Engine Knocks Cold and Continues for Two-Three Minutes and/or Knock Increases with Engine Torque
| Step | Action | Value(s) | Yes | No |
|---|---|---|---|---|
| 1 | Does the engine knock when it is cold and continue for two to three minutes or does the knock increase with torque? | Go to Step 2 | System OK | |
| 2 | Inspect the flywheel. Is the flywheel contacting the splash shield? | Go to Step 3 | Go to Step 4 | |
| 3 | Reposition the splash shield. Is the repair complete? | Go to Step 1 | ||
| 4 | Inspect the balancer and the drive pulleys. Is either the balancer or the drive pulleys loose or broken? | Go to Step 5 | Go to Step 6 | |
| 5 | Tighten or replace the balancer or the drive pulleys. Is the repair complete? | Go to Step 1 | ||
| 6 | Inspect the piston-to-bore clearance. Is the clearance more than the specified value? | 0.010 - 0.030 mm (0.00039 - 0.00110 in.) | Go to Step 7 | Go to Step 8 |
| 7 | Rebore the cylinder and hone to size. Replace the piston. Is the repair complete? (1) | Go to Step 1 | ||
| 8 | Inspect the connecting rod. Is the connecting rod bent? | Go to Step 9 | System OK | |
| 9 | Replace the connecting rod. Is the repair complete? | Go to Step 1 | ||
| (1) Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock, which disappears in about 1.5 minutes, is considered acceptable. | ||||
| (1) | Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock, which disappears in about 1.5 minutes, is considered acceptable. |
ENGINE KNOCKS COLD AND CONTINUES FOR TWO-THREE MINUTES AND/OR KNOCK INCREASES WITH ENGINE TORQUE
Heavy Knock Hot with Torque Applied
| Step | Action | Value(s) | Yes | No |
|---|---|---|---|---|
| 1 | Is there a heavy knock when the engine is hot and torque is applied? | Go to Step 2 | System OK | |
| 2 | Inspect the balancer and the pulley hub. Is the balancer or the pulley hub broken? | Go to Step 3 | Go to Step 4 | |
| 3 | Replace the broken balancer or the pulley hub. Is the repair complete? | Go to Step 1 | ||
| 4 | Inspect the torque converter bolts. Are the bolts tightened to specified value? | 45 N.m (33 lb-ft) | Go to Step 5 | Go to Step 6 |
| 5 | Tighten the torque converter bolts. Is the repair complete? | Go to Step 1 | ||
| 6 | Inspect the accessory drive belts. Are the belts too tight or nicked? | Go to Step 7 | Go to Step 8 | |
| 7 | Replace and/or tension the belts to specifications, as necessary. Is the repair complete? | Go to Step 1 | ||
| 8 | Inspect the exhaust system. Is the system grounded? | Go to Step 9 | Go to Step 10 | |
| 9 | Reposition the system, as necessary. Is the repair complete? | Go to Step 1 | ||
| 10 | Inspect the flywheel. Is the flywheel cracked? | Go to Step 11 | Go to Step 12 | |
| 11 | Replace the flywheel. Is the repair complete? | Go to Step 1 | ||
| 12 | Inspect the main bearing clearance. Is the clearance more than the specified value? | 0.015 - 0.040 mm (0.00059 - 0.00157 in.) | Go to Step 13 | Go to Step 14 |
| 13 | Replace the main bearings, as necessary. Is the repair complete? | Go to Step 1 | ||
| 14 | Inspect the rod bearing clearance. Is the clearance more than the specified value? | 0.019 - 0.070 mm (0.0007 - 0.0028 in.) | Go to Step 15 | System OK |
| 15 | Replace the rod bearings, as necessary. Is the repair complete? | Go to Step 1 |
HEAVY KNOCK HOT WITH TORQUE APPLIED
Engine Specifications
| Application | Description |
|---|---|
| General Data | |
| Engine Type | U20SED |
| Displacement | 1,998 cm 3 (121.92 in 3 ) |
| Bore Stroke | 86 x 86 mm (3.38 x 3.38 in.) |
| Compression Ratio | 9.6 ± 0.02:1 |
| Firing Order | 1-3-4-2 |
| Cylinder Bore | |
| Diameter | 85.975 - 86.025 mm (3.3848 - 3.3868 in.) |
| Out of Round (Maximum) | 0.013 mm (0.0005 in.) |
| Taper (Maximum) | 0.013 mm (0.0005 in.) |
| Piston | |
| Diameter | 85.955 - 86.485 mm (3.384 - 3.404 in.) |
| Clearance to Bore | 0.0100 - 0.0300 mm (0.00039 - 0.00110 in.) |
| Piston Protrusion | 0.5 mm (0.019 in.) Maximum |
| Piston Taper | 0.013 (0.0005 in.) |
| Piston Rings | |
| Ring, End Gap: Top Compression | 0.2 - 0.35 mm (0.008 - 0.014 in.) |
| Ring, End Gap: Second Compression | 0.3 - 0.5 mm (0.011 - 0.019 in.) |
| Ring, End Gap: Oil | 0.25 - 0.76 mm (0.01 - 0.03 in.) |
| Piston Pin | |
| Diameter | 20.9970 - 20.9985 mm (0.82665 - 0.82671 in.) |
| Pin Offset | 1.0 mm (0.04 in.) Towards Thrust Side |
| Clearance: In Piston | 0.0035 - 0.0140 mm (0.00013 - 0.00055 in.) |
| Clearance: In Rod | Interference Fit in Rod |
| Length | 61.5 mm (2.42 in.) |
| Camshaft | |
| Lift - Intake | 9.2 mm (0.36 in.) |
| Lift - Exhaust | 9.2 mm (0.36 in.) |
| End Play | 0.040 - 0.14 mm (0.0015 - 0.0055 in.) |
| Bearing Journal OD | 42.455 - 43.470 mm (1.6714 - 1.7114 in.) |
| Crankshaft | |
| Main Journal: Diameter (All) | 57.974 - 57.995 mm (2.2824 - 2.2832 in.) |
| Out of Round (Maximum) | 0.003 mm (0.0001 in.) |
| Main Bearing Clearance (All) | 0.015 - 0.040 mm (0.00059 - 0.00157 in.) |
| Crankshaft End Play | 0.070 - 0.302 mm (0.0027 - 0.0118 in.) |
| Service Oversize | Available in 2 sizes 0.25 mm and 0.50 mm (0.0098 and 0.0196 in.) |
| Connecting Rod Journal: Diameter (All) | 48.970 - 48.988 mm (1.9279 - 1.9287 in.) |
| Out of Round (Maximum) | 0.004 mm (0.00015 in.) |
| Cylinder Head | |
| Valve Stem Protrusion | 39.2 - 39.8 mm (1.54 - 1.56 in.) |
| Valve Guide Height | 13.7 - 14.0 mm (0.54 - 0.57 in.) |
| Overall Height | 134 ± 0.025 mm (5.2755 ± 0.0009 in.) |
| Minimum Overall Height After Machining | 133.9 mm (5.27 in.) |
| Valve System | |
| Valve Lash Compensators | Hydraulic Tappet |
| Seat Runout (Maximum, All) | 0.03 mm (0.00118 in.) |
| Face Runout (Maximum, All) | 0.03 mm (0.00118 in.) |
| Valve Stem Diameter | |
| Intake | 5.945 - 5.960 mm (0.2341 - 0.2346 in.) |
| Exhaust | 5.945 - 5.960 mm (0.2341 - 0.2346 in.) |
| Valve Diameter | |
| Intake | 32 ± 0.1 mm (1.2598 ± 0.0039 in.) |
| Exhaust | 29 ± 0.1 mm (1.1417 ± 0.0039 in.) |
| Valve Seat Width | |
| Intake | 1.0 - 1.5 mm (0.039 - 0.059 in.) |
| Exhaust | 1.7 - 2.2 mm (0.066 - 0.086 in.) |
| Valve Face Angle | 44° |
| Valve Guide Inside Diameter | 6.000 - 6.012 mm (0.236 - 0.237 in.) |
| Sealants and Adhesives | |
| Rear Main Bearing Cap | GE p/n RTV 159 |
| Camshaft Carrier to Cylinder Head | HN 1581 (Loctite® 515) |
| Coolant Jacket Caps and Plugs (Freeze Plugs) | HN 1756 (Loctite® 176) |
| Exhaust Manifold Studs/Nuts | Anti-seize Compound (HMC Spec HN1325) |
ENGINE SPECIFICATIONS
Tightening Torque Specifications
| Application | N.m |
|---|---|
| Air Cleaner Element Cover Screw | 2 |
| Air Cleaner Housing Bolts | 10 |
| Automatic Tensioner Bolt | 25 |
| Crankshaft Bearing Bridge and Oil Pan Scraper Bolts | 20 + 45° |
| Camshaft Bearing Cap Bolts | 8 |
| Camshaft Cover Bolts | 8 |
| Charcoal Canister Purge and Exhaust Gas Recirculation Solenoid Bracket Bolt | 5 |
| Connecting Rod Bearing Cap Bolts | 35 + 45° + 15° |
| Crankshaft Bearing Cap Bolts | 50 + 45° + 15° |
| Crankshaft Pulley Bolts | 20 |
| Crankshaft Gear Bolt | 145 + 30° + 15° |
| Cylinder Head Bolts | 25 + 90°+ 90° + 90° |
| Engine Mount Bracket Retaining Bolts | 55 |
| Engine Mount Retaining Bolts | 45 |
| Exhaust Camshaft Gear Bolt | 50 + 60° + 15° |
| Flywheel Bolts | 65 + 30° + 15° |
| Front Timing Belt Cover Bolts | 6 |
| Generator-to-Intake Manifold Support Bracket Bolt | 22 |
| Generator-to-Intake Manifold Support Bracket Bolts | 37 |
| Intake Camshaft Gear Bolt | 50 + 60° + 15° |
| Intake Manifold Retaining Bolt and Nuts | 22 |
| Intake Manifold Support Bracket Lower Bolt | 25 |
| Intake Manifold Support Bracket Upper Bolts | 25 |
| Rear Timing Belt Cover Bolts | 7 |
| Spark Plug Cover Bolts | 8 |
| Spark Plugs | 20 |
| Timing Belt Automatic Tensioner Bolts | 25 |
| Timing Belt Idler Pulley Bolt | 25 |
| Timing Belt Idler Pulley Nut | 25 |
| Transaxle Torque Converter Bolts | 60 |
| Exhaust Flex Pipe-to-Exhaust Manifold Retaining Nut | 35 |
| Lower Reaction Rod Mount Bolt | 55 |
| Lower Reaction Rod Bracket Bolt | 69 |
| Exhaust Flex Pipe-to-Catalytic Converter or Connecting Pipe Retaining Nut | 35 |
| Oil Suction Pipe Bolt | 8 |
| Oil Suction Pipe Bracket Bolt | 6 |
| Direct Ignition System Coil and Exhaust Gas Recirculation Mounting Bracket Bolt | 25 |
| Exhaust Manifold Retaining Nut | 22 |
| Exhaust Manifold Heat Shield Bolt | 8 |
| Oil Pan Retaining Bolt | 10 |
| Transaxle Bell Housing Bolts | 75 |
| Oil Pan Flange-toTransaxle Bolts | 40 |
| Thermostat Housing Mounting Bolts | 15 |
| Coolant Bypass Housing Bolts | 15 |
| Oil Pump Retaining Bolts | 10 |
TIGHTENING TORQUE SPECIFICATIONS