Engine Mechanical: Removal & Installation Kia Sorento I рестайлинг

REMOVAL

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

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1. Remove the engine cover (A).
2. Recover refrigerant by opening the high & low pressure pipe caps and connecting the refrigerant station. Refer to «AIR CONDITIONING SYSTEM»(ref-278806-S00566106252008020400000) .
3. Remove the under cover (A).
4. Drain engine oil, transaxle fluid and engine coolant.
5. Disconnect the negative terminal from the battery and remove the battery (A).
6. 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) with the resonator (D).
7. Disconnect the PCM connectors (A).
8. Remove the battery tray while recovering refrigerant.
9. Disconnect the high and low pressure pipes from the radiator or the compressor. Refer to «AIR CONDITIONING SYSTEM»(ref-278806-S00566106252008020400000) .
10. Remove the radiator. Refer to «RADIATOR»(ref-278796-S23492528822008020400000) .
11. Disconnect the engine wiring harness connectors. Disconnect the oil control valve (OCV) harness connector (A) and the knock sensor (LH) harness connector (B) Disconnect the MAP (A), ETC (B), ignition coil harness connector (C) and the injection harness connector (D). Disconnect the battery connector (A), the power steering switch connector (B) and the knock sensor (RH) harness connector (C). Disconnect the oxygen sensors (A), CMP (B), CKP (C), VIV (D) and the condenser harness connector (E). Disconnect the water temperature sensor (WTS) harness connector (A), the oil temperature sensor (OTS) harness connector (B) and the purge control solenoid valve (PCSV) harness connector (C).
12. Disconnect the transaxle wire harness connector and remove the transaxle assembly. Refer to «AUTOMATIC TRANSAXLE SYSTEM»(ref-278800) .
13. Disconnect the fuel hose tube (A).
14. Disconnect the front exhaust muffler with the exhaust manifolds.
15. Remove the front wheels and tires. Refer to Suspension system in «SUSPENSION SYSTEM (TPMS)»(ref-278801) .
16. Remove heater hose (A) and disconnect the brake vacuum hose (B).
17. Remove the exhaust and intake manifold covers. Refer to «INTAKE AND EXHAUST SYSTEM»(ref-278796-S08513696532008020400000) .
18. Remove the power steering pump assembly.
19. Remove the hood assembly. Refer to Hood in «BODY (INTERIOR AND EXTERIOR)»(ref-278816) .
20. Install a jack for supporting the engine assembly.
21. Remove the engine mounting brackets (A).
22. Jack up the engine assembly in order to remove the engine from the vehicle.

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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Radiator removal is required for this procedure. (Refer to 'Radiator removal')

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1. Remove the drive belt(A). see scheme 32: Identifying Drive Belt
2. Remove the power steering pump(A). (Scheme 26): Identifying Power Steering Pump
3. Remove the air compressor(A). (Scheme 27): Identifying Air Compressor
4. Remove the alternator(A). (Scheme 28): Identifying Alternator
5. Remove drive belt idler(A). (Scheme 29): Identifying Drive Belt Idler With Mounting Bolt
6. Remove drive belt auto tensioner(A). (Scheme 30): Identifying Drive Belt Auto Tensioner With Mounting Bolts
7. Remove water pump pulley(A). (Scheme 31): Identifying Water Pump Pulley
8. Remove intake manifold.

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1. Install intake manifold.
2. Install water pump pulley(A). Tightening torque 7.84 ~ 9.80Nm(0.8 ~ 1.0kgf.m, 5.78 ~ 7.23lb-ft) (Scheme 32): Identifying Water Pump Pulley
3. Install drive belt auto tensioner(A). Tightening torque 81.4 ~ 85.3Nm(8.3 ~ 8.7kgf.m, 60.0 ~ 62.9lb-ft) 29.4 ~ 33.3Nm(3.0 ~ 3.4kgf.m, 21.7 ~ 24.6lb-ft) (Scheme 33): Identifying Drive Belt Auto Tensioner With Mounting Bolts
4. Install drive belt idler(A). Tightening torque 52.92 ~ 57.82Nm(5.4 ~ 5.9kgf.m, 39.06 ~ 42.67lb-ft) (Scheme 34): Identifying Drive Belt Idler With Mounting Bolt
5. Install alternator
6. Install air compressor
7. Install power steering pump.
8. Install drive belt(A).

Crankshaft pulley --> A/C pulley --> idler pulley --> alternator pulley --> water pump pulley --> P/S pump pulley --> tensioner pulley.

Rotate auto tensioner arm in the counter - clockwise moving auto tensioner pulley bolt with wrench.

After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.

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1. Remove the engine cover. (Scheme 36): Identifying Engine Cover With Mounting Screw
2. Remove the engine room resonator(A). (Scheme 37): Identifying Engine Room Resonator With Mounting Screws
3. After disconnecting the MAF sensor connector(A) and the breather hose(B), remove the air cleaner assembly(C). (Scheme 38): Identifying MAF Sensor Connector, Breather Hose And Air Cleaner Assembly
4. After disconnecting the other breather hose(A), the Purge Control Solenoid Valve(PCSV) hose(B), the Positive Crankcase Ventilation (PCV) hose(C) and the Electronic Throttle Control(ETC) cooling hoses(D), remove the surge tank assemlby(E). (Scheme 39): Identifying Positive Crankcase Ventilation Hose And Electronic Throttle Control Cooling Hoses (Scheme 40): Identifying Other Breather Hose
5. Remove the wiring over the surge tank. Disconnect the injection harness connector(A). Disconnect the camshaft position sensor(CMP) harness connector(B). Disconnect the ground lines(C). Disconnect the ignition coil harness connector(D). Disconnect the condensor connector(E). Disconnect the oil control valve(OCV) harness connector(F). (Scheme 41): Identifying Injection Harness Connector, Ground Lines, Ignition Coil Harness Connector, Condensor Connector And Oil Control Valve Harness Connector
6. Loosen the cylinder head cover bolts and then remove the cover(A) and gasket. (Scheme 42): Identifying Cylinder Head Cover
7. 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 43): Identifying Timing Mark On 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 44): Identifying Mark On Camshaft Timing Sprockets NOTE: Do not rotate engine counterclockwise.
8. Remove the lower oil pan(A). Insert the blade of SST(09215-3C000) between the upper oil pan and lower oil pan, and cut off applied sealer and removed lower oil pan. (Scheme 45): Inserting Blade Of SST (09215-3C000) Between Upper Oil Pan And Lower Oil Pan CAUTION: Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of (1) arrow. After tapping the SST with a plastic hammer along the direction of (2) arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame. Do not turn over the SST abruptly without tapping. It can result in damage of the SST.
9. Remove the crankshaft damper pulley(A). (Scheme 46): Identifying Crankshaft Damper Pulley
10. Remove the timing chain cover(A). (Scheme 47): Identifying Timing Chain Cover NOTE: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover. Mark on the timing chain on the basis of the marking on sprocket and CVVT.
11. Install a set pin after compressing the timing chain tensioner. (Scheme 48): Installing Set Pin
12. Remove RH cam-to-cam guide(A). (Scheme 49): Identifying RH Cam-To-Cam Guide
13. Remove RH timing chain auto tensioner(A) and RH timing chain tensioner arm(B). (Scheme 50): Identifying RH Timing Chain Auto Tensioner And RH Timing Chain Tensioner Arm
14. Remove oil pump chain cover(A). (Scheme 51): Identifying Oil Pump Chain Cover With Mounting Bolts
15. Remove oil pump chain tensioner assembly(A). (Scheme 52): Identifying Oil Pump Chain Tensioner Assembly
16. Remove oil pump chain guide(A). (Scheme 53): Identifying Oil Pump Chain Guide
17. Remove RH timing chain.
18. Remove RH timing chain guide(A). (Scheme 54): Identifying RH Timing Chain Guide
19. Remove oil pump chain sprocket(A) and oil pump chain(B). (Scheme 55): Identifying Oil Pump Chain Sprocket And Oil Pump Chain With Mounting Bolts
20. Remove crankshaft sprocket(A)(O/P&RH camshaft drive). (Scheme 56): Identifying Crankshaft Sprocket (O/P And RH Camshaft Drive)
21. Remove LH cam-to-cam guide(A). (Scheme 57): Identifying LH Cam-To-Cam Guide
22. Remove LH timing chain auto tensioner(A) and LH timing chain tensioner arm(B). (Scheme 58): Identifying LH Timing Chain Auto Tensioner And LH Timing Chain Tensioner Arm
23. Remove LH timing chain.
24. Remove LH timing chain guide(A). (Scheme 59): Identifying LH Timing Chain Guide
25. Remove crankshaft sprocket(A)(LH camshaft drive). (Scheme 60): Identifying Crankshaft Sprocket (LH Camshaft Drive)
26. Remove tensioner adapter assembly(A).

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

Engine removal is required for this procedure.

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1. Remove exhaust manifold.
2. Remove intake manifold.
3. Remove timing chain.
4. Remove water temperature control assembly.
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. 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.

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1. Install the cylinder head. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC. 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 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. Tightening torque 1st step: 39.2 N.m (4.0 kgf.m, 28.9 lb-ft) 2nd step: 120° 3rd step: 90° 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 bolt.
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. At this time, attend not to be installed to oil hole of camshaft-inlet. 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. Be careful the right, left bank, intake, exhaust side before assembling. INTAKE CAMSHAFT INTAKE CAMSHAFT SPECIFICATION LH RH 3.3L A: 27 mm (1.0630 in.) A: 30 mm (1.1811 in.) B: 27 mm (1.0630 in.) B: 30 mm (1.1811 in.) 3.8L 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 SPECIFICATION LH RH 3.3L/3.8L A: 27 mm (1.0630 in.) A: 30 mm (1.1811 in.) INTAKE AND EXHAUST CAMSHAFT SPECIFICATION LH RH 3.3L A: 30 mm (1.1811 in.) A: 30 mm (1.1811 in.) B: 27 mm (1.0630 in.) B: 27 mm (1.0630 in.) 3.8L A: 30 mm (1.1811 in.) A: 30 mm (1.1811 in.) B: 27 mm (1.0630 in.) B: 27 mm (1.0630 in.)
6. Install camshaft bearing caps with the order below. Tightening torque 1st step: 5.9 N.m (0.6 kgf.m, 4.3 lb-ft) 2nd step: 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft) NOTE: Be careful the right, left bank, intake, exhaust side before assembling. L(LH), R(RH) I (Intake), None (Exhaust) Journal number Front mark CAUTION: Rotate the crankshaft not to contact the valves to the pistons by making the pistons below 10 mm (0.3937 in.) from the top of cylinder block.
7. Install water temperature control assembly.
8. Install timing chain.
9. Check and adjust valve clearance.
10. Install the exhaust manifold.
11. Install the intake manifold.

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Note. Mark all wiring and hoses to avoid mis-connection. Inspection the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

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1. Remove exhaust manifold.
2. Remove intake manifold.
3. Remove timing chain.
4. Remove water temperature control assembly.
5. Remove cylinder head.
6. Remove oil pump.
7. Remove oil filter assembly.
8. Remove A/C compressor (A) from engine.
9. Remove alternator (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.
8. Check the connecting rod oil clearance.
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.
11. Check the crankshaft end play.
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.

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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, 14.46lbf.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 CLASS MARK OUTSIDE DIAMETER OF PIN I 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) PLACE OF IDENTIFICATION MARK (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) DISCRIMINATION OF CONNECTING ROD BEARING SELECTION SPECIFICATION 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) Selection
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 1 A 68.954-68.960 mm (2.7147-2.7150 in.) II B 68.948-68.954 mm (2.7145-2.7147 in.) III 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 SELECTION SPECIFICATION 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.) CONNECTING RODS 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. 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. 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: 0.05 mm / 100 mm (0.0020 in./3.94 in.) or less Allowable twist of connecting rod: 0.1 mm / 100 mm (0.0039 in./3.94 in.) or less

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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 0.05 mm (0.0020 in.), Less than 0.02 mm (0.0008 in.) / 150 x 150
4. Inspect cylinder bore diameter Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.
5. Inspect cylinder bore diameter Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions. Standard diameter 92.00-92.03 mm (3.6220-3.6232 in) - 3.3L engine 96.00-96.03 mm (3.7795-3.7807 in) - 3.8L engine
6. Check the cylinder bore size code on the cylinder block. CYLINDER BORE INNER DIAMETER SPECIFICATION Class Size code Cylinder bore inner diameter 3.3L 3.8L A A 92.00-92.01 mm (3.6220-3.6224 in) 96.00-96.01 mm (3.7795-3.7799 in) B B 92.01-92.02 mm (3.6224-3.6228 in) 96.01-96.02 mm (3.7799-3.7803 in) C C 92.02-92.03 mm (3.6228-3.6232 in) 96.02-96.03 mm (3.7803-3.7807 in)
7. Check the piston size code (A) and the front mark (B) on the piston top face. PISTON OUTER DIAMETER SPECIFICATION Class Size code Piston outer diameter 3.3L 3.8L A A 91.96-91.97 mm (3.6205-3.6209 in.) 95.96-95.97 mm (3.7779-3.7783 in) B B 91.97-91.98 mm (3.6209-3.6213 in.) 95.97-95.98 mm (3.7783-3.7787 in) C C 91.98-91.99 mm (3.6213-3.6219 in.) 95.98-95.99 mm (3.7787-3.7791 in)
8. Select the piston related to cylinder bore class. Clearance: 0.03-0.05 mm (0.0012-0.0020 in)

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1. Clean piston Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or broken ring, clean the piston ring grooves. 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 14 mm (0.5512 in.) from the bottom of the piston. Standard diameter 91.96-91.99 mm (3.6205-3.6216 in) - 3.3L engine 95.96-95.99 mm (3.7779-3.7791 in) - 3.8L engine
3. Calculate the difference between the cylinder bore diameter and the piston diameter. Piston-to-cylinder clearance 0.03-0.05 mm (0.0012-0.0020 in)
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 Standard No.1: 0.03-0.07 mm (0.0012-0.0027 in) No.2: 0.03-0.07 mm (0.0012-0.0027 in) Oil ring: 0.06-0.15 mm (0.0024-0.0059 in) Limit No. 1: 0.1 mm (0.004 in) No. 2: 0.1 mm (0.004 in) Oil ring: 0.2 mm (0.008 in) 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. If the bore is over the service limit, the cylinder block must be replaced. Piston ring end gap Standard No. 1: 0.17-0.32 mm (0.0067-0.0126 in) No. 2: 0.32-0.47 mm (0.0126-0.0185 in) Oil ring: 0.20-0.70 mm (0.0079-0.0275 in) Limit No. 1: 0.6 mm (0.0236 in) No. 2: 0.7 mm (0.0275 in) Oil ring: 0.8 mm (0.0315 in.)

Scheme 110

1. Measure the diameter of the piston p in. Piston pin diameter 23.001-23.006 mm (0.9055-0.9057 in)
2. Measure the piston pin-to-piston clearance. Piston pin-to-piston clearance 0.010-0.020 mm (0.0004-0.0008 in)
3. Check the difference between the piston pin diameter and the connecting rod small end diameter. Piston pin-to-connecting rod interference -0.032 to 0.016 mm (-0.0012 to 0.00063 in)

1. Install power steering pump.
2. Install alternator.
3. Install air compressor
4. Install oil filter assembly.
5. Install oil pump.
6. Install cylinder head.
7. Install water temperature control assembly.
8. Install timing chain.
9. Install intake manifold.
10. Install exhaust manifold.

Scheme 111

OIL PUMP

Scheme 112

Scheme 113

Scheme 114

Scheme 115

1. Drain engine oil.
2. Remove the front member. Refer to Front suspension system in «SUSPENSION SYSTEM (TPMS)»(ref-278801) .
3. Using SST (09215-3C000) remove lower oil pan (A). CAUTION: Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of (1) arrow. After tapping the SST with a plastic hammer along the direction of (2) arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame. Do not turn over the SST abruptly without tapping. It can result in damage of the SST.
4. Remove oil pump chain cover (A).
5. Remove oil pump chain sprocket (A).
6. Remove oil pump (A).

Scheme 116

1. Remove the engine assembly. Refer to «ENGINE AND TRANSAXLE ASSEMBLY»(ref-278796-S42913372672008020400000) .
2. Loosen the oil filter cap by turning it counterclockwise to drain well the oil in the oil filter.
3. Remove surge tank and intake manifold.
4. Disconnect oil pressure switch connector.
5. Drain engine coolant.
6. Disconnect water hoses from water temperature control assembly.
7. Remove water temperature control assembly.
8. Remove oil filter body cover (B).
9. Remove oil filter body (A).

Scheme 117

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 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 50 kPa (7 psi) vacuum is applied through the oil hole, the switch is operating properly.

Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

Scheme 118

REPLACEMENT

[RH SIDE OR BANK 1]

Scheme 119

Scheme 120

1. Remove the engine cover (A).
2. After disconnecting the MAF sensor connector (A) and the breather hose (B), remove the air cleaner assembly (C).
3. Remove the RH cooling pipe (A).
4. Remove the RH exhaust manifold heat protector. CAUTION: Handle the heat protector with caution not to be deformed.
5. After removing the under cover, disconnect the exhaust manifolds from the front muffler.
6. Remove the RH exhaust manifold (A) and the stay (B).

[LH SIDE OR BANK 2]

Scheme 121

Scheme 122

1. Remove the engine oil level gauge.
2. Remove the battery assembly (A).
3. Remove the LH exhaust manifold heat protector. CAUTION: Handle the heat protector with caution not to be deformed.
4. Remove the LH cooling pipe (A).
5. Remove the automatic transaxle fluid oil level gauge.
6. Disconnect the oil pressure switch harness connector and the battery ground line.
7. After removing the under cover, disconnect the exhaust manifolds from the front muffler.
8. Remove the LH exhaust manifold.
9. To install, reverse the removal procedure.

Scheme 123