You are on page 1of 55

9-1

9-1 ENGINE CONTENTS <2.6L> 2 <3.OL> 56 CYLINDER HEAD GASKET   17 CYLINDER

ENGINE

CONTENTS

<2.6L>

2

<3.OL>

56

CYLINDER

HEAD

GASKET

 

17

CYLINDER HEAD GASKET

 

72

ENGINE

ADJUSTMENT

11

ENGINE ADJUSTMENT

65

Compression

Pressure

Check

 

11

Compression

Pressure

Check

 

65

Drive Belts Tension

Adjustment

13

Drive Belts Tension

Adjustment

67

Ignition

Timing

Inspection

and

Ignition

Timing

Inspection

and

Adjustment

 

13

Adjustment

 

-

67

Lash Adjuster Check

13

Lash Adjuster Check

 

67

Manifold Vacuum inspection

12

Manifold Vacuum Inspection

65

Silent Shaft Drive Chain Tension

 

Timing

Belt Tension

Adjustment

 

66

Adjustment

 

11

ENGINE

ASSEMBLY

83

ENGINE

ASSEMBLY

20

Crankshaft,

Flywheel

and Drive Plate

 

105

Crankshaft

and Flywheel

 

~~~~

49

Cylinder Block

 

109

Cylinder

Block

52

Cylinder

Head

and Valve

92

Cylinder

Head

30

Oil Pan and

Oil Pump

 

97

Front

Case,

Oil Pump

and Silent

Shaft

39

Piston

and Connecting

Rod

100

Jet Valve Assembly

 

37

Rocker

Arm

and Shaft

Assembly

 

90

Piston

and Connecting

Rod

 

43

Rocker

Arms,

Rocker

Arm Shafts

 

Rocker

Arm

and Shaft

Assembly

 

28

and Camshaft

 

86

Rocker

Arms,

Rocker

Arm Shafts

 

ENGINE

MOUNTING

68

and Camshaft

 

25

ENGINE OIL COOLER

 

.llO

Timing

Chain Train

 

22

GENERAL INFORMATiON

56

Valves

and Valve Springs

32

Lubrication Diagram

56

ENGINE

MOUNTING

14

Sectional View

56

GENERAL

INFORMATION

2

OIL PAN AND

OIL SCREEN

69

Lubrication Diagram

 

2

SPECIAL TOOLS

63

Sectional View

2

SPECIFICATIONS

57

OIL PAN AND

OIL SCREEN

 

16

General Specifications

57

SPECIAL

TOOLS

9

Sealants and Adhesives

 

-

63

SPECIFICATIONS

 

3

Service Specifications

 

57

General

Specifications

 

3

Torque

Specifications

61

Sealants

and Adhesives

 

-

9

TIMING

BELT

77

Service

Specifications

3

Torque

Specifications

7

TROUBLESHOOTING

 

10

Compression

Too

Low

Connecting

Rod Noise/Main

Bearing

Noise

Excessive

Engine

Rolling

and Vibration

Noisy Valves

 

Oil Pressure

Drop

Oil Pressure Too High Timing Chain Noise

Engine Rolling and Vibration Noisy Valves   Oil Pressure Drop Oil Pressure Too High Timing Chain

9-2

ENGINE

ENGINE

GENERAL

<2.6L>

INFORMATION

;ECTIONAL VIEW

<2.6L>

-

General

Information

NG3NA-A

INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION

.-

INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION

LUBRICATION

DIAGRAM

INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION
INFORMATION ;ECTIONAL VIEW <2.6L> - General Information N G 3 N A - A .- LUBRICATION

ENGINE <2.6L>

SPECIFICATIONS

GENERAL SPECIFICATIONS

-

Specifications

9-3

-4

 

Items

Specifications

Type

in-line OHC

Vumber

of cylinders

4

3ore

mm (in.)

91.1 (3.587)

 

Stroke

mm (in.)

98.0 (3.858)

‘iston

displacement

cc (cuin.)

2,555 (155.9)

Zompression

ratio

8.7

Yring order

1-342

Jalve timing intake valve Opens (BTDC)

25”

Closes (ABDC)

59”

Exhaust valve Opens (BBDC)

64”

Closes (ATDC)

20”

Jet valve Opens (BTDC)

25”

Closes (ABDC)

59”

SERVICE SPECIFICATIONS

 

Items

Standard

value

Limit

General

Compression

pressure

kPa (psi)/rpm

 

840 (119)/250--400

Pressure difference

of all cylinder

kPa (psi)

Less than

100 (14)

Manifold

vacuum

kPa (in.Hg)

67 (20)

Cylinder

head

Overall height

mm (in.)

90.0 (3.543)

“-0.2

(-.008)

Flatness

of

gasket

surface

mm (in.)

Less than

0.05

l.0020)

0.2 (.008)

Flatness

of

manifold

mounting

surface

mm (in.)

Less than

0.15 (0059)

0.3(.012)

Over size rework dimension

of valve seat hole

mm (in.)

 

Intake

0.3

(012)

O.S.

47.306-47.325 (1.8622-I .8632)

 

0.6

(024)

O.S.

47.600-47.625 (1.8740-l .8750)

 

Exhaust

0.3

(012)

O.S.

40.300-40.325 (1.5866-l .5876)

 

0.6

(024)

O.S.

40.600-40.625 (1.5984-l .5994)

*Limit

must be -0.2 t-.008)

combined

with amount

of grinding

of cylinder block gasket surface.

/ TSB Revision

  ENGINE <2.6L> - Saecifications   Items Standard value   Limit   -
 

ENGINE

<2.6L>

-

Saecifications

 

Items

Standard

value

 

Limit

 

-

Oversize rework of valve guide hole (both inlet and

 

exhaust)

mm (in.)

 

0.05

(002)

0,s.

13.056-13.068(.5136-5145)

 

0.25

LOlO) OS.

13.250-73.268

(.5217-.5224)

0.50

(.OZO)O.S.

13.500-13.518(.5315-.5422)

 

Oversize rework of valve

seat height

mm (in.)

 

Intake

0.3 (.012)

 

7.9-8.1

(.311-.319)

 
 

0.6

(024)

8.2-6.4

(.323-,331)

Exhaust

0.3 (012)

 

7.9-8.1

(31 l-.319)

 

0.6

(024)

8.2-6.4

(.323-,331)

Oversize rework of valve guide hole

 

(both intake and exhaust)

mm (in.)

 

0.05

(002)

O.S.

13.050-13.068(.5138-.5145)

 

0.25

(.OlO) 03.

13.250-13.268(.5217-5224)

0.50

(.020) 0,s.

13.500-13.518

(5315-5322)

riming

chain

 

No. of links

 

102

Pitch

mm (in.)

9.5 (374)

 

riming

chain “9” for silent shaft drive

 

No. of links

 

so

Pitch

mm (in.)

8.0 (315)

 

Clearance

between

chain and chain guide

mm (in.)

0.2-0.8(.00&.031)

Camshaft

Cam height

mm

(in.)

 

Intake

 

42.43 (1.6705)

 

41.93 (1.6508)

Exhaust

42.43 (1.6705)

41.93 (1.6508)

Height of fuel pump drive

cam

mm (in.)

 

37 (1.46)

 

Journal

diameter

mm (in.)

 

34 (1.34)

Oil clearance

mm (in.)

0.05-0.09

(.OO20--0035)

 

End play

mm (in.)

 

0.1-0.2

(.004-.008)

0.4 (016)

 

-~

-

?ocker arm

 

I.D.

mm (in.)

19 (75)

 

Clearance (Rocker arm-to-shaft)

mm (in.)

0.01-0.04

(.0004-.0016)

0. IO (.0039)

?ocker arm shaft

 

O.D.

mm (in.)

78.9(.744)

 

qocker arm shaft spring

 

Free length

mm (in.)

Intake

 

64.5 (2.539)

 

Exhaust

64.5 (2.539)

1 TSB Revision

-

  Free length mm (in.) Intake   64.5 (2.539)   Exhaust 64.5 (2.539) 1 TSB Revision

ENGINE <2.6L>

-

SDecifications

terns

Standard value

Limit

tialve

Valve length

mm (in.)

intake

107.96

(4.2504)

 

Exhaust

 

105.86

(4.1677)

Stem O.D.

mm (in.)

Intake

7.960-7.975

(.3134-.3140)

 

Exhaust

 

7.930-7.950

(.3122-.3130)

 

%

Face angle

45”-45”30

 

Thickness

of valve

head

mm (in.)

(Margin) Intake

 

1.2

(047)

0.7 (028)

Exhaust

2.0

LO791

1.5 i.059)

Valve stem to valve guide clearance

mm (in.)

Intake

 

0.03-0.06

(.OOlZ-.0024)

0.10 (.0039)

Exhaust

0.05-0.09

(.0020-.0035)

0.15 (.0059)

/alve guide

Length

mm (in.)

 

intake

47

(1.85)

Exhaust

 

52

(2.05)

Service

size

mm

(in.)

0.05

(002).

0.25 LOlO),

 

0.50

(.020) Oversize

ialve seat

mm (in.)

 

0.7-I

.2 (.028-.047)

Width of seat contact Seat angle

 

45”

/alve spring

Free length

mm (in.)

49.8(1.961)

48.8(1.921)

Load

N (Ibs.)

329 (73) at installed height

Installed

height

mm (in.)

40.4(1.591)

41.4(1.630)

Out of squareness

 

Less than 2”

4”

let valve

Length

mm (in.)

 

92.53 (3.6429)

 

Stem O.D.

mm (in.)

4.3 t.169)

Seat angle

45”

engine

mm (in.)

0.25 (.0098)

 

Valve clearance-Hot Valve clearance-Cold

engine (Reference)

mm (in.)

0.17(.0067)

let valve spring Free length

mm (in.)

29.60 (1.1654)

height

Load

N (Ibs.)

35 (7.7) at installed

Installed

height

mm (in.)

21.50 (9465)

Out of squareness

 

Less than 1.5”

Cylinder block

 

Cylinder

bore

mm (in.)

91 .I (3.587)

(0008)

 

Out-of-roundness

mm (in.)

Less than 0.02

and taper of cylinder bore mm (in.)

316(12.44)

*-0.2

(-.008)

Overall height Flatness of gasket

surface

mm (in.)

Less than 0.05

(0020)

0.1 (004)

--

NOTE

*Limit

must

be-O.2

(-,008)

combined

with amount

of grinding

of cylinder

head gasket surface.

TSB Revision

9-6

-

-

-’

*I-L,

-.A,Ld

as-1

_

.-

ENGINE

----

----

<2AL>

--.---

-

Saecificatiann

-r-

-

-

--_-

-

Items

 

Standard

value

 

Limit

Right silent shaft Front journal

diameter

diameter

 

mm (in.)

21 (.83)

 

mm (in.)

43 (I .69)

Rear journal

mm (in.)

 

Oil clearance Rear

 

0.094-0.135(.0037-.0053)

 
 

Front journal diameter

 

mm (in.)

23i.91)

 

Rear journal diameter mm (in.)

 

43(1.69)

Oil clearance

mm (in.)

 

Front

 

0.020-0.062

(.0008-.0024)

 

Rear

0.094-0.135

(.0037-.0053)

Piston

 
 

O.D.

mm (in.)

 

91 .I (3.587)

 

Clearance

(piston-to-cylinder)

mm (in.)

 

0.02-0.04

(.0008-.0016)

 

Ring groove width

 

mm (in.)

No.

1 and

No. 2

 

1.5 (.059)

 

Oil

4.0(.157)

Service size

mm (in.)

 

0.25

(.OlO),0.50 (.020),

 
 

0.75

(.030), 1.OO(039) Oversize

Piston ring

 
 

Side clearance

mm (in.)

 

No.

1

0.05-0.09

(.0020:0035)

0.12 (0047)

No. 2

 

0.02-0.06

(.OOOS--0024)

0.10 (.0039)

End gap

 

mm (in.)

No.

1

0.30-0.45

(.Ol IS-.0777)

0.8 (031)

No. 2

 

0.25-0.40

(.0098-.0157)

0.8(.031)

0.30-0.80

(01 l&.0315)

1.o (039)

Oil ring side rail Service size

mm (in.)

 

0.25

(.OlO),0.50 (.020).

 

0.75

(030). 1.OO(039) Oversize

 

--

Connecting

 

rod

 

Bend

mm (in.)

 

0.05(.0020) or less

 

Twist

mm (in.)

0.10

(.0039) or less

Connecting rod big end to crankshaft

side clearance

mm (in.)

0.10-0.25 (.0039-.009B) 0.4(.016)

Piston pin press-in load

N (Ibs.)

7.500-17.500

(1.653-3.858)

 

Connecting

rod bearing

 

Oil clearance

mm (in.)

0.019-0.056

(.0007-.0822)

0.1 1.004)

Service size

mm (in.)

0.25

(.OlO). 0.50 (020).

 

0.75

(.030) Undersize

 

-.

Crankshaft

main bearing

 

Oil clearance

mm (in.)

0.021-0.046(.0008-.oDlS)

0.1 (004)

Service size

mm (in.)

0.25

(.OlO). 0.50 (.020).

 

0.75

(.030) Undersize

( TSB Revision

ENGINE <2.6L>

-

SDecifications

9-7

Items

Standard

value

Limit

Crankshaft

Pin O.D.

mm (in.)

53

(2.09)

Journal

O.D.

mm (in.)

60

(2.36)

Out-of-roundness

of journal

and pin

and pin

mm (in.)

0.015

(0006)

or less

Taper of journal

mm

(in.)

0.005

(0002)

or less

End play

mm (in.)

0.05-0.18(.0020-.0071)

0.4 (016)

Undersize

rework dimension

of pin

mm (in.)

0.25

(.OlO) U.S.

52.735-52.750 (2.0762-2.0768)

0.50

(020)

U.S.

52.465-52.500 (2.0663-2.0669)

0.75

(030)

U.S.

52.235-52.250 (2.0565-2.0571)

Undersize

rework dimension

of journal

mm (in.)

 

0.25

(.OlO) U.S.

59.735-59.750 (2.3516-2.3524)

 

0.50

(020)

U.S.

59.465-59.500 (2.3419-2.3425)

0.75

(030)

U.S.

59.235-59.250 (2.3321-2.3327)

$vvheel

 
 

Runout

mm (in.)

0.13

(0051)

or less

Iii

pressure

at curb idle speed [conditions:

oil

80 (11.4)

or more

emperature

is 75-9o”C

(167-I

94’F)J

kPa (psi)

Iii

pump

Driven gear

 

Tip clearance

mm (in.)

 

0.1

l-0.15

(.0043-.0059)

0.20

(.0079)

Side clearance

mm (in.)

0.04-0.10

(.0016-.0039)

0.15

(.0059)

Drive gear

 

Tip clearance

mm (in.)

 

0.1

l-0.15

(.0043--0059)

0.20

(.0079)

Side clearance

mm (in.)

0.05411

(.0020-.0043)

0.15

(.0059)

jelief spring

 
 

Free height

 

46.6(1.835)

 

Load

mm (in.) N (Ibs.) [at 40.1

mm (1.579 in.)]

61

(13)

NOTE

 

O.D.

= Outer

Diameter

I.D. = Inner Diameter

 

OS.

= Oversize

Diameter

U.S. = Undersize

Diameter

TORQUE SPECIFICATIONS

Items

 

Nm

ftlbs.

Cylinder

head bolts-Cold

engine

90-100

65-72

Cylinder

head bolts-Hot

engine

100-l

10

73-79

Cylinder

head bolts (M8 bolt)

15-22

11-15

Camshaft

bearing

cap bolts (M8X70 bolt)

19-21

14-15

(M8X25 bolt)

20-27

15-19

Camshaft

sprocket

bolts

50-60

37-43

Rocker cover bolts

 

5-7

4-5

Jet valve assembly

18-22

13-15

Rocker arm adjusting

nuts for jet valve

8-10

6-7

Main bearing cap bolts

75-85

55-61

Connecting

rod cap nuts

45-48

33-34

/ TSB Revision

1

9-8

ENGINE <2.6L>

-

Specifications

Items

Nm

ft.lbs.

Crankshaft

pulley bolts

110-130

80-94

Oil pump

driven gear bolt

60-70

44-50

Silent shaft sprocket

bolt

 

60-70

44-50

cover bolts

 

5-7

4-5

Silent shaft chamber Flywheef bolts

 

130-140

94-101

Engine support

brackets

bolts

50-60

374

Chain guide “B” bolt (Upper)

 

&IO

6-7

Chain guide “B” bolt (Lower)

15-22

11-15

Oil pump cover bolt

 

IO-12

7-9

Oil pump

body screw

8-10

6-7

Oil pump

assembly

mounting

bolt

IO-12

7-9

Thrust plate bolt

 

IO-12

7-9

Oil pan bolt

6-8

4-6

Oil pan drain plug

35-45

26-32

Oil screen bolt

15-22

11-15

Oil relief valve plug

30-45

22-32

Oil pressure switch

15-22

11-15

Exhaust manifold to front exhaust pipe

20-30

14-22

Engine mounting front insulator to frame

30-40

22-29

Engine to engine mounting front insulator

13-20

9-15

No. 2 crossmember to frame

55-75

40-54

Plate to body

18-25

13-18

Plate to transfer mounting insulator

18-25

13-18

Transfer mounting insulator to transfer mounting bracket

16-25

13-18

Transfer mounting

bracket to transfer

 

18-25

13-18

No. 2 crossmember to engine mounting rear insulator

 

18-25

13-18

Engine mounting rear insulatorto engine

18-25

13-18

Rear engine support member to No. 2 crossmember

18-25

13-18

Power steering oil pump to pump bracket

25-33

18-24

Power steering breather pipe

8-12

6-9

Front insulator stopper to heat protector

6-10

4-7

Chain guide access hole cover bolt

IO-12

7-9

Timing chain case bolt

12-15

9-l

‘I

Chain guide “A” bolt

IO-12

7-9

   

IO-12

7-9

Chain guide “C” bolt Oil filter

11-12

8-9

 

j TSB Revision

_1-

I

    IO-12 7-9 Chain guide “C” bolt Oil filter 11-12 8-9   j TSB Revision

ENGINE <2.6L> SEALANTS AND ADHESIVES

-

Specifications

/ Special

Items

Semi-circular packing Oil pressure switch Contact surface between cylinder block and chain case Oil pan gasket

Specified

sealants and adhesives

3M ART Part No. 8660 or equivalent 3M ART Part No. 8660 or equivalent 3M ART Part No. 8660 or equivalent

MITSUBISHI

No. MZ100168or

GENUINE Part

equivalent

SPECIAL

TOOLS

Tools

!

As required

As required

As required

SPECIAL TOOLS Tools ! As required As required As required removed or installed Use with MIT304204

removed

or installed

SPECIAL TOOLS Tools ! As required As required As required removed or installed Use with MIT304204
SPECIAL TOOLS Tools ! As required As required As required removed or installed Use with MIT304204
SPECIAL TOOLS Tools ! As required As required As required removed or installed Use with MIT304204
SPECIAL TOOLS Tools ! As required As required As required removed or installed Use with MIT304204
SPECIAL TOOLS Tools ! As required As required As required removed or installed Use with MIT304204
SPECIAL TOOLS Tools ! As required As required As required removed or installed Use with MIT304204
SPECIAL TOOLS Tools ! As required As required As required removed or installed Use with MIT304204
SPECIAL TOOLS Tools ! As required As required As required removed or installed Use with MIT304204
SPECIAL TOOLS Tools ! As required As required As required removed or installed Use with MIT304204

Use with MIT304204

SPECIAL TOOLS Tools ! As required As required As required removed or installed Use with MIT304204

[ TSB Revision

I

ENGINE Special Tools /Troubleshooting <2.6L> - TROUBLESHOOT1NG Symptom Probable cause Remedy  

ENGINE

Special Tools /Troubleshooting

ENGINE Special Tools /Troubleshooting <2.6L> - TROUBLESHOOT1NG Symptom Probable cause Remedy  

<2.6L>

-

ENGINE Special Tools /Troubleshooting <2.6L> - TROUBLESHOOT1NG Symptom Probable cause Remedy  
ENGINE Special Tools /Troubleshooting <2.6L> - TROUBLESHOOT1NG Symptom Probable cause Remedy  
ENGINE Special Tools /Troubleshooting <2.6L> - TROUBLESHOOT1NG Symptom Probable cause Remedy  
ENGINE Special Tools /Troubleshooting <2.6L> - TROUBLESHOOT1NG Symptom Probable cause Remedy  
ENGINE Special Tools /Troubleshooting <2.6L> - TROUBLESHOOT1NG Symptom Probable cause Remedy  
ENGINE Special Tools /Troubleshooting <2.6L> - TROUBLESHOOT1NG Symptom Probable cause Remedy  
ENGINE Special Tools /Troubleshooting <2.6L> - TROUBLESHOOT1NG Symptom Probable cause Remedy  
ENGINE Special Tools /Troubleshooting <2.6L> - TROUBLESHOOT1NG Symptom Probable cause Remedy  
ENGINE Special Tools /Troubleshooting <2.6L> - TROUBLESHOOT1NG Symptom Probable cause Remedy  

TROUBLESHOOT1NG

Symptom

Probable

cause

Remedy

 

Compression

too low

Cylinder

head gasket

blown

Replace gasket

 

Piston ring worn or damage

Replace rings

Piston or cylinder worn

 

Repair or replace piston and/or cylinder block

-.

Valve seatworn

or damage

Repair

orreplace

valve and/&-seat

ring

Oil pressure

drop

Engine oil level too low

 

Check

engine oil level

Oil pressure

switch

faulty

Replace oil pressure .~.

switch

 

Oil filter clogged

 

Install new filter

 

Oil pump

gears or body worn

Replacegears

and/or

body

Thin or diluted engine

oil

Change engine

oil correct

viscosity

Oil relief valve stuck (opened)

--

Excessive bearing clearance

/ TSB Revision

Repair relief valve

Replace bearings

Oil relief valve stuck (opened) -- Excessive bearing clearance / TSB Revision Repair relief valve Replace

ENGINE <2.6L>

-

Troubleshooting/Engine

Adjustment

9-11

Symptom

Probable cause

Remedy

Oil pressure too high

Oil relief valve stuck (closed)

Repair relief valve

Noisy valves

Incorrect

auto-lash adjuster

Replace auto-lash

adjuster

Thin or diluted

engine oil (low oil pressure)

Change

engine oil

Valve

stem

or valve guide worn or damage

Replace valve and/or guide

Connecting

rod noise/

lnsuff

icient

oil supply

Check engine

oil level

main bearing

noise

Low oil pressure

Refer to “Oil pressure

drop”

 

Thin or diluted

engine oil

Change engine oil

Excessive bearina clearance

Reolace bearinas

1 Timing

chain noise

1 Loose timing

chain

1 Replace timing

chain and/or

sprockets

I

Excessive engine

rolling

Loose No. 2 member

/ Retighten

and vibration

 

Broken mount insulator

Replace

and vibration   Broken mount insulator Replace ENGINE ADJUSTMENT SILENT SHAFT DRIVE CHAIN

ENGINE ADJUSTMENT

SILENT

SHAFT

DRIVE

CHAIN

TENSION

AD-

JUSTMENT

 

No9”A4

When

a loose

silent

shaft

drive

chain

is suspected

as the

pro-

bable

cause

of

abnormal

noise,

the

tension

must

be

read-

justed.

Tension

of

silent

shaft

drive

chain

can

be adjusted

without

removing

timing

chain

cover

as follows:

(1)

Remove

cover

from

access

hole provided

at center

of chain

case (underwater

pump).

 

(2)

Loosen

special

bolt “B”.

Chain guide

“B’

bolt

“B”

(3)

Using

your

finger

push

projection

on chain

guide

“OB”

in

direction

of

arrow.

Do

not

push

projection

with

a

screwdriver

or

other

tool.

Improperly

chain

tension

will

cause

abnormal

noise.

(4) Tighten

special

bolt “B”.

(5)

Install

cover.

Do not

reuse

damaged

gasket.

 

Cover

bolt tightening

torque:

10-12

Nm (7-9

ft.lbs.1

Projection

5ENOO7

COMPRESSION PRESSURE CHECK

NWFFAE

(1)

Before checking compression,

ensure

that

engine

oil, the

starter

motor,

and battery

are

all in normal

operating

condi-

tion.

(2)

Start

the

engine

and wait

until

engine

coolant

temperature

 

has risen to 85”-95°C

(185-205°F).

(3)

Stop the engine

and

pull the

spark

plug

cables.

(4)

Remove

the

spark

plugs.

(5)

Crank

the

enigne

to

remove

any

foreign

objects

in

the

cylinders.

 

1 TSB Revision

9-12

ENGINE <2.6L>

Caution

-

Engine

Adjustment

 

Cover

the

spark

plug

boles

with

shop

towel,

etc.,

in

order

to

keep

expelled

foreign

objects

from

flying

out,

and

keep

away

from

the

holes.

When

measuring

compression

with

water,

oil,

or fuel

having

entered

the

cylinder

through

a crack,

etc.,

these

will

come

flying

out

of

the

spark

plug

hole

hot

and

fast,

so

to

sure

to

take

the

proper

precautions.

 

(6)

Set

the

compression

 

gauge

to

the

spark

plug

hole.

(7)

Holding

the

throttle

valve

full

open,

crank

the

engine

and

measure

compression.

 

Limit

:

640

kPa

(119

psi)

1256-400

rpml

 

(8)

Perform

(6)

and

(7) above

for

all the

cylinders,

ensuring

that

compression

pressure

differential

for

each

of

the

cylinders

is within

the

specified

limit.

 

Limit

:

Less

than

100

kPa

(14

psi)

(9)

If a cylinder’s

compression

or pressure

differential

exceeds

 

the

limit,

add

a small

amount

of oil through

the

spark

plug

hole and repeat

steps

(6) to

(8).

0

If the

addition

of

oil brings

compression

up,

it is possi-

 

ble that

there

is harmful

friction

between

 

the

piston

ring

and cylinder

wall.

 
 

0

If

not

compression

 

up,

valve

seizure,

 

poor

valve

 

seating,

or a compression

leak from

the

gasket

are

all

possible.

 

MANIFOLD

VACUUM

INSPECTION

 

(1)

Before

inspection,

put the

vehicle

into

the following

cty

tion.

e

Engine

coolant

temperature

: 85-95°C

(185205°F)

 

l

Lights, motor

cooling fan, and accessories

: OFF

e

Transmission

: Neutral

 

e

Steering wheel : Straight forward position

 

(2)

Connect

a tachometer.

 

(3) Disconnect

the

ventilation

hose

from

the

positive

 
 

crankcase

ventilation

valve,

and then

connect

the

hose

to

a

vacuum

gauge.

 

(4) Start

the

engine

and

check

that

idle

speed

is within

the

 

standard

value

range.

Read

off the vacuum

gauge.

Standard

value

: 67 kPa

(20 in.Hg)

 
value range. Read off the vacuum gauge. Standard value : 67 kPa (20 in.Hg)   1

1 TSB Revision

ENGINE

<2.6L>

(5)

If

not

-

Engine

at standard

Adjustment

value,

refer

to following

chart

for

9-13

cause

 

and repair.

 

Symptom

 

Cause

Remedy

l

The vacuum gauge reading is less than

l

Ignition timing

is retarded.

l

Adjust the ignition timing.

 

standard

value, but the needle

is

 

stable.

 

l

The vacuum

gauge

needle

swings

l

The gas

mixture

is excessively

l

Check carburetor.

 

slowly.

rich.

 

l

The vacuum

gauge

needle

drops

l

The gas

mixture

is excessively

l

Check carburetor.

 

irregularly.

lean.

 

l

The vacuum

gauge

needle

drops

l - Incomplete

close contact

of

l

Check and repair the valve.

 

intermittently

to 4.0 to 21.3

kPa (1.2 to

intake and exhaust

valve seats.

 

6.3 in.

Hg).

l

The vacuum

gauge needle drops sud-

l

Malfunction

of cylinder

head

l

Replace cylinder

head gasket.

denly from the normal reading to 33.3 kPa (9.8 in.Hg). then returns to normal.

gasket

DRIVE BELTS TENSlON

ADJUSTMENT

NOSFMBDD

TENSION

ADJUSTMENT

OF

THE

ALTERNATOR

DRIVE

BELT

Refer

to

GROUP

0

-

Maintenance

Service.

DEFLECTION ADJUSTMENT

OF

POWER

STEERING

OIL

PUMP

DRIVE

BELT

Refer

to

GROUP

19

-

Service

Adjustment

Procedures.

TENSION

ADJUSTMENT

OF THE AIR CONDITIONER

COM-

PRESSOR

DRIVE

BELT

 

Refer

to

GROUP

24

-

Service

Adjustment

Procedures.

IGNITION

TIMING

INSPECTION

AND ADJUST-

MENT

NWFIABO

Refer

to

GROUP

8

-

Ignition

system.

LASH ADJUSTER

CHECK

 

No9FE4h

If

an

abnormal

noise

is

heard

from

the

lash

adjusters

(tappets),

check

as follows.

 

(1)

While

installed

 

to

the

cylinder

head,

press

the

part

where

the

rocker

arm contacts

the

lash adjuster

at the

very top.

If

the

adjuster

is normal,

the

part

pressed

will

feel

very hard.

(2)

If

it easily

moves

all

the

way

downward

when

pressed

there

is a malfunction

of

the

lash adjuster

and it should

be

replaced

with

 

a

new

one.

 

(3)

If

it feels

spongy

or elastic,

probably

oil

with

air mixed

in it

has entered

the

lash adjuster,

so follow

the

steps

below:

 

( TSB Revision

i

?

-.L-

-_

;~

9-14

ENGINE

<2&L>

-

Engine

Adjustment

/

Engine

Mounting

 
 

a

Check

whether

the

amount of oil is too

much

or

is not

 

enough.

 
 

0

Check

whether

the

cause

of

air becoming

mixed

into

 

the

oil

is a damaged

oil

screen

 

or

oil

screen

gasket.

 

After

repairing

the

cause

of

the

air leak.

warm

up the

engine

and then

drive

the

vehicle

 

at

low

speed

for

a

while.

Stop

the

engine

and

leave

it

off

for

a

few

minutes;

 

then

restart

the

engine

and drive

at low

speed.

Repeat

this

procedure

several

times

during

 

the

course of

about

one

hour

so

as

to

remove

the

air from

the

oil.

ENGINE

MOUNTING

 

REMOVAL

AND

INSTALLATION

 

W9GA-A

 

Pre-removal

Operation

 

e

Removal

of

the

Air

Cleaner

(Refer

to

GROUP

11

-

Air

Cleaner.)

 

e

Removal

of

the

Hood

(Refer

to

GROUP

23

-

Hood.)

 

o

Removal

of

the

Under

Skid

Plate,

Undercover

and

Transfer

Case

Pro-

tector

(Refer

to

GROUP

23

-

Under

Cover.)

610

Nm

Post-installation

 

Operation

 
 

l

installation

of

the

Under

Skid

Plate,

Undercover

and

Transfer

Case

Pro-

tector

(Refer

to GROUP

23

-

Under

l

Cover.)

installation

of

the

Air

Cleaner

(Refer

to

GROUP

11

-

Air

Cleaner.)

l

Installation

of

the

Hood

(Refer

to

GROUP

23

-

Hood.)

 

Removal

steps

 

1. Heat

protector

2. Front

insulator

stopper

 

++

WI

3. Engine

mounting

front

insulator

 

4.

Plate

Transfer

5. mounting

insulator

 

Transfer

6. mounting

 

bracket

7.

No.

2

crossmember

8.

Engine mounting

 

insulator

 

//---

mws?3

rear

55-75

Nm

NOTE

 

40-54

ft.lbs.

 

(I)

Reverse

the

removal

procedures

to

reinstall,

(2)

++

:

Refer

to

“Service

Points

of

Removal”.

(3)

H

:

Refer

to

“Service

Points

of

Installation”.

/ TSB Revision

1:

of Removal”. (3) H : Refer to “Service Points of Installation”. / TSB Revision 1 :

ENGINE

<2.6L>

-

Engine

Mounting

9-15

SERVICE

POINTS

OF

REMOVAL

NOSBBAm

3.

REMOVAL OF ENGINE

MOUNTING

FRONT

INSULATOR

(I)

Attach

a chain

to

the

engine

hangers.

(2)

Using

a chain

block-and-tackle,

hang

the

engine

slight-

ly

up

so

that

the

insulator

is free