GENERAL SPECIFICATIONS. TIGHTENING TORQUE COMPRESSION VALVE CLEARANCE INSPECTION AND ADJUSTMENT. ADJUSTING SHIM SEIECTION CHART (INTAKE) ADJUSTING SHIM SEIECTION CHART (EXHAUST) TROUBLESHOOTING REMOVAL TIMING BELT COMPONENTS REMOVAL INSPECTION INSTALLATION CYLINDER HEAD ASSEMBLY COMPONENTS REMOVAL. DISASSEMBLY. INSPECTION REPLACEMENT. REASSEMBLY. INSTALLATION ENGINE AND TRANSAXLE ASSEMBLY REMOVAL INSTALLATION ENGINE BLOCK COMPONENTS. DISASSEMBLY INSPECTION. REASSEMBLY EMA2 EMA EMA EMA-1 EMS EMA-16 EMA7 EMA-20 EMA22 EMA23 EMA27 EMA27 EMA-33 EMA35 EMA41 EMA42 EMA47 EMA48 EMA49 EMA.S6 EMA64 EMA65 EMAG7 EMA-69 EMA-80 Engine (G4GC — GSL 2.0) COOLING SYSTEM COMPONENTS: ENGINE COOLANT REFILLING AND. BLEEDING RADIATOR CAP TESTING RADIATOR LEAKAGE TESTING. REMOVAL. WATER PUMP, THERMOSTAT. INSPECTION WATER PUMP, THERMOSTAT. INSTALLATION WATER PUMP, THERMOSTAT. LUBRICATION SYSTEM COMPONENTS. OIL AND FILTER SELECTION OF ENGINE OIL. REMOVAL DISASSEMBLY. INSPECTION REASSEMBLY. INSTALLATION INTAKE AND EXHAUST SYSTEM COMPONENTS: REMOVAL, EMA-86 EMA-87 EMA-88 EMA-88 EMA-88 EMA-89 EMA-89 EMA-90 EMA91 EMA1 EMA-92, EMA94 EMA-95 EMA-96 EMA-97 EMA.97 EMA-99 EMA-99 EMA-101 EMA-104EMA -2 ENGINE (G4GC) GENERAL SPECIFICATIONS cross Description Specifications Limit General ype Incline, Double Overhead Camshaft Number of cylinder 4 Bore 82mm (3.228in) Stroke 93.5mm (3.68tin.) ‘otal displacement 1975ce (120.52cu.in.) Compression ratio 40.4 Firing order 1342 Valve timing Intake valve Opens (ATDC) Ww Closes (ABDC) 59° Exhaust Opens (BBDC) an Closes (ATOC) 6 Valve Valve length Intake 114.34mm (4.5016in.) Exhaust 116.8mm (4.598in.) Stem 0.D. Intake 5.965 ~ 5.98mm (0.2348 ~ 0.2354in,) Exhaust 5.950 ~ 5.985mm (0.2343 ~ 0.2348in,) Face angle thickness of valve head (Margin) Intake Exhaust 4.45mm (0.0462in,) 1.35mm (0.053tin.) 0.8mm (0.031in.) 4.0mm (0.039in.) Valve stem to valve guide clearance Intake 0.02 ~ 0.05mm (0.0008 ~ 0.0018in,) 010mm (0.0038in.) Exhaust 0.035 ~ 0.065mm (0.0014 ~ 0.0026in.,) 043mm (0.0051in.) Valve guide Installed dimension 0.0 Intake 46mm (1.814in.) Exhaust 4.5mm (2.146in.) Service oversize 0.08, 0.25, 0.50mm (0.002, 0.010, 0.020in.) oversize Valve seat Width of seat contact Intake 4.1 ~ 1.5mm (0.043 ~ 0.05ain.) Exhaust 4.3 ~ 1.7mm (0.051 ~ 0.066in.) Seat angle 45° Oversize 0.3, 0.6mm (0.012, 0.024in.) oversize Valve spring Free length 48.86mm (1.9236in.) Load 18.8kg/39mm (41.45Ib/1.535in,) Installed height ‘Squarences 39mm (1.5354in,) 1.5° MAX.GENERAL EMA -3 Description ‘Specifications Limit Valve clearance Cold (20°C{68'F)) 0.12 ~ 028mm Fiatness of gasket surface Flatness of manifold mounting surface Oversize rework dimensions of valve seat hole Intake 0.3mm (0.012in.) OS. 0.6mm (0.024in.) OS. Exhaust 0.3mm (0.012in.) OS. 0.6mm (0.024in.) OS. (Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05mm (0.002in.) 0.S 0.25mm (0.010in.) 0.8 0.50mm (0.020in.) 0.8 Max. 0.03mm (0.0012in.) Max. 0.15mm (0.0058in.) 33,300 ~ 33.326mm (1.3110 ~ 1.9120in.) 33,600 ~ 33.625mm (1.3228 ~ 1.3238in.) 28,800 ~ 28.821mm (1.1338 ~ 1.1346in,) 29.100 ~ 29.121mm (1.1456 ~ 1.1466in.) 11.08 ~ 11.068mm (0.435 ~ 0.4357in.) 11.25 ~ 11.268mm (0.443 ~ 0.4436in,) 11.50 ~ 11.518mm (0.453 ~ 0.4536in,) intake 020mm (0.0078in) onan oem 020 ~0.38mm Exhaust 0.26mm (0.0110 in) (0007s oots0in) Cylinder Resa 0.06mm (0,0024in,) 0.03mm (0.0012in,) Cylinder block Cylinder bore (Out-of-round and taper of cylinder bore Clearance with piston (To set limits to new parts) £82.00 ~ 82.03mm (3.2283 ~ 3.2295in.) Less than 0.01mm (0.0004in.) 0.02 ~ 0.04mm (0.0008 ~ 0.0046in.) Piston O.D (To set limits to new parts) Service oversize 81.97 ~ 82.00mm (3.2271 ~ 3.2283in.) 0.25, 0.50mm (0.010, 0.020in.) oversize Piston ring Side clearance No.t No.2 End gap No.t No.2 il ring side rail Service oversize 0.04 ~ 0.08mm (0.0015 ~ 0,003tin.) 0.03 ~ 0.07mm (0.0012 ~ 0,0027in.) 0.23 ~ 0.38mm (0.0080 ~ 0.0149in.) 0.33 ~ 0.48mm (0.0130 ~ 0.0189in.) 0.20 ~ 0.60mm (0.0078 ~ 0.0236in.) 0.25, 0.50mm (0.010, 0.020in.) oversize 0.4mm (0.004in,) ‘mm (0.039in.) ‘4mm (0.038in.) ‘4mm (0.038in.) ‘Connecting rod Bend Twist Connecting rod big end to crankshaft side clearance (0.05mm (0.0020in.) oF less ‘0.1mm (0.004in.) or less (0.100 ~ 0.250mm (0.0039 ~ 0.010in.) 0.4mm (0.0187in,) Connecting rod bearing il clearance (To seat limits to new parts) Undersize 0.024 ~ 0.042mm (0.0009 ~ 0.0016in.) 0.25, 0.50, 0.7Smm (0.01, 0.02, 0.03in.)EMA -4 ENGINE (G4GC) Description Specifications Limit ‘Camshaft Cam height Intake 44.618mm (1.7566in.) 44.518mm (1.7527in,) Exhaust 44.518mm (1.7527in.) 44.418mm (1.7487in.) Jourmal 0.0. 28mm (1.1023in.) Bearing oil clearance 0.02 ~ 0.061 mm (0.0008 ~ 0.0024in,) (0.1mm (0.0039%n.) End play 0.4 ~ 0.2mm (0.004 ~ 0.008in.) ‘Crankshaft Pin OD. 45mm (1.77in.) Journal 0.D. 57mm (2.244in.) Bend 0.03mm (0.0072in.) or less ‘Out-of-round, taper of journal and pin ©.01mm (0.0004in.) or less 0.030mm (0.0012in.) End play 0.06 ~ 0.260mm (0.0023 ~ 0.0%0in.) Undersize rework dimension of pin 0.25mm (0.010in.) (050mm (0.020in.) 0.75mm (0.030in.) Undersize rework dimension of journal 0.25mm (0.010in.) 0.50mm (0.020in.) 0.75mm (0.030in.) 44.725 ~ 44.740mm (1.7608 ~ 1.7614in.) 44.475 ~ 44.490mm (1.7509 ~ 1.7516in.) 44.225 ~ 44.240mm (1.7411 ~ 1.7417in.) 56.727 ~ 56.742mm (2.2333 ~ 2.2339in.) 56.477 ~ 56.492mm (2.2235 ~ 2.2240in.) 56.227 ~ 56.242mm (2.2136 ~ 2.2142in,) Crankshaft bearing Gil clearance 0.028 ~ 0.046mm (0.0011 ~ 0.00/8in.) Flywheel Runout 04mm (0.0038in.) 013mm (0.0081in.) Cooling method Water-cooled, pressurized. Forced circulation with electrical fan Coolant Quantity 6 lter (6.3U.S ats, 5.2imp. ats) Radiator Type Pressurized corrugated fin type Radiator cap Main valve opening pressure Vacuum valve opening pressure 83 ~ 110kpa (12 ~ 16psi, 0.83 ~ 1.1kglem?) -Tkpa (-100psi, -0.07kg/em) oF loss Thermostat Type Valve opening temperature Fullopening temperature Wax pellet type with jiggle valve 82°C (17°F) 95°C (201°F) Coolant pump Centrifugal type impeller Drive belt ‘Type V-ribbed belt Engine coolant temperature sensor Type Heat-sensitive thermistor type Resistance 2.31 ~ 2.5K9 at 20°C (68°F)GENERAL EMA -5 Description ‘Specifications Limit il pump Clearance between outer circumference and front case. Front case tip clearance Side clearance Inner gear Outer gear Engine oil pressure at 1500 RPM [Oil temperature is 90 to 110°C (194 to 230°F)) 0.120 ~ 0.185mm (0.0049 ~ 0.0073in.) 0.025 ~ 0.069mm (0.0009 ~ 0.0027in.) 0.04 ~ 0.085mm (0.0016 ~ 0.0033in,) (0.04 ~ 0.08mm (0.0016 ~ 0.0035in.) 245KPa (2.5kglem?, 35.Spsi) Relief spring Free height 43,8mm (1.725in.) Load 3.70.4kg at 40.1mm (3.1520,86Ib/1.578in.) Air cleaner Type Dry type Element Unwoven cloth type Exhaust pipe Muffler Expansion resonance type Suspension system Rubber hangers SERVICE STANDRDS ‘Standard value Antifreeze ‘Maxture ratio of anti-freeze in coolant ETHYLENE GLYCOL BASE FOR ALUMINUM 50%EMA -6 ENGINE (G4GC) TIGHTENING TORQUE tem Nm kgfem Tbe Cylinder Block Front engine support bracket bolt and nut 35 ~ 50 360 ~ 500 25 ~37 Front roll stopper bracket bolt 70 ~ 90 700 ~ 900 51 ~ 65 Rear roll stopper bracket bolt 70 ~ 90 700 ~ 900 51 ~ 65 Rear engine support bracket bolt 40 ~ 50 400 ~ 500 30 ~ 37 Engine Mounting Right mounting insulator (large) nut 90 ~ 110 900 ~ 1100 65 ~ 80 Right mounting insulator (small) nut 45 ~ 60 450 ~ 600 33 ~ 44 Right mounting bracket to engine 50 ~ 65 500 ~ 650 36 ~ 48, nuts and bolts Transmission mount insulator nut 90 ~ 110 900 ~ 1100 65 ~ 80 ‘Transmission insulator bracket to side 40 ~ 50 400 ~ 500 30 ~ 36, ‘member bolt Rear roll stopper insulator nut 50 ~ 65 500 ~ 650 36 ~ 48 Rear roll stopper bracket to center 40 ~ 50 400 ~ 500 30 ~ 36, ‘member bolts Front roll stopper insulator nut 50 ~ 65 500 ~ 650 36 ~ 48 Front roll stopper bracket to center 40 ~ 50 400 ~ 500 30 ~ 36, ‘member bolts. ‘Main Moving Connecting rod cap nut 50 ~ 53 500 ~ 530 36 ~ 39 Crankshaft bearing cap bolt 28~32 + (60°~-64") | 280-320 + (60'~64") | 20.6-23.6 + (60°~64") Fly wheel MIT bolt 420 ~ 130 1200 ~ 1300 88 ~ 95, Drive plate AIT bolt 420 ~ 130 1200 ~ 1300 88 ~ 95 Engine cover 4-6 40 ~ 60 34 Heat protector 15 ~ 20 160 ~ 200 11-15 Water pipe bracket bolts 12~15 120 ~ 150 gi Cooling system Alternator support bolt and nut 20 ~ 25 200 ~ 250 14 ~18 Alternator lock bolt 12~ 15 120 ~ 150 a~11 Alternator brance mounting bolt 20 ~ 27 200 ~ 270 15~20 Coolant pump pulley bolts 8~ 10 80 ~ 100 6~7 Coolant pump bolts 20 ~ 27 200 ~ 270 14-19 Coolant temperature sensor 20 ~ 40 200 ~ 400 15~30 Coolant inlet fiting nuts 15 ~ 20 150 ~ 200 n~14 Thermostat housing bolts and nuts 15 ~ 20 150 ~ 200 1-14 Lubrication system il iter 12~16 120 ~ 160 9-12 il pan bolts 10 ~ 12 100 ~ 120, 7-9 il pan drain plug 40 ~ 45, 400 ~ 450 30 ~33 il screen bolts 16 ~ 22 160 ~ 220 11-16 Gil pressure switch 13 ~ 18 190 ~ 150 e711GENERAL EMA-7 tem Nm kgfem Weft Intake and Exhaust system Air cleaner body mounting bolts a 10 80 ~ 100 6-7 Resonator mounting bolts 4-6 40 ~ 60 374 Intake manifold to cylinder head nuts and bolts 16 ~ 23 160 ~ 230, 12~17 Intake manifold stay to cylinder block bolts 18 ~ 25 480 ~ 250 13 ~ 18 Throttle body to surge tank nuts 15 ~20 450 ~ 200 114 Exhaust manifold to cylinder head nuts 43 ~ 55 430 ~ 550 32 ~ 40 Exhaust manifold cover to exhaust 17 ~22 470 ~ 220, 125 ~ 16 manifold bolts Oxygen sensor to front muffler 50 ~ 60 500 ~ 600 36 ~ 43 ‘Oxygen sensor to exhaust manifold 50 ~ 60 500 ~ 600 36 ~ 43 Front exhaust pipe to exhaust manifold nuts 30 ~ 40 300 ~ 400 22 ~ 29 Front exhaust pipe bracket bolts 30 ~ 40 300 ~ 400 22 ~ 29 Front exhaust pipe to catalytic converter bolts 40 ~ 60 400 ~ 600 29 ~ 43 ‘Main muffler hanger support bracket bolts 10~15 400 ~ 150 7-11 Cylinder head Cylinder head bolts - M10 25 + (60-65) + 18 + (60-657) + (60"-65") Cylinder head bolts - M12 30 + (60°~65") + 22 + (60°~65") + (60"-65") (60"~65°) Intake manifold nuts 18 ~ 25 180 ~ 250 13-18 Exhaust manifold nuts 43 ~ 55 430 ~ 550 32-41 Cylinder head cover bolts 8-10 80 ~ 100 6-7 Camshaft bearing cap bolts, 14-15 140 ~ 160 10-11 il control valve bolt 10-12 400 ~ 120 73-88 CV Fiter 41 ~ 54 410 ~ 510 30 ~ 97.6 CWVT unit to exhaust camshaft bolt 66 ~ 78 660 ~ 780 48.7- 57.5 Rear plate bolts 8-10 80 ~ 100 6-7 Timing Belt Crankshaft pulley bott 160 ~ 170 ‘1600 ~ 1700 116 ~ 123 Camshaft sprocket bolt 100 ~ 120 1000 ~ 1200 74 ~ 89 Timing belt tensioner bolts 43 ~ 550 430 ~ 550 31 ~40 Timing belt cover bolts @~10 80 ~ 100 6-7 Front case bolts 20 ~ 27 200 ~ 270 14 ~ 20 Timing belt idler bott 43 ~ 55 430 ~ 550 31~ 40 WIT : Manual Transmission ANT : Automatic TransmissionEMA -8 ENGINE (G4GC) COMPRESSION (nore 1 the theo (slack of power, excessive ol consump ton or poor ful economy, measure he compression prossure, 1. Warm up and stop engine. Allow the engine to warm up to normal operating tem- perature. 2. Remove ignition coils. (See EE group - igrition) 3. Remove spark plugs. Using a 16mm plug wrench, remove the 4 spark plugs. 4, Check cylinder compression pressure, a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. ©. While cranking the engine, measure the com- Pression pressure. OTE Always use a fully charged battery to obtain engine speed of 250 rpm or more. d. Repeat steps (a) through (c) for each cylinder. NOTE This measurement must be done in as short a time as possible, ‘Comprassion prassure 1,420kPa (14.Skgficm?, 206psi) Minimum pressure 1,270kPa (13kgficm*, 184psi) Difference between each cylinder 100kPa (1.Okgticm?, 15psi) or less fe. Ithe cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low com- pression. + Ifadding oilhelps the compression, itis ikely that the piston rings andlor cylinder bore are worn or damaged. + If pressure stays low, a valve may be stick- ing or seating is improper, or there may be leakage past the gasket, 5. Reinstall spark plugs. 6. Install ignition coils. (See EE group - ignition) TIMING BELT TENSION ADJUSTMENT 1. Remove the engine cover(A). 2. Remove RH front wheelGENERAL EMA -9 3. Remove the 4botts(B) and timing belt upper cover(A). 5. Temperarily loosen tensioner pulley(A) by center bolt 4, Tum the crankshaft pulley, and align its groove with ‘timing mark "T" of the timing belt cover. Timing belt tension adjusting, 1) Rotate crankshaft in regular direction (clock wise ‘view from front) through angle equivalent to two teeth (18°) of camshatt sprocket(A).EMA -10 ENGINE (G4GC) 2) Give tension to timing belt rotating tensioner in 7. Tur the crankshaft two turns in the operating dirac- arrow direction tool and set timing belt not to give tion (clockwise) and realign crankshaft sprocket and slack to tension side. camshaft sprocket timing mark. 8. Install the timing belt upper cover(A) with 4bolts(B), Tightening torque 8 ~ 10Nm (80 ~ 100kgf.om, 6 ~ 7ibtst) 3) Tightening tensioner bolt Tightening torque Tensioner bolt 43 ~ 55Nm (430 ~ S50kgf-om, 32 ~ 40)bf.A) cormresn 9. Install RH front wheel 4) Recheck the belt tension, When the tension side af timing bel is pushed horizontal with a mod- 10. Install engine cover(A. erate force [approx. 2kg (20N, SIb)], the timing belt cog end sags in approx. 4 ~ 6mm (0.16 ~ 0.24in.) 2g (20N, sib)GENERAL EMA -11 VALVE CLEARANCE INSPECTION AND ADJUSTMENT MLA (MECHANICAL LASH ADJUSTER) NOTE Inspect and adjust the valve clearance when the en- gine is cold (Engine coolant temperature : 20°C) and cylinder head is installed on the cylinder block. 4. Remove the engine cover. (See page EMA - 8) 2. Remove the upper timing belt cover. (See page EMA -9) a. Loosen the upper timing cover bolts and then re- ‘move the cover. 3, Remove the cylinder head cover. a. Disconnect the spark plug cables and do not pull, ‘on the spark plug by force. NOTE Pulling on or bending the cables may damage the con- inductor inside. b. Disconnect the P.C.V hose(A) and the breather hhose(B) from the cylinder head cover. ©. Disconnect the accelerater cable(A) from the yfinder head cover. 4d. Loosen the cylinder head cover bolts(B) and then remove the cover(A) and gasket.EMA -12 ENGINE (G4GC) 4. Sot No.1 eylinder to TOC/compression. 5. Inspect the valve clearance ‘a. Turn the crankshaft pulley and align its groove ‘a. Check only the valve indicated as shown. [No. 1 with the timing mark "T* of the lower timing belt cylinder : TOC/Compression] measure the valve cover. clearance, + Using a thickness gauge, measure the clear- ance between the tappet shim and the base Circle of camshaft. ERTS + Record the out-of-specification valve clear- : Srscmeturannte Thy ssi heck tat hl of to camsha ring pa Sasumine toreuted ower ahr lx Sosnin I not, turn the crankshaft one revolution (360°) Valve clearance Specification Engine coolant temperature : 20°C [68°F] Intake : 0.20mm (0.0079in.) Exhaust : 0.28mm (0.0110in,) Limit Intake : 0.12 ~ 0.28mm (0.0047 ~ 0.0110in.) Exhaust : 0.20 ~ 0.38mm (0.0079 ~ 0.0150in.) b. Tum the crankshaft pulley one revolution (360°) and align the groove with timing mark "T™ of the lower timing belt cover.GENERAL EMA -13 ©. Check only valves indicated as shown. [NO. 4 c. Remove the adjusting shim with a small screw cylinder : TDCicompression]. Measure the valve driver(A) and magnet(B). clearance. (See procedure in step (6)) sae PQ d. Measure the thickness of the removed shim using 6. Adjust the intake and exhaust valve clearance. a micrometer. ‘a. Turn the crankshaft so that the cam lobe of the ‘camshaft on the adjusting valve is upward, . Using the SST(09220-20000), pros down the valve lifter and place the stopper between the ‘camshaft and valve lifter and remove the special tolEMA -14 ENGINE (G4GC) ©. Calculate the thickness of a now shim so that the valve clearance comes within the specifcified Valve clearance (Engine coolant tem- perature : 20°C) T: Thickness of removed shim A: Measured valve clearance N : Thickness of new shim Intake : N = T + [A - 0.20mm(0.0079in.)} Exhaust : N= T + (4-0.28mm (0.0110in.)} 1. Select a new shim with a thickness as close as possible to the caculated value. [Refer to the Ad- justing shim selection chart} nore ‘Shims are available in 20size increments of 0.04mm (0.0016in) from 200mm (0.079in,) to 2.76mm (0.1087in) g. Place a new adjusting shim on the valve liter. hh. Using the $ST(09220-20000), press down the valve lifter and remove the stopper. i. Recheck the valve clearance. Valve clearance (Engine coolant tom- perature : 20°C) [Specification] Intake : 0.20mm (0,0078in.) Exhaust : 0.28mm (0.0170in.) [Limit (After adjusting valve clearance) Intake : 0.17 ~ 0.23mm (0.0087 ~ 0.009tin.) Exhaust : 0.25 ~ 0.31mm (0.0098 ~ 0.0722in,)EMA -15 GENERAL (e4eIU]) UeYD UONDe]ag WH us BunsnipyAdjusting Shim Selection Chart (Exhaust) ENGINE (G4GC) New shi thins tin)GENERAL EMA -17 TROUBLESHOOTING ‘Symption Suspect area Remedy (See page) Engine misfire with abnormal internal lower engine noises. Loose or improperly installed engine flywheel Repair or replace the flywheel as required Worn piston rings (Oil cousnmption may or may not cause the engine to misfire.) Inspect the cylinder for a loss of compression Repair or replace as required Worn crankshaft thrust bearings Replace the crankshaft and bearings as required Engine misfire with abnormal valve train noise. ‘Stuck valves. (Carbon buidup on the valve stem) Repair or replace as required Excessive worn or mis-aligned timing chain Replace the timing chain and sprocket as required Worn camshaft lobes. Replace the camshaft and valve liters, Engine mistire with coolant consumption + Faulty cylinder head gasket andlor cranking or other damage to the cylinder head and engine block cooling system, *+ Coolant consumption may or may not cause the engine to overheat, * Inspect the cylinder head and engine block for damage to the coolant passages andor a faulty head gasket. + Repair or replace as required Engine misfire with excessive oll consumption Worn vaives, guides and/or valve stem oil seals, Repair or replace as required Worn piston rings. (Oil consumption may or may not cause the engine to misfire) * Inspect the cylinder for a loss of compression. + Repair or replace as required. Engine noise on start-up, but only lasting a few seconds. Incorrect oll viscosity * Drain the oil + Install the correct viscosity cil ‘Worn erankshaft thrust bearing * Inspect the thrust bearing and crankshaft + Repair or replace as required Upper engine noise, regardless of engine speed. Low oil pressure Repair or repalce as required, Broken valve spring Replace the valve spring Worn or dirty valve liters Replace the valve lifters ‘Stetched or broken timing chain and/or damaged sprocket teeth, Replace the timing chain and sprockets, Worn timing chain tensioner, if applicable. Replace the timing chain tensioner as required Worn camshaft lobes. * Inspect the camshaft lobes. + Replace the timing camshaft and valve liters as required. Worn valve guides or vaive stems. Inspect the valves and valve guides, then repair as required, ‘Stuck valves. (Carbon on the valve stem or valve seat may cause the valve to stay open. Inspect the valves and valve guides, then repair as required,EMA -18 ENGINE (G4GC) ‘Symption ‘Suspect area Remedy (See page) Lower engine noise, regardless of engine speed Low oil pressure. Repair or required. Loose or damaged flywheel Repair or replace the flywheel Damaged oil pan, contacting the oil ump screen. * Inspect the oll pan + Inspect the oil pump screen. + Repair or replace as required (il pump screen loose, damaged or restircted. + Inspect the oll pump screen. + Repair or replace as required Excessive piston-to-cylinder bore clearance. * Inspect the piston, piston pin and cylinder bore. + Repair as required Excessive piston pin-to-piston clearance * Inspect the piston, piston pin and the connecting rod. + Repair or replace as required Excessive connecting rod bearing clearance Inspect the following components and repair as required. + The connecting rod bearings. + The connecting rods. + The crankshaft pin journals. Excessive crankshaft bearing clearance inspect the following components, and repair as required. + The crankshaft bearings + The crankshaft main journals. + The cylinder block Incorrect piston, piston pin and connecting rod installation * Verify the piston pins and connecting rods are installed correctly, + Repair as required. Engine noise under load Low oil pressure Repair or replace as required Excessive connecting rod bearing clearance inspect the following components and repair as required + The connecting rod bearings. + The connecting rods. + The crankshaft Excessive crankshaft bearing clearance inspect the following components, and repair as required. + The crankshaft bearings. + The crankshaft main journals. + The cylinder blockGENERAL EMA -19 ‘Symption Suspect area Remedy (See page) Engine will not crank-crankshaft will not rotate Hydraulically locked cylinder Remove spark plugs and check for ud. * Coolantantifreeze in cylinder. 2. Inspect for broken head gasket. + Olin cylinder. 3. Inspect for cracked engine biock + Fuel in cylinder or cylinder head. 4. Inspect for a sticking fuel injector andior leaking fuel regulator. Broken timing chain andior timing chain 1. Inspect timing chain and gears. andior timing chain gears, 2. Repair as required. Material in cylinder Inspect cylinder for damaged + Broken valve ‘components andior foreign materials. + Piston material 2. Repair or replace as required. + Foreign material ‘Seized crankshaft or connecting rod bearings. | 1. Inspect crankshaft and connecting rod bearing 2. Repair as required. Bent or broken connecting rod 4. Inspect connecing rods, 2._ Repair as required. Broken crankshaft 4. Inspect crankshaft 2._ Repair as required.EMA -20 ENGINE (G4GC) SPECIAL TOOLS eso: Tool (Number and name) llustration Use (Crankshaft front oll seal installer Installation of the front oil seal (09214-33000) Valve clearance adjust tool set Removal and installation of the tappet shim (09220-20000) Phot Stopper ‘Camshaft oll seal installer (09221-21000) Installation of the camshaft oll seal Valve guide installer (09221-3F 100 AB) Remove and installation of the valve guide Valve stom oll seal installer (09222-22001) Installation of the valve stem cil sealGENERAL EMA -24 Tool (Number and name) illustration Use Valve spring compressor Removal and installation of the intake & adaptor or exhaust valve (09222-28000, 09222-28100) > L (Crankshaft rear oil seal installer (09231-21000) 4. Installation of the engine rear oil seal 2. Installation of the crankshaft rear oll seal &EMA -22 ENGINE (G4GC) TIMING SYSTEM COMPONENT cover Cylinder head cover 100 ~ 120 (1000 ~ 1200, 74 - 88) Toning belt 43 ~ 55 (430 ~ 550, 32 ~ 40) Camshatt sprocket sroersndin eg UK © as Thin btoner ow - Flange 160 ~ 170 (1600 ~ 1700, 116 ~ 128) TORQUE : Nm (kgf.cm, Ibf.ft)TIMING SYSTEM EMA -23 REMOVAL cesses 2) Remove the bolt(B), Snuts(C, D) and engine ‘mount bracket(A) Engine removal is not required for this procedure. 4. Remove the engine cover. (See page EMA - 8) 2. Remove RH front wheel. 3, Remove 2bolts(B) and RH side cover(A). 3) Remove the bolt(B) and stay plate(A). 4, Remove the engine mount bracket, 41) Set the jack to the engine cil pan. (NOTE Place wooden block between the jack and engine oi pan,EMA ENGINE (G4GC) 5. Temporarily loosen the water pump pulley bolts. 12, Remove the crankshaft pulley bolt(B) and crankshaft puley(A. 6. Remove alternator belt. (See EE group - alternator) 7. Remove air compressor belt. (See HA group - air ‘compressor) 8. Remove power steering belt. (See ST group - power steering pump) 9. Remove 4bolts and water pump pulley. 10. Remove the 4bolts and timing belt upper cover. (See page EMA - 9) 11. Turn the crankshaft pulley, and align its groove with timing mark ~ T” of the timing belt cover. (See page EMA- 9) 13. Remove the crankshaft flange(A),TIMING SYSTEM EMA -25 14, Remove the Sbolts(B) and timing belt lower cover(A). roxwsom (nore 15. Remove the timing belt tensioner(A) and timing If the timing belt is roused, make an arrow indicating belt(@), the tuning direction to make sure that the belt is rein- stalled in the same direction as before. Remove the bolt(B) and timing belt idler(A)..EMA -26 ENGINE (G4GC) 17. Remove the crankshaft sprockat(A) 18. Remove the cylinder head cover. 1» 2) 3) 4) Remove the spark plug cable, Remove the accelerator cable from the cylinder head cover. (See page EMA - 11) Remove the PCV(Positive Crankcase ventilation) hose and breather hose. (See page EMA - 11) Remove the 12bolts and cylinder head cover. (See page EMA - 11) 19. Remove camshatt sprocket. 1) Hold the hexagonal head wrench(A) portion of the camshatt with a wrench(B), and remove the bolt and camshaft sprocket(C), A caution Be careful not to damage the cylinder head and valve ter with the wrenchTIMING SYSTEM EMA -27 INSPECTION x22 INSTALLATION | esscso POCKETS, TENSIONER, IDLER 41. Install the camshatt sprocket and tighten the bolt to the specified torque. 4. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, 1) Temporarily install the camshaft sprocket bolt cracks, or damage. Replace as necessary. 2) Hold the hexagonal head wrench(A) portion of 2. Inspect the tensioner pulley and the idler pulley for the camshaft with a wrench(B), and tighten the ‘easy and smooth rotation and check for play or noise. camshaft sprocket(C) bolt, Replace as necessary. ightening torque Camshaft sprocket bolt 100 ~ 120Nm (1000 ~ 1200kgf.cm, 74 ~ 89) 3. Replace the pulley if there is a grease leak from its bearing TIMING BELT 41. Check the batt for oll or dust deposits Replace, if necessary. ‘Small deposits should be wiped away with a dry cloth (oF paper. Do not clean with solvent. 2. When the engine is overhauled or belt tension ad- justed, check the belt carefully. f any of the folowing flaws are evident, replace the bett NOTE * Do not bend, twist or turn the timing belt inside out. *+ Do not allow the timing belt fo come into contact with oi, water and steam.EMA -28 ENGINE (G4GC) 2. Install cylinder head cover. 3) Install the accelerator cablo(A) from the cyii hhoad cover. 1) Install eylinder head cover(A) and 12boIts(B). 4) Install the spark plug cable. 2) Install the PCV hose(A) and breather hose(B). 3. Install the crankshaft sprocket(A).TIMING SYSTEM EMA -29 4, Align the timing marks of the camshaft sprocket(A) 5. _Installthe idler pulley(A) and tighten the bolt(B) to the and crankshaft sprockel(B) with the No.1 piston ‘spectfied torque. placed at top dead center and its compression stroke. Tightening torque Idler pulley bolt 43 ~ 55Nm (430 ~ S50kghm, 32 ~ 40lbf.t) Timing Mark — 6. Temporarily install the timing belt tensioner(A) with plain washer(B). ‘ining MarEMA -30 ENGINE (G4GC) 7. Install the timing belt so as not to give excessive slack 2) Give tension to timing belt by ratating tensioner atthe center of the bal. Install the timing belt with the in direction of the arrow with tool and set timing following procedure. belt nat to give slack to tension side. Crankshaft sprocket (A) —> Idler pulley (8) —> Camshaft sprocket (C) —» timing belt tensioner (0). 3) Tightening tensioner bot Tightening torque fom Tensioner bolt 8. Temporarily fasten tensioner pulley by center bot fo 227 SSNm (480 ~ S60kgtem, 92 ~ 4OF A) ad force at bel, 8. Timing bett tension adjusting 4) Recheck the belt tension, When the tension side of timing belt is pushed horizontally with a mod- 41). Rotate crankshalt in regular direction (clock wise erate force lapprox. 2kg (20N, Sib), the timing view from front through angle equivalant to two belt cog end sags in approx. 4 ~ émm (0.16 = teeth (18°) of camshaft sprocket(A). 0.24in.) 2g (20N, 5)TIMING SYSTEM EMA -34 40. Turn the crankshaft two turns in the operating dirao- tion (clockwise) and realign crankshaft sprocket and ‘camshaft sprocket timing mark 41. Install the timing belt lower cover(A) with 5 bolts(B). Tightening torque ‘Timing belt cover bolt 8 ~ 10Nm (80 ~100kg.cm, 6 ~ 7Ibt) 412. Install the flange and crankshaft pulloy(A). Mako sure that crankshaft sprocket pin fits the small hole in the pulley. Graahat pully bot 18. Install the timing belt upper cover with 4botts. (See page EMA - 10) 14, Install the coolant pump pulley with 4botts. 16. Install power steering belt. (See ST group - power steering pump) 16. Install air compressor belt, (See HA group - air com- perssor) 17. Install alternator belt. (See EE group- alternator)EMA -32 ENGINE (G4GC) 18. Install the engine mount bracket. 19. Install RH side cover(A) with 2bolts(B). 1) Install the stay plate(A) with bolt(). Tightening torque Stay plate bolt 35Nm (23 S50kgt.em 3: 40lbt) 20. Install RH front wheel. 21. Install engine cover with 4bolts, (See page EMA- 10) 2). Install engine mount bracket(A) with 3nuts and bolt. Tightening torque Bolt(B), Nuts(C) 50 ~ 60Nm (500 ~ 600kgf‘, 37 ~ 48Ibf ft) Nut(D) : 60 ~ 80Nm (600 ~ 800kgf.m 4 Solbt.t)CYLINDER HEAD ASSEMBLY. EMA -33 CYLINDER HEAD ASSEMBLY COMPONENTS | cxeico: Cylinder head cover es oe 8-10 @0 ~ 100, 6-7.) M10 : 25(250, 18) + (60°-65') + (60"-65°) Oylinder head bot yaa ; 300, 22)» (0°-85) + (60"-65>) Cylinder head TORQUE : Nm (kgf.cm, Ibf.ft)EMA -34 ENGINE (G4GC) onyma Freon re eterna awe spr00—_ g — Auto Tensioner Peng CWT only y aust camshal OGY filer CVT ont Seach age SPH ly QE _ 10 510, 90-378 ‘Washer TORQUE : Nm (kgf.cm, Ibf-ft)CYLINDER HEAD ASSEMBLY. EMA -35 REMOVAL | cscs: 2. Disconnect the negative terminal from the battery. Engine removal is not required for this procedure. Q\ caurion + Use fender covers to avoid damaging painted surfaces. + To.avoid damaging the cylinder head, wait un- til the engine coolant temperature drops be- ow normal temperature before removing it. + When handling a metal gasket, take care not to fold the gasket or damage the contact sur- face of the gasket. + To avoid damage, unplug the wiring connec- tors carefully while holding the connector portion. + Mark ail wiring and hoses to avoid misconnec- tion. + Inspect the timing belt before removing the cylin- der head. 3 + Turn the crankshaft pulley so thatthe No.1 piston is at top dead center. (See page EMA - 9) coolant. 4. Remove the air duct(A\. 4. Remove the engine cover. (See page EMA - 8) 5. Remove the intake air hose and air cleaner assembly, 1) Disconnect the AFS connector(A). 2). Disconnect the breather hose(B) from air cleaner hose.EMA -36 3) Remove the intake air hose and air clean ny (C). 6. Remove the upper radiator hose(A) and lower radiator hose(B). ENGINE (G4GC) Remove the heater hoses(A). Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold, 1) OCV(OIl control Valve) connector(A). 2) Oil temperature sensor connector(B). 3) ECT\Engine Coolant Temperature) sensor con- nnector(C). 4) Ignition coll connector(D).. 5) TPS(Throttle Position Sensor) connector(A).CYLINDER HEAD ASSEMBLY. EMA -37 6) ISA(Idle Spead Actuator) connactor(B). 11) Front heated oxygen sensor connactor(A), 7) CMP(Camshaft Poston Sensor) connector( 12) PCSV{Purge Control Solenoid Valve) connec- 8) Four fuel injector connectors(8). ie 9) Knock sensor connector), ; ; 10) Oseznee your eab) em ena ner © QW iol. d (EMA -38 9. Remove the fuel inlet hase(A) from delivery pipe. 10. Remove the PCSV hose(A). ENGINE (G4GC) 11. Remove the brake booster vacuum hose(A). eK 4 _ | 12. Remove the accelerator cable by loosening the lock- rut, then slip the cable end out of the throttle linkage. 13. Remove the power steering pump. (See ST group - power steering pump) 14. Remove the power steering pump bracket bots(A), Remove the spark plug cable. (See EE group - igni- tion) Remove the PCV hose. (See page EMA - 11) Remove the cylinder head cover. (See page EMA - 1)CYLINDER HEAD ASSEMBLY. EMA -39 18. Remove the timing belt. (See page EMA - 23) 24. Remove the OCV(oll control valve A). 49. Remove the exhaust manifold. (See page EMA- 105) 20. Remove the intake manifold. (See page EMA - 104) 21. Remove the camshaft sprocket. (See page EMA- 26) 22, Remove the timing chain auto tensioner(A). 25. Remove the OCV(cil control valve) fiter(A). 23. Remove the camshaft bearing caps(A) and camshatts(8).EMA -40 ENGINE (G4GC) 26. Remove the water hose(B) from the water pipe(A). 2) Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench Q caurion Be careful not to damage the contact surfaces of the cylinder head and cylinder block. 27. Remove the cylinder head bolts, then remove the cylinder head, 1) Using &mm and 10mm hexagon wrench, uni- formly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown, Remove the 10 cylinder head bolts and plate washers, (h\ caurion Head warpage or cracking could result from re mnoving bots In an Incorrect order,CYLINDER HEAD ASSEMBLY. EMA -41 DISASSEMBLY | erescax 4) Remove the valve. 5) Using needle-nose pliers, remove the oll seal. Identify MLA(Mechanical Lash Adjuster), valves, 6) Using a magnetic finger, remove the spring seat. valve springs as they are removed so that each item can be reinstalled in its original position. 1. Remove MLAS(A). 2. Remove valves. 1) Using $S1(09222-28000, 0922-28: press the valve spring and remove retainer lock. 2) Remove the spring retainer. 3) Remove the valve spring,EMA -42 ENGINE (G4GC) INSPECTION CYLINDER HEAD 4. Inspect for fatness. Using a precision straight edge and feeler gauge, ‘measure the surface the contacting the cylinder block and the manifolds for warpage. Flatness of cylinder head gasket surface Standard : Less than 0.03mm(0.0012in.) Limit : 0.05mm ( 0.0020in.) 2. Inspect for cracks. Chock the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. Ifcracked, replace the cylinder head, VALVE AND VALVE SPRING Inspect valve stems and valve guides. 41) Using a caliper gauge, measure the inside diam- eter or the valve guide. y By A a 2) Using a micrometer, measure the diameter of the valve stem,CYLINDER HEAD ASSEMBLY. EMA -43 3) Subtract the valve stem diameter measurement from the valve guide inside diameter measure- ment. Valve stom-to-guide clearance [Standard) Intake : 0.02 ~ 0.05mm (0.0008 ~ 0.0020in.) Exhaust : 0.035 ~ 0.065mm (0.0014 ~ 0.0026in.) [Limit] Intake : 0.imm (0.0040in.) Exhaust : 0.13mm (0.005tin,) Ifthe clearance is greater than maximum, replace the valve and valve guide, 2. Inspect valves. 1) Check the valve is ground to the correct valve face angle, 2) Check that the surface of the valve for wear. If the valve face is worn, replace the valve. 3) Check the valve head margin thickness. Ifthe margin thickness is less than minimum, re- place the valve. Margin [Standard] Intake : 1.15mm(0.0453in,) Exhaust : 1.35mm(0.053tin.) {Limit} Intake : 0.8mm(0.0315in) Exhaust : 1.0mm(0.040in,) Marsin 4) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve. 3. Inspect valve seats Chock the valve seat for evidence of overheating and improper contact with the valve face. Replace the seat if necessary, Before reconditioning the seat, check the valve guide for wear. If the valve guido is worn, replace it, then recondition the seat, Recondition the valve seat with ‘a valve seat grinder or cutter. The valve seat contact Width should be within specifications and centered on the valve face. 4. Inspect valve springs. 1). Using a stee! square, measure the out-of-square of the valve spring, 2) Using a vernier calipers, measure the free length of the valve spring, Valve spring [Standard] Free height : 48.86mm (1.9236in.) Load : 18.8kg/39 mm (¢1.45Ib/1.535in.) {Limit} Free height : ~1.0mmi(-0.0394in,) Out-of-square : 3 If the free length is not as specified, replace the valve springEMA -44 ENGINE (G4GC) ‘CAMSHAFT 1. Inspect cam lobes. Using a micrometer, measure the cam lobe height. ‘cam height [Standard value} intake : 44.618mm (1.7586in.) Exhaust : 44.518mm (1.7527in.) [uimit] Intake : 44.518mm (1.7527in.) Exhaust : 44.418mm (1.7487in.) It the cam lobe height is less than minimum, replace the camshaft 2. Inspect camshaft journal clearance. 1). Clean the bearing caps and camshaft journals. 2) Place the camshafts on the cylinder head, 3) Lay a strip of plastigage across each of the camshaft journal 4) Install the bearing caps. (See page EMA - 51) CAUTION Do not turn the camshaft. 5) Remove the bearing caps.CYLINDER HEAD ASSEMBLY. EMA -45 6) Measure the piastigage at its widest point. 2) Using a dial indicator, measure the end play while ‘moving the camshaft back and forth. Bearing oil clearance [Standard value] : 0.02 ~0.061mm (0.0008 ~ 0.0024in.) Camshaft end play [Limit] ; 0.1mm (0.0039in,) [Standard value] : 0.4 ~ 0.2mm(0.004 ~ 0.008in.) Ifthe oil clearance is greater than maximum, re- Ifthe end play is greater than maximum, replace place the camshaft. If necessary, replace the the camshaft. If necessary, replace the bearing bearing caps and cylinder head as a sot caps and cylinder head as a set. 7) Completely remove the plastigage. 3) Remove the camshafts. 8) Remove the camshafts. 3, Inspect camshaft end play. 1) Install the camshafts. (See page EMA - 51)EMA -46 ENGINE (G4GC) CVVT ASSEMBLY 1. Inspect CWT assembly. 1) Check that the CVVT assembly will nt turn, 2) Apply vinyl tape to all the parts except the one indicated by the arrow in the illustration, 3) Wind tape around the tip of the air gun and apply air of approx. 100kpa(tkgticm, 14psi) to the port of the camshatf (Perform this order to release the lock pin for the maximum delay angle locking.) (nore When the oll splashes, wipe it off with a shop rag and the likes. 4) Under the condition of (3), turn the CVVT assam- bly to the advance angle side (the arrow marked direction in the illustration) with your hand. Depending on the airpressure, the CVT assem- bly wil turn to the advance side without applying force by hand. Also, under the condition that the pressure can be hardly applied because af the air laakago from the port, thera may be the case that the lock pin could be hardly released. vance | Retard 5) Except the position where the lock pin meets at the maximum delay angle, let the CVVT assem- bly turn back and forth and check the movable range and that there is no disturbance. ‘Standard: Movable smoothly in the range about 20° 6) Turn the CVT assembly with your hand and lock itat the maximum delay angle position,CYLINDER HEAD ASSEMBLY. EMA -47 REPLACEMENT cies 3. Using the $$1(09221-3F 1004/8), press-ft the valve uido. The valve guide must be pross-fttad from the VALVE GUIDE Upper side of the cylinder head. Keep in mind that tho intake and exhaust valve guides are different in 4. Using the SS7(09221-3F100A), withdraw the old length valve guide toward the bottom of cylinder head. ‘Over size | Size | Oversize valve guide mm(in.) | mark | hole size mm(in.) 77.05 ~ 11.088 998 (0.092) | & (0.4350 ~ 0.4357) 77.25 ~ 11.268 9.28(0.010) | 26 (0.4429 ~ 0.4438) 77.50 ~ 11.518 0.500.020) | 50 (osaen oases) Valve guide length Intake : 48mm (1.8in.) Exhaust : 4.5mm (2.16in 2, Recondition the valve guide hole so that it can match the newly press-ftted oversize valve guide. 99221-9F1008 4. After the valve guide is press-ftted, insert a new valve land check for proper stem -to-guide clearance. 5. Alter the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as necessary.EMA -48 ENGINE (G4GC) REASSEMBLY | cxcarooz Thoroughly clean ail parts to be assembled. Before installing the parts, apply fresh engine ollo all sliding and rotating surfaces. Replace oil seals with new ones. 1. Install valves. 1) Install the spring seats. 2). Using $81(08222-22001), push in anew oi seal NOTE Do not reuse old vaive stem seals. Incorrect installation ofthe seal could resultin ollleak- age past the valve guides. 3) Install the valve, valve spring and spring retainer. pore Pac vb sri so thet the sil coated wth Seen te ie ae a er es 4) Using the SS1(09222-28000, 09222-28100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are corractly in place before releasing the valve spring compressor, 5) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating ofthe valve and retainer lock,CYLINDER HEAD ASSEMBLY. EMA -49 2. Install MLAs. INSTALLATION ‘Check that the MLA rotates smoothly by hand NOTE + Thoroughly clean all parts to be assembled. + Always use anew head and manifold gasket. + The cylinder head gasket is a metal gasket. Take care not to bend it + Rotate the crankshaft, setthe No.1 piston at TDC. (See page EMA - 9) 1. Install the cylinder head gasket(A) on the cylinder block: (pore Be careful ofthe installation direction. 2. Place the cylinder head careful in order not to dam- age the gasket with the bottom part of the end. 3. Install eyinder head bolts. 1) Apply a light coat if engine oil on the threads and Under the heads of the cylinder head bolts.EMA -50 2). Using &mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate ‘washers, in several passes, in the sequence shown. Tightening torque M10 25Nm (250kgf.cm, *8Ibf.) + (60° ~ 65°) + (60° ~ 65°) waz 30Nm (300kgf.cm, 22Ibt.f) + (60° ~ 65") + (60" 65) ENGINE (G4GC) (Gaore Always use a new OCV filler gasket Keep clean the OCV fiter 5. Install OCV(A). Tightening torque 10 ~ *2Nm(100 ~ 120kgt.om, 7.3 ~ 8.8lbfs) 4. Install OCV fiter(A). Tightening torque 41~ 51Nm (410 ~ 510kgfem, 30 ~ 37.6Ibt.A) & caution + Do not reuse the OCV when dropped. Keep clean the OCV. Do not hold the OCV sleeve during servicing. When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.CYLINDER HEAD ASSEMBLY. EM. 6. Install the camshafts, 3) Install the timing chain auto tensioner(A). 41) Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown, Tightening torque 8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~ 7.41bf.:) 2) Install the camshatts(A) and bearing caps(B). Tightening torque 4) Remove the auto tensioner stopper pin(B) 14 ~ 15Nm (140 ~ 150kgf.cm, 10 ~ 11ibf.ft) > per pin) Check and adjust valve clearance. (See page EMA - 1) 8. Using the SST(09221-21000), install the camshaft bearing oll seal owes 09221-21000 9. Install the camshaft sprocket. (See page EMA - 27)EMA -52 ENGINE (G4GC) 10. Install the timing batt. (See page EMA - 27) 11. Install the cylinder head cover. NOTE 1) Install the cylinder head cover gasket(A) in the groove of the cylinder head cover(B), + Use liquid gasket, loctite No. 5999, + Check that the mating surfaces are cloan and dry before applying liquid gasket + After assembly, wait at least 30 minutes before filing the engine with oil. 3) Install the cylinder head cover(A) with the ‘2eolts(B). Uniformly tighten the bolts in several passes. Tightening torque 8 ~ 10Nm (80 ~ 100kgt.om, 6 ~ 7.4lbf.A) OTE * Before installing the head cover gasket, thor- oughly clean the head cover gasket and the groove, + When instaling, make sure the head cover gas~ ket is seated securely in the corners of the re- cesses with no gap. 2) Apply liquid gasket to the head cover gasket at the corners of the recess. ecrmtisn 12, Install the intake manifold. 418. Install the exhaust manifold 414, Install the PCV. (See page EMA - 28) 16, Install the spark plug cable, (See EE group - ignition)CYLINDER HEAD ASSEMBLY. EMA -53 16. Install the power steering pump bracket botts(A). 20. Install the PCSV hose(A). Tightening torque 35 ~ 50Nm (350 ~ 500kgf.cm, 26 ~ 37Ibf.t) 21. Install the fue! inlet hose(A), 117. Install the power steering pump. (See ST group - power steering pump) 48. Install the accelerator cable. 19. Install the bake booster hose(A). ye KT JIC — 4EMA -54 2, Install the engine wire hamess connectors and wire harness clamps to the cylinder head and the intake manifold. 1) PCSV connector(A). 2) Front heated oxygen sensor connector(A). ENGINE (G4GC) 6) CMP connectar(A). 7) ISA connector(B). 8) TPS connector(A). Connect the ground cable to the intake mani- fold(0), 4) Knock sensor connector(C), 5 Four fuel injector connectors(8). 9) Ignition coil connector(D), 10) ECT sensor connactor(C). 11) Oil temperature sensor connector(B).CYLINDER HEAD ASSEMBLY. EMA -55 12) OCV connactor(A). 24. Install the upper radiator hose(A) and lower radiator hhose(8). 23. Install the heater hoses(A) 2 Install the intake air hose and air cleaner assembly. 2 Install the engine cover. (See page EMA - 10) 23 Connect the negative terminal to the battery 28 Fill with engine coolant. a Start the engine and check for leaks, a Recheck engine coolant level and oil levelEMA -56 ENGINE AND TRANSAXLE ASSEMBLY REMOVAL csssos QS caution ‘+ Use fender covers to avold damaging painted surfaces. + To avoid damage, unplug the wiring connec tors carefully while holding the connector portion. Dore * Mr a wing and hose oad miscomes Me + ccton te ting bet eo remoting cylinder head. Here conta ta te aa 1. Remove the air duct(A). ENGINE (G4GC) Disconnect the neagative terminal from the battory. Drain the engine coolant. Remove the radiator cap to speed draining. Remove the engine cover. Remove the intake air hose and air cleaner assembly. 1) Disconnect the AFS connector(A\. 2). Disconnect the breather hose(B) from air cleaner hose.ENGINE AND TRANSAXLE ASSEMBLY 3) Remove the intake air hose and air cleaner(C). 6. Remove the upper radiator hose) and lower radiator hhose(®) EMA -57 Remove the heater hoses(A). Remove the engine wire harness connectors and wire harness clamps from the eylinder head and the intake manifold. OCV(OIl Control Valve) connector(A). il temperature sensor connector(B). ECT(Engine Coolant Temperature) sensor(C) connector. Ignition coll connector(0). 5) TPS(Throttle Position Sensor) connector(A).EMA -58 ENGINE (G4GC) 6) ISA(idle Speed Actuator) connactor(B). 14) Oil pressure switch(C) connector. 7) CMP(Camshatt Position Sensor) connector(A). 15) PCSV(Purge Control Solencid Valve\(A) connec- tor. 8) Four fuel injector connectors(B), 9) Knock sensor connector(©). 10) Disconnect ground cable(D) from the intake man- iol, 11) Compressor switch(F), 12) Front heated oxygen sensor(A) connector. 13) CKP sensor(B) connector.ENGINE AND TRANSAXLE ASSEMBLY EMA -59 11, Remove the brake booster vacuum hose(A). 9. Remove the fuel inlet from delivery pipet). 10. Remove the PCSV hose(A). 12. Remove the accelerator cable by loosening the lock- ‘nut, then slip the cable end out of the throttle linkage. 18, Remove the power steering pump. (See page ST ‘group - power steering pump)EMA -60 ENGINE (G4GC) 14, Remove the battery body bracket. ©. Disconnect the input shaft speed connector(C). 4. Disconnect the output shaft speed connector(A). 8. Disconnect the vehicle speed sensor connec- tor(B), mel 16. Disconnect the transaxle wire harness connector. ‘a, Disconnect the inhibitor switch connector(A). b. Disconnect the transaxle range connactor(B). coonENGINE AND TRANSAXLE ASSEMBLY EMA -61 16. Remove the control cable(A) transaxle range switch. 18. Remove the under cover(A), 17. Remove the transaxle oil cooler hose(A) (AIT). 19. Remove the front exhaust pipe(A).EMA -62 ENGINE (G4GC) 20. Disconnect the ABS wheel speed sensor{A)fromboth 22. Remove the caliper and hang the caliper assem- BIy(A), 21. Remove the front strut lower mounting bolts and nuts. 23. Remove the steering ujoint mounting bolt(A). (See (Gee SS griup - front strut) ST group - steering) eZ ING th ls Ne 2 AN JNM 24. Install the jack for supporting engine and transaxle assembly,ENGINE AND TRANSAXLE ASSEMBLY 25. Remove the engine mounting brackat(A). 26. Remove the transaxle mounting brackat(A). EMA -63 27. Remove the sub frame mounting bolts and nuts. Tightening torque ‘A: 160 ~ 180Nm (1600 ~ 1800kgf.cm, 118 ~ 1991bf.8) B: 70 ~ 90Nm (700 ~ 900kgf.cm, 52 ~ 86iR.) RX Kt RY AeEMA -64 ENGINE (G4GC) 28 Jack up the vehicte. INSTALLATION | srorsaco Installation isin the reverse order of removal Perform the following ‘Adjust the shift cable. ‘Adjust the throttle cable. Refill the engine with engine oil Refill the transaxle with uid Rofl the radiator with engine coolant. 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 fine, turn on the ignition switch (do not operate the starter) so that the fuel ump runs for approximately two seconds and fuel line pressureizes. Repeat this operation two or three times, then check for fuel leakage at any point inthe fuel line.ENGINE BLOCK EMA -65 ENGINE BLOCK COMPONENTS | z2s0sscz (xray ‘a0 ~ 199 TN ak =a, 8 = 95) AN Qe \ curay > Osea Gasket Drain pag 40 ~ 45 (400 ~ 450, 30 ~ 33) TIL ose TORQUE : Nm (kgf.cm, Ibf-ft) 2 Drive plate AQ’ WON eS a eo = 0 23 = Rearcil seal case Gasket Cylinder block ~ Main bearings / Main bearing oa 28 ~ 32 (280 ~ 320, 206 ~ 236) + 60" ~ 64 — 10 ~ 12 (100 ~ 120, 73 ~ 88)EMA -66 ENGINE (G4GC) Piston pin TORQUE : Nm (kgf.cm, Ibf-ft) Qa Commesina od vena ‘@<—— 50 ~ 53 (600 ~ 530, 37 - 39)ENGINE BLOCK EMA -67 DISASSEMBLY | ccrsux 8. Remove oil pressure sensor(A) 4. MIT: remove fyweol 2. AT : remove drive plate. Install engine to engine stand for disassembly. Remove timing belt. (See page EMA - 23) Remove cylinder head. (See page EMA - 35) Remove oil level gauge assembiy(A). 9. Remove water pump. (See page EMA - 88) 10, Remove oil pan(A). 7. Remove knock sensor(A).EMA -68 ENGINE (G4GC) 11, Remove oil screen. 16. Remove rear all seal case. Remove the 2bolts(C), oll screen(A) and gasket(B). Remove the § bolts(B) and rear oll seal case(A). 12. Check the connecting rod end play. (See page EMA 17. Remove crankshaft bearing cap and check oll clear- ~ 69) nea. (See page EMA - 72) 13, Remove the connecting rod caps and check oil lear- 18, Check the erankshaft end play, (See page EMA - 74) ance. (See page EMA - 70) 19. Lift the erankshaf(A) out of the engine, being careful 14, Remove piston and connecting rod assemblies not to damage journals. 1) Using a ridge reamer, remove allthe carbon from (Gore the top of the cylinder. Arrange the main bearings and thrust bearings in the 2) Push the piston, connecting rod assembly and correct order. upper bearing through the top of the cylinder block. OTE ‘+ Keep the bearings, connecting rod and cap to- gether, + Arrange the piston and connecting rod assom- blies in the correct order. 15. Remove front case. (See page EMA - 96)ENGINE BLOCK EMA -69 20. Check fit between piston and piston pin. ‘Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a sot 21. Remove piston rings 41) Using a piston ring expender, remove the 2 com- pression rings. 2) Remove 2 side rails and the spacer by hand. NOTE Arrange the piston rings in the correct order only. 22. Disconnect connecting rod from piston, INSPECTION CONNECTING ROD AND CRANKSHAFT 1. Check the connecting rod end play. Using a feeler gauge, measure the end play while moving the connecting rod back and forth ‘Standard end play : 0.1~ 0.25mm(0.004 ~ 0.010in.) Maximum end play : 0.4mm(0.016in.) + If outoftolerance, install a new connecting rod. + If til out-of-tolerance, replace the crankshaft 2. Check the connecting road bearing oil clearance. 1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassem- by. 2) Remove 2 connecting rod cap nuts. 3) Remove the connecting rod cap and bearing halt. 4) Clean the crank pin and bearing '5) Place plastigage across the crank pin 6) Reinstall the bearing half and cap, and torque the ruts. Tightening torque 50 ~ 53Nm (500 ~ 530kgt.cm, 36.9 ~ 39Ibt:t) Gore Do not tur the cranksha.EMA -70 ENGINE (G4GC) 7) Remove 2 nuts, connecting rod cap and bearing halt 8) Measure the plastigage at its widest point ‘Standard oil clearance 0.024 ~ 0.042mm(0.0009 ~ 0.0017in.) 8) If the plastigage measures too wide or too nar- row, remove the upper half of the bearing, in- stall a new, complete bearing with the same color ‘mark (select the color as shown in the next col- umn), and recheck the clearance, (\ caution Do not file, shim, or scrape the bearings or the caps to adjust clearance. 10) If the plastigage shows the clearance is stil in- correct, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again (nore 1 the proper clearance cannot be obtained by using the appropiate larger or sale bearings, replace the Crankshaft and start over Qy caution if tho marks are indecipherable bocause ofan ac- cumulation of dirt and dust, do not serub them witha wire brash orseraper. Clan them oniy wth Solvent or detergent Connecting rod mark location Discrimination of connecting rod CLASS MARK _| INSIDE DIAMETER : A 48,00 ~ 48.006mm (1.8896 ~ 1.8899in,) b B 48,006 ~ 48,012mm (1.8899 ~ 1.8902in,) ° c 48.012 ~ 48.018mm (1.8902 ~ 1.8904in,)ENGINE BLOCK EMA -74 Crankshaft pin mark location Place of identification mark (Connecting rod bearing) Discrimination of crankshaft ™ Discrimination of connecting rod bearing ‘OUTSIDE cusass | MARK | DIAMETER OF PIN THICKNESS OF cLass MARK ICKNESS. ; 44,980 ~ 44.966mm (1.7700 ~1.7703in) 7514 ~ 1.517mm 44.952 ~ 44,860mm “ BLUE | (0.0596 - 0.0597in.) fi 2 (1.7698 ~ 1.7700in.) 7511 ~1.514mm A BLACK “AS46745 SEI (0.0595 ~0.0596in, f 3 (1.7695 ~ 1.7698in) 7/508 ~1.51imm 8 NONE | (0.0596 ~ o.0595in) 7/5085 ~ 1.506mm c GREEN | (010593 ~ 0.0594in) 7502 ~1.506mm ° YELLOW | (0.0501 ~0.0583n)EMA -72 ENGINE (G4GC) 11) Selection CRANKSHAFT | CONNECT- | ASSEMBING INDENTIFICATION | ING ROD | CLASSIFL. MARK IDENTIFICA- | CATION OF TION MARK | BEARING aQWHITE) | (YELLOW) Ievettow) —[b (NONE) | C (GREEN) (YELLOW) |B (NONE) awrite) [C (GREEN) WNONE) —[b(NONE) _ |B (NONE) (YELLOW) [A (BLACK) ‘a (WHITE) _ |B (NONE) miqwaire) — [b (NONE) [A (BLACK) (YELLOW) | AA (BLUE) 3. Check the crankshatt bearing cil clearance, 1) To check main bearing-to-journal oil clearance, remove the main caps and bearing halves. 2) Clean each main journal and bearing half with a clean shop tower. 3) Place one strip of plastigage across each main journal. 4) Reinstall the bearings and caps, then torque the botts ightening torque 30Nm (300kgi.cm, 221bf.f) + 60° ~ 65° JOTE Do not turn the crankshaft. 5) Remove the cap and bearing again, and measure the widest part ofthe plastigage. ‘Standard oll clearance 28 ~ 0.046mm (0.001 0018in.) 6) I the plastigage measures too wide or too nar- row, remove the upper haif of the bearing, in- stall anew, complete bearing with the same color ‘mark (select the color as shown in the next col- umn), and recheck the clearance. A caution Do not fl, shim, or scrape the bearings oF the caps to adjust clearance. 7) If the plastigage shows the clearance is stil in- correct, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again, (Gore 1 the proper clearance cannot be obtained by using the appropriate gor or oraba’ bears, replace a crankahah and start ove A) caution ithe marks are indecipherable because of an ae- Cumulaton of e and dust, do not serub thom wiina ie broshorsreper Clean ther ont wth Scent or detergentENGINE BLOCK Connecting rods. 1 When reinstalling, make sure that cylinder numbers. put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make ‘sure that the notches for holding the bearing in place are on the same side. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well Using a connecting rod aligning tool, check the rod for bend and twist, Ifthe measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been saverely bent or distorted should be replaced, ‘Allowable bend of connecting rod (0,05mm / 100mm (0.0020 in./3.94 in.) oF less Allowable twist of connecting rod 0.1mm / 100mm (0.0039 in./3.94 in.) oF less Crankshaft bore mark location Letters have been stamped on the end of the block as ‘mark forthe size of each of the 5 main journal bores, Use them, and the numbers or bar stamped on the crank (marks for main journal size), o choose the cor- rect bearings EMA -73 Discrimination of cylinder block CALSS MARK _| INSIDE DIAMETER a A 61.000 ~ 61.006mm (2.4015 ~2.4018in.) > 3 1.006 ~ 61.012mm (2.4018 ~2.4020In.) c 61.012 ~ 61.018mm © (2.4020 ~ 2.4023in.) Crankshaft journal mark location Discrimination of crankshaft ‘OUTSIDE CLASS MARK DIAMETER OF JOURNAL 56.956 ~ 56,962mm ' YELLOW | (2.2428 ~ 2.2426in.) 156,948 ~ 56,956mm " NONE | (2.2420 ~2.2423in,) 156.942 ~ 56.948mm u WHITE | (2.2418 ~ 2.242010.)EMA -74 ENGINE (G4GC) Place of identification mark (Crankshaft bearing) DISCRIMINATION OF CRANKSHAFT BEARING SELECTION CRANKSHAFT || syart BORE | BLING GLAS- MIEICATION | ‘DeniFioa. | SIFICATION THON MARK | OF BEARING a (A) D (YELLOW) 1 (YELLOW) = [b (8) C (GREEN) e(c) B (NONE) aa (GREEN) Ml (NONE) b (8) B (NONE) ce ‘A (BLACK) aA) B (NONE) wowire Pe) AGLAGK) c©) AA (BLUE) 4. Check crankshaft end play. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with 2 screwdriver. ‘Standard end play (0.06 ~ 0.26mm (0.0023 ~ 0.010in.) Limit : 0.30mm (0.0178in.) cuss [wane | na” ae ey a | medic, eo | rove | mean | veen | dae 0 | reson | e-em Ifthe end play is greater than maximum, replace the thrust bearings as a set Thrust bearing thickness 2.44 ~ 2.47mm(0.096 ~ 0.097in.)ENGINE BLOCK EMA -75 5. Inspect main journals and crank pins 3. Inspect top surface of cylinder block for flatness. Using a micrometer, measure the diameter of each Using a precision straight edge and feeler gauge, main journal and crank pin. measure the surface contacting the cylinder head gasket for warpage, Main journal diameter : 57mm (2.165in.) Crank pin diameter : 45mm (1.77in.) Flatness of cylinder block gasket surface Standard : Less than 0.03mm(0.0092 in.) Limit : 0.05 mm (0.0020 in.) 4. Inspect cylinder bore diameter Visually chack the cylinder for vertical scratchs. exon If deep scratches are present, replace the cylinder block. CYLINDER BLOCK 4, Remove gasket material Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. 2. Clean cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block.EMA -76 ENGINE (G4GC) 55. Inspect cylinder bore diameter Size Using a cyinder bore gauge, measure the cylinder | Class | Cylinder bore inner diameter | OG, bore siameter at position in the thrust and axial di- aaa A 22.00 ~ 82.01mm A (2.228- 32287!) Standard diameter 3 82.01 ~ 62.02mm 3 82.00 ~ 82.03mm (3.2283 ~ 3.2298in.) (3.2287- 3,2291In.) c 82.02 ~ 62.03mm ¢ (3.2291~ 3.2295in.) 7. Check the piston size code on the piston top face. 6. Check the cylinder bore size code on the cylinder block bottom face, NOTE ‘Stamp the grade mark of basic diameter with rubber stamp. Size Class Piston outer diameter oe 81.97 ~ 81.98mm (3.2271 ~ 3.2275in.) 81.98 ~ 81.98mm 5 (8.2278 ~ 3.2279In.) None 81.99 ~ 82,00mm A A c (3.2279 ~ 3.2283in,) ce 8. Select the piston related to cylinder bore class, Form “Clearance : 0.02 ~ 0,04mm (0.00078 ~ 0.00167in.)ENGINE BLOCK EMA -77 Boring cylinder 4. Oversize pistons should be selected according to the largest bore cylinder. identification Wark Sie 0.25 0.25mm (0.010in.) 00 50mm (0.000%) (pore The size of piston is stamped on top of the piston. 2, Measure the outside diameter of the piston to be used 3. According to the measured O.D., calculate the new bore size. New bore size = Piston 0.0 + 0.02 to 0.04mm (0.0008 to 0.0016in.) (clearance between piston and cylinder) - 0.01mm (0.0004in.) (honing margin.) PISTON AND RINGS 1. Clean piston 1). Using a gasket scraper, remove the carbon from the piston top. 2). Using groove cleaning tool or broken ring, clean the piston ring grooves. 3) Using solvent and a brush, thoroughly clean the piston. NOTE Do not use a wire brush. 2. The standard measurement of the piston outside di- ameter is taken 47 mm (1.85 in.) from the top land of the piston. ‘Standard diameter 81.97 ~ 82.00mm (3.2272 ~ 3.2283in) 4. Bore each of the cylinders to the calculated size, A caution To prevent tortion that may result rom temper ature ree ding honing, bore the cylinder holes inthe frig order 5. Hone the cylinders, finishing them to the proper di- ‘mension (piston outside diameter + gap with cylinder) 6. Check the clearance between the piston and cylinder. Standard : 0.02 ~ 0,04mm (0.0008 ~ 0.0076in.) (Gore Wen boring the ender, finish a ofthe cyinders tote samo oversize. Do not bore only one ender toe owrsieEMA -78 ENGINE (G4GC) 3. Calculate the difference between the cylinder bore di- ameter and the piston diameter. Piston-to-cylinder cl 0.02 ~ 0.04mm(0.0008 0016in.) 4. Inspect the piston ring side clearance. Using a feeler gauge, measure the clearance between rnew piston ring and the wall of the ring groove. Piston ring side clearance No. 1 : 0.04 ~ 0.08mm (0.0016 ~ 0.003tin.) No. 2: 0.03 ~ 0.07mm (0.0012 ~ 0.0028in.) Limit No. 1 0.1mm (0.00¢in.) No. 2: 0.1mm (0.004in.) Ifthe clearance is greater than maximum, replace the piston. Inspect piston ring end gap. ‘To measure the piston ring end gap, insert a piston fing into the cylinder bore. Position the ring at right angles to the cylinder wall by gently prassing it down ‘with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter against the wear limits on page EMA - 76, Ifthe bore is over the service limit, the cylinder block ‘must be rabored. (See page EMA 76) Piston ring end gap Standard No.1: 0.23 ~ 0.98mm (0.0091 ~ 0.0150in.) No.2 : 0.33 ~ 0.48mm (0.0130 ~ 0.0189in.) Limit No. 1, 2, oll rin Omm (0.039in.)ENGINE BLOCK EMA -79 PISTON PINS OIP PRESSURE SWITCH 4. Measure the diameter of the piston pin Check the continuity between the terminal and the body with an ohmmeter. Piston pin diameter If there is no continuity, replace the oil pressure 20.001 ~ 20.008mm (0.7874 ~ 0.7876in.) switch. 2. Check the continuity between the terminal and the 2, Measure the piston pin-to-piston clearance. body when the fine wire is pushed, If there is con- tinuity even when the fine wire is pushed, replace the Piston pin-to-piston clearance we pushed, 0.01 ~ 0.2mm (0.0004 ~ 0.0008in.) 3. If there is no continuity when a 80kpa (7psi) vacuum 3. Check the difference between the piston pin diameter is applied throgh the oil hole, the switch is operaing and the connecting rod small end diameter. properly Check for air leakage. If air leaks, the diaphragm is Piston pin-to-connecting rod interference broken. Replace it 0,016 ~ 0.032mm (0.00063 ~ 0.00726in.)EMA -80 ENGINE (G4GC) REASSEMBLY OTE + Thoroughly clean all parts to assembled. + Before installing the parts, apply fresh engine oll to all sliding and rotating surfaces. + Replace all gaskets, O-rings and oil seals with new parts. 1. Assemble piston and connecting rod. 1) Use a hydraulic press for installation 2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine, 2. Install piston rings. 4) Install the oilring spacer and 2 side rails by hand. 2) Using a piston ring expander, install the 2 com- pression rings with the code mark facing upward, 3) Position the piston rings so that the ring ends are as shown. 3. Install connecting rod bearings. 41) Align the bearing claw with the groove of the con- necting rod or connecting rod cap. 2) Install the bearings(A) in the connecting rod and connecting rod cap(6).ENGINE BLOCK EMA -81 4, Install main bearings, NOTE Upper 1,2,4,5 bearings have an oil groove of oil holes; Lower bearings do not 41) Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings(A). 2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings, 5. Install thrust bearings. Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder black withthe oil grooves fac- ing outward 6. Place crankshaft on the cylinder block. 7. Place main bearing caps on cylinder block. 8. Install main bearing cap bos. Tightening torque Main bearing cap bolt 28 ~ 32Nm (280 ~ 320kgf.cm, 20.6 ~ 23.6Ib.t) + 60" ~ 6 NOTE + The main bearing cap bolts are tightened in 2 progressive stops. + If any of the bearing cap bolts in broken or de- formed, replace it 1) Apply a light coat of engine oil on the threads and Under the bearing cap bolts.