Motor Diesel

Engine Mechanical
System [DIESEL]
GENERAL ENGINE BLOCK rg
SPECIFICATION ........................................... EMB - 2 COMPONENTS ............................................ EMB -42ili::ill
TROUBLE SHOOTING ................................. EMB - 8 REMOVAL ..................................................... EMB -46
SPECIAL TOOLS .......................................... EMB -10 DISASSEMBLY ............................................. EMB -50
REPLACEMENT ........................................... EMB -54
ENGINE ANDTRANSAXLE ASSEMABLY INSPECTION ................................................ EMB -60
REMOVAL ..................................................... EMA -12 REASSEMBLY .............................................. EMB -66
INSTALLATION ............................................. EMA -18 INSTALLATION ............................................. EMB -71
TIMING SYSTEM COOLING SYSTEM

COMPONENTS ............................................ EMB -19 COMPONENTS ............................................ EMB -75
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REMOVAL ..................................................... EMB -20 REPLACEMENT ........................................... EMB -76
INSPECTION ................................................ EMB -22 INSPECTION ................................................ EMB -77
INSTALLATION ............................................. EMB -23
LUBRICATION SYSTEM
CYLINDER HEAD ASSEMABLY COMPONENTS ............................................ EMB -78
COMPONENTS ............................................ EMB -25 REMOVAL ..................................................... EMB -79
REMOVAL ..................................................... EMB -27 DISASSEMBLY ............................................. EMB -81
DISASSEMBLY ............................................. EMB -31 REPLACEMENT ........................................... EMB -82
INSPECTION ................................................ EMB -33 INSPECTION ................................................ EMB -84
REASSEMBLY .............................................. EMB -36 REASSEMBLY .............................................. EMB -86
INSTALLATION ............................................. EMB -38
INTAKE AND EXHAUST SYSTEM
COMPONENTS ............................................ EMB- 88
REMOVAL ..................................................... EMB- 91
INSTALLATION ............................................. EMB- 92
EMB -2 ENGINE MECHANICAL SYSTEM [DIESEL]
GENERAL
SPECIFICATIONS ECD268CO
Description Specification 2.0(D4EA) Limit

General
Type In-line, Single Overhead Camshaft
Number of cylinders 4
Bore 83mm (3.27in.)
Stroke 92mm (3.62in.)
Total displacement 1991 cc (121.5cu.in.)
Compression ratio 17.7 : 1
Firing order 1 - 3 - 4 - 2
Valve timing
Intake valve
Opens (BTDC)
Closes (ABDC)
Exhaust valve
Opens (BBDC)
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Closes (ATDC)
Cylinder head
Faltness of gasket surface 0.03mm (0.0012in.) for width
0.09mm (0.0035in.) for length
0.012mm (0.00047in.) I 51 x51 mm
Camshaft
Cam height
Intake 34.697mm (1.366in.) 34.197mm (1.346in.)
Exhaust 34.570mm (1.361 in.) 34.070mm (1.341 in.)
Journal O.D 28mm (1.10in.)
Bearing oil clearance 0.040- 0.074mm (0.0020- 0.0029in.)
End play 0.05 - 0.15mm (0.002 - 0.006in.)
Valve
Valve length
Intake 95.7mm (3.77in.)
Exhaust 95.4mm (3.76in.)
Stem O.D.
Face angle 44.5°
Thickness of valve head (margin)
Valve stem to valve guide clearance
Intake 0.022 - 0.067mm (0.00086 - 0.00263in.) 0.1 mm (0.0039in.)
Exhaust 0.050 - 0.095mm (0.0020 - 0.0037in.) 0.15mm (0.0059in.)
Valve guide
Length
Valve seat
Width of seat contact 1.21 mm (0.0477in.} I 1.61 mm
(0.0634in.} (IN/EX)
Seat angle 44° - 44.5°
GENERAL EMB -3
Description Specification 2.0(D4EA) Limit

Valve spring
Free length 39.14mm (1.541in.) 38.14mm (1.502in.)
Load 21.4kg/32mm (47.21b/1.26in.)
at installed height
Cylinder block
Cylinder bore 83 + 0.03mm (3.27 + 0.0012in.)
Flatness of gasket surface 0.042mm (0.00165in.) for width
0.096mm (0.00378in.) for length
0.012mm (0.00047in.) I 50x50mm
Piston
O.D 82.919 - 82.951 mm (3.26 - 3.27in.)
Piston-to-cylinder clearance 0.069 - 0.091 mm (0.0027 - 0.0036in.)
Ring groove width
No. 1 1.915 - 1.945mm (0.075 - 0.076in.)
No. 2 2.06 - 2.08mm (0.08 - 0.082in.)
Oil 3.02- 3.04mm (0.1190- 0.1196in.)
Service size 0.25mm (0.01 Oin.), 0.5mm (0.020in.)
oversize
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Piston ring
Side clearance
No. 2 0.065 - 0.11 mm (0.00256 - 0.00433in.)
Oil ring 0.03 - 0.07mm (0.00118 - 0.00275in.)
End gap
No. 1 0.2- 0.3mm (0.0079- 0.0118in.)
No. 2 0.3 - 0.45mm (0.0118 - 0.0177in.)
Oil ring side rail 0.2 - 0.45mm (0.0079 - 0.0177in.)
Connecting rod
Connecting rod pin O.D 28.022 - 28.034mm (1.1 03 - 1.1 04in.)
Connecting rod bearing oil clearance 0.024 - 0.042in. (0.0009 - 0.0016in.) 0.1 mm (0.0039in.)
Crankshaft main bearing oil clearance 0.024 - 0.042in. (0.0009 - 0.0016in.) 0.1 mm (0.0039in.)
Crankshaft
Journal O.D 60.002 - 60.020mm (2.362 - 2.363in.)
Out-of-round of journal and pin Less than 0.015mm (0.0006in.}
Taper of journal and pin Less than 0.005mm (0.0002in.)
End play 0.09 - 0.32in. (0.0035 - 0.0126in.)
Flywheel
Run out 0.13mm (0.0051in.)
Oil pressure (1500rpm)
More than
[Oil temperature is 95 - 105°C(203
250kPa (36.26in.)
- 221°F)]
Oil pump
Tip clearance 0.12 - 0.2mm (0.00472 - 0.0078in.)
Radial clearance 0.13- 0.23in. (0.0051 - 0.009in.)
Side clearance 0.02 - 0.07mm (0.00078 - 0.0027in.)
Relief spring
Freen length 47.5mm (1.835in.)
Opening pressure 570 ± 50kPa (82.67 ± 7.25psi)
EMB-4 ENGINE MECHANICAL SYSTEM [DIESEL]
Description Specification 2.0(04EA) Limit

Silent shaft
Front journal diameter 27.99- 28.01mm (1.102- 1.1027in.)
Rear journal diameter 41.99 - 42.01 mm (1.6531 - 1.6539in.)
Oil clearacne
Front 0.050 - 0.09mm (0.0020 - 0.0036in.)
Rear 0.050 - 0.091 mm (0.0020 - 0.0036in.)
Cooling method
Cooling system quantity (Radiator) Forced circulation with electrical fan
5 lit (5.3U.S.qts, 4.4 lmp.qts)
Thermostat
Type Wax pellet type with jiggle valve
Normal opening temperature 85°C (185°F)
Opening temperature range 83.5 - 86SC (182 - 188°F)
100°C (212°F)
Radiator cap 107.9 ± 14.7kPa

Main valve openg pressure (1.1 ±0.15kg/cm2 , 15.64±2.13psi)
Main valve closing pressure 83.4kPa (0.85kg/cm 2 , 12.1 psi )
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Vacuum valve openting pressure -6.86kPa (-0.07kg/cm 2 , -1.00psi)
Air cleaner
Type Dry type
Element Unwoven cloth type
Exhaust
Muffler Expansion resonance type
Suspension system Rubber hangers
Coolant tempreature sensor
Type Thermister type
Resistance
20°C (68°F) 2.45 ± o.14kn
80°C (176°F) o.3222kn
GENERAL EMB-5
SERVICE STANDARDS
Standard value
Coolant concentration
Tropical area 40%
Other area 50%
LUBRICANT
Engine coolant Elthylene glycol base for aluminum radiator

Engine oil SAE 30 (0°C - 40°C}
SAE 20W-40 (ABOVE -10°C)
SAE 15W-40 (ABOVE -15°C)
SAE 1OW-30 (-20 - 40°C}
SAE 5W-30 (-25°C - 10°C)
SAE OW-30 (BELOW 10°C} *1 *2
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*1. Restricted to driving condition and area
*2. Not recommeded for sustained high speed
SEALANT
Engine coolant temperature sensor LOCTITE 262, three bond No. 1324 or equivalant
Oil pressure switch 3M ATD No. 8660 or Three bond No. 1141E
[QJ) NOTE
O.D. = Outer Diameter
/.D. = Inner Diameter
O.S. =Oversize Diameter
U.S. = Undersize Diameter
EMB-6 ENGINE MECHANICAL SYSTEM [DIESEL]
TIGHTENING TORQUE
Item Nm kgf·cm lbHt

Engine mount insulator bolt 90 - 110 900- 1100 65- 80
Engine mounting bracket nuts 60- 80 600- 800 43- 58
Engine mounting bracket bolts 60- 80 600- 800 43- 58
Engine support bracket bolt and nut 43- 55 430- 550 32- 40
Front roll stopper bracket to cross 40- 55 400- 550 29- 40
member bolts
Front roll stopper insulator bolt and nut 50- 65 500- 650 36- 47
Rear roll stopper bracket to cross 50- 65 500- 650 36- 47
member bolts
Rear roll stopper insulator bolt and nut 50- 65 500- 650 36- 47
Transaxle mounting bracket bolts 60- 80 600- 800 43- 58
Transaxle mounting insulator bolt 90 - 110 900- 1100 65- 80
Front exhaust pipe to exhaust manifold 30- 40 300- 400 22- 29
Head cover bolt 8- 10 80 - 100 6- 7
Camshaft sprocket bolt 125 - 140 1250- 1400 92 - 103
Camshaft bearing cap bolt 26.5- 29.5 265- 295 20- 22
Crankshaft position sensor 7- 11 70 - 110 5-8
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Crankshaft sprocket bolt 185 - 195 1850- 1950 136- 144
Damper pulley to crankshaft sprocket 30- 34 300- 340 22- 25
Cylinder head bolt (cold engine) 50+ 120°+90° 500+ 120°+90° 36+ 120°+90°
Timing belt auto tensioner bolt 50- 55 500- 550 36- 40
Drive belt auto tensioner bolt 26- 31 260- 310 19- 23
Timing belt auto tensioner adjustable bolt 10 - 12 100- 120 7- 9
Drive belt idler bolt 46- 51 460- 510 34- 38
Front exhaust pipe clamp bolt 20- 30 200- 300 14- 22
Oil pan 10 - 12 100- 120 7- 9
Oil pan drain plug 35- 45 350- 450 25- 33
Oil screen 10 - 12 100 - 120 7- 9
Oil pressure switch 15- 22 150 - 220 11 - 16
Oi screen bracket bolt 34- 38 340- 380 25- 28
Oil pump bolt 20- 27 200- 270 15- 20
Oil seal case bolt 10 - 12 100- 120 7- 9
Plug cap 20- 27 200- 270 14- 20
Oil jet bolt 9 - 13 90 - 130 7- 10
Oil pump rotor bolt 8 - 10 80- 100 6- 7
"-
Timing belt upper cover 8 - 12 80- 120 6- 9
Timing belt lower cover 8 - 12 80- 120 6- 9
Relief plug 42 - 52 420- 520 31 - 38
Flywheel 70- 80 700- 800 52- 59
Drive plate 70- 80 700- 800 52- 59
Connecting rod bolt 25+90° 250+90° 18 +90°
GENERAL EMB-7
Item Nm kgf·cm lbHt

Engine coolant pump to cylinder block bolt
14mm 48- 52 480- 520 35- 38
10mm 10 - 12 100- 120 7- 9
Engine coolant temperature sensor 40- 55 400- 550 30- 41
Engine coolant inlet fitting attaching bolt 20- 25 200- 250 15 - 18
Air cleaner mounting bolts 8 - 10 80 - 100 6- 7
Resonator mounting bolt (Nut) 8 - 10 80 - 100 6- 7
Intake manifold mounting bolt (M8) 15- 20 150- 200 11 - 14
Hanger bolt to body 10 - 15 100- 150 7- 11
Hanger bolt to main muffler 10 - 15 100- 150 7- 11
Exhaust manifold nuts 25- 38 250- 380 18- 28
Heat protector bolt to exhaust manifold 15- 20 150- 200 11 - 14
Air cleaner bracket bolt 10 - 13 100- 130 7- 9
Oil level gauge 10 - 12 100 - 120 7- 9
Balance shaft bolt 53- 57 530- 570 39- 42
Starter bolt to cylinder block 48- 52 480- 520 35- 38
Turbocharger support bolt 35- 45 350- 450 26- 33
Crankshaft bedplate bolt
15mm 28 - 32+120° 280 - 320+ 120° 20.65- 23.6+120°
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12mm 33.7- 37.7 337- 377 24.9- 27.8
TROUBLESHOOTING EDC9B08C
Symptom Suspect Area Remedy (See page)

Low compression Damaged cylinder head gasket Replace gasket
Worn or damaged piston rings Replace rings
Worn piston or cylinder Repair or replace piston and/or
cylinder block
Worn or damaged valve seat Repair or replace valve and/or seat ring
Oil pressure drop Low engine oil level Check engine oil level
Faulty oil pressure switch Replace
Clogged oil filter Replace
Worn oil pump rotor or cover Replace
Thin or diluted engine oil Change and find out cause
Oil relief valve stuck (open) Repair
Excessive bearing clearance Replace
High oil pressure Oil relief valve stuck (closed) Repair
Excessive engine vibration Loose engine roll stopper (front, rear) Re-tighten
Loose transaxle mount bracket Re-tighten
Loose engine mount bracket Re-tighten
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Loose center member Re-tighten
Broken transaxle mount insulator Replace
Broken engine mount insulator Replace
Broken engine roll stopper insulator Replace
Noisy valves Thin or diluted engine oil (low oil pressure) Change
Worn or damaged valve stem or Replace
valve guide
Connecting rod andlmain Insufficient oil supply Check engine oil level
bearing noise Thin or diluted engine oil Change and find out cause
Excessive bearing clearance Replace
Timing belt noise Incorrect belt tension Adjust belt tension
Low coolant level Leakage of coolant
Damaged radiator core joint Replace
Corroded or cracked hoses (radiator Replace
hose, heater hose, etc)
Faulty radiator cap valve or setting Replace
of spring
Faulty thermostat Replace
Faulty engine coolant pump Replace
Clogged radiator Foreign material coolant Replace
Abnormally high coolant Faulty thermostat Replace
temperature Faulty radiator cap Replace
Restricted of flow in cooling system Replace
Loose or missing drive belt Adjust or replace
Faulty engine coolant pump Replace
Faulty temperature sensor wiring Repair or replace
Faulty electric fan Repair or replace
Faulty thermo-sensor on radiator Replace
Insufficient coolant Refill coolant
Abnormally low coolant Faulty thermistat Replace
temperature Faulty temperature sensor wiring Repair or repalce
Leakage from oil cooling Loose hose and pipe connection Retighten
system Blocked or collapsed hose and pipe Replace
GENERAL EMB-9
Symptom Suspect Area Remedy (See page)

Inoperative electrical
Damaged fuse Replace or repair
cooling fan
Exhaust gas leakage Loose connections Retighten
Broken pipe or muffler Repair or replace
Abnormal noise Detached baffle plate in muffler Replace
Broken rubber hanger Replace
Pipe or muffler contacting vehicle body Correct
Broken pipe or muffler Repair or repalce
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SPEICAL TOOLS E4AEEC1F
Tool (Number and name) Illustration Use

Camshaft oil seal installer Installation of the camshaft oil seal
(09212-271 00)
ECA9930C
Valve spring compressor Removal and installation of intake

(09222-27300) and exhaust valves
KCHB600C
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Valve stem oil seal installer Installation of valve stem oil seals
(09222-27200)
KCHB600E
Crankshaft rear oil seal installer Installation of the crankshaft

(09231-27000) real oil seal
KCHB600G
Front case oil seal installer Installation of the front case oil seal
(09231-271 00)
ECA9930C
Injector oil seal installer Installation of the injector oil seal

(09351-27401)
KCHB600A
GENERAL EMB -11
Tool (Number and name) Illustration Use

Compression gauge&adapter Checking engine compression
(09351-27000) pressure
(09357-271 00)
KCHB6000
Oil filter wrench Removal and installation of oil filter

(09263-27000) For Europe LHD
KCHB600H
Oil filter wrench Removal and installation of oil filter
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(09263-271 00) For the rest area except Europe LHD
KCHB600H
ENGINE AND TRANSAXLE 3. Remove the battery and battery base(A).
ASSEMBLY
REMOVAL E4803EBD
& CAUTION
• Make sure jacks and sefety stands are placed
properly.
• Make sure the vehicle will not roll off stands
and fall while you are working under it.
• Use fender covers to avoid damaging painted
surface.
• Unplug the wiring connectors carefully while
holding the connector portion to avoid dam-
age.
• Mark all wiring and hoses to avoid miscon-
nection.
Also, be sure that they do not contact other
wiring or hoses or interfere with other parts.
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EDKD501A
1. Secure the hood as open as possible.

4. Remove the intake air duct (C) and air cleaner hous-
2. Disconnect the battery negative terminai(A) first, then ing (D).
the positive terminai(B). Remove the battery(C) after a. Remove the air cleaner cover.
the cover(D).
EKKD105B
b. Remove the air cleaner filter.
EDKDSOOA
ENGINE AND TRANSAXLE ASSEMBLY EMB -13
c. Remove the three air cleaner body mounting 11 . Disconnect the engine coolant temperature sensor.
bolts (B).
12. Disconnect the back-up switch.
13. Disconnect the vehicle speed sensor.
14. Disconnect the generator connector(A).
-------------- -----------------------
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EKKD106A
d. Remove the air cleaner body (A).
5. Remove the intercooler hoses.

EDKD513A
6. Disconnect the engine wire harness connectors on

15. Disconnect the battery positive terminai(A) on the
the left side of the engine compartment.
generator(B).
7. Disconnect the air-flow sensor(A).
EDKD514A
EDKD505A
8. Disconnect the rail pressure sensor.
9. Disconnect the injector connectors.
10. Disconnect the camshaft position sensor.

16. Disconnect the battery negative terminal (A) on the 18. Remove the clutch release cylinder (B) after removing
starter (B). the bolts, the pin and clip (A).
\
A
EMKD103A
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EDKD517A
[QJ) NOTE
Disconnect the connector on the starter after remov-
ing a splash shield.
17. Remove the brake booster hose and vacuum hose.
EMKD102A
19. Remove the cable assembly after removing the gear

shift lever cable clip (A).
EMKD005A
20. Disconnect the heater hoses.
21. Remove the front tires/wheels and splash shield.

22. Disconnect the starter connector which was men- 30. Disconnect the power steering oil hoses(A) by loos-
tioned in the 'NOTE' of 16 step. ening the clamps(B).
23. Remove the radiator cap.

B
Q WARNING
Use care when removing the radiator cap to avoid
scalding by hot coolant or steam.
24. Drain the engine coolant. Loosen the drain plug in the
radiator.
25. Remove the upper and lower radiator hoses.
26. Disconnect the hose from the engine coolant reservoir

tank to the thermostat.
27. Disconnect the hoses from the fuel tank.
28. Remove the engine ground cable.
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29. Drain the power steering oil.
EDKD524A
EDKD525A
EMB -16 ENGINE MECHANICAL SYSTEM (DIESEL)
31. Remove exhaust pipe(A). 33. Remove the front strut (B) lower mounting bolts and
nuts (A). (see SS group - front strut)
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EDKD803A
KXDSE05A
32. Disconnect the wheel speed sensors(A) from both
front knuckles. (see OS group- front axle) 34. Remove the bolts (B) and nuts (C) of the engine
mounting (A).
KXDSE03A
ECKD103A
35. Remove the sub frame(A) mounting bolts(B) and

nut( C).
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EDKD601A
EDKD602A
INSTALLATION E93DFC3A 18. Perform the following :

• Clean the areas where the driveshafts contact
Install the engine in the reverse order of removal. the transmission thoroughly with solovent or car-
Reinstall the mount bolts/nuts in the following sequence. buretor cleaner, and dry with compressed air.
Failure to follow these procedures may cause excessive • Check that the snap rings on the ends of the
noise and vibration, and reduce bushing life. driveshaft click into place.
1. Install the sub frame installation bolt.

& CAUTION
2. Tighten the engine and transmission mounting bolts. Use new snap rings.
3. Connect the power steering oil hoses. • Adjust the shift cable.
• Refill the radiator with engine coolant.
4. Install the exhaust pipe (A). • Bleed air from the cooling system with the heater
valve open.
• Clean the battery posts and cable terminals with
sandpaper, assemble them, then apply grease to
prevent corrosion.
• 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
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the fuel line pressurizes. Repeat this operation .
two or three times, then check for fuel leakage at
any point in the fuel line.
-------
--------
~-
EDKD803A
5. Connect the starter terminal and connector.
6. Install the front tires/wheels and splash shield.
7. Connect the air condition hoses.
8. Plug in the alternator hoses.
9. Install the transmission links.
10. Connect the fuel hoses.
11. Connect the engine wire harness connectors.
12. Install the clutch release cylinder.
13. Connect the fuel upper and lower hoses.
14. Connect the heater hoses.
15. Connect the hose to the reservoir tank.
16. Connect the intercooler hoses.
17. Install the air cleaner and the battery.

TIMING SYSTEM EMB -19
TIMING SYSTEM
COMPONENT ED335141
Upper cover mounting

r-4--------, 7.8 - 11.8 (78- 118, 5.75- 8.70)
Auto tensioner
mounting
26- 31 (260- 310,
19.18- 22.86)
Camshaft
sprocket
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50-55 Engine support bracket
Bracket mounting bolts

43 - 55 (430 - 550,
Timing belt
31.72- 40.57)
tensioner
Timing belt
Timing belt lower cover
NOTE Damper pulley

. See page EMB-42 for how to postion the crankshaft and
pulley before Installing the belt.
· Mark the direction of rotation on the belt before removing
· Do not use the upper cover and low cover for storing
removeed items.
· Clean the upper cover and low cover before installing.
TORQUE : Nm (kgf.cm, lbf·ft)

EDKD542A
REMOVAL E2A30EC3 2. Remove the damper pulley (A) and timing belt lower
cover (B).
@)NOTE
• Inspect the water pump before installing the tim-
ing belt (see page EMB-75).
Before carrying out this step, remove the transmission as-

sembly.
1. Remove the drive belt(A).
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EDKD530A
EDKD529A
EDKD531A
EMB -21
TIMING SYSTEM (A) and engine
~~ket
kt~~C) cranksha~ s(~) and the oil pump
3 Remove the timing) belt upPer cover . timing marks (A, B)
the camshaft
(D) with the
. support bracket (B . 4. Align and the
sproc e the cylinder hea
marks(E,F)_ ohn tating the engine.
case (H) Wit ro
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EDKD532A
EDKD534A
H F
EDKD533A D
EDKD535A
5. Insert a pin (A) into the aligned holes in the auto- INSPECTION EFE07FC5
tensioner (B).
1. Remove the upper cover (see EMB-21 ).
2. Inspect the timing belt (A} for cracks and oil or coolant
soaking.
@)NOTE
• Replace the belt if oil or coolant soaked.
• Remove any oil or solvent that gets on the belt.
Inspect this area

for wear
B
A
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EDKD536A
6. Using a hexagonal wrench (5mm) (A}, loosen the

stop bolt (B). And then, turning the auto-tensioner
(C) clockwise fully with the boss bolt (D) and 12mm
spanner (E), retighten the stop bolt (B).
EDKD541A
EDKD537A
7. Remove the timing belt.
@)NOTE
To be prepared in case the removed belt is used, mark
an arrow on the timing belt in the direction of rotation
before removing it.
TIMING SYSTEM EMB -23
ATION E8A45CD8 r ing belt. . r

INSTALL haft sprocket (B) 3. Install the lm in into the auto-tenslon)e(A) loosen the
a. Insert. aa hexagona
P I wrench (5mm '
m~n the cylinder head (D).
k (A) on the cams
1. Alignthe
with themark
timing(C)
b ~~;~9,ensioner ~;;~g:~ounterckock~~ :~;
Turnt the
stop
auto-te~s'?
c. ·Install the timing belt using the boss o
c ley o r (E).
and 12mm spanne
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EDKD538A
c
2 Align thethe . . mark
tlml_ng (A) on the cran_kshaft m sprocket
housing
· (B) with Pin (C) Press fitted in the Oil pu p EDKD537A
(D).
d.
c
EDKD539A
EDKD540A
4. Rotate the crankshaft by hand 2 complate revolutions

(clockwise) to take up any slack and set to TDC(Top
Dead Center).
@)NOTE
Verify the timing marks are aligned again.
5. Tighten the stop bolt and remove the fixing pin.
Tightening torque
Auto tensioner adjustable bolt :
10 - 12Nm (1 00 - 120 kgf·cm, 7 - 91bf·ft)
6. Reinstall all removed components in the reverse order

of removal.
a. Install the engine bracket.
Tightening torque :
43 - 55Nm (430 - 550kgf·cm, 31.72 - 40.571bg·ft)
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b. Install the timing belt lower cover.
Tightening torque :
7.8 - 11.8Nm (78 - 118kgf·cm, 5.75 - 8.701bf·ft)
c. Install the drive belt pulley
Tighten torque
Damper pulley mounting bolt :
20 - 30Nm (200 - 300kgf-ft, 14 - 221bf·ft)
d. Install the drive belt, following the sequence be-

low.
1.Aiternator --7 2.Power steering --7 3.1dler --7
4.Air compressor --7 5.Crankshaft pulley.
The tensioner should be lifted up to install the
driver belt.
@)NOTE
Clean the upper and lower covers before installation.
CYLINDER HEAD ASSEMBLY EMB -25
CYLINDER HEAD
ASSEMBLY
COMPONENT ECAA22DF
CAUTION ~
. To avoid damage, wait until the engine coolant u _ _ _ _ __
Fuel installation plug
coolant temperature before removing u
cylinder head. u
u.----Cilp
damage the contact surface. ,..____ __
..-- Injector
Injector installation plug Jlf;:;1_ f
Cylinder head cover bolt----J~~~<»

~Jj/~· '
~~~~
/~--J~!
~~·
~~ ~ r..-
~~-----;
-- :~,
'
/' ~
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8- 10 (80- 100, 5.90- 7.38) '/ ' 1
1 / ' J
'
1/
0~~~-., ',-'- '--~--
~~· / .-·
. //1
~~-
~"/ y~J~~ '. / . ,r
·l0c~~
Cylinder head cover
Cylinder head bolt

:e:7~
50 (500, 38.9) + 120" +90"
11 0 - - C y l i n d e r head cover gasket
~-----Cylinder head
Cylinder head gasket
Cylinder block assembly
TORQUE : Nm (kgf.cm, lbf·ft)

EDKD543A
~------- Cam shaft bearing cap bolt

26.5 - 29.5 (265 - 295, 20 - 22)
JJJ..E - - - - - - - - Cam shaft bearing cap

Cam shaft
Oil seal
Exhaust cam follower
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Cam shaft sprocket
Intake cam follower
Valve c a p - - - - -
Valve spring retainer lock

Lash adjuster
Valve spring retainer-------,
Valve spring--------~
Cam shaft sprocket bolt

125- 140 (1250- 1400,
92.19 - 103.26)
Cylinder head
Intake valves
TORQUE : Nm (kgf-cm, lbf·ft)

EDKD598A
CYUNDERHEADASSEMB~ EMB -27
REMOVAL E185A975 2. Disconnect the fuel return hose after removing the
clips(A).
Engine removal is required for this procedure.
Before carrying out this step, remove the transnission as-
sembly(A). R
I
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EDKD545A
3. Remove the plugs(A).

EDKD544A a. Pull the plug up slightly. (more than 1mm)
b. Rotate the plug 90° clockwise.
G WARNING c. Remove the plug with inserting a (-) driver be-
tween the plug assy(B) and the cylinder head
Make sure jacks and safety stands are placed cover( C).
properly and hoist brackets are attached to the
correct positions on the engine.
ffi CAUTION
• Use fender covers to avoid damaging painted
surfaces.
• To avoid damage, unplug the wiring connec-
tors carefully while holding the connector
portion to avoid damage.
• To avoid damaging the cylinder head, wait un-
til the engine coolant temperature drops be-
low normal temperature before loosening the
retaining bolts.
@)NOTE
Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring or
hoses, or interfer with other parts.
1. Before removing the cylinder head, the timing belt EDKD546A
should be removed first. Refer to the timing belt 're-

moval' step. (See page EMB-20)
ENG IN E MECHANICAL SY STEM [DIESE.!:!
MB
E
-4 -28 the injector holder bolt(A) with Smm hexago-
Loosen 6. Remove the injectors(A).
. nal wrench(B).
~rrr- .. ,
A
EDKD549A
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EDKD547A
Remove the cylinder head Cover(B) mounting
5. Pull the .lnJ·ector holders(A) with the bolts(B). ?. bolts(A).
EDKD548A
EDKD550A
8. Remove the cylinder head cover(A). 10. Remove the cylinder head cover gasket(A).
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EDKD553A
11. Remove the metal tube(A) between the fuel pump(B)

and the deliery pipe(C).
EDKD551A
9. Remove the injector holders(A) with the bolts(B)

which was loosened in the step 5.
EDKD554A
EDKD552A
12. Remove the fuel pump(A) after removing the three 15. Remove the cylinder head bolts(A), then remove the
bolts( B). cylinder head(B).
~-"----8
··~. Z'"'-')k---A
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EDKD555A EDKD556A
13. Remove the exhaust manifold. (see page EMB-91) & CAUTION
14. Remove the intake manifold (see pages EMB-91) To prevent warpage, unscrew the bolts in sqience
1/3 turn at a time; repeat the sequence until all
bolts are loosened.
CYLINDER HEAD BOLTS LOOSENING SEQUENCE
2 8 10 6 4
3
I
5 9 7
EDKD557A
DISASSEMBLY E3BA04E2 3. Remove the camshaft(A) with the oil seai(B).
~NOTE
• Identify parts as they are removed to ensure re-
installation in original locations.
• Inspect camshafts. (see page EMB-33)
1. Remove the engine hangers, the knock bushes and

the studs.
2. Remove the camshaft bearing caps(A).
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EDKD600A
4. Remove the In/Ex cam followers(A,B).
EDKD599A
EDKD601A
5. Remove the lash adjusters(C).
6. Remove the valve caps(D).

7. Using an appropriate-sized socket and plastic mal- 9. Remove the valve stem seals(A).
let, lightly tap the valve retainer to loosen the valve
retainer locks before installing the valve spring com-
pressor.
[QJj NOTE
Identify valves and valve springs as they are removed
so that each item can be reinstalled in its original po-
sition.
8. Using the SST (09222-27300), compress the valve

spring(A) in order to remove the valve spring retainer
locks(8).
09222-27300
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EDKD603A
11+------- B -------+1
EDKD602A
EDKD608A
Intake Valve Dimensions

A Standard (New) : 28.5 - 28. 7mm (1.1220 - 1.1299in.)
8 Standard (New): 94.0- 94.2mm (3.7008- 3.7087in.)
C Standard (New) : 5.933 - 5.953mm
(0.2336 - 0.0669in.)
D Standard (New) : 1.5- 1.7mm (0.0591 - 0.0669in.)
Exhaust Valve Dimensions

A Standard (New): 24.3- 24.5mm (0.9567- 0.9646in.)
8 Standard (New): 94.0- 94.2mm (3.7008- 3.7087in.)
C Standard (New) : 5.905 - 5.925mm
(0.2325 - 0.2333in.)
D Standard (New) : 1.2 - 1.4mm (0.0472 - 0.0551 in.)
INSPECTION EOA6CDA6 3. Zero the dial indicator(A) against the end of the
camshaft(B).
CAMSHAFT Push the camshaft(B) back and forth, and read the
end play.
~NOTE
Do not rotate the camshaft during inspection. Camshaft End Play
Standard (New) : 0.05 - 0.15mm (0.002 - 0.006in.)
1. Put the camshaft(A) and the camshaft bearing
caps(B) on the cylinder head(C), then tighten the
bolts to the specified torque with the following se-
quence below.
Specified torque
26.5 - 29.5Nm (265 - 295kgf-cm, 20 - 221bf·ft)
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EDKD605A
4. Remove the bolts, then remove the camshaft bearing

caps from the cylinder head(A).
• Lift the camshaft(B) out of the cylinder head(A),
wipe it clean. Replace the camshaft if any lobes
are pitted, scored, or excessively worn.
EDKD604A
• Clean the camshaft bearing surfaces in the cylin-
der head, then set the camshaft back in place.
2. Seat the camshaft by pushing it toward the rear of the • Place a plastigauge strip(C) across each journal.
cylinder head.
5. Install the camshaft bearing caps and tighten the bolts
to the specified torque.
6. Remove the camshaft bearing caps, then measure 7. If the camshaft-to-camshaft bearing cap oil clearance
the widest portion of the plastigauge(C) on each jour- is out of tolerance :
nal. • And the camshaft(A) has already been replaced,
you must replace the cylinder head.
Camshaft-to-Camshaft bearing cap oil clearance • If the camshaft has not been replaced, first check
Standard (New) : the total runout with the camshaft supported on
0.040 - 0.074mm (0.0020 - 0.0029in.) V-blocks.
Camshaft Total Runout

Standard (New) :
0.035mm (0.0014in.) for No.2 and 4
0.050mm (0.0019in.) for No.3
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EDKD606A
EDKD607A
• If the total runout of the camshaft is within toler-

ance, replace the cylinder head.
• If the total runout is out of tolerance, replace the
camshaft and recheck the camshaft-to-camshaft
bearing cap oil clearance. If the oil clearance is
still out of tolerance, replace the cylinder head.
8. Check the cam height wear. WARPAGE
[Standard] Check the cylinder head(A) for warpage.

Intake : 34.697mm (1.366in.) • If warpage is less than 0.03mm (0.0012in.) for
Exhaust : 34.570mm (1.361 in.) width, 0.09mm (0.0035in.) for length and 0.012mm
[Limit] (0.0035in) for 51 mm x51 mm, cylinder head is in good
Intake : 34.197mm (1.346in.) condition.
Exhaust : 34.070mm (1.341 in.) • If warpage is over the standard value, replace the
cylinder head.
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ECKD223A
EDKD609A
Measure along edges, and three ways across center.
Cylinder Head Height

Standard (New) : 130mm (5.1181 in.)
EDKD610A
REASSEMBLY E18345F2 3. Install the valve spring(A) and valve spring re-
tainer(B), then install the SST (09222-27300, the
[hjJJ NOTE valve spring compressor). Compress the spring(A)
and install the valve spring retainer lock(C).
Prior to reassembling, cylinder head assembly shall
be cleaned sufficiently to remove scrap and clust.
(Clean holes with special care. 09222-27300
1. Using the SST (09222-27200) insert the valve stem

seals(A).
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EDKDB10A
EDKD611A
4. Lightly tap the end of each valve stem two or three

2. Insert the valves through the valve stem seals. times with a plastic mallet to ensure proper seating of
the valve and valve spring retainer locks.
~NOTE
Make sure the valves move up and down smoothly. ~NOTE
Tap the valve stem only along its axis so you do not
bend the stem.
5. Assembly of lash adjuster.

a. Until installing, lash adjuster shall be held upright
so that gas oil in lash adjuster should not spill and
assured that dust does not adhere to adjuster.
b. Last1 adjust shall be inserted tenderly to the cylin- 12. Tighten each bolt two turns at a time in the sequence
der head not to spill gas oil from lash adjuster. In shown below to ensure that the cam followers do not
case of spilling air bent shall be done in accor- bind on the valves.
dance with the air bent procedure below.
Tightening torque
[QJj NOTE 26.5 - 29.5Nm (265 - 295kgf·cm, 20 - 221bf·ft)
Air bent procedure
1. In case of lash adjuster alone.
Stroke lash adjuster in gas oi14-5 times by push-
ing its cap while pushing the ball down slightly by
hard steel wire.
Take care not to severely push hard steel wire
down since ball is several grams.
2. After installed on engine
Lash adjuster might give out unusual noise if air is
mingled. Apply slow racing from idle to 3,000rpm
(Approximately one minute per one racing) and
the air shall be removed from adjuster.
Therefore noise can be extinguished.
6. Install the valve-caps.
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7. Put the cam followers on the lash adjusters and valve
caps.
8. After wiping down the camshaft and camshaft seal in

the cylinder head, lubricate both surfaces and install EDKD604A
the camshaft with engine oil.
9. Confirm that cam followers are located on lash ad-

justers and their rollers are in touch with camshaft.
10. In assembly camshaft bearing cap, to the cylinder

head with the cylinder block, all pistons should be in
the middle position between TDC(Top Dead Center)
and BDC(Botten Dead Center) because valves come
out of the bottem surface of the cylinder head.
11. Install the bolts loosely.

INSTALLATION E4A1FD47
Install the cylinder head in the reverse order of removal :

b. Select the gasket in the table below using the
@)NOTE average value of piston protrusions.
Although even the only 1 point is over than the
• Always use a new head gasket. each rank limit, use 1 rank upper gasket than
• Cylinder head and cylinder block surface must be specified in the table below.
clean.
• Turn the crankshaft so the No. 1 piston is at
TDC(Top Ded Center).
1. Cylinder head dowel pins must be aligned.
2. Select the cylinder head gasket.

a. Measure the piston protrusion from the upper
cylinder block face (I) on 8 places (A- H) at T.D.C.
Measure on the crankshaft center line consider-
ing the piston migration.
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H G F E D C B A
ECJD200C
ECJD200B
0
LCAC319B
CYUNDERHEADASSEMB~ EMB -39
Displacement 2.0 L
Average of pisston 0.194 - 0.337mm 0.337 - 0.440mm 0.440 - 0.542mm
protrusion (0.0079 - 0.013in.) (0.013 - 0.017in.) (0.017 - 0.021 in.)
1.13 ± 0.05mm 1.23 ± 0.05mm 1.33 ± 0.05mm
Gasket thickness
(0.0445 ± 0.0019in.) (0.0484 ± 0.0019in.) (0.0523 ± 0.0019in.)
Limit of each rank extant 0.43mm (0.0169in.) 0.53mm (0.0208) -
_/\__/\_ ...fLI\....I\_
Identification code
EDDD510C EDDD510D EDDD510E
Part number 22311-27000 22311-27010 22311-27200
c. Install the gasket so that the identification mark 7. Install the fuel pump assembly.
faces toward the flywheel side.
8. Install the intake/exhaust manifold assemblies. (see
3. Position the cylinder head assembly over the gasket. page EMB-92)
4. Tighten the cylinder head bolts slightly. 9. Install the hose between the vacuum pump and the
cylinder head.
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5. Install the camshaft sprocket, aligning ·the timing
mark. 10. If it is necessary to replace the oil seals on the cylinder
head cover for injectors, use the SST(09351-27401 ).
Tighten torque :
125- 140Nm (1250- 1400kgf·cm, 92.19 - 103.261bf·ft) 11. Install the head cover gasket in the groove of the cylin-
der head cover.
6. Tighten the bolts to the specified torque [QJ) NOTE

Tightening torque : • Before installing the head cover gasket, thor-
50Nm (500kgf·cm, 36.91bf·ft) + 120° + 90° oughly clean the seal and the groove.
• When installing, make sure the head cover gas-
ket is seated securely in the corners of the re-
cesses with no gap.
9 5 4 8
12. Apply liquid gasket to the head cover gasket at the
four corners of the recesses.
[QJ) NOTE
• Use liquid gasket LOCT/TE 5699 or TH1212D.
• Check that the mating surface are clean and dry
before applying liquid gasket.
• Do not install the parts if five minutes or more
have elapsed since applying liquid gasket.
Instead, reapply liquid gasket after removing old
residue.
• After assembly, wait at least 30 minutes before
filling the engine with oil.
10 6 2 3 7
EDKD557B
~NOTE
• Tightening sequence of cylinder head bolt should
conform to upper drawing.
• Re-use of the bolts must be limited to 3 times.
13. When installing the cylinder head cover, hold the head 16. Insert the injectors(C), moving back the injector hold-
cover gasket in the groove by placing your fingers on ers(A) with the bolts(B).
the camshaft holder contacting surfaces (top of the
semicircles).
Once the cylinder head cover is on the cylinder head,
slide the cover slightly back and forth to seat the head
cover gasket. B
(QJ] NOTE
• Before installing the cylinder head cover, clean
the cylinder head contacting surfaces with a shop
towel.
• Do not touch the parts where liquid gasket was
r
applied.
• Take care not to damage the oil seals when in-
stalling the cylinder head cover.
• Visually check the oil seals for damage.
• Replace any washer that is damaged or deterio-
rated.
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14. Tighten the nuts in two or three steps. In the final step,
tighten all bolts, in sequence. EDKD548A
Tightening torque
8 - 1ONm (80 - 1OOkgf·ft, 5.90 - 7 .381bf·ft)
(_QJ) NOTE
After assembly, wait at least 30 minutes before filling
the engine with oil.
15. After installation check that all tubes, hoses and con-
nectors are installed correctly.
EDKD549C
CYLINDER HEAD ASSEMBLY EMS -41
17. Tighten the injector holder bolts(A) with 5mm hexag-

onal wrench(B).
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EDKD547A
18. Install the injector plug(A).
EDKD546A
a. Make sure that the stopper of the plug faces

'OPEN' side. Otherwise pull and rotate the plug
clockwise so the stopper should face 'OPEN'
side.
b. Apply the engine oil on the head cover mating
surface or the gasket of the plug.
c. Insert the plugs in the head cover
d. Rotate the plug inserted counterclockwise 90"
e. After installation, rotate the plug clockwise. If it is
rotated, repeat the step a) - d).
ENGINE BLOCK
COMPONENT EA16F20E
h
t/ Oil pan mounting bolts
10- 12 (100 -120,7.37- 8.85)
r~
I !i Oil pan
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Oil screen
53-57
(530- 570,
39.09 - 42.04)
~
I
Flywheel assembly
Engine block assembly
TORQUE : Nm (kgf.ft, lbf.ft)

EDKD580A
ENGINE BLOCK EMB -43
Balance shaft
carrier sub assy
Balance shaft carrier

rear cover
Intermediate gear shaft
Intermediate gear
Intakemediate
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Balance shaft driver gear
Balance shaft carrier

front cover Balance shaft gear shim
/1
~
~.
r----- 34 - 38 (340 - 380, 25.08 - 28.03)
~// ~
()Y ./~
~-~
r
10 ± 2 (100 ± 20,
7.38 ± 1.48)

EDKD621A
i~15mmbolt
28 - 32 (280 - 320, 20.65 - 23.60)+120.
12mm bolt ~ff

33.7-37.7 (337- 377,24.9- 27.8) w
i
Bad plate ------l~
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Crankshaft rear oil seal
Main bearings ~--- Crankshaft gear
Crankshaft
Hexsgon socket head bolt

9 - 13 (90 - 130, 7 - 10)
Piston cooling jet

(Oil jet)
Engine block
TORQUE : Nm (kgf·cm, lbf·ft)

EDKD581A
Piston ring No. 1
Oil r i n g - - - - - -
Snap ring
Piston
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Connecting rod
Piston pin
Connecting rod
bearings
Engine block
r}r
V
0
Connecting rod bolt

25 (250, 18) + 90"
TORQUE·N
. m (kgf-cm, lbf·ft)
REMOVAL E62E6AF9 9. Remove the CKP(Crankshaft Position Sensor)(A) and

the oil pressure switch(B).
1. Remove the engine and transaxle assembly from the
vehicle. (see page EMB-12).
2. Remove the transmission from the engine and

transaxle assembly by loosening bolts.
3. Remove the eight flywheel bolts, then separate the

flywheel from the crankshaft flange.
4. Remove the timing belt assembly. (see page EMB-20)
5. Remove the intake and the exhaust manifold. (see

page EMB-91)
6. Remove the cylinder head assembly. (see page

EMB-27)
7. Remove the alternator. (see EE group- alternator)
8. Remove the engine oil level gauge(A).
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EDKD559A
10. Remove the heater and oil cooler return pipe assem-
bly(A) after loosening the hose clamps(B) and the
bolts(C,D,E).
EDKD558A
EDKD560A
ENGINE BLOCK EMS -47
11. Remove the tube(A) between the vacuum pump and 13. Remove the water inlet pipe assembly(A) by loosen-
the cylinder head. ing a bolt(B) and clamps .
....
Vacuum pump side
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EDKD561A EDKD564A
12. Remove the power steering pump mounting bracket 14. Remove the air compressor(A). (see HA group- com-
assembly(A). pressor)
EDKD562A EDKD563A
15. Remove the auto-tensioner(A) by loosening the 17. Remove the water pump assembly(A) with the gas-
bolt(B). ket(B).
BoltB
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EDKD565A EDKD567A
16. Remove the timing belt rear cover(A). 18. Remove the oil pan(A) after removing the oil-pan
acoustic shield.
EDKD566A
EDKD568A
(mJ NOTE
An oil-pan acoustic shield can be also removed when
removing a transmission from an engine.
19. Remove the oil screen(A) for removal of the oil pump 21 . Remove the oil-pump assembly(B) by loosening the
case(B). bolts(A).
~
~i~
~--~-::"--=--== '--
~~~
~~~~JJ! 0
B
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EDKD569A EDKD571A
20. Remove the crankshaft bolt(A), then separate the 22. Remove the crankshaft key(A).
crankshaft sprocket(B).
EDKD570A
EDKD572A
DISASSEMBLY E40D23BC 2. Remove the bed plate assembly(C).

• Remove the bolts(A).
1. Remove the balance shaft assembly(A) by loosening To prevent warpage, unscrew the bolts in se-
the flange bolts(B,C). quence 1/3 turn at a time : repeat the sequence
until all bolts are loosened.
• Remove the bolts(B).
A---; I
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EDKD564A
EDKD563A
3. Remove the connecting rod bearing caps(A) and 6. Lift the crankshaft (A) out of the engine block( B), being
bearings(B). careful not to damage the journals.
• After removing No. 1 and 4 connecting rod bear-
ing caps and turn the crankshaft No. 2 and 3
crankpins are at the top.
• Remove the rest bearing caps and bearings.
• Keep all caps/bearings in order.
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EDKD586A
7. Remove the piston oil jet(A) by loosening the hexag-

onal bolt(B) with a hexagonal wrench.
EDKD585A
4. If you can feel a ridge of metal or hard cabon around

the top of each cylinder, remove it with a ridge reamer.
Follow the reamer manufacturer's instructions. If the
ridge is not removed, it may damage the pistons as
they are pushed out.
5. Drive out the piston assembly from the engine block.

a. Reinstall the connecting rod bearings and caps
after removing each piston/connecting rod as-
sembly.
b. To avoid mixup on reassembly, mark each pis-
ton/connecting rod assembly with its cylinder
number. EDKD587A
EMB -52 2 ENGINE MECHANICAL SYSTE
. Remove the into . M [DIESEL]
BALANCER rmed1ate gear assembly(B).
1. Remove the balance shaft carrier fronVrear

cover(A,B).
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EDKD615A
EDKD614A 3· Remove the balance shaft dnve

. gear(A).
EDKD618A EDKD616A
4. Remove the balance shaft gear shim(A). 6. After loosening the balance shaft gear bolt, remove
the balance shaft driven gear(B).
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EDKD617A
EDKD619B
5. Remove the balance shaft driver gear(A).
7. Remove the balance driver/driven shafts(A,B).
EDKD619A
EDKD620A
REPLACEMENT E848A330 Main Journal Code Locations
MAIN BEARING SELECTION 2. The main Journal Codes are stamped on the No.1
web.
Crankshaft Bore Code Location
1. Letters have been stamped on the end of the block as

a code for the size of each of the 5 main journal bores.
Write down the crank bore codes.
If you can't read the codes because of accumulated
dirt and dust, do not scrub them with a wire brush or
scraper. Clean them only with solvent or detergent.
Main journal code
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EDKD593A
Discrimination of crank shaft
Discrimination SIZE (mm)

(Outside diameter of
Class Mark main journal)
060
EDKD590A I A
(+0.014-+0.020)
Discrimination of cylinder block 060
II B
(+0.008-+0.014)
060
(Inside diameter of Ill c (+0.002-+0.008)
Class Mark crank bore)
064
A A
(0-+0.006)
064
B B
(+0.006-+0.012)
064
c c (+0.012-+0.018)
3. Use the crank bore codes and crank journal codes to Connecting Rod Big End Bore Code Locations
select the appropriate replacement bearings from the
following table. 2. Each rod has tolernance range from 0 to 0.018mm
(0.0007in.), in 0.006mm (0.0002in.) increments, de-
pending on the size of its big end bore. It's then
~NOTE
stamped with a letter (A, B or C) indicating the range.
• Color code is on the edge of the bearing. Refer to You may find any combination of letters in any engine.
the talde in the step 6 of the main bearing clear-
ance inspection. If you can't read the code because of an accumulation
• When using bearing halves of different colors, it of oil and varnish, do not scrub them with a wire bruch
dose not matter which color is used in the top or or scraper. Clean them only with solvent or detergent.
bottom.
Installing procedure of bearing
Shaft bore
combination Bearing
Oil clearance
Shaft Bore mark
mark mark
A
A (A)
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(BLUE)
I (A) B
B (B)
(BLACK)
C (C) c (-)
B
A (A)
(BLACK)
II (B) B (B) c (-) 0.024 - 0.042 mm
D
C (C) EDKD592A
(GREEN)
A (A) c (-) [Qj1 NOTE
D Discrimination of connecting rod
B (B)
Ill (C) (GREEN)
E (VEL- Discrimination SIZE (mm)
c (C) LOW) (Inside diameter of
Class Mark connecting rod big
end bore)
ROD BEARING SELECTION
0 53
A A
1. Inspect each connecting rod for cracks and heat dam- (0-+0.006)
age.
0 53
B B
(+0.006-+0.012)
0 53
c c (+0.012-+0.018)
Connecting Rod Journal Code Locations 4. Use the big end bore codes and rod journal codes
to select appropriate replacement bearings from the
3. The connecting Rod Journal Codes are stamped on following table.
the No. 1 web.
~NOTE
Connecting rod journal code locations (letters)
Color code is on the edge of the bearing.
Refer to the table in the step 5 of rod bearing clear-
ance inspection.
Shaft bore combination Bearing Oil

Sahft mark Bore mark mark clearance
A (A) A (BLUE)
I B (B) B (BLACK)
C (C) C (WHITE)
A (A) B (BLACK)
II B (B) C (WHITE) 0.024 -
0.042 mm
c (C) D (GREEN)
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A (A) C (WHITE)
Main journal code
B (B) D (GREEN)
Ill
E
C (C)
EDKD593A
(YELLOW)
~NOTE
Discrimination of crank shaft pin.

Class Mark (Outside diameter of pin)
050
I A
(+0.020-+0.025)
050
II B
(+0.014-+0.020)
050
Ill c (+0.008-+0.014)
PISTON, PIN AND CONNECTING ROD 7. Measure the piston pin-to-connecting rod clearance.
1. Apply engine oil (lard or non-water-soluble press oil Piston Pin-to-Connecting Rod Clearance
acceptable) to the piston pin snap rings and turn them Standard (New) : 0.022 - 0.039mm (0.00087
in the ring grooves. - 0.00154in.)
~NOTE 8. Set a snap ring in one side of piston pin hole.

Take care not to damage the ring grooves.
9. Before inserting the piston pin, apply a sufficient
2. Remove both snap rings (A) carefully so they do not amount of the lubricant oil (engine oil, lard or non-wa-
go flying or get lost. Wear eye protection. ter-soluble press oil) to the outer surface of the piston,
the inner surface of the piston pin hole and the small
end bore of the connecting rod.
[Q_JJ NOTE
Non-water-soluble press oil: YUKEN KOGYO/STAN-
DARD DS-711 or equivalent.
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EDK0549A
3. Remove the piston pin and the conecting rod assem-

bly.
4. Measure the diameter of the piston pin.
Piston Pin Diameter

Standard (New) :
27.995- 28.000mm (1.1022- 1.1024in.)
@)NOTE
Inspect the piston, piston pin and connecting rod
when they are at room temperature.
5. Zero the dial indicator to the piston pin diameter.
6. Check the difference between the piston pin diameter

and piston pin hole diameter in the piston ..
Piston Pin-to-Piston Clearanace

Standard (New) :
0.015 - 0.030mm (0.00059 - 0.00118in.)
10. Insert the piston pin(A). Assembly the piston and con- PISTON RING
necting rod with the embossed front marks on the
same side. 1. Using a piston, push a new ring into the cylinder bore.
I\
\
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ECKD001M
~NOTE
The front mark of the piston is embossed on the piston
whereas some letters are located on a side surface of
the connecting rod as the front mark.
ffi CAUTION ECKD001K
• Be sure to keep the small end bore, piston

2. Measure the piston ring end-gap(B) with a feeler
pin hole and piston pin undamaged and un-
scratched when inserting the piston pin. gauge:
• Set the snap rings to be sure for contacting • If the gap is too small, check to see if you have
the proper rings for your engine.
with the groove of the piston pin hole.
• If the gap is too large, recheck the cylinder bore
diameter against the wear limits (see page EMB-
64).
If the bore is over the service limit, the cylinder
block must be rebored.
Piston Ring End-Gap

Top ring
Standard (New) :
0.20 - 0.30mm (0.008 - 0.012in.)
Second Ring
Standard (New) :
0.30 - 0.45mm (0.012 - 0.018in.)
Oil Ring
Standard (New) :
0.20 - 0.40mm (0.008 - 0.016in.)
3. Using a ring expander, remove the old piston rings.

4. Clearance all ring grooves thoroughly with a 6. After installing a new set of rings, measure the ring-to-
squared-off broken ring or ring groove cleaner groove clearances :
with a blade to fit the piston grooves.
Scond Ring Clearance
Top ring groove : Standard (New) :
1.915 - 1.945mm (0.07539 - 0.07657in.) 0.065 - 0.11 Omm (0.00256 - 0.00433in.)
2nd ring groove :
2.060 - 2.080mm (0.0811 0 - 0.08189in.) Oil Ring Clearance
Oil ring groove : Standard (New) :
3.020 - 3.040mm (0.11889 - 0.00968in.) 0.03 - 0.07mm (0.00118- 0.00275in.)
File down a blade if necessary.

Do not use a wire brush to clean the ring grooves, or
cut the ring grooves deeper with cleaning tools.
@)NOTE
If the piston is to be separated from the connecting
rod, do not install new rings yet.
5. Install the piston rings.
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a. No.1 , No.2 piston ring
• Fit the rings into the mating grooves with the
manufacturer's mark near the end-gap up-
ward (toward cylinder head).
• The end-gap of No. 2 ring should be located
with turned approximately 180° to that of No.
1 ring.
b. Oil ring
• Insert the piston into the cylinder bore, after ECKD001G
applying sufficient engine oil to the piston
with ring fitted into the groove.
• The end-gap of oil ring should be located
with 180° to the gap of coil spring and 90°
to that of No. 2 ring.
~NOTE
Confirmation after installing to piston : check to en-
sure that the oil ring assy(oil ring & coil spring) can be
turned smoothly.
c. The end-gap positions to the thrust direction :

confirm through to the position.
Do NOT position any ring gap in line with the pis-
ton pin hole.
Piston Ring Dimensions

Top Ring (Standard) :
Width : 2.95 - 3.25mm (0.116 - 0.128in.)
Thickness : 2mm (0.079in.)
Second Ring (Standard)
Width: 3.60- 3.90mm (0.142- 0.154in.)
Thickness : 1.970 - 1.995mm (0.078 - 0.079in.)
INSPECTION EAFE8225 4. Place one strip of plastigauge across each main jour-
nal on the cylinder block and the bed plate, avoiding
FLYWHEEL the oil holes.
1. Inspect ring gear teeth for wear or damage. 5. Reinstall the bearings, crankshaft and bed plate then
torque the bolts to the specified valve.
2. Flywheel bolts should be free from detrimental flaws.
CONNECTING ROD AND CRANKSHAFT END PLAY [QJj NOTE
Do not rotate the crankshaft during inspection.
1. Measure the connecting rod end play with a feeler
gauge(A) between the connecting rod(B) and crank- 6. Remove the bed plate and bearings again and mea-
shaft(C). sure the widest part of the plastigauges with a cali-
brated scale on which an arrow of marks has beeen
Connecting Rod End play printed.
Standard (New): 0.10- 0.35mm (0.004- 0.014in.)
Service Limit : 0.40mm (0.016in.) Main bearing-to-journal Oil Clearance
Standard (valve) :
0.024 - 0.042mm (0.0009 - 0.0017in.)
B
[QJj NOTE
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Discrimination of crankshaft main bearing.
Discrimina- SIZE (mm)

tion Place of
(Thickness
identification mark
Class Mark of bearing)
YEL-
E 1.987-1.990
LOW
D GREEN 1.984-1.987
c 1.981-1.984
B BLACK 1.978-1.981
A BLUE 1.975-1.978 EDKDSOOA
EDKD589A
7. If the plastigauge mesaure too wide or too narrow, re-
move the crankshaft, and remove the upper half of
2. If the connecting rod end play is out-of-tolerance,
the bearing. Install a new, complete bearing with the
install a new connecting rod, and recheck. If it is still
same color code(s), and recheck the clearance. Do
out-of-tolerance, replace the crankshaft (see page
not file, shim, or scrape the bearings to adjust clear-
EMB-54).
ance.
3. If the end play is excessive. Replace parts as neces-
8. If the plastigauge shows the clearance is still incor-
sary.
rect, try the next larger or smaller bearing (the color
MAIN BEARING CLEARANCE listed above or below that one), and check again. If
the proper clearance cannot be obtained by using the
1. To check main bearing-to-journal oil clearance, re- appropriate larger or smaller bearings, replace the
move the bed plate, the crankshaft and the bearing crankshaft and start over.
halves.
2. Clean each main journal and bearing half with a clean

shop towel.
3. Cut plastigauge to the same length as the width of the

bearing.
ROD BEARING CLEARANCE 6. If the plastigauge measure too wide or too narrow,
remove the upper half of the bearing, install a new,
1. Remove the connecting rod cap and bearing half. complete bearing with the same color code(s), and
recheck the clearance. Do not file, shim, or scrape
2. Clean the crankshaft rod journal bearing half with a the bearings or the caps to adjust clearance.
clean shop towel.
3. Place pastigauge across the rod journal. @)NOTE

Discrimination of connecting rod bearing.
4. Reinstall the bearing half and cap, and torque the bolt.
Discriminati Size
[QJ) NOTE Class Mark
(Thickness Place of Identification
of bearing)
Do not rotate the crankshaft during inspecition.
VEL- 1.484 -
5. Remove the rod cap(A) and bearing half(B) and mea- E
LOW 1.487
sure the widest part of the plastigauge(C).
1.481 -
D
1.484
Connectinng Rod Bearing-to-Journal Oil
Clearance : 0.024 - 0.042mm (0.0009 - 0.0017in.) 1.478 -
c 1.481
1.475 -
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B BLAC
1.478 EDKDSOOA
1.472 -
A BLUE
1.475
7. If the plastigauge shows the clearance is still incor-

rect, try the next larger or smaller bearins (the color
listed above or below that one), and check clearance
again. If the proper clearance cannot be obtained by
using the appropriate larger or smaller bearing, re-
place the crankshaft and start over.
EOKD591A
BALANCER SHAFTS 2. Measure the diameters of the journals on the balance

shafts(A).
1. Measure runout on the journals of each balance
shaft(A) to make sure the balancer shafts are not Journal Diameter
bent. Standard (New) :
No. 1 journal :
Balancer Shaft Total Indicated Runout 19.980- 19.993mm (0.7866- 0.7871in.)
Standard (New) : 0.025mm (0.00098in.) No. 2 journal :
27.99- 28.01mm (1.1020- 1.1028in.)
No. 3 journal :
41.99 - 42.01 mm (1.6531 - 1.6539in.)
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EDKD596A
EDKD597A
3. Measure the inner diameters of the bearings for the

balance shafts.
Bearing Inner Diameter

Standard (New) :
No. 1 journal :
20.00 - 20.02mm (0.7874 - 0.7882in.)
No. 2 journal :
28.06 - 28.08mm (1.1 047 - 1.1 055in.)
No. 3 journal :
42.06 - 42.08 (1.6559 - 1.6567in.)
4. Claculate the shaft-to-bearings oil clearances.

BEARING I.D- JOURNAL O.D =OIL CLEARANCE
Shaft-to-Bearings Oil clearance

Standard (New) :
No. 1 journal :
0.007 - 0.041 mm (0.00028 - 0.00161 in.)
No. 2 journal :
0.050 - 0.090mm (0.00197 - 0.00354in.)
No. 3 journal :
0.050 - 0.090mm (0.00197 - 0.00354in.)
CRANKSHAFT Out-of-Round and Taper

1. Measure out-of-round at the middle of each rod and
Straightness main journal in two places. The difference between
measurements on each journal must not be more than
[QJ) NOTE the serivce limit.
• Clean the crankshaft oil passages with pipe
Journal Out-of-Round
cleaners or a suitable brush.
Standard (New) : 0.0035mm (0.0001 in.) max.
• Check the keyway and threads.
1. Support the crankshaft with a lathe-type tool or

V-blocks.
2. Measure runout on all main journals to make sure the

crank is not bent. Rotate the cranklshaft two com plate
revolutions. The difference between measurements
on each journal must not be more than the stardard
value.
Crankshaft Total Indicator Runout

Standard (New) : 0.06mm (0.002in.) max.
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ECKD001E
2. Measure taper at the edge of each rod and main jour-

nal. The difference between measurements on each
journal must not be more than the serive limit.
Journal Taper
ECKD001C Standard (New) : 0.006mm (0.0002in.) max.
BLOCK AND PISTON Piston Diameter and Cylinder Bore

Standard value :
1. Check the piston for distortion or cracks.
2. Measure the piston diameter at a point 1Omm (0.4in)

Grade A B c
from the bottom of the skirt. There are three standard- Piston Outer 82.92- 82.93- 82.94-
size pistons (A. B and C). The letter is stamped on Diameter (mm) 82.93 82.94 82.95
the top of the piston. Letters are also stamped on the 83.00- 83.01 - 83.02-
block as cylinder bore sizes. Cylinder Bore (mm)
83.01 83.02 83.03
Clearance (mm) 0.070 - 0.090
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EDKD590A
ECKD316A
ECKD001D
3. Measure wear and taper in direction X and Y at three 6. Calculate the difference between the cylinder bore di-
levels in each cylinder as shown. If measurements ameter and the piston diameter. If the clearance is
in any cylinder are beyond the cylinder bore standard near or exceeds the standard value, inspect the pis-
value (Refer to the previous page), replace the block. ton and cyllinder block for excessive wear.
If the block is to be rebored, refer to step 6 after re-
boring. Piston-to-Cylinder Clearance
Standard (New) :
Oversize 0.070 - 0.090mm (0.0028 - 0.0035in.)
0.25 : 83.250 - 83.280mm (3.2776 - 3.2787in.) Oversize Piston Piameter :
0.50: 83.500- 83.530mm (3.2874- 3.2886in.) 0.25 : 83.170 - 83.200mm (3.27 44 - 3.2756in.)
Bore Taper 0.50: 83.420- 83.450mm (3.2882- 3.2881in.)
Limit : (Difference betweem first amd
thired measurement) CYLINDER HONING
0.01 mm (0.0004in.) MAX.
Only a scored or scratched cylinder bore must be honed.
Level 1 : No. 1 piston ring position at TDC(Top Dead
1. Measure the cylinder bores (see page EMB-64).
Center)
If the block is to be reused, hone the cylinders and
Level 2 : Center of cylinder
remeasure the bores.
Level 3: Bottom of cylinder.
2. Hone the cylinder bores with honing oil and a fine
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stone. Do not use stones that are worn or broken.
3. When honing is complate, thoroughly clean the en-

gine block of all metal particles. Wash the cylinder
bores with hot soapy water, then dry and oil them im-
mediately to prevent rusting. Never use solvent, it will
redistribute the grit on the cylinder walls.
4. If scoring or scratches are still present in the cylinder

bores after honing to the service limit, rebore the cylin-
der block. Some light vertical scoring and scratching
is acceptable if it is not deep enoough to catch your
fingernail and does not run the full length of the bore.
ECKD318A
4. Scored or scratched cylinder bores must be honed.
5. Check the top of the block for warpage. Measure

along the edges and across the center.
Engine Block Warpage

Standard (New)
0.042mm (0.00165in.) for width
0.96mm (0.00378in.) for legth
0.12mm (0.00047in.)
Servicr Limit : 0.1 Omm (0.004in.)
EMB -66 ENGINE M ECHANICAL SYS
3. Install the balance TEM [DIESEL]
REASSEMBLY E4CC7E5D shaft carrier rear cover(B).
BALANCE SHAFT
1. Insert
rier.
.. the ba lance driver/driven shafts(A,B) in the car-
8
[YJJ NOTE
There are th .
shafts(A,B) a~~dentification marks (DR, DN) on the
the carrier(C).
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EDKD618A
4. Install the bala nee shaft gear shim(A).
2. Install the balance shaft dnver/driven

. EDKD622A
gears(A,B).
EDKD617A
EDKD623A
@)NOTE
Confirm the gearmarks.
5. Install the balance shaft drive gear(A) and the inter- 6. Tighten the balance shaft gear bolts with plain wash-
mediate gear assembly(B). ers.
To use a vice(A) as shown below will make the tight-
ening work much easier.
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EDKD616A
EDKD624A
7. Install the balance shaft carrier front cover(A).
EDKD615A
@)NOTE
Confirm the gear marks. EDKD614A
PISTON 5. Check the connecting rod bearing clearance with

plastigauge (see page EMB-61 ).
1. Remove the connecting rod caps then install the ring
compressor and check that the bearing is securely in 6. Apply engine oil to the bolt threads, then install the
place. rod caps with bearings.
2. Position the marks(A,B) facing the timing belt side of

the engine.
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ECKD320A
3. Position the piston in the cylinder and tap it in using

the wooden handle of hammer.
Maintain downward force on the ring compressor to
prevent the rings from expanding before entering the
cylinder bore.
ECKD001F
4. Stop after the ring compressor pops free, and check

the connecting rod-to-crank journal alignment before
pushing the piston into place.
CRANKSHAFT AND BALANCER 8. Rotate the crankshaft clockwise to be seated properly.
1. Install the oil jets, tightening the hexagon socket head 9. Check the main bearing clearance with plastigauge
bolts with the torque 9 - 13Nm (98 - 130kgf·cm, 6.61 (see page EMB-60)
- 5.591bHt)
10. Install the piston and connecting rod assemblies.
2. Apply a coat of engine oil to the main bearings. a. Apply coat of engine oil to the connecting rod
bearings.
3. Install the bearing halves in the engine block. b. Install the bearing halves in the connecting rods.
c. Insert the assemblies into the cylinder bores.
4. Hold the crankshaft so rod journal No. 2 and rod jour- d. Install the connecting rod caps and bolts finger
nal No. 3 are straight up. tight
e. Rotate the crankshaft clockwise, seat the jour-
5. Lower the crankshaft into the block.
nals into connecting rod No. 2 and connecting
6. Install the bearing halves in the bed plate after apply- rod No. 3. Install the connecting rod caps and
ing a coat of engine oil. bolts finger tight. Install caps so the bearing re-
cess is on the same side as the recess in the rod.
7. Install the bed plate(C) to the engine block. After ap- f. Check the connecting rod bearing clearance with
plying the sealant. plastigage (see page EMB-61)
g. Apply engine oil to the bolt threads, then install
Tightening torque the rod caps witjn bearings and torque the bolts
to 25+90°Nm (250+90°kgf·cm, 18.44+90°lbHt).
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15mm(B) :
28 - 32+ 120°Nm (280 - 320+ 120°kgf·cm,
20.65 -23.60+ 120°lbf·cm) 11. Using the SST(09231-27000), install the crankshaft
12mm(A) oil seai(A) squarely.
33.7 - 37.7+120°Nm (337 - 377kgf·cm,
24.9 -27.81bf·cm)
09231-27000
EDK0630A
12. Clean and dry the mating surfaces.

Apply a light coat of oil to the crankshaft and to the lip
of the seal.
EOKD584A
13. Install the balance shaft assembly(A) onto the bed

plate with the bolts(B,C).
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EDKD583A
Tightening torque :
53 - 57Nm (530 -570kgf·ft, 39.09 - 42.041bf·ft)
@)NOTE
Pay attertion to the timing marks on the driver gears
of the balance shaft and the crankshaft.
INSTALLATION E8C44413 3. Install the crankshaft key(A) on the crankshaft assem-

bly.
1. Clean and dry the oil pump mating surface.
2. Install the oil pump

a. Install a new crankshaft oil seal in the oil pump
(see page EMB-69)
b. Apply liquid gasket evenly to the block mating sur-
face of the oil pump.
Standard liquid gaskets (or seaants) :

ORE BOND 2210, HYLOMAR 101
LOCTITE5900 or equivalent
[QJ) NOTE
• Apply liquid gasket in a wide bead: 2.5±0.5mm
• Apply the liquid gasket without stoping.
• Assemble the oil pump within 5 minutes after
applying.
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c. Grease the lips of the oil seals
d. Align the inner rotor with the crankshaft drive gear
and install the oil pump(B).
Tightening torque(A) :
20- 27Nm (200- 270kgf·cm, 14.75- 19.911bf·ft)
EDKD572A
EDKD571A
e. Clean the excess grease off the crankshaft and

check the seals for distortion.
4. Insert the crankshaft sprocket then tighten the crank- 5. Install the oil screen(A) on the oil pump case(B) and
shaft bolt. the engine block.
Tightening torque Tightening torque

185 - 195Nm (1850 - 1950kgf·cm, 13.6 - 143.831bf·ft) Bolt A : 10 - 12Nm (1 00- 120kgf·cm, 7.37 - 8.851bf-ft)
Bolt B : 34 - 38Nm (340 - 380kgf·cm,
25.08 - 28.031bf·ft)
~NOTE
Align the timing mark on the sproket.
[YJj NOTE
The bolt B should be tightened after the installation of
the bolt A.
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EDKD570A
EDKD569A
6. Clean and dry the bed plate and the oil pan mating
surfaces.
7. Apply liquid gasket evenly to the bed plate mating sur-

face of the oil pan. Install the oil pan.
~NOTE
• Standard liquid gasket : LOTITE 5900
• Assemble the oil pan in 5 mimutes after applying
the liquid gasket.
• Apply liquid gasket in a 3mm wide bead without
stopping.
• The clearance between the liquid gasket and the
flange inner end should be 2 - 3mm.
8. Tighten the bolt in two ir three steps. In the final step, 11. Install the air compressor(A). (see HA group - com-
tighten all bolts. pressor)
Tightening torque
10- 12Nm (100- 120kgf·cm, 7.38- 8.8511bHt)
[gJj NOTE
After installing the oil pump assembly and the oil pan,
remove the oil cooler and fill the 50cc engine oil.
9. Install the water pump. (see page EMB-76)
Tighten torque
Bolt A : 48 - 52Nm (480 - 520kgf.cm,
35.40 - 38.351bf·ft)
Bolt B: 10- 12Nm (100- 120kgf.cm, 7.37- 8.851bf.ft)
10. Install the auto-tensioner(A).
Tightening torque
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Pivot bolt (B) : EDKD563A
50 - 55Nm (500 - 550kgf·cm, 36.88 - 40.571bf·ft)
Stop bolt : 12. Install the water inlet pipe assembly(A), tightening the
10- 12Nm (100- 120kgf·cm, 7.38- 8.851bf-ft) bolt( B).
Tightening torque
20 - 25Nm (200 - 250kgf·cm, 14.75 - 18.441bf·ft)
EDKD565A
EDKD564A
13. Install the power steering pump mounting bracket as- 15. Install the CKP(Crankshaft Position Sensor) (A) and
sembly(A). the oil pressure switch (B).
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EDKD562A EDKD559A
14. Install the heater and oil cooler return pipe(A) assem- 16. Install the cylinder head assembly. (see page EMB-
bly. 38).
Tightening torque 17. Install the intake/exhaust manifold assemblies. (see

Rear side bolt and left side bolt (C,D) : page EMB-92)
20 - 25Nm (200 - 250kgf·cm, 14.75 - 18.441bHt)
Right side bolt (B) : 18. Install the oil level gauge(A).
8- 10Nm (80- 100kgf·cm, 5.90- 7.381bHt)
Tightening torque
10- 12Nm (100- 120kgf·cm, 7.38- 8.851bHt)
EDKD560A
EDKD558A
19. Install the timing belt assembly. (see page EMB-23)

COOLING SYSTEM EMB -75
COOLING SYSTEM
COMPONENT EFD96C1E
Upper bracket
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Radiator lower
Reservior
tank
' Lower insulator
Fan motor
TORQUE : Nm (kgf.cm, lbf.ft)
ECKD011A
EMB -76 ENGINE MECHANICAL SYSTEM [DIESEL)
REPLACEMENT EOOC3F87 5. Install the water pump, with a new gasket in the re-
verse order of removal.
WATER PUMP
Tightening torque
1. Remove the timing belt. (see page EMB-20) For timing belt rear cover :
7.8- 11.8Nm (78- 1180kgf·cm, 5.75 - 8.701bf·ft)
2. Remove the timing belt rear cover(A).
For water pump :
Bolt A : 48 - 52Nm (480 - 520kgf·cm,
35.40 - 38.401bf·ft)
Bolt B : 10 - 12Nm (1 00 - 120kgf·cm, 7.38 - 8.851bf·ft)
6. Clean the spilled engine coolant.
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EDKD566A
3. Remove the water pump(A) with the gasket(B) by re-

moving four bolts. (One bolt A and three bolt B)
BoltB
EDKD567A
4. Inspect, repair and clean the mating surface on the

engine block.
COOLING SYSTEM EMB -77
INSPECTION E6A4A4B7
THERMOSTAT
Replace the thermostat if it is open at room temperature.
To test closed thermostat :
1. Suspend the thermostat in a container of water.

Do not let the thermometer touch the bottom of the
hot comtainer.
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ECKD503B
2. Heat the water and check the temperature with the

thermomster. Check the temperature at which the
thermostat first opens, and at which it is fully open.
3. Measure the lift height of the thermostat when it is fully

open.
STANDARD THERMOSTAT
Lift height : above 8.0mm (0.31 in.)
Starts opening: 85 ± 1.SOC (185 ± 34.7°F)
Fully open : 1oooc (212°F)
LUBRICATION SYSTEM
COMPONENT EEB73DB3
FOR THE REST

FOR AREA EXCEPT
EUROPE LHD ONLY : EUROPE-LHD:
111----- Oil filter upper cap
23-25
(230- 250, 16.96- 18.44)
Oil filter
assembly
Oil filter
lower case /1
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~ ~Q;I!;Ite•fiH;og
,//// ////
v 48 - 52 (480 - 520, 35,40 - 38,35)
Oil cooler
Oil pump housing
0-ring
Oil seal
Oil pump
drive gear
V
o
I
I
'
~
0
Relief plunger
~ Relief spring
~ ~ Relief cap washer

8-10
(80- 100, 5.90- 7.38)
TORQUE : Nm (kgf-cm, lbf-ft)

Oil pump cover
v ~ -""Relief cap
42- 52 (420- 520, 30,98- 38,35)
EDKD635A
LUBRICATION SYSTEM EMB -79
REMOVAL EE9AAED8 5. Remove the timing rear cover(A).
OIL PUMP
1. Drain the engine oil.
2. Remove the timing belt assembly. (see page EMB-

20).
3. Remove the timing belt tensioner(A).
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EDKD566A
6. Separate the oil pan(A) from the engine block with an

oil pan seal cutter.
EDKD565A
4. Remove the timing belt drive pulley(A).
EDKD568A
EDKD530A 7. Remove the balance shaft carrier and the oil screen.
8. Remove the crankshaft sproket(B) with the bolt(A).
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EOKD570A
9. Remove the mounting bolts(A) and the oil pump as-

sembly(B).
EOK0571A
DISASSEMBLY E9A2ABC7 6. Remove the 0 ring(A} from the oil pump case(B}.
OIL PUMP
1. Remove the three hexagon socket head bolts(A} from

the oil pump cover(B}.
r-·
I
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EDKD639A
7. Remove the oil filter. Refer to the engine oil filter re-
placement. (see page EMB-82}.
8. Remove the oil cooler and hose assembly after separ-

ating the oil filter fitting.
9. Remove the relief cap(A}, relief cap washer(B}, relief

spring(C} and relief plunger(D}.
EDKD638A
2. Remove the oil pump cover with the inner rotor and
the drive gear.
3. Sepreate the inner rotor and the drive gear from the
oil pump cover.
4. Remove the outer rotor from the oil pump case.

EDKD640A
5. Remove the old oil seals from the oil pump case.
REPLACEMENT E42970AO ENGINE OIL
ENGINE OIL FILTER [Ql) NOTE

Under normal conditions, the oil filter should be re-
~NOTE placed at every other oil chang. Use severe con-
There are two kinds of oil filters. One is for Eurpe LHD ditions, the oil filter should be replaced at each oil
(Part No. 26310-27002) and the orther is for the rest change.
area (Part No. 26310-27200) except Eurpe LHD(Left
Hand Drive). 1. Warm up the engine.
For Eurpe LHD : 2. Remove the drain bolt, and drain the engine oil.
1. Remove the oil filter upper cap from lower case with 3. Reinstall the drain bolt with a new washer.
SST(09263-271 00, the oil filter wrench.).
Tightening torque
2. Inspect the threads and rubber packing. Wipe off the 35 - 45Nm (350 - 450kgf·cm, 25.8 - 33.21bf-ft)
seat on the oil pump assembly, then apply a light coat
of oil to the oil pump assembly upper cap packing.
3. Install the new oil filter by hand to the upper cap.
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4. After the rubber seal seats, tighten the oil filter clock-
wise with the special tool.
For the rest area except Eurpe LHD :
1. Remove the oil filter(A) with the SST(09263-27000,

the oil filter wrench).
EDKD634A
2. Inspect the threads and the packing on the apply a

light coat of oil new filter. Wipe off the seat.
3. Install the new oil filter by hand.
4. After the packing seats, tighten the oil filter clockwise
with the SST (09263-27000).
4. Refill with the recommended oil.

SELECTION OF ENGINE OIL
RECOMMENDED SAE VISCOSITY GRADES :
Temperature range
anticipated before
Recommended SAE viscosity number
next oil change
·c
40
"F
104
-
1\/\
30 20W 15W
10W
-30
40 68 - -40 -40
20 50 -
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5W
...__
10 32 - -30
0 14 -
ow
-10 5 -
-30
-20 -4 -
-25 -13 -
*1
*2
*1 Restricted by driving condition and environment.

*2 Not recommended for sustained high speed vehicle operation
ECJD001B
~NOTE
For best performance and maximum protection of all
types of operation, selection only those lubricants
which:
1. Sa tis the requirement of the API classification.
2. Have the proper SAE grade number for expected
ambient temperature range.
Lubricants which do not have both SAE grade num-

ber and an API service classification on the container
should not be used.
INSPECTION E6A90CFF 2. Check the housing-to-rotor axial clearance between

the rotor(A) and oil pump cover housing(B). If the
OIL PUMP housing-to-rotor axial clearance exceeds the service
limit, replace the set of inner and outer rotors and/or
1. Check the inner-to-outer rotor radial clearance be- the pump housing.
tween the inner rotor (A) and outer rotor (B). If the in-
ner-to-outer rotor clearance exceeds the service limit, Housing-to-Rotor Axial Clearance
replace the inner and outer rotors. Standard (New) :
0.020 - 0.070mm (0.00079 - 0.00276in.)
Inner Rotor-to-Outer Rotor Radial Clearance
Standard (New) :
0.12 - 0.20mm (0.0047 - 0.0079in.)
________ _____/
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EDKD637A
3. Inspect both rotors and the oil pump cover housing for
scoring or other damage. Replace parts if necessary.
EDK0636A
OIL PRESSURE SWITCH After diassembling engine :

1. Remove the oil pressure switch(A) from the engine
On vehicle: block.
2. Connect a tester (ohm range) between the terminai(B)
1. Remove the wire from the engine oil pressure switch and the body(C) of the switch to check for continuity.
(B). The switch is normal if there is continuity. If they is no
continuity, replace the switch.
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EDKD559A
EDKD632A
2. Check for continuity between the positive terminal and
the engine (ground). There should be continuity with 3. Insert a thin rod(A) in the oil hole of the switch and
the engine stopped. There should be no continuity push it in lightly. The switch is normal of no continuity
with the engine running. os detected (infinite resistance on the tester). If there
is continuity, replace the switch.
3. If the switch fails to operate, check the engine oil level.
If the engine oil level is OK, check the engine oil pres-
sure.
EDKD633A
OIL PRESSURE REASSEMBLY E292F612
If the oil pressure warning light stay on with the engine OIL PUMP
running, check the engine oil level. If the oil level is correct
1. Insert the relief plunger, the relief spring and the relief
cap washer. Then torque the relief cap.
1. Connect a tachometer.
Tightening torque :
2. Remove the engine oil pressure and install an oil pres- 42 - 52Nm (420 - 520kgf·cm, 30.98 - 38.351bHt)
sure gauge.
3. Start the engine. Shut if off immediately if the gauge ~NOTE

registers no oil pressure. Repaur the problem before
When assembling the relief spring. Apply an anti-rust
continuing.
oil.
4. Allow the engine to reach operating temperature (fan
comes on at least twice). The pressure should be: 2. Install the 0 ring(A) to the oil pump case (B) after
applying engine oil.
Engine Oil Temperature :
203 - 221" F (95 - 105" C)
Engine Oil Pressure (At 1,500rpm) :
250kPa (2.5kgf/cm2 , 36psi)
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5. If oil pressure is NOT within specifications, inspect the
oil pump. (see page EMB-84)
EDKD639A
3. Assemble the inner/outer rotors with engine oil the

drive gear and the oil pump cover.
4. Install the oil pump cover(B) assembly to the oil pump 9. Install the oil filter for Eurpe LHD.
case with the three hexagon socket head bolts(A). a. Install the non return valve assy of the oil filter
lower case to the oil filter fitting.
Tightening torque
34 - 36Nm (340 - 360kgf·cm, 25.08 - 26.551bf·ft)
iI b. After fixing the filter, tighten the oil filter upper
cap.
Tighteningtorque
23 - 25Nm (230 - 250kgf·cm, 16.96 - 18.441bf·ft)
10. Install the oil filter for the rest areas except Europe
B LHD.
a. Torque the oil filter assy with the SST (09263-
27000).
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0
EDKD638A
5. The oil seal which was disassembled in 'Disassembly'

step is recommended to be installed after the instal-
lation of the crankshaft.
6. Install the oil pump case and the oil pan on the engine
block.
7. Fill the engine oil in the room below the oil cooler
(50cc)
8. Tightening the oil filter fitting, install the oil cooler and
hose assembly.
[QJj NOTE
Before assembling the oil cooler. Apply SAE 20w oil
on the 0 rings.
Tightening torque
48- 52Nm (480- 520kgf·cm, 35.4- 38.141bf·ft)
INTAKE AND EXHAUST

SYSTEM
COMPONENT E6BODDDC
INTAKE MANIFOLD Cylinder head assembly
NOTE:
. Use new gaskets when reassembly.
· Check for folds or scratches on the surface of the gasket.
· Replace with a new gasket if damaged.
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Intake manifold assy
Water circuit
Flange nut
15-20 (150- 200,11.06 -14.75)
fff\
Washer bolt ~
15-20 (150- 200m 11.06 -14.75) '"(lj
EGR (Emission Gas Recirculation)
throttle body
EDKD612A
INTAKE AND EXHAUST SYSTEM EMB -89
EXHAUST PIPE
NOTE:
Use new gasket and self-locking nuts when
reassembly.
Tail pipe with muffler
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.. - 60 (400 - 600, 29.50 - 44.25)
Heat protector center panel
40-60
(400 - 600, 29.50 - 44.25)
Exhaust pipe gasket
- - - - - - - 3 0 - 40 (300 - 400, 13.29- 29.50)
TORQUE : Nm (kgf.ft, lbf·ft)

EDKD631A
EXHAUST MANIFOLD
NOTE: Cylinder head

· Use new gasket and self-locking nut assembly ---~#~illr
when assembly .
. Check for folds or scratches on the surface of the gasket.
· Replace with a enw gasket of damaged.
EGR(Emission Gas Recirculation

valve-pipe assembly)
EGR valve gasket

12-18 (120 -180,
8.85- 13.85) ~
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EGR valve gasket
8- 10 (80- 100, 5.90- 7.38)
-~
~ Self locking nut

I I '~ '~ 25 - 38 (250 - 380, 18.44 - 28.03)
~' "
.a·
II
T~rbo_ch~nger ~yTurbo '~
o charger
oil dram ' support
A bracket "
Turbo charger dissharge pipe
Heat protector
"~12 -16 (120- 200,11.06- 14.75)

EDKD613A
REMOVAL E6AA2992 4. Remove the intake manifold.
INTAKE MANIFOLD EXHAUST MANIFOLD
After engine - removal. Aafter engine - removal.
1. Remove the alternator. (see EE group - alternator) 1. Remove the EGR valve(A) and pipe(B).
2. Remove the delivery pipe(A) by loosening the three

bolts(B) and brackets(C).
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EDKD578A
3. Remove the thermostat(A) by loosening the bolt(B)

and the nut(C).
EDKD573A
2. Remove the heat protector (A) by loosening the five

bolts (B).
EDKD579A EDKD574A
3. Remove the protector (A) by loosing the three bolts. INSTALLATION E92EEEB9
(B).
INTAKE MANIFOLD
8
~ I
1. Install the intake manifold assembly, clamping the wa-
ter bypass hose.
Tightening torque
15- 20Nm (150- 200kgf·cm, 11.06- 14.751bf-ft)
2. Assemble the thermostat(A) with a bolt(B) and a

nut(C) to the intake manifold assembly.
Tightening torque
20 - 25Nm (200 - 250kgf·cm, 14.75 - 18.441bf·ft}
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EDKD575A
4. Disconnect the turbo charger oil drain and feed pipe

(A) assembly between the turbo charger(B) and the
engine block (C).
EDKD579A
3. Install the delivery pipe with the three bolts and brack-
ets.
4. Install the alternator. (see EE group - alternator)
EDKD576A
5. Remove the turbo charger support bracket mounting

lower bolt.
EXHAUST MANIFOLD 3. Install the EGR (Emission Gas Recirculation) valve(A)

and pipe(B) assembly with the gaskets.
1. Install the exhaust manifold assembly (A) with a gas-
ket (B) on the cylinder head (C), tightening the turbo Tightening torque
charger support bracket, the oil feed pipe and the oil
drain pipe. EGR valve mounting belt :
25 - 30Nm (250 - 300kgf·cm, 18.44 - 22.131bf·ft)
Tightening torque
EGR pipe mounting belt :
Turo charger support bracket bolt : 20 - 30Nm (200 - 300kgf·cm, 14.75 - 22.131bf·ft)
35 - 45Nm (350 - 450kgf·cm, 25.81 - 33.19 lbHt)
~
Turbo charger oil feed pipe :
UP - 12 - 18Nm (120 - 180 kgf·cm, 8.85 - 13.28 lbHt) 8 @)
~I
DOWN - 18 - 23Nm (180 - 230kgf·cm, @} <§)
I
13.28 - 16.961bHt) <§) i
lI
I
II
Exhaust mounting bolts : !
25 - 38Nm (250 - 380kgf·cm, 18.44 - 28.031bf·ft)
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c
EDKD573A
EDKD577A
2. Install the protectors.
Tightening torque :
8 - 1ONm (80 - 1OOkgf-cm, 5.90 - 7 .381bf·ft)
for the protector
15 - 20Nm (150 - 200kgf·cm, 11.06 - 14. 751bf·ft)
for the heat protectors

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Engine Mechanical

TIMING SYSTEM COOLING SYSTEM

Description Specification 2.0(D4EA) Limit

Description Specification 2.0(D4EA) Limit

Description Specification 2.0(04EA) Limit

Radiator cap 107.9 ± 14.7kPa

Main valve closing pressure 83.4kPa (0.85kg/cm 2 , 12.1 psi )

Engine coolant Elthylene glycol base for aluminum radiator

Item Nm kgf·cm lbHt

Item Nm kgf·cm lbHt

Symptom Suspect Area Remedy (See page)

Symptom Suspect Area Remedy (See page)

SPEICAL TOOLS E4AEEC1F

Tool (Number and name) Illustration Use

Valve spring compressor Removal and installation of intake

Crankshaft rear oil seal installer Installation of the crankshaft

Injector oil seal installer Installation of the injector oil seal

Tool (Number and name) Illustration Use

Oil filter wrench Removal and installation of oil filter

Oil filter wrench Removal and installation of oil filter

ENGINE AND TRANSAXLE 3. Remove the battery and battery base(A).

1. Secure the hood as open as possible.

b. Remove the air cleaner filter.

13. Disconnect the vehicle speed sensor.

14. Disconnect the generator connector(A).

d. Remove the air cleaner body (A).

5. Remove the intercooler hoses.

6. Disconnect the engine wire harness connectors on

8. Disconnect the rail pressure sensor.

9. Disconnect the injector connectors.

10. Disconnect the camshaft position sensor.

17. Remove the brake booster hose and vacuum hose.

19. Remove the cable assembly after removing the gear

20. Disconnect the heater hoses.

21. Remove the front tires/wheels and splash shield.

23. Remove the radiator cap.

25. Remove the upper and lower radiator hoses.

26. Disconnect the hose from the engine coolant reservoir

27. Disconnect the hoses from the fuel tank.

28. Remove the engine ground cable.

35. Remove the sub frame(A) mounting bolts(B) and

INSTALLATION E93DFC3A 18. Perform the following :

1. Install the sub frame installation bolt.

5. Connect the starter terminal and connector.

6. Install the front tires/wheels and splash shield.

7. Connect the air condition hoses.

8. Plug in the alternator hoses.

9. Install the transmission links.

10. Connect the fuel hoses.

11. Connect the engine wire harness connectors.

12. Install the clutch release cylinder.

13. Connect the fuel upper and lower hoses.

14. Connect the heater hoses.

15. Connect the hose to the reservoir tank.

16. Connect the intercooler hoses.

17. Install the air cleaner and the battery.

Upper cover mounting

Bracket mounting bolts

Timing belt lower cover

NOTE Damper pulley

TORQUE : Nm (kgf.cm, lbf·ft)

Before carrying out this step, remove the transmission as-

1. Remove the drive belt(A).

Inspect this area