corresponding size should be installed.

Oil Seal

Check the front and rear oil seals for damage or worn surfaces.

Replace any seat that is defective.

Drive Plate

Replace distorted, damaged, or cracked drive plates.

Scheme 358

Scheme 359

Scheme 360

Scheme 361

Scheme 362

1. Install the grooved main bearing (upper bearing) on the cylinder block side.
2. Install the grooveless main bearing (lower bearing) on the main bearing cap side.
3. Install the crankshaft. Apply engine oil to the journal and pin.
4. Caps should be installed with the arrow mark directed toward the front of the engine. The cap number sequence must be correct.
5. Tighten all cap bolts to the specified torque and then rotate all bolts to specified angle. Tightening torque Main bearing cap bolts : M8:14-18 Nm (140-180 kg.cm, 10-13 lb.ft) + (90°~94°) M10: 27-33 Nm (270-330 kg.cm, 19.5-23.9 lb.ft)+(90°~94°)
6. Cap bolts should be tightened evenly in from 4 to 5 stages before they are tightened to the specified torque.
7. Make certain that the crankshaft turns freely and has the proper end play. Crankshaft end play Standard : 0.070-0.250 mm (0.0028-0.0098 in.) Limit : 0.35 mm (0.014 in.)
8. Using the special tool (09231-33000), install the rear oil seal in the oil seal case.
9. Apply sealant to the area shown in the illustration. Install the oil seal case on the cylinder block. Tightening torque Oil seal case bolt : 10-12 Nm (100-120 kg.cm, 7.3-8.6 lb.ft)
10. Tighten the transaxle mounting plate to the specified torque. Tightening torque Transaxle mounting plate bolt: 10-12 Nm (100-120 kg.cm, 7.3-8.6 lb.ft)
11. Tighten the drive plate and the adapter plate. Tightening torque Drive plate and adaptor plate bolt : 73-77 Nm (730-770 kg.cm, 53-55 lb.ft)

Scheme 363

Scheme 364

Main Muffler

1. Disconnect the main muffler from the center exhaust pipe.
2. Remove the rubber hangers and take out the main muffler.

Scheme 365

Center Exhaust Pipe

1. Disconnect the center exhaust pipe from the main muffler.
2. After disconnecting from the front exhaust pipe, remove the center exhaust pipe.

Scheme 366

Front Exhaust Pipe (Including Catalytic Converter)

1. Remove the front exhaust pipe from the center exhaust pipe.
2. Remove the front exhaust pipe from the exhaust manifold (Including catalytic converter)
3. Remove the front exhaust pipe from the rubber hanger.

Scheme 367

Scheme 368

1. Check the mufflers and pipes for corrosion and damage.
2. Check the rubber hangers for deterioration and cracks.

Valve Guides

Check the valve stem-to-guide clearance. If the clearance exceeds the service limit, replace the valve guide with a new oversize guide.

Valve stem-to-guide clearance

Standard value

Intake : 0.02-0.05 mm (0.0009-0.0020 in.)

Exhaust: 0.035-0.065 mm (0.0014-0.0026 in.)

Service limit

Intake : 0.10 mm (0.0039 in.)

Exhaust : 0.15 mm (0.0059 in.)

Scheme 369

Scheme 370

1. Replace the valve stem if it is worn (stepped, worn or damaged). Also replace it if the stem end (the surface contacting the auto-lash adjuster) is recessed.
2. Check the valve face contact area, and recondition or replace as necessary.
3. Replace the valve if the width of the margin (thickness of the valve head) is less than the minimum specified. Valve margin Standard value Intake side : 1.0 mm (0.0394 in.) Exhaust side : 1.3 mm (0.0512 in.) Service limit Intake side : 0.5 mm (0.0197 in.) Exhaust side : 0.8 mm (0.0315 in.)

Scheme 371

Valve Springs

1. Check free height of each valve spring and replace if necessary.
2. Using a square, test squareness of each valve spring. If spring is excessively out of square, replace it. Valve spring Standard value Free height : 42.5 mm (1.6732 in.) Load : 21.9 kg/35 mm (49 lb/1.3780 in.) Out of squareness : Max. 1.5° Service limit Free height: 41.5 mm (1.6339 in.) Load : 21.9 kg/34 mm (49 lb/1.3386 in.) Out of squareness : Max. 3°

Scheme 372

Reconditioning Valve Seat

1. Before reconditioning, check the valve guide for wear. Replace worn guide if necessary, and then recondition the valve seat.
2. To recondition the valve seat, use the Valve Seat Cutter and Pilot.
3. After reconditioning, the valve and valve seat should be lapped lightly with a lapping compound.

Scheme 373

Scheme 374

Scheme 375

1. Using the Special tool (09222-32200), press down the old valve guide toward the bottom of cylinder head.
2. Recondition the valve guide hole so that it matches the newly press-fit oversize valve guide.
3. Using the special tool (09221-29000A), 09221-22000B)) 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 valve guides are different in length.
4. After the valve guide is press-fit, insert a new valve and check for proper clearance.
5. After the valve guide has been replaced, check proper valve face to valve seat contact. NOTE: Do not install a valve guide of the same size again.

Scheme 376

Scheme 377

Scheme 378

1. Cut away the inner face of the valve seat to reduce thickness.
2. Adjust the press fit diameter of the valve seat on the cylinder head side so that it can match the diameter of the oversize valve seat.
3. Heat the cylinder head to about 250°C (480°F ) and press an oversize seat insert fit for the insert bore in the cylinder head at normal temperature.
4. Use the lapping compound, and lap the valve. Valve seat contact width Intake : 1.1-1.5 mm (0.043-0.059 in.) Exhaust : 1.3-1.7 mm (0.051-0.067 in.)

Scheme 379

Scheme 380

1. Install the spring seats.
2. Using the special tool (09222-22001), lightly tap the seal into place. The seal is installed in the specified position, using the special tool. NOTE: Do not reuse old valve stem seals. Incorrect installation of the seal could result in oil leakage down the valve guides.
3. Apply engine oil to each valve. Insert valves into guides. Avoid forcing the valve into the seal. After installing the valve, check that it moves smoothly.
4. Valve springs should be installed with the enamel coated side toward the valve spring retainer.
5. Using the special tool (09222-28000), compress the spring and install the retainer locks. After installation of the valves, make certain that the retainer locks are correctly in place before releasing the valve spring compressor. NOTE: When the spring is compressed, check that the valve stem seal is not pressed against the bottom of retainer.

Scheme 381

Scheme 382

Scheme 383

Scheme 384

Scheme 385

Scheme 386

Scheme 387

Scheme 388

1. Remove the engine cover.
2. Using the spanner [16 mm], rotate the tensioner arm clockwise (about 14°) and remove the belt from pulley.
3. Remove the coolant pump pulley, idler pulley, tensioner pulley and crankshaft pulley.
4. Remove the upper and lower timing belt covers.
5. Support the engine with garage jack or wooden block and remove the engine mounting insulator.
6. Remove the engine mount bracket from the engine.
7. Remove the auto tensioner. NOTE: Rotate the crankshaft clockwise and align the timing mark to get the No. 1 cylinder's piston to be in TDC position (compression stroke). At this time, the timing mark of camshaft sprocket and cylinder head cover should coincide each other.
8. Remove the timing belt. NOTE: When using the timing belt again, make sure of marking the rotating direction on the belt so as to install correctly.

Scheme 389

Scheme 390

Scheme 391

Scheme 392

Scheme 393

1. Closely inspect the belt. If the following problems are evident, replace the belt with a new one. Hardened back surface rubber, back surface glossy. Non-elastic and so hard that even if a finger nail is forced into it, no mark is produced. Cracked surface rubber Side of belt badly worn NOTE: A belt in good condition should have clear-cut sides as if cut with a sharp knife. Teeth badly worn Initial stage: Canvas on the load side of the tooth flank worn (fluffy canvas fibers, rubber gone and color changed to white, unclear canvas texture). Last stage: Canvas on the load side of the tooth flank worn down and rubber exposed (tooth width reduced). Missing tooth
2. If backlash or an irregular noise is observed when rotating the pulley, replace the timing belt tensioner and idler pulley.

Scheme 394

Scheme 395

Scheme 396

Scheme 397

Scheme 398

Scheme 399

1. Install idler pulley to water pump boss. NOTE: Insert and install idler pulley to the pin spring that is pressed and inserted in the water pump boss.
2. Install tensioner arm and plane washer to cylinder block.
3. Install tensioner pulley to the tensioner arm.
4. Install sprockets and align the timing mark. NOTE: When installing camshaft sprocket, fasten the sprocket tightly while holding the hexagonal part of the camshaft. Before installing timing belt, if the timing marks of cam sprocket and cylinder head cover do not coincide, do not rotate the cam sprocket more than 3 teeth of sprocket in any direction. Rotating sprocket more than 3 teeth might make valve and piston touch each other. In case of rotating the cam sprocket unavoidably more than 3 teeth, rotate the cam sprocket after rotating 3 teeth in the side of crank counter-clockwise on the base of timing mark.
5. Install the auto tensioner to the front case. NOTE: At this time auto tensioner's set pin should be assembled completely.
6. Align the timing marks of each sprocket and install the timing belt in this order. Crankshaft sprocket -> Idler pulley -> Intake cam sprocket (LH side) -> Water pump pulley -> Intake cam sprocket (RH side) -> Tensioner pulley. NOTE: In this step, No. 1 is in TDC (Compression stroke) Do not insert fingers.
7. Pull out the set pin of the auto tensioner.
8. Install the engine mount bracket from the engine.
9. Install the engine mounting insulator.
10. Install the upper and lower timing belt covers.
11. Install the coolant pump pulley, idler pulley, tensioner pulley and crankshaft pulley.
12. Using the spanner [16 mm], rotate the tensioner arm clockwise (about 14°) and unstall the belt from pulley.
13. Install the engine cover.
14. Install the oil filler cap.

Adjusting The Tension Of Timing Belt

1. Rotate the crankshaft in 2 turns clockwise and measure the projected load of auto tensioner in the TDC (#1 Compression stroke) after 5 minutes.
2. Check the projected length is 6-8 mm.
3. Check again if the timing marks of each sprocket are in specified position. NOTE: If not within specified position, redo procedure from step 6 in the method of installing timing belt and auto tensioner.