Engine Mechanical: Removal & Installation Kia Sedona II

REMOVAL

Note. Mark all wiring and hoses to avoid misconnection.

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1. Remove the engine cover (A).
2. Recover refrigerant, opening the high & low pressure pipe caps and connecting the refrigerant station (Refer to «AIR CONDITIONING SYSTEM»(ref-269657) ).
3. Disconnect the negative terminal from the battery and remove the battery (A).
4. Remove the intake air hose and air cleaner assembly. Disconnect the MAF connector (A). Disconnect the breather hose (B) from air cleaner hose. Remove the intake air hose and air cleaner assembly (C).
5. Remove the battery tray (A).
6. Remove the radiator grille upper cover (A).
7. Disconnect the RH and LH oxygen sensor connectors (A, B).
8. Coolant should be drained.
9. Remove the radiator upper and lower hoses (A).
10. Disconnect the automatic transaxle fluid cooler hoses (A).
11. Disconnect the high and low pressure pipes from the radiator or the compressor.
12. Disconnect engine wiring. Remove the engine room fuse and relay box cover (A). Disconnect the PCM connectors (B). Disconnect the FAM connectors (C) (Refer to «AIR CONDITIONING SYSTEM»(ref-269657) ). Unscrew the FAM mounting bolts (D-3 EA) and take the FAM (E) out of the splash shield (F). Disconnect the connector (G) from the splash shield (B).
13. Disconnect the transaxle wire harness connector and remove the transaxle control cable (Refer to «AUTOMATIC TRANSAXLE SYSTEM»(ref-269576) ).
14. Remove heater hose (A).
15. Remove the brake vacuum hose (A).
16. Remove power steering pump hose (Refer to «MECHANICAL POWER STEERING SYSTEM»(ref-269605) ).
17. Remove front wheels (Refer to «TIRES/WHEELS»(ref-269600) ).
18. Remove the radiator grille upper cover (A) for convenience sake.
19. Disconnect the power steering return hose (A).
20. Remove the under cover (A).
21. Remove the radiator support upper member assembly for convenience sake. NOTE: The bottom side bolt (A) which can be seen after removing the under cover should be loosened for removal of the radiator support upper member assembly.
22. Drain engine oil.
23. Remove front exhaust pipe (A).
24. Disconnect the wheel speed sensor and the stabilizer bar link (Refer to «FRONT SUSPENSION SYSTEM»(ref-269598) ).
25. Remove the caliper assembly and suspend it with a wire (Refer to «BRAKE SYSTEM»(ref-269616) ).
26. Supporting the engine and transaxle assembly with sub frame, remove the engine mounting bracket (A).
27. Remove the transaxle insulator mounting bolt (A).
28. Supporting the engine and transaxle assembly with a jack, remove the sub frame with the engine and transaxle assembly. NOTE: When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.

INSTALLATION

Installation is in the reverse order of removal.

Perform the following

1. Adjust the shift cable.
2. Refill the engine with engine oil.
3. Refill the transaxle with fluid.
4. Refill the radiator with engine coolant.
5. Bleed air from the cooling system with the heater valve open.
6. Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.
7. 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.

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Note. Mark all wiring and hoses to avoid misconnection. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

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1. Disconnect the battery negative cable (A). (Scheme 29): Locating Battery Negative Cable
2. Remove the engine cover (A). (Scheme 30): Locating Engine Cover
3. Remove the intake air hose and air cleaner assembly. Disconnect the MAF sensor connector (A). Disconnect the breather hose (B) from air intake hose. Remove the intake air hose and air cleaner assembly (C). (Scheme 31): Identifying MAF Connector, Breather Hose, Intake Air Hose And Air Cleaner Body
4. Remove the RH front wheel.
5. Remove the under cover (A). (Scheme 32): Locating Under Cover
6. Remove the side cover.
7. Loosen the drain plug and drain the engine coolant.
8. Drain the engine oil.
9. Remove the surge tank. Disconnect the RH oxygen sensor connector (A) and loosen the power steering hose mounting bolts (B). (Scheme 33): Locating RH Oxygen Sensor Connector And Power Steering Hose Mounting Bolts Disconnect the RH injector connector (A) and ignition coil connector (B). (Scheme 34): Locating RH Injector Connector And Ignition Coil Connector Disconnect the PCSV connector (A), MAP sensor connector (B) and PCSV hose. (Scheme 35): Locating PCSV Connector, MAP Sensor Connector And PCSV Hose Disconnect the ETC connector (A) and knock sensor connector (B). (Scheme 36): Locating ETC Connector And Knock Sensor Connector Disconnect the OCV connector (A) and knock sensor connector (B). (Scheme 37): Locating OCV Connector And Knock Sensor Connector Disconnect the LH front oxygen sensor connector (A). (Scheme 38): Locating LH Front Oxygen Sensor Connector Disconnect the LH ignition coil connector (A), injector connector (B), condenser connector (C) and ground (D), and remove the wiring harness protector (E). (Scheme 39): Locating LH Ignition Coil Connector, Injector Connector, Condenser Connector, Ground And Wiring Harness Protector Disconnect the LH CMPS (A) and oil pressure switch connector (B). (Scheme 40): Locating LH CMPS And Oil Pressure Switch Connector Remove the ETC bracket (A). Disconnect the water hoses (B) from ETC. Disconnect the PCV hose (C). (Scheme 41): Locating ETC Bracket, Water Hoses And PCV Hose Disconnect the brake vacuum hose. Remove the surge tank stay (A). (Scheme 42): Locating Surge Tank Stay Remove the connector bracket (A) from surge tank. (Scheme 43): Locating Surge Tank Connector Bracket Remove the surge tank (A). (Scheme 44): Locating Surge Tank NOTE: Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
10. Remove the cylinder head cover. Remove the connector bracket (A) from LH cylinder head cover. (Scheme 45): Locating LH Cylinder Head Cover Connector Bracket Disconnect the RH ignition coil connector (A), condenser connector (B) and remove the wiring bracket (C). (Scheme 46): Locating RH Ignition Coil Connector, Condenser Connector And Wiring Bracket Remove the LH, RH ignition coil. Remove the LH, RH cylinder head cover (A). (Scheme 47): Locating RH Cylinder Head Cover
11. Using SST (09215-3C000) remove lower oil pan (A). (Scheme 48): Removing Lower Oil Pan Using SST (09215-3C000) NOTE: Be careful not to damage the contact surfaces of upper oil pan and lower oil pan.
12. Set a jack to the upper oil pan. (Scheme 49): Locating Upper Oil Pan
13. Remove the coolant reservoir tank.
14. Remove the engine mounting bracket (A). (Scheme 50): Identifying Transaxle Mounting Bracket, Bolts And Nuts
15. Set No. 1 cylinder to TDC/compression. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover. NOTE: Do not rotate engine counterclockwise. (Scheme 51): Aligning Crankshaft Pulley Groove With Timing Mark "T" Of 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 one revolution (360°). (Scheme 52): Checking Mark Of Camshaft Timing Sprockets Are In Straight Line On Cylinder Head Surface NOTE: Do not rotate engine counterclockwise.
16. Remove the drive belt (A). (Scheme 53): Locating Drive Belt
17. Remove the crankshaft damper pulley (A). (Scheme 54): Locating Crankshaft Damper Pulley NOTE: There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley. Install the SST (09231-3C300) to hold the ring gear after removing the starter. (Scheme 55): Installing SST (09231-3C300) To Hold Ring Gear After Removing Starter Install the SST (09231-3D100) to hold the ring gear after removing the dust cover. Remove the front muffler. (Refer to Intake And Exhaust system) Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B). (Scheme 56): Locating Dust Cover On Bottom Of Upper Oil Pan And Transaxle Mounting Bolts Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth. Fasten the two transaxle mounting bolts in the original mounted holes. (Scheme 57): Locating Holder Nuts, Front Plate Holder And Ring Gear Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely. (Scheme 58): Identifying SST (09231-3D100) And Mounting Bolts
18. Lift up the engine assembly to using the jack.
19. Remove the drive belt idler (A). (Scheme 59): Locating Drive Belt Idler
20. Remove the drive belt auto tensioner (A). (Scheme 60): Locating Drive Belt Auto Tensioner
21. Remove the water pump pulley (A). (Scheme 61): Locating Water Pump Pulley (Scheme 62): Locating Timing Chain Cover
22. Remove the timing chain cover (A). NOTE: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover. 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.
23. Install a set pin after compressing the timing chain tensioner. (Scheme 63): Installing Set Pin After Compressing Timing Chain Tensioner
24. Remove the RH cam-to-cam guide (A). (Scheme 64): Locating RH Cam-To-Cam Guide
25. Remove the RH timing chain auto tensioner (A) and RH timing chain tensioner arm (B). (Scheme 65): Locating RH Timing Chain Auto Tensioner And RH Timing Chain Tensioner Arm
26. Remove the RH timing chain.
27. Remove the RH timing chain guide (A). (Scheme 66): Locating RH Timing Chain Guide
28. Remove the oil pump chain cover (A). (Scheme 67): Locating Oil Pump Chain Cover
29. Remove the oil pump chain tensioner assembly (A). (Scheme 68): Locating Oil Pump Chain Tensioner Assembly
30. Remove the oil pump chain guide (A). (Scheme 69): Locating Oil Pump Chain Guide
31. Remove the oil pump chain sprocket (A) and oil pump chain (B). (Scheme 70): Locating Oil Pump Chain Sprocket And Oil Pump Chain
32. Remove the crankshaft sprocket (A) (Oil pump&RH camshaft drive). (Scheme 71): Locating Crankshaft Sprocket (Oil Pump & RH Camshaft Drive)
33. Install a set pin after compressing the LH timing chain tensioner. (Scheme 72): Installing Set Pin After Compressing LH Timing Chain Tensioner
34. Remove the LH cam-to-cam guide (A). (Scheme 73): Locating LH Cam-To-Cam Guide
35. Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B). (Scheme 74): Locating LH Timing Chain Auto Tensioner And LH Timing Chain Tensioner Arm
36. Remove the LH timing chain.
37. Remove the LH timing chain guide (A).
38. Remove the crankshaft sprocket (A) (LH camshaft drive).
39. Remove the tensioner adapter assembly (A).

Locating Tensioner Adapter Assembly. Scheme 76

Note. Mark all wiring and hoses to avoid /Disconnection. Turn the crankshaft pulley so that the No. 1 piston is at top dead center. (Refer to VALVE CLEARANCE INSPECTION AND ADJUSTMENT )

Engine removal is required for this procedure.

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1. Remove exhaust manifold. (Refer to «EXHAUST MANIFOLD»(ref-269574-S12863900962007110100000) )
2. Remove intake manifold. (Refer to «INTAKE MANIFOLD»(ref-269574-S34478033732007110100000) )
3. Remove timing chain. (Refer to «REMOVAL»(ref-269574-S38297141332012040400000) )
4. Remove water temperature control assembly. (Refer to «WATER TEMPERATURE CONTROL ASSEMBLY»(ref-269574-S39998063932007110100000) )
5. Remove camshaft bearing cap (A).
6. Remove camshaft assembly (A).
7. Remove cylinder head bolts, then remove cylinder head. Uniformly loosen and remove the 16 cylinder head bolts, in several passes, in the sequence shown in illustration. Remove the 16 cylinder head bolts and plate washers. CAUTION: Head warpage or cracking could result from removing bolts in an incorrect order. 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.

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. (Refer to VALVE CLEARANCE INSPECTION AND ADJUSTMENT )

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1. Install the cylinder head. The sealant locations on cylinder head and cylinder block must be free from contamination. Apply sealant on cylinder block top face before assembling cylinder head gaskets. The part must be assembled within 5 minutes after sealant was applied. NOTE: Refer to below illustration to apply the sealant. Bead width: 2.0-3.0 mm Sealant locations: 1.0-1.5 mm from block surface Recommended sealant: Liquid sealant TB1217H Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block. The part must be assembled within 5 minutes after sealant was applied. NOTE: Be careful of the installation direction. Install the cylinder head. NOTE: Remove the extruded sealant after assembling cylinder heads.
2. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts. Do not apply engine oil on the threads and under the heads of the cylinder head bolts. Using SST (09221 -4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown in illustration. Tightening torque 1st step: 37.3-41.2 N.m (3.8-4.2 kgf.m, 27.5-30.4 lbf.ft) 2nd step: 120° ±2° 3rd step: 90° ±2° 18.62-23.52 N.m (1.9-2.4 kgf.m, 13.74-17.36 lb-ft) (A) NOTE: Always use new cylinder head bolts.
4. Install the CVVT and camshaft sprocket. Tightening torque 64.68-76.44 N.m (6.6-7.8 kgf.m, 47.74-56.4 lb-ft) NOTE: Install camshaft-inlet to dowel pin of CVVT assembly. Ensure that the camshaft oil inlet is not obstructed. Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly. Do not rotate CVVT assembly when camshaft is installed to dowel pin of CVVT assembly.
5. Install camshafts (A). NOTE: Apply a light coat of engine oil on camshaft journals. Assemble the key groove of camshaft rear side to the same level of head top surface. Ensure that the camshaft components are installed in the correct locations. INTAKE CAMSHAFT INTAKE CAMSHAFT SPECIFICATIONS LH RH A: 30 mm (1.1811 in.) A: 27 mm (1.0630 in.) B: 27 mm (1.0630 in.) B: 30 mm (1.1811 in.) EXHAUST CAMSHAFT EXHAUST CAMSHAFT SPECIFICATIONS LH RH A: 27 mm (1.0630 in.) A: 30 mm (1.1811 in.)
6. Install camshaft bearing caps (A). Assemble camshaft bearing caps as the order below. Tightening torque 5.9 N.m (0.6 kgf.m, 4.3 lb-ft) - 1st step 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft) - 2nd step NOTE: Ensure that the cam bearing caps are installed in the correct location and direction. Refer to the table below. A: L (LH), R (RH) B: l (Intake), None (Exhaust) C: Journal number D: Front mark CAUTION: Rotate the crankshaft to position the pistons 10 mm (0.3937 in.) from the top of the cylinder block.
7. Install water temperature control assembly. (Refer to «WATER TEMPERATURE CONTROL ASSEMBLY»(ref-269574-S08855888072007110100000) )
8. Install timing chain (Refer to «INSTALLATION»(ref-269574-S23059894772007110100000) )
9. Check and adjust valve clearance. (Refer to «VALVE CLEARANCE INSPECTION AND ADJUSTMENT»(ref-269574-S13793833042007110100000) )
10. Install the exhaust manifold. (Refer to «EXHAUST MANIFOLD»(ref-269574-S41551048552007110100000) )
11. Install the intake manifold. (Refer to «INTAKE MANIFOLD»(ref-269574-S00420520242007110100000) )

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Note. Mark all wiring and hoses to avoid misconnection. Turn the crankshaft pulley so that the No. 1 piston is at top dead center. (Refer to VALVE CLEARANCE INSPECTION AND ADJUSTMENT ) Engine removal is required for this procedure.

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1. Remove exhaust manifold. (Refer to «EXHAUST MANIFOLD»(ref-269574-S12863900962007110100000) )
2. Remove intake manifold. (Refer to «INTAKE MANIFOLD»(ref-269574-S34478033732007110100000) )
3. Remove timing chain. (Refer to «REMOVAL»(ref-269574-S38297141332012040400000) )
4. Remove water temperature control assembly. (Refer to «WATER TEMPERATURE CONTROL ASSEMBLY»(ref-269574-S39998063932007110100000) )
5. Remove cylinder head. (Refer to «CYLINDER HEAD»(ref-269574-S39645237592007110100000) )
6. Remove oil pump. (Refer to «OIL PUMP»(ref-269574-S26931458712007110100000) )
7. Remove oil filter assembly. (Refer to «OIL FILTER ASSEMBLY»(ref-269574-S02066924082007110100000) )
8. Remove A/C compressor (A) from engine.
9. Remove generator (A) from engine.
10. Remove power steering pump (A) from engine.

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1. Remove drive plate.
2. Remove knock sensor (A).
3. Remove upper oil pan (A).
4. Remove baffle plate (A).
5. Remove rear oil seal case (A).
6. Remove oil drain cover (A).
7. Check the connecting rod end play. (Refer to «CONNECTING ROD AND CRANKSHAFT»(ref-269574-S20596064862007110100000) )
8. Check the connecting rod cap oil clearance. (Refer to «CONNECTING ROD AND CRANKSHAFT»(ref-269574-S20596064862007110100000) )
9. Remove piston and connecting rod assemblies. Using a ridge reamer, remove all the carbon from the top of the cylinder. 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.
10. Remove crankshaft main bearing cap and check oil clearance. (Refer to «CONNECTING ROD AND CRANKSHAFT»(ref-269574-S20596064862007110100000) )
11. Check the crankshaft end play. (Refer to «PISTON AND RINGS»(ref-269574-S19599174122007110100000) )
12. Lift the crankshaft (A) out of engine, being careful not to damage journals. NOTE: Arrange the main bearings and thrust bearings in the correct order.
13. Check fit between piston and piston p in. Try to move the piston back and forth on the piston p in. If any movement is felt, replace piston and piston pin as a set.
14. Remove piston rings. Using a piston ring expender, remove the 2 compression rings. Remove 2 side rails and the spacer by hand. NOTE: Arrange the piston rings in the correct order only.
15. Disconnect connecting rod from piston. Using a press, remove the piston pin from piston. (Press-in load: 800-1400 kg (1764-3086 1b)

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1. Check the connecting rod end play. Using a feeler gauge, measure the end play while moving the connecting rod back and forth. Standard end play: 0.1-0.25 mm (0.004-0.010 in.) If out-of-tolerance, install a new connecting rod. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. Remove 2 connecting rod cap bolts. Remove the connecting rod cap and bearing half. Clean the crank pin and bearing. Place plastigage across the crank p in. Reinstall the bearing half and cap, and torque the bolts. Tightening torque 19.6 N.m (2.0 kgf.m, 14.46 lb-ft) + 90° NOTE: Do not turn the crankshaft. Remove 2 bolts, connecting rod cap and bearing-half. Measure the plastigage at its widest point. Standard oil clearance 0.038-0.056 mm (0.0015-0.0022 in.) 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. 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 ROD MARK LOCATION DISCRIMINATION OF CONNECTING ROD DISCRIMINATION OF CONNECTING ROD CLASS MARK INSIDE DIAMETER 0 a 58.000-58.006 mm (2.2834-2.2837 in.) 1 b 58.006-58.012 mm (2.2837-2.2839 in.) 2 c 58.012-58.018 mm (2.2839-2.2842 in.) CRANKSHAFT PIN MARK LOCATION DISCRIMINATION OF CRANKSHAFT DISCRIMINATION OF CRANKSHAFT DISCRIMINATION OF CRANKSHAFT CLASS MARK OUTSIDE DIAMETER OF PIN 1 1 or A 54.966-54.972 mm (2.1640-2.1642 in.) II 2 or B 54.960-54.966 mm (2.1638-2.1640 in.) III 3 or C 54.954-54.960 mm (2.1635-2.1638 in.) PLACE OF IDENTIFICATION MARK (CONNECTING ROD BEARING) DISCRIMINATION OF CONNECTING ROD BEARING DISCRIMINATION OF CONNECTING ROD BEARING CLASS MARK THICKNESS OF BEARING E BLUE 1.514-1.517 mm (0.0596-0.0597 in.) D BLACK 1.511-1.514 mm (0.0595-0.0596 in.) C BROWN 1.508-1.511 mm (0.0594-0.0595 in.) B GREEN 1.505-1.508 mm (0.0593-0.0594 in.) A YELLOW 1.502-1.505 mm (0.0591-0.0593 in.) Selection CONNECTING ROD IDENTIFICATION MARK REFERENCE CONNECTING ROD IDENTIFICATION MARK 0 (a) 1 (b) 2 (c) CRANKSHAFT IDENTIFICATION MARK 1 or A A (YELLOW) B (GREEN) C (BROWN) 2 or B B (GREEN) C (BROWN) D (BLACK) 3 or C C (BROWN) D (BLACK) E (BLUE)
3. Check the crankshaft bearing oil clearance. To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves. Clean each main journal and bearing half with a clean shop tower. Place one strip of plastigage across each main journal. Reinstall the bearings and caps, then torque the bolts. Tightening torque 49.00 N.m (5.0 kgf.m, 36.16 lb-ft) + 90° 19.60 N.m (2.0 kgf.m, 14.46 lb-ft)+ 120° 29.40-31.36 N.m (3.0-3.2 kgf.m, 21.70-23.14 lb-ft) NOTE: Do not turn the crankshaft. Remove the cap and bearing again, and measure the widest part of the plastigage. Standard oil clearance 0.022-0.040 mm (0.0009-0.0016 in.) 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. 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. Crankshaft bore mark location Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores. Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings. DISCRIMINATION OF CYLINDER BLOCK DISCRIMINATION OF CYLINDER BLOCK CLASS MARK INSIDE DIAMETER a A 73.500-73.506 mm (2.8937-2.8939 in.) b B 73.506-73.512 mm (2.8939-2.8942 in.) c C 73.512-73.518 mm (2.8942-2.8944 in.) CRANKSHAFT JOURNAL MARK LOCATION DISCRIMINATION OF CRANKSHAFT DISCRIMINATION OF CRANKSHAFT DISCRIMINATION OF CRANKSHAFT CLASS MARK OUTSIDE DIAMETER OF JOURNAL I 1 or A 68.954-68.960 mm (2.7147-2.7150 in.) II 2 or B 68.948-68.954 mm (2.7145-2.7147 in.) III 3 or C 68.942-68.948 mm (2.7142-2.7145 in.) PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING) DISCRIMINATION OF CRANKSHAFT BEARING DISCRIMINATION OF CRANKSHAFT BEARING CLASS MARK THICKNESS OF BEARING E BLUE 2.277-2.280 mm (0.0896-0.0897 in.) D BLACK 2.274-2.277 mm (0.0895-0.0896 in.) C BROWN 2.271-2.274 mm (0.0894-0.0895 in.) B GREEN 2.268-2.271 mm (0.0893-0.0894 in.) A YELLOW 2.265-2.268 mm (0.0892-0.0893 in.) SELECTION CRANKSHAFT BORE IDENTIFICATION MARK REFERENCE CRANKSHAFT BORE IDENTIFICATION MARK a (A) b (B) c (C) CRANKSHAFT IDENTIFICATION MARK 1 or A A (YELLOW) B (GREEN) C (BROWN) 2 or B B (GREEN) C (BROWN) D (BLACK) 3 or C C (BROWN) D (BLACK) E (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 0.10-0.28 mm (0.0039-0.0110 in.) If the end play is greater than maximum, replace the thrust bearings as a set. Thrust bearing thickness 2.41-2.45 mm (0.0949-0.0964 in.)
5. Inspect main journals and crank pins Using a micrometer, measure the diameter of each main journal and crank p in. Main journal diameter: 68.942-68.960 mm (2.7142-2.7149 in.) Crank pin diameter: 54.954-54.972 mm (2.1635-2.1642 in.)

1. Install power steering pump.
2. Install generator.
3. Install air conditioner compressor
4. Install oil filter assembly. (Refer to «OIL FILTER ASSEMBLY»(ref-269574-S32753654002007110100000) )
5. Install oil pump. (Refer to «OIL PUMP»(ref-269574-S26931458712007110100000) )
6. Install cylinder head. (Refer to «INSTALLATION»(ref-269574-S38637390152007110100000) )
7. Install water temperature control assembly. (Refer to «WATER TEMPERATURE CONTROL ASSEMBLY»(ref-269574-S08855888072007110100000) )
8. Install timing chain. (Refer to «INSTALLATION»(ref-269574-S23059894772007110100000) )
9. Install intake manifold. (Refer to «INTAKE MANIFOLD»(ref-269574-S00420520242007110100000) )
10. Install exhaust manifold. (Refer to «EXHAUST MANIFOLD»(ref-269574-S41551048552007110100000) )

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