Engine Knocks Cold and Continues for 2 - 3 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 2 - 3 min 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 value specified? | 0.015 - 0.027 mm (-0.00059 - 0.001063 in.) | Go to Step 7 | Go to Step 8 |
| 7 | Measure the diameter of the piston. Is the diameter greater than the specification? | 76.973 - 77.015 mm (3.0304 - 3.0320 in.) | Go to Step 8 | Go to Step 9 |
| 8 | Replace the piston and piston rings. Is the piston-to-bore clearance still more than the value specified? | Go to Step 10 | Go to Step 11 | |
| 9 | Measure the diameter of the cylinder bore. Is the diameter greater than the specification? | 76.994 - 77.006 mm (3.0313 - 3.0317 in.) | Go to Step 10 | Go to Step 11 |
| 10 | Replace the cylinder block. Is the repair complete? | Go to Step 1 | ||
| 11 | Inspect the connecting rod. Is the connecting rod bent? | Go to Step 12 | System OK | |
| 12 | Replace the connecting rod. Is the repair complete? | Go to Step 1 |
ENGINE KNOCKS COLD AND CONTINUES FOR 2 - 3 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 value specified? | 40 - 50 N.m (30 - 37 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 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? | System OK | 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 value specified? | 0.019 - 0.049 mm (0.00075 - 0.00193 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? | 0.031 - 0.065 mm (0.00122 - 0.00256 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 | 6 Cylinder (In-Line) | |
| Displacement | 2,492 cm 3 (152 in 3 ) | |
| Bore Stroke | 77 x 89.2 mm (3.03 x 3.51 in.) | |
| Compression Ratio | 9.8 : 1 | |
| Firing Order | 1-5-3-6-2-4 | |
| Cylinder Bore | ||
| Diameter | 76.994 - 77.006 mm (3.0313 - 3.0317 in.) | |
| Out of Round (Maximum) | 0.007 mm (0.00028 in.) | |
| Cylinder Bore Taper (Maximum) | 0.01 mm (0.0004 in.) | |
| Piston Protrusion | 0.457 - 0.132 mm (-0.01799 - 0.00520 in.) | |
| Oversize (Measure Replacement Piston before Re-boring) | None | |
| Block Face Distortion | 0.007 mm (0.0003 in.) | |
| Piston | ||
| Diameter | 76.973 - 77.015 mm (3.0304 - 3.0320 in.) | |
| Clearance to Bore | 0.015 - 0.027 mm (-0.00059 - 0.001063 in.) | |
| Ring Groove Width | Top | 1.23 - 1.25 mm (0.0484 - 0.0492 in.) |
| 2nd | 1.50 - 1.52 mm (0.0590 - 0.0598 in.) | |
| Oil | 2.01 - 2.03 mm (0.0791 - 0.0799 in.) | |
| Ring Grove Inner Diameter | Top | 69.3 - 69.5 mm (2.7283 - 2.7362 in.) |
| 2nd | 68.7 - 68.9 mm (27047 - 2.7125 in.) | |
| Oil | 68.2 - 68.4 mm (2.6850 - 2.6929 in.) | |
| Piston Rings | ||
| Ring, End Gap, Top Compression | 0.2 - 0.35 mm (0.00787 - 0.01378 in.) | |
| Ring, End Gap, Second Compression | 0.35 - 0.5 mm (0.01378 - 0.01969 in.) | |
| Oil | 0.2 - 0.7 mm (0.00787 - 0.02756 in.) | |
| Piston Ring Width | Top | 1.170 - 1.190 mm (0.0460 - 0.0468 in.) |
| 2nd | 1.470 - 1.490 mm (0.0578 - 0.0586 in.) | |
| Oil | 1.88 - 1.95 mm (0.0740 - 0.0767 in.) | |
| Piston Ring Thickness | Top | 2.75 - 3.05 mm (0.1082 - 0.1200 in.) |
| 2nd | 3.05 - 3.35 mm (0.1200 - 0.1318 in.) | |
| Oil | 2.90 - 3.10 mm (0.1141 - 0.1220 in.) | |
| Ring Groove Clearance | Top | 0.04 - 0.08 mm (0.00157 - 0.00314 in.) |
| 2nd | 0.01 - 0.05 mm (0.00039 - 0.00196 in.) | |
| Oil | 0.06 - 0.15 mm (0.00236 - 0.00590 in.) | |
| Piston Pin | ||
| Diameter | 18.995 - 19.000 mm (0.74783 - 0.74803 in.) | |
| Pin Offset | 0.6 mm (0.02362 in.) | |
| Clearance: In Piston | 0.009 - 0.019 mm (0.00035 - 0.00075 in.) | |
| Clearance: In Rod | Interference Fit in Rod (-0.010 - 0.025 mm) | |
| Length | 55.7 - 56.0 mm (2.193 - 2.205 in.) | |
| Camshaft | ||
| Lift - Intake | 10 mm (0.39 in.) | |
| Lift - Exhaust | 9 mm (0.35 in.) | |
| Camshaft Cap to Bearing Journal Clearance | 0.03 - 0.071 mm (0.00118 - 0.00280 in.) | |
| Bearing Journal OD | 24.95 - 24.97 mm (0.98228 - 0.98307 in.) | |
| Crankshaft | ||
| Main Journal-Diameter (All) | 57.980 - 58.000 mm (2.2827 - 2.2835 in.) | |
| Main Journal - Radial Run out (Shaft Support on No. 1 and No. 7 Bearings Measured at No. 4 Journal) | 0.06 mm (0.00236 in.) | |
| Main Bearing Clearance (All) | 0.019 - 0.049 mm (0.00075 - 0.000193 in.) | |
| End Play | 0.055 - 0.265 mm (0.002 - 0.010 in.) | |
| Service Oversize, Available in 2 sizes | Not Necessary | |
| Connecting Rod Journal | ||
| Diameter (All) | 47.2 - 47.212 mm (1.8583 - 1.8587 in.) | |
| Out of Round (Maximum) | 0.008 mm (0.00031 in) | |
| Rod Bearing Play | 0.080 - 0.260 mm (0.00315 - 0.01024 in.) | |
| Rod Bearing Clearance | 0.031 - 0.065 mm (0.00122 - 0.00256 in.) | |
| Cylinder Head | ||
| Valve Stem Protrusion | 27 mm (1.063 in.) | |
| Valve Guide Height | 11.7 - 12.0 mm (0.46063 - 0.47244 in.) | |
| Overall Height | 128.2 - 128.4 mm (5.04724 - 5.05512 in.) | |
| Minimum Overall Height After Machining | 128.1 mm (5.04331 in.) | |
| Valve System | ||
| Valve Lash Compensators | Hydraulic | |
| Seat Run Out (Maximum, All) | 0.05 mm (0.00197 in.) | |
| Face Run Out (Maximum, All) | 0.03 mm (0.00118 in.) | |
| Valve Stem Diameter Intake | 5.465 - 5.479 mm (0.21516 - 0.21571 in.) | |
| Valve Stem Diameter Exhaust | 5.465 - 5.470 mm (0.21480 - 0.21535 in.) | |
| Valve Diameter Intake | 30.1 - 30.3 mm (1.18504 - 1.19291 in.) | |
| Valve Diameter Exhaust | 25.7 - 25.9 mm (1.01181 - 1.01969 in.) | |
| Valve Seat Width Intake | 1.0 - 1.4 mm (0.03937 - 0.05512 in.) | |
| Valve Seat Width Exhaust | 1.4 - 1.8 mm (0.05512 - 0.07087 in.) | |
| Valve Face Angle | 90° - 90° 40' | |
| Valve Seat Angle | 89.5° - 90° | |
| Valve Guide Inside Diameter | 5.5 - 5.512 mm (0.21654 - 0.21701 in.) | |
| Oil Pump | ||
| Outer Gear to Body | 0.1 - 0.19 mm (0.00394 - 0.00748 in.) | |
| Outer Gear to Crescent | 0.02 - 0.07 mm (0.00079 - 0.00276 in.) | |
| Inner Gear to Crescent | 0.02 - 0.07 mm (0.00079 - 0.00276 in.) | |
| End Clearance (TIP clearance) | 0.02 - 0.16 mm (0.00079 - 0.00630 in.) | |
| Sealants and Adhesives | ||
| Oil Pan Bolts (Oil pan x Bed plate) | Loctite® 5900 | |
| Oil Gallery Plug | Loctite® 242 | |
| Coolant Jacket Caps and Plugs (Freeze Plugs) | Dry seal-lock coated in plug | |
ENGINE SPECIFICATIONS
Tightening Torque Specifications
| Application | N.m | Lb-in. |
|---|---|---|
| Intake Manifold Retaining Bolt/Nut | 10 - 14 | 89 - 124 |
| Engine Beautification Cover Bolt | 8 - 12 | 71 - 106 |
| Front Support Bracket Bolt | 15 - 25 | |
| Rear Support Bracket Bolt (Intake-side) | 8 - 12 | 71 - 106 |
| Rear Support Bracket Bolt (Exhaust-side) | 18 - 25 | |
| Cylinder Head Cover Bolt | 12 - 14 | 106 - 124 |
| Air Filter Housing Bolt | 8 - 12 | 71 - 106 |
| Oil Filter Adapter Retaining Bolt | 20 - 26 | |
| Connecting Piece | 17 - 23 | |
| Oil Filter | 12 - 16 | |
| Oil Pump Sprocket Retaining Nut | 18 - 22 | |
| Oil Pump Bolt | 18 - 22 | |
| Oil Suction Pipe-to-Oil Pump Retaining Bolt | 8 - 12 | 71 - 106 |
| Oil Suction Pipe Bracket Bolt | 8 - 12 | 71 - 106 |
| Oil Pump Sprocket Cover Bolt | 5 - 7 | 44 - 62 |
| Oil Pan Retaining Bolt | 8 - 12 | 71 - 106 |
| Oil Pan Flange-to-Transaxle Bolt | 27 - 35 | |
| Oil Pan Drain Plug | 30 - 40 | |
| Engine Mount Bracket-to-Hydro Mount Nut | 55 - 70 | |
| Engine Mount Bracket Nut | 42 - 60 | |
| Engine Mount Bracket Bolt | 42 - 60 | |
| Transaxle Mount Cage-to-Longitudinal Member Bolt | 55 - 75 | |
| Transaxle Mount Cage-to-Transaxle Mount Bracket Bolt | 55 - 75 | |
| Transaxle Mount Cage-to-Transaxle Mount Bracket Nut | 55 - 75 | |
| Transaxle Mount Cage Through Bolt | 100 - 120 | |
| Exhaust Manifold Retaining Nut | 27 - 30 | |
| Exhaust Manifold Heat Shield Bolt | 18 - 22 | |
| Engine Block-to-Transaxle Bolt | 60 - 85 | |
| Center Front Suspension Member Bolt | 80 - 100 | |
| Transaxle Torque Converter Bolt | 40 - 50 | |
| Front Engine Mount Bracket-to-Damper Bush Bolt | 70 - 90 | |
| Engine Under Cover Retaining Bolt | 17 - 27 | |
| Fixed Timing Chain Guide Bolt | 18 - 22 | |
| Timing Chain Lever Bolt | 18 - 22 | |
| Timing Chain Tensioner Bolt | 18 - 22 | |
| Top Chain Guide Bolt | 9 - 11 | 80 - 97 |
| Timing Chain Cover Bolt | 6 - 10 | 53 - 89 |
| Timing Chain Cover Bolt (Center) | 18 - 22 | |
| Drive Belt Automatic Tensioner | 20 - 30 | |
| Water Pump Pulley Bolt | 8 - 12 | 71 - 106 |
| Engine Mount Bracket Support Bolt | 25 - 31 | |
| Crankshaft Pulley Bolt | 500 - 600 | |
| Flexible Plate Bolt | 70 - 80 | |
| Cylinder Head Bolt | 20, 25 + 70° + 70° | |
| Upper Pad Bracket Bolt | 35 - 55 | |
| Coolant Outlet Port Retaining Bolt | 8 - 12 | 71 - 106 |
| EGR Adapter Retaining Bolt | 18 - 22 | |
| Power Steering Pump Retaining Bolt | 20 - 30 | |
| Intake Manifold Support Bracket Bolt | 20 - 30 | |
| Bed Plate Inner Bolt | 33+135° | |
| Bed Plate Outer Bolt | 20 - 26 | |
| Oil Pump Chain Lever Bolt | 6 - 10 | 53 - 89 |
| Engine Oil Dipstick Tube Bracket Bolt | 18 - 22 | |
| Engine Oil Dipstick Tube Bolt | 8 - 10 | 71 - 89 |
| Bed Plate Baffle Bolt | 7 - 9 | 62 - 80 |
| Lower Pad Bracket Bolt | 35 - 45 | |
| Idler Retaining Bolt | 35 - 55 | |
| Upper Pad-to-Lower Pad Bracket Bolt | 30 - 40 | |
| Compressor Retaining Bolt/Nut | 20 - 30 | |
| Rocker Arm Shaft Plug | 35 - 45 | |
| Camshaft Cap Bolt | 10 - 14 | 89 - 124 |
| Cam Sprocket Bolt | 18 - 22 | |
| Connecting Rod Cap Bolt | 20 + 45° + 90° | |
| Front Damper Bush Bracket Bolt | 55 - 75 | |
| Rear Transaxle Mount Bracket Bolt | 55 - 75 | |
| Target Wheel Bolt | 7 - 11 | 62 - 97 |
| Heater Adapter Bolt | 18 - 22 | |
| Engine Block Ground Bolt | 15 - 25 | |
| PCV Valve Bolt | 8 - 12 | 71 - 106 |
| Spark Plug | 20 - 30 | |
| Wiring Harness Bracket Bolt | 8 - 12 | 71 - 106 |
| IAT (Intake Air Temperature) Sensor | 20 - 30 | |
| MAP (Manifold Absolute Pressure) Sensor Bolt | 6 - 10 | 53 - 89 |
| ECTS (Engine Coolant Temperature Sensor) | 15 - 20 | |
| CMP (Camshaft Position) Sensor | 10 - 14 | 89 - 124 |
| O2S (Oxygen Sensor) | 34 - 44 | |
| CKP (Crankshaft Position) Sensor Bolt | 5 - 8 | 44 - 71 |
| Knock Sensor | 18 - 20 | |
| Throttle Body Bolt | 8 - 18 | |
| Ignition Coil Bolt | 6 - 8 | 53 - 71 |
| EGR Bolt | 20 - 30 | |
| Water Pump Bolt | 20 - 26 | |
| Thermostat Housing Bolt | 8 - 12 | 71 - 106 |
| Cooling Fan Assembly Bolt | 3.5 - 4.5 | 31 - 40 |
| Radiator Bracket Bolt | 10 - 8 | |
| Coolant Reservoir Bolt | 3.5 - 4.5 | 31 - 40 |
| Front Exhaust Pipe Nut | 32 - 48 | |
| Front Exhaust Pipe Lower Bracket Bolt | 32 - 48 | |
| Front Exhaust Pipe-to-Front Muffler Nut | 25 - 35 | |
| Front Muffler-to-Rear Muffler Nut | 32 - 48 | |
| Catalytic Converter Heat Shield Nut | 2 - 3 | 18 - 27 |
| Front Muffler Heat Shield Nut | 2 - 3 | 18 - 27 |
| Rear Muffler Heat Shield Nut | 2 - 3 | 18 - 27 |
| Generator Upper Bolt | 30 - 40 | |
| Generator Lower Bolt | 30 - 45 | |
| Starter Motor Mount-to-Engine Block Bolt | 40 - 50 | |
| Starter Motor Mount-to-Transaxle Bolt | 45 - 55 | |
| Battery Rod Clamp Nut | 4 | 35 |
| Fuel Tank Shield Retaining Nuts | 2 - 3 | |
| Evaporative Emission Canister Vapor Pipe Retaining Bolts | 7 - 12 |
TIGHTENING TORQUE SPECIFICATIONS