Engine (G6BA - GSL 2.7)
Engine
(G6BA - GSL 2.7)
GENERAL
SPECIFICATIO NS....................................................EMA-2
TIGHTENING T O R Q U E ..........................................EMA-5
CO M PR ESSIO N .......................................................EMA-7
TROUBLESHOO TING.............................................EMA-8
SPECIAL TO O LS......................................................EMA-11
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TIMING BELT
C O M PO N EN TS........................................................ EMA-12
R E M O V A L.................................................................EMA-13
INSPECTION............................................................ EMA-16
IN STA LLATIO N ........................................................ EMA-17
wt
CYLINDER HEAD ASSEM BLY
C O M PO N EN TS........................................................ EMA-21
R E M O V A L.................................................................EMA-23
DISASSEM BLY......................................................... EMA-28
INSPECTION............................................................ EMA-29
R EPLACEM ENT.......................................................EMA-33
REASSEMBLY.......................................................... EMA-34
IN STA LLATIO N ........................................................ EMA-35
LUBRICATION SYSTEM
C O M PO N EN TS.......................................................EMA-77
OIL AND FILTE R .................................................... EMA-78
SELECTION OF ENGINE O IL .............................. EMA-79
R E M O V A L............................................................... EMA-80
DISASSEMBLY........................................................EMA-81
IN SPEC TIO N ........................................................... EMA-81
REASSEMBLY.........................................................EMA-82
IN STALLATIO N .......................................................EMA-83
on
ENGINE AND TRANSAXLE ASSEMBLY
R E M O V A L.................................................................EMA-42
IN STA LLATIO N ........................................................ EMA-48
COOLING SYSTEM
C O M PO N EN TS.......................................................EMA-71
ENGINE COOLANT REFILLING AND
BLEEDING ............................................................... EMA-72
RADIATOR CAP T E S T IN G ...................................EMA-73
RADIATOR LEAKAGE TESTING .........................EMA-73
REMOVAL
W ATER P U M P .................................................... EMA-74
THERM O STAT.................................................... EMA-74
INSPECTION
W ATER P U M P .................................................... EMA-75
THERM O STAT.................................................... EMA-75
INSTALLATION
W ATER P U M P .................................................... EMA-75
THERM O STAT.................................................... EMA-76
ENGINE BLOCK
CO M PO N EN TS.......................................................EMA-49
D ISA SS EM BLY.......................................................EMA-51
INSPECTION........................................................... EMA-54
R EA SSE M B LY........................................................ EMA-64
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INTAKE AND EXHAUST SYSTEM
COMPONENTS
INTAKE M AN IFO LD ........................................... EMA-85
EXHAUST M ANIFOLD....................................... EMA-86
M U F F L E R ............................................................ EMA-87
REMOVAL
INTAKE M AN IFO LD ........................................... EMA-88
EXHAUST M ANIFOLD....................................... EMA-89
IN STALLATIO N .......................................................EMA-90
EMA-2
ENGINE (G6BA - GSL 2.7)
GENERAL
SPECIFICATIONS
E97CEC21
Description
6°
O
CO
Cogged type belt
4 3.9 5 -44.15m m (1.7 30 3 - 1.7382in.)
4 3 .9 5 - 44.15mm (1.7 30 3 - 1.7382in.)
25.964 - 25.980mm (1.0222 - 1.0228in.)
0.02 - 0.061mm (0.0007 - 0.0024in.)
0.1 - 0.15mm (0.0039 - 0.0059in.)
43.45mm (1.7106in.)
43.45mm (1.7106in.)
25.914mm (1.0202in.)
0.1mm (0.0039in.)
Max. 0.03mm (0.0012in.)
0.05mm (0.0020in.)
Max. 0.15mm (0.0059in.)
Max. 0.15mm (0.0059in.)
0.15mm (0.0059in.)
0.15mm (0.0059in.)
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Cylinder head
Flatness of cylinder head surface
Flatness of manifold mounting surface
Intake
Exhaust
Valve guides hole diameter
0.05 (0.002) O.S.
0.25 (0.010) O.S.
0.50 (0.020) O.S.
Intake valve seat ring hole diameter
0.3 (0.012) O.S.
Exhaust valve seat ring hole diameter
0.3 (0.012) O.S.
Valve
Overall length
Intake
Exhaust
Stem diameter
Intake
Exhaust
Face angle
Margin
Intake
Exhaust
Clearance (Stem-to-guide)
Intake
Exhaust
44°
8
on
Camshaft
Drive mechanism
Cam height
Intake
Exhaust
Journal diameter
Bearing oil clearance
End play
Limit
V-type, DOHC
6
86.7mm (3.4133in.)
75mm (2.9528in.)
2,656cc
10 : 1
1-2-3-4-5-6
wt
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General
Type
Number of cylinder
Bore
Stroke
Total displacement
Compression ratio
Firing order
Valve timing
Intake valve
Opens (BTDC)
Closes (ABDC)
Exhaust valve
Opens (BBDC)
Closes (ATDC)
Specifications
11.05 - 11,068mm (0.435 - 0.436in.)
11.25 - 11,268mm (0.443 - 0.444in.)
11.50 - 11.518mm (0.453 - 0.453in.)
33.300 - 33.325mm (1.311 - 1.312in.)
2 8 .6 0 0 - 28.621mm (1 .1 2 6 - 1.127in.)
96.1mm (3.783in.)
97.15mm (3.825in.)
5.965 - 5.98mm (0.235 - 0.2354in.)
5.95 - 5.965mm (0.234 - 0.235in.)
45° - 45.5°
1.0mm (0.0394in.)
1.3mm (0.0512in.)
0.5mm (0.0197in.)
0.8mm (0.0315in.)
0.02 - 0.05mm (0.008 - 0.0020in.)
0.030 - 0.065mm (0.0012 - 0.0026in.)
0.10mm (0.0039in.)
0.13mm (0.0051 in.)
GENERAL
EMA-3
Description
Valve spring
Free length
Load
Specifications
Limit
42.5mm (1.6732in.)
21kg/35mm (48.4lb/1,3780in.)
41.5mm (1.6339in.)
21,9kg/34mm
(48.4lb/1.3386in.)
Max. 3°
Out of squareness
Max.
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Piston
Diameter (Standard)
Clearance (Piston-to-cylinder)
Ring groove width
No.1
No.2
Oil
Piston for service
86.68 - 86.71mm (3.413 ~ 3.414in.)
0.01 - 0.03mm (0.0004 - 0.0012in.)
1.230 ~ 1.250mm (0.0484 ~
1.220 ~ 1.240mm (0.0480 ~
2.515 - 2.535mm (0.0990 0.25mm (0.01 Oin.), 0.50mm
wt
Piston ring
Number of rings per piston
Compression ring
Oil ring
Compression ring type
No.1
No.2
Oil ring type
Ring end gap
No.1
No.2
Oil ring side rail
Ring side clearance
No.1
No.2
Rings for service
Bearing oil clearance
Crankshaft
Journal O.D.
Pin O.D.
Out-of-round, taper of journal and pin
Taper of journal and pin
End play
Main bearing clearance
Cylinder block
Cylinder bore
Flatness of gasket surface
Out-of-round of cylinder bore
Oil pump
Body clearance
Side clearance
Relief spring
Free height
Load
3
2
1
Inner bevel type
Taper type
3-piece type
0.20 - 0.35mm (0.0079 ~ 0.0138in.)
0.37 - 0.52mm (0.0146 - 0.0205in.)
0.2 - 0.7mm (0.0079 - 0.0276in.)
0.8mm (0.031 in.)
0.8mm (0.031 in.)
1.0mm (0.039in.)
0.04 - 0.08mm (0.0016 ~ 0.0031 in.)
0.03 - 0.07mm (0.0012 - 0.0028in.)
0.25mm (0.01 Oin.), 0.50mm (0.020in.)
0.1mm (0.004in.)
0.1mm (0.004in.)
2,450 - 12.225N
(250 ~ 1,250kg, 551 - 2,755lb)
0.10 ~ 0.25mm (0.0039 ~ 0.0098in.)
0.05mm or less/100mm
(0.0020in. or less/3.937in.)
0.018 - 0.036mm (0.0007 - 0.0014in.)
0.4mm (0.016in.)
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Side clearance (big end)
Bend
0.0492in.)
0.0488in.)
0.0998in.)
(0.020in.)
on
Connecting rod
Piston pin installation force
1.5°
61.982 - 62.000mm (2.4402 - 2.4409in.)
47.982 - 48.000mm (1.8891 - 1.8898in.)
Max. 0.003mm (0.0012in.)
Max. 0.005mm (0.00020in.)
0.070 - 0.250mm (0.0028 - 0.0098in.)
0.004 - 0.022mm (0.0002 - 0.0009in.)
86.7mm (3.4134in.)
Max. 0.03mm (0.0012in.)
Max. 0.02mm (0.0008in.)
0.100 ~ 0.181mm (0.0039 - 0.0071in.)
0.040 - 0.095mm (0.0016 - 0.0037in.)
43.8mm (1.724in.)
4.6kg/39.3mm (10lb/1.548in.)
0.1mm (0.004in.)
0.4mm (0.016in.)
0.1mm (0.004in.)
0.05mm (0.002in.)
EMA-4
ENGINE (G6BA - GSL 2.7)
Description
Specifications
Oil filter
Type
Engine oil pressure
Cooling method
Ne
Cooling system quantity
Theromstat
Type
Normal opening temperature
Opening temperature range
Wide open temperature
Radiator cap
Main valve opening pressure
Air cleaner
Type
Element
SERVICE STANDRDS
Standard value
Coolant concentration
Tropical areas
Other areas
Engine coolant
SEALANT
Engine coolant temperature sensor
PCV valve
107.9 ± 14.7kPa (1.1 ± 0.15kg/cm2,
15.65 ± 2.13psi)
83.4kPa (0.85kg/cm2, 12.1psi)
-6.86kPa (-0.07kg/cm2, -1 .OOpsi)
Dry
Paper type
Expansion resonance type
Rubber hangers
40%
50%
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COOLANT
Oil pressure switch
Wax pellet type with jiggle valve
82 ± 2.0°C (179.6 ± 3.6°F)
80 - 84°C (176 ~ 183.2T)
95°C (203°F)
on
Exhaust pipe
Muffler
Suspend system
Cartridge, full flow
50kPa (7.3psi) or more
[Conditions : Oil temperature is 75 to
90°C (167 to 194°F)]
Engine coolant cooling, forced circulation
with electric fan
7.0lit (7.4U.S.qts., 6.1lmp.qts)
wt
Main valve closing pressure
Vacuum valve opening pressure
Limit
Ethlylen glycol base for aluminum radiator
LOCTITE 262 or equivalent, Three bond
No. 1324 or equivalent.
3M ATD No.8660 or Three bond No.1141E
LOCTITE 242 or equivalent
GENERAL
EMA-5
TIGHTENING TORQUE
Item
Nm
kgf.cm
Ibf.ft
90 ~ 110
900 - 1,100
65 - 85
8 -1 0
80 - 100
5.8 - 7.2
27-33 + (90°~94°)
13-19 + (90°~94°)
270-300 + (90°~94°)
130-190 + (90°~94°)
19.5-24 + (90°~94°)
10-14 + (90°~94°)
Connecting rod bolt
16-20 + (90°~94°)
160-200 + (90°~94°)
12-15 + (90°~94°)
Cylinder head bolt(Cold engine)
25 + (58°~62°) +
(43°~47°)
250 + (58°~62°) +
(43°~47°)
18 + (58°~62°) +
(43°~47°)
Oil pan drain plug
35 - 45
350 - 450
25 - 33
Lower oil pan bolt
10 - 12
100 - 120
7 -9
Upper oil pan bolt
[10 x 38mm (0.937 x 1.4961 in.)]
[8 x 22mm (0.3150 x 0.8661 in.)]
[161.5mm (6.3582in.)]
[152.5mm (6.0039in.)]
30
19
5
5
300
190
50
50
Oil screen bolt
15 - 22
150 - 220
11 - 16
12 - 15
120 - 150
9-11
40 - 50
400 - 500
29 - 36
15 - 22
150 - 220
11 - 16
8-12
80 - 120
6 -9
Camshaft sprocket bolt
Cylinder head cover bolt
Main bearing cap bolt
M10
M8
Oil relief valve plug
Oil pressure cover screw
Oil filter
on
Oil pressure switch
wt
Ne
Oil pump case bolt
- 42
- 28
-7
-7
-
420
280
70
70
22
14
4
4
- 30
- 20
-5
-5
120 - 160
9-12
730 - 770
53 - 56
8-12
80 - 120
6 -9
15 - 20
150 - 200
11 - 14
15 - 20
150 - 200
11 - 14
15 - 20
150 - 200
11 - 14
19 - 21
190 - 210
14 - 15
17 - 22
170 - 220
12 - 16
30 - 35
300 - 350
22 - 26
12 - 15
120 - 150
9-11
17 - 20
170 - 200
12 - 14
17 - 26
170 - 260
12 - 19
5 -6
50 - 60
3.6 - 4.3
Engine mounting insulator bolt
50 - 65
500 - 650
36 - 47
Engine mounting bracket nut
60 - 80
600 - 800
43 - 58
Engine mounting bracket bolt
60 - 80
600 - 800
43 - 58
Engine support bracket bolt
60 - 70
600 - 700
43 - 51
Front roll stopper bracket sub frame bolt
50 - 65
500 - 650
36 - 47
Air cleaner body installation bolt
Surge tank stay
Air intake surge tank to intake manifold(bolt)
Air intake surge tank to intake manifold(nut)
Intake manifold to cylinder head
Heat protector exhaust manifold
Exhaust manifold to cylinder head
(Self-locking nut)
Oil level gauge guide to engine
Water outlet fitting bolt
Power steering oil pump bracket to
cylinder head
Crank position sensor wheel screw
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12 - 16
73 - 77
Drive plate and adapte
EMA-6
ENGINE (G6BA - GSL 2.7)
Item
kgf.cm
Ibf.ft
Front roll stopper insulator bolt and nut
50 ~ 65
500 - 650
36 - 47
Rear roll stopper bracket to sub frame
50 ~ 65
500 - 650
36 - 47
Rear roll stopper Insulator bolt and nut
50 ~ 65
500 - 650
36 - 47
Transaxle mounting bracket bolt
50 ~ 65
500 - 650
36 - 47
Transaxle mounting insulator bolt
90-110
900 - 1,100
65 - 80
Fuel hose clamp to rear cylinder
head assembly
12 - 15
120 - 150
9-11
Transaxle mounting plate
10 - 12
100 - 120
7 -9
Rear plate
10 - 12
100 - 120
7 -9
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Nm
10 - 12
100 - 120
7 -9
Crankshaft pulley bolt
180 - 190
1,800 - 1,900
130 - 138
Timing belt cover bolt
10 - 12
100 - 12
7 -9
Engine hanger bracket to engine
20 - 27
200 - 270
14 - 20
Alternator mounting bracket to engine
20 - 30
200 - 300
14 - 22
Alternator mounting nut (Engine front
case side)
20 - 30
200 - 300
14 - 22
Alternator mounting bolt (Alternator
mounting bracket side)
20 - 30
200 - 300
14 - 22
Starter to transmission(nut)
20 - 30
200 - 300
14 - 22
27 - 34
270 - 340
20 - 25
35 - 55
350 - 550
25 - 40
20 - 27
200 - 270
14 - 20
Engine coolant pump to cylinder block
bolt (Head mark "7" mark)
15 - 22
150 - 220
11 - 16
Engine coolant temperature sensor
20 - 40
200 - 400
14 - 29
Oil seal case
Drive belt pulley bolt
Drive belt tensioner bolt
Engine coolant inlet fitting attaching bolt
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on
wt
Starter to transmission(bolt)
17 - 20
170 - 200
12 - 14
15 - 20
150 - 200
11 - 14
40 - 50
400 - 500
29 - 36
30 - 40
300 - 400
22 - 29
40 - 60
400 - 600
29 - 43
40 - 60
400 - 600
29 - 43
40 - 60
400 - 600
29 - 43
10 - 15
100 - 150
7 -1 1
Delivery pipe installation bolt
10 - 15
100 - 150
7 -1 1
Timing belt tensioner pulley bolt
43 - 55
430 - 550
31 - 40
Timing belt idler puley bolt
50 - 60
500 - 600
36 - 43
Timing blelt tensioner arm fixed bolt
35 - 55
350 - 550
25 - 40
Auto tensioner fixed bolt
20 - 27
200 - 270
14 - 20
Accelerator cable bracket
4 -6
40 - 60
3 -4
20 - 30
200 - 300
14 - 22
Throttle body to surge tank bolt
Oxygen sensor to exhaust manifold
Front exhaust pipe to exhaust manifold nut
Front exhaust pipe to catalytic converter bolt
Catalytic converter to center exhaust pipe nut
Center exhaust pipe to main muffler nut
Main muffler hanger support bracket bolt
Spark plug
GENERAL
EMA-7
COMPRESSION
c.
IU ) NOTE
U ) NOTE
If the there is lack o f power, excessive oil consump­
tion or poor fuel economy, measure the compression
pressure.
1.
3.
4.
Warm up and stop engine
Allow the engine to warm up to normal operating tem­
perature.
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2.
Repeat steps (a) through (b) for each cylinder.
Remove ignition coils. (See EE group - ignition)
This measurement must be done in as short a time as
possible.
Compression pressure :
1,420kPa (14.5kgf/cm2, 206psi)
Minimum pressure :
1,270kPa (13kgf/cm2, 184psi)
Difference between each cylinder:
100kPa (1.0kgf/cm2, 15psi) or less
Remove spark plugs.
Using a 16mm plug wrench, remove the 6 spark plugs.
d.
Check cylinder compression pressure
a. Insert a compression gauge into the spark plug
hole.
Reinstall spark plugs. (See EE group - ignition)
on
wt
5.
If the 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 (b) for cylinders with low com­
pression.
• If adding oil helps the compression, it is likely
that the piston rings and/or 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.
6.
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EOQF1B5A
b.
While cranking the engine, measure the com­
pression pressure.
[U ) NOTE
Install ignition coils. (See EE group - ignition)
Always use a fully charged battery to obtain engine
speed o f 250 rpm or more.
EMA-8
ENGINE (G6BA - GSL 2.7)
TROUBLESHOOTING
EAE1F8CD
Symption
Engine misfire with
abnormal internal
lower engine noises.
Suspect area
Remedy (See page)
Repair or replace the flywheel as required.
Inspect the cylinder for a loss of compression.
Repair or replace as required.
Worn crankshaft thrust bearings
Replace the crankshaft and bearings
as required
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 lifters.
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Loose or improperly installed engine flywheel.
Worn piston rings
(Oil cousumption may or may not cause
the engine to misfire.)
Engine misfire with
abnormal valve
train noise.
Engine misfire with
coolant consumption
• Inspect the cylinder head and engine
block for damage to the coolant passages
and/or a faulty head gasket.
• Repair or replace as required.
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.
Incorrect oil viscosity
• Drain the oil.
• Install the correct viscosity oil.
Worn crankshaft thrust bearing.
• Inspect the thrust bearing and crankshaft.
• Repair or replace as required.
Low oil pressure
Repair or replace as required.
Broken valve spring.
Replace the valve spring.
Worn or dirty valve lifters.
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Upper engine noise,
regardless of engine
speed.
Worn valves, guides and/or valve
stem oil seals.
on
Engine noise on
start-up, but only
lasting a few seconds.
wt
Engine misfire
with excessive oil
consumption
• Faulty cylinder head gasket and/or
cranking or other damage to the cylinder
head and engine block cooling system.
• Coolant consumprion may or may not
cause the engine to overheat.
Stetched or broken timing chain and/or
damaged sprocket teeth.
Worn timing chain tensioner, if applicable.
Worn camshaft lobes.
Replace the valve lifters.
Replace the timing chain and sprockets.
Replace the timing chain tensioner
as required.
• Inspect the camshaft lobes.
• Replace the timing camshaft and
valve lifters as required.
Worn valve guides or valve 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.
GENERAL
EMA-9
Symption
Lower engine noise,
regardless of engine
speed
Suspect area
Low oil pressure.
Repair or required.
Loose or damaged flywheel.
Repair or replace the flywheel.
• Inspect the oil pan.
• Inspect the oil pump screen.
• Repair or replace as required.
Oil pump screen loose, damaged or restircted.
• Inspect the oil pump screen.
• Repair or replace as required.
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Damaged oil pan, contacting the oil
pump screen.
Excessive piston-to-cylinder bore clearance.
• Inspect the piston, piston pin and
cylinder bore.
• Repair as required.
Excessive piston pin-to-connecting
rod clearance
• Inspect the piston, piston pin and
the connecting rod.
• Repair or replace as required.
Excessive connecting bearing rod clearance
wt
Excessive crankshaft bearing clearance
on
Incorrect piston, piston pin and connecting
rod installation
Engine noise under
load
Remedy (See page)
Inspect the following components and
repair as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
• The crankshaft journal.
Inspect the following components, and
repair as required.
• The crankshaft bearing.
• The crankshaft journals.
• Verify the piston pins and connecting
rods are installed correctly.
• Repair as required.
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
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Low oil pressure
Excessive crankshaft bearing clearance
Inspect the following components, and
repair as required.
• The crankshaft bearings.
• The crankshaft journals.
• The cylinder block crankshaft
EMA -10
ENGINE (G6BA - GSL 2.7)
Symption
Engine will not
crank-crankshaft
will not rotate
Suspect area
Remedy (See page)
Hydraulically locked cylinder
• Coolant/antifreeze in cylinder.
• Oil in cylinder.
• Fuel in cylinder
1.
2.
3.
4.
Broken timing chain and/or timing chain gears.
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Material in cylinder
• Broken valve
• Piston material
• Foreign material
1.
2.
Inspect timing chain and gears.
Repair as required.
1.
Inspect cylinder for damaged
components and/or foreign materials.
Repair or replace as required.
2.
Seized crankshaft or connecting rod bearings.
Remove spark plugs and check for fluid.
Inspect for broken head gasket.
Inspect for cracked engine block
or cylinder head.
Inspect for a sticking fuel injector and/or
leaking fuel regulator.
1.
Bend or broken connecting rod.
1.
2.
Inspect connecing rods.
Repair as required.
Broken crankshaft
1.
2.
Inspect crankshaft.
Repair as required.
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on
wt
2.
Inspect crankshaft and connecting
rod bearing.
Repair as required.
GENERAL
SPECIAL TOOLS
EMA -11
E4E4BACD
Illustration
Tool (Number and name)
Crankshaft front oil seal installer
(09214-33000)
Use
Installation of the front oil seal
Ne
CD
EDKA010A
Camshaft oil seal installer
(09214-21000)
wt
Valve guide installer
(09221-3F100 A/B)
Installation of the camshaft oil seal
EDDA005B
Remove and installation of the valve guide
(-----------------------
on
ECKA010B
Valve stem oil seal installer
(09222-22001)
Installation of the valve stem oil seal
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ECKA01QA
Valve spring compressor
& adaptor
(09222-28000, 09222-28100)
Removal and installation of the intake
or exhaust valve
EDDA005C
Crankshaft rear oil seal installer
(09231-33000)
1.
2.
EDDA005F
Installation of the engine rear oil seal
Installation of the crankshaft rear oil seal
EMA -12
ENGINE (G6BA - GSL 2.7)
TIMING SYSTEM
COMPONENT
EB323873
~
12
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on
wt
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10
TO R Q U E : Nm (kgf.cm , Ibf.ft)
EDQF200A
EMA -13
TIMING SYSTEM
REMOVAL
5.
EF2F0D8C
Remove drive belt(A) and belt tensioner(B).
Engine removal is not required for this procedure.
1.
Remove the engine cover.
2.
Remove RH front wheel.
3.
Remove 2bolts(B) and RH side cover(A).
6.
Remove the engine mount bracket.
1)
Set the jack to the engine oil pan.
on
wt
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EDQF100A
KXDSE16A
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pan.
EDQF102A
[LJ] note
Always turn the crankshaft clockwise.
EMA -14
2)
ENGINE (G6BA - GSL 2.7)
Remove the 2bolts, 2nuts and engine mount
bracket(A).
9.
Remove the crankshaft pulley bolt and crankshaft pulley(A).
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EDQF017A
Remove the power steering pump. (See ST group power steering pump)
8.
Remove the 7bolts(B) and timing belt upper cover(A).
10. Remove the drive belt idler pulley(A).
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on
7.
EDQF104A
EDQF103A
EDQF105A
EMA -15
TIMING SYSTEM
11. Remove the 4bolts(B) and timing belt lower cover(A).
14. Remove timing belt tensioner.
Alternately loosen the 2bolts, and remove the tensioner(A).
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EDQF105B
12.
Remove the engine support bracket(A).
EDQF107A
15.
Remove the timing belt(A).
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EDQF106A
13.
Check that timing marks of the camshaft timing pul­
leys and cylinder head covers are aligned.
If not, turn the crankshaft 1revolution(360°).
EDQF108A
\Uj\ note
If the timing belt is reused, make an arrow indicating
the turning direction to make sure that the belt is rein­
stalled in the same direction as before.
EMA -16
ENGINE (G6BA - GSL 2.7)
16. Remove the tensioner pulley(A) and timing belt idler
pulley(B).
INSPECTION
EDAFCA96
SPOCKETS, TENSIONER, IDLER
Check the camshaft sproket, crankshaft sprocket,
tensioner pulley, and idler pulley for abnormal wear,
cracks, or damage. Replace as necessary.
2.
Inspect the tensioner pulley and the idler pulley for
easy and smooth rotation and check for play or noise.
Replace as necessary.
wt
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1.
EDQF11QA
17. Remove the crankshaft sprocket.
/i\
CAUTION
on
18. Remove camshaft sprockets.
Hold the hexagonal head wrench portion of the
camshaft with a wrench and remove the bolt and
camshaft sprocket.
Be careful not to damage the cylinder head and
valve lifter with the wrench.
3.
EDQF111A
Replace the pulley if there is a grease leak from its
bearing.
TIMING BELT
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1.
Check the belt for oil or dust deposits.
Replace, if necessary.
Small deposits should be wiped away with a dry cloth
or paper. Do not clean with solvent.
2.
When the engine is overhauled or belt tension ad­
justed, check the belt carefully. If any of the following
flaws are evident, replace the belt.
|U] NOTE
• Do not bend, twist or turn the timing belt inside
out.
• Do not allow the timing belt to come into contact
with oil, water and steam.
EMA -17
TIMING SYSTEM
INSTALLATION
4.
E1ED1397
1.
Install the crankshaft sprocket.
Align the pulley set key with the key groove the crank­
shaft sprocket and slide on the crankshaft sprocket.
2.
Install the camshaft sprockets and tighten the bolts to
the specified torque.
Temporarily install the camshaft sprocket bolts.
2)
Hold the hexagonal head wrench portion of
the camshaft with a wrench, and tighten the
camshaft sprocket bolts.
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1)
Align the timing marks of the camshaft sprocket and
crankshaft sprocket with the No. 1 piston placed at top
dead center and its compression stroke.
Tightening torque
Camshaft sprocket bolt
90 - 110Nm (900 - HOOkgf.cm, 65 - 80lbf.ft)
Install the idler pulley(B) and the tensioner pulley(A).
wt
3.
Tightening torque
Idler pulley bolt
50 ~ 60Nm (500 - 600kgf.cm, 36 - 43lbf.ft)
Tensioner arm fixed bolt
35 ~ 55Nm (350 ~ 550kgf.cm, 25 ~ 40lbf.ft)
on
( u j NOTE
Insert and install the idler pulley to the roll pin that is
pressed in the water pump boss.
5.
EDQF109A
Set timing belt tensioner.
1)
Using a press, slowly press in the push rod.
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6.
2)
Align the holes of the push rod and housing pass
a set pin through the holes to keep the setting
position of the push rod.
3)
Release the press.
Install the timing belt tensioner.
1)
EDQF110A
Temporarily install the tensioner with the 2bolts.
EMA -18
2)
ENGINE (G6BA - GSL 2.7)
Alternately tighten the 2bolts.
8.
Remove the set pin(A) from the tensioner.
Tightening torque
20 - 27Nm (200 - 270kgf.cm, 14 ~ 20lbf.ft)
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EDQF161A
7.
EDQF162A
9.
Timing belt tensioner checking.
1)
Install the timing belt.
on
1)
Remove any oil or water on the sprockets, and
keep them clean.
2)
Install the tming belt in this order.
Crankshaft sprocket(A) —• Idler pulley(B)
Camshaft sprocket LH side(C) > Water pump
pulley(D) —* Camshaft sprocket RH side(E) —►
Tensioner pulley(F).
2)
Rotate the crankshaft 2turns clockwise and mea­
sure the projected length of the auto tensioner at
TDC(#1 compression stroke) after 5 minutes.
The projected length should be 7 ~ 9mm (0.27 ~
0.31 in.)
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A
EDQF163A
EMA -19
TIMING SYSTEM
10.
Install the engine support bracket(A).
12.
Tightening torque
B : 60 - 70Nm (600 - 700kgf.cm, 43 - 51 Ibf.ft)
C : 15 - 22Nm (150 - 220kgf.cm, 11 - 16lbf.ft)
Install the drive belt idler pulley(A).
Tightening torque
Idler pulley bolt
35 - 55Nm (350 - 550kgf.cm, 25 - 40lgf.ft)
wt
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EDQF106B
on
11.
EDQF105A
Install the timing belt lower cover(A) with 4bolts(B).
Tightening torque
Timing belt cover bolt
10 - 12Nm (100 -120kgf.cm, 7 - 9lbf.ft)
13.
Install the crankshaft pulley(A).
Make sure that crankshaft sprocket pin fits the small
hole in the pulley.
Tightening torque
Crankshaft pulley bolt
180 - 190Nm (1800 - 1900kgf.cm, 130 ~ 138lbf.ft)
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EDQF105B
EDQF104A
EMA -20
14.
ENGINE (G6BA - GSL 2.7)
Install the timing belt upper cover(A) with 7bolts(B).
17.
Install the engine mount bracket.
Install engine mount bracket with 2nuts and 2bolt.
Tightening torque
60 - 80Nm (600 - 800kgf.cm, 44 - 59lbf.ft)
A
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A
EDQF103A
15. Install the power steering pump.
power steering pump)
(See ST group -
EDQF017A
16. Install the drive belt tensioner(B) and drive belt(A).
on
18.
Install RH side cover(A) with 2bolts(B).
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EDQF100A
KXDSE16A
19. Install RH front wheel.
20. Install engine cover.
CYLINDER HEAD ASSEMBLY
EMA -21
CYLINDER HEAD
ASSEMBLY
COMPONENTS
EAAAFFA1
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TO R Q U E : Nm (kgf.cm , Ibf.ft)
EDQF201A
EMA -22
ENGINE (G6BA - GSL 2.7)
HLA
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Valve spring retainer lock
Valve spring retainer
Valve stem seal
Valve spring
Valve spring seat
Valve guide/Tim ing chain
8 - 10 (80 - 100, 5.8 ~ 7 .2)
1 0 - 1 2 ( 100 - 120, 7 - 9)
Camshaft
bearing cap
Oil seal
1 4 -1 6
( 140 - 160, 1 0 - 12)
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on
wt
Camshaft sprocket
9 0 -1 1 0
(900 - 1100, 65 - 80)
Valve
Cylinder head
TORQUE : Nm (kgf.cm, Ibf.ft)
EDQF202A
CYLINDER HEAD ASSEMBLY
REMOVAL
EMA -23
4.
EDA7EDAA
Engine removal is not required for this procedure.
A
CAUTION
Ne
• Use fender covers to avoid damaging painted
surfaces.
• To avoid damaging the cylinder head, wait un­
til the engine coolant temperature drops be­
low normal temperature before removing it.
• When handling a metal gasket, take care not
to fold the gasket or damage the contact sur­
face o f the gasket.
• To avoid damage, unplug the wiring connec­
tors carefully while holding the connector
portion.
5.
Remove the intake air hose and air cleaner assembly.
1)
Disconnect the AFS connector.
2)
Disconnect the breather hose from air cleaner
hose.
3)
Remove the intake air hose and air cleaner as­
sembly.
Remove the upper radiator hose(A) and lower radiator
hose(B).
(Q j) NOTE
wt
• Mark all wiring and hoses to avoid misconnection.
• Inspect the timing belt before removing the cylin­
der head.
• Turn the crankshaft pulley so that the No. 1 piston
is at top dead center. (See page EMA -13).
Disconnect the negative terminal from the battery.
on
1.
6.
EDQF037A
Remove the heater hoses(A).
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2.
Remove the engine cover.
3.
Drain the engine coolant. (See page EMA - 72)
Remove the radiator cap to speed draining.
EDQF019A
EMA -24
7.
ENGINE (G6BA - GSL 2.7)
Remove the engine wire harness connectors and wire
harness clamps from the cylinder head and the intake
manifold.
TPS(Throttle Position Sensor) connector(A).
2)
ISA(ldle Speed Actuator) connector(B).
3)
PCSV(Purge Control Solenoid Valve) connec­
to r^ ).
Oxygen sensor connector(D).
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1)
10)
4)
Injector connector(E).
5)
Knock sensor connedors(F).
6)
CMP(Camshaft Position Sensor) connector(G).
11)
Three fuel injector connectors(A).
on
wt
EDQF033A
ECOF001A
t
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7)
ECT(Engine Coolant Temperature) sensor connector(A).
8)
Ignition coil connector(B).
9)
Crankshaft position sensor connector(C).
EDQF028A
CYLINDER HEAD ASSEMBLY
8.
EMA -25
Remove the fuel inlet hose(A) from delivery pipe.
12.
Remove the PCV hose(A).
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EDQF025A
9.
Remove the PCSV hose.
10. Remove the brake booster vacuum hose(A).
EDQF014A
13. Remove the intake manifold. (See page EMA - 88)
14. Remove the power steering pump. (See ST group power steering pump).
on
15. Remove the exhaust manifold. (See page EMA - 89)
16. Remove the timing belt. (See page EMA -1 3 )
17. Remove the spark plug cable. (See EE group - igni­
tion)
18. Remove the cylinder head covers(A).
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EDQF020A
11.
Remove the accelerator cable by loosening the lock­
nut, then slip the cable end out of the throttle linkage.
EDQF050A
EMA -26
ENGINE (G6BA - GSL 2.7)
19. Remove the camshaft sprocket.
21. Remove the camshafts(A).
20. Remove the camshaft bearing caps(A).
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EDQF053A
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EDQF055A
EDQF054A
CYLINDER HEAD ASSEMBLY
EMA -27
22. Remove the timing belt rear cover(A).
24. Remove the cylinder head bolts, then remove the
cylinder heads.
1)
Uniformly loosen and remove the 8 cylinder head
bolts on each cylinder head in several passes and
in the sequence shown, then repeat for the other
side, as shown. Remove the 16 cylinder head
bolts and plate washer.
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EDQF057A
23. Remove the water temperature control assembly(A)
and water pipe.
on
EDQF166A
A , CAUTION
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Head warpage or cracking could result from re­
moving bolts in an Incorrect order.
2)
Lift the cylinder head from the dowels on the
cylinder block and place the cylinder head on
wooden blocks on a bench.
A , CAUTION
EDQF058A
Be careful not to damage the contact surfaces of
the cylinder head and cylinder block.
EMA -28
DISASSEMBLY
ENGINE (G6BA - GSL 2.7)
E60D4118
( g j) NOTE
Identify HLA(Hydnaulic Lash Adjuster), valves, valve
springs as they are removed so that each item can be
reinstalled in its original position.
1.
4)
Remove the valve.
5)
Using needle-nose pliers, remove the oil seal.
6)
Using a magnetic finger, remove the spring seat.
Remove HLAs(A).
on
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ECKD217A
2.
Remove valves.
1)
Using SST(09222-28000, 09222-28100), com­
press the valve spring and remove retainer lock.
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EDQF169A
2)
Remove the spring retainer.
3)
Remove the valve spring.
CYLINDER HEAD ASSEMBLY
INSPECTION
EMA -29
CYLINDER HEAD
E29C1FBF
CLEANING
1.
Clean top surfaces of pistons and cylinder block.
1)
Turn the crankshaft, and bring each piston to top
dead center(TDC).
Using a gasket scraper, remove all the carbon
from the piston top surface.
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2.
1.
2)
Using a gasket scraper, remove all the gasket
material from the cylinder block surface.
3)
Using compressed air, blow carbon and oil from
the bolt holes.
Inspect for flatness.
Using a precision straight edge and feeler gauge,
measure the surface the contacting the cylinder block
for warpage.
Flatness of cylinder head gasket surface
Standard : Less than 0.03mm(0.0012 in.)
L im it: 0.05 mm ( 0.0020 in.)
Remove gasket material.
Using a gasket scraper, remove all the gasket material
from the cylinder block contact surface.
wt
/ t \ CAUTION
Be careful not to scratch the cylinder block con­
tact surface.
3.
, / t \ CAUTION
on
Clean combustion cambers.
Using a wire brush, remove all the carbon from the
combustion cambers.
Be careful not to scratch the cylinder block con­
tact surface.
Clean cylinder heads.
Using a soft brush and solvent, throrghly clean the
cylinder head.
5.
Clean valves.
2.
Inspect for cracks.
Check the combustion chamber, intake ports, exhaust
ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.
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4.
1)
Using a gasket scraper, chip off any carbon from
the valve head.
2)
Using a wire brush throroghly clean the valve.
EDQF160A
EMA -30
ENGINE (G6BA - GSL 2.7)
VALVE AND VALVE SPRING
1.
3)
Inspect valve stems and valve guides.
1)
Using a caliper gauge, measure the inside diam­
eter or the valve guide.
Valve guide inside.
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[Standard]
Intake : 0.02 - 0.05mm (0.0008 ~ 0.0020in.)
Exhaust: 0.030 - 0.065mm (0.0012 ~ 0.0026in.)
[Lim it]
Intake : 0.1mm (0.0040in.)
Exhaust : 0.13mm (0.0051 in.)
If the clearance is greater than maximum, replace
the valve and valve guide.
2.
wt
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.
If the margin thickness is less than minimum, re­
place the valve.
Margin
[Standard]
Intake : 1.0mm (0.0394in.)
Exhaust : 1.3mm (0.0512in.)
[Limit]
Intake : 0.5mm (0.0197in.)
Exhaust : 0.8mm (0.0315in.)
on
ECKD219A
2)
Subtract the valve stem diameter measurement
from the valve guide inside diameter measure­
ment.
Valve stem-to-guide clearance
Using a micrometer, measure the diameter of the
valve stem.
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ECKD220A
ECKD221A
CYLINDER HEAD ASSEMBLY
4)
EMA -31
Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
CAMSHAFT
1.
3.
Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 43.95 -4 4 .15mm (1.7303 - 1.7382in.)
Exhaust: 43.95 - 44.15mm (1.7303 - 1.7382in.)
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4.
Inspect valve seats
Check 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 guide 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.
Inspect valve springs.
Using a steel square, measure the out-of-square
of the valve spring.
2)
Using a vernier calipers, measure the free length
of the valve spring.
wt
1)
on
Valve spring
[Standard]
Free height : 42.5mm (1.6732in.)
Load : 21kg/35mm (48.4kg/1,378mm)
[Limit]
Free h eigh t: -1.0mm (-0.0394 in.)
Out-of-square : 3°
ECKD223A
If the cam lobe height is less than minimum, replace
the camshaft.
2.
Inspect cam journals.
Using a micrometer, measure the journal diameter.
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Journal diameter
Standard value
25.964 - 25.980mm (1.0222 - 1.0228in.)
If the journal diameter is not as specified, check the
oil clearance.
ECKD222A
If the free length is not as specified, replace the
valve spring.
3.
Inspect camshaft bearings.
Check that bearing for flaking and scoring. If the
bearings are damaged, replace the bearing caps and
cylinder head as a set.
4.
Inspect camshaft journal oil clearance.
1)
Clean the bearing caps and camshaft journals.
2)
Place the camshafts on the cylinder head.
EMA -32
3)
ENGINE (G6BA - GSL 2.7)
Lay a strip of plastigage across each of the
camshaft journal.
If the oil clearance is greater than maximum, re­
place the camshaft. If necessary, replace the
bearing caps and cylinder head as a set.
5.
7)
Completely remove the plastigage.
8)
Remove the camshafts.
Inspect camshaft end play.
Ne
1)
Install the camshafts. (See page EMA - 37)
2)
Using a dial indicator, measure the end play while
moving the camshaft back and forth.
Camshaft end play
Standard value : 0.1 - 0.15mm (0.004 - 0.0059in.)
wt
ECKD224A
4)
Install the bearing caps. (See page EMA - 37)
/ t \ CAUTION
on
Do not turn the camshaft
5)
Remove the bearing caps.
6)
Measure the plastigage at its widest point.
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Bearing oil clearance
Standard value : 0.02 - 0.061mm (0.0008 - 0.0024in.)
Limit : 0.1mm (0.0039in.)
EDQF053B
If the end play is greater than maximum, replace
the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.
3)
ECKD225A
Remove the camshafts.
CYLINDER HEAD ASSEMBLY
REPLACEMENT
EMA -33
3.
EED266F4
VALVE GUIDE
1.
Using the SST(09221-3F100A), withdraw the old
valve guide toward the bottom of cylinder head.
Using the SST(09221-3F100A/B), press-fit the valve
guide. The valve guide must be press-fitted from the
upper side of the cylinder head. Keep in mind that
the intake and exhaust valve guides are different in
length.
wt
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Over size
mm(in.)
Size
mark
Oversize valve guide
hole size mm(in.)
0.05 (0.002)
5
11.05 - 11.068
(0.4350 ~ 0.4357)
0.25 (0.010)
25
11.25 - 11.268
(0.4429 ~ 0.4436)
0.50 (0.020)
50
11.50 - 11.518
(0.4528 - 0.4535)
Valve guide length
Intake : 39mm (1.535in.)
Exhaust : 43mm (1.693in.)
EDKD900A
on
2.
Recondition the valve guide hole so that it can match
the newly press-fitted oversize valve guide.
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EDKD900B
4.
After the valve guide is press-fitted, inserts new valve
and check for proper stem -to-guide clearance.
5.
After the valve guide is replaced, check that the valve
is seated properly. Recondition the valve seats as
necessary.
EMA -34
REASSEMBLY
ENGINE (G6BA - GSL 2.7)
4)
EDCA3D22
(gj) NOTE
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all
sliding and rotating surfaces.
Replace oil seals with new ones.
Install valves.
Ne
1.
Using the SST(09222-28000, 09222-28100),
compress the spring and install the retainer
locks. After installing the valves, ensure that
the retainer locks are correctly in place before
releasing the valve spring compressor.
1)
Install the spring seats.
2)
Using SST(09222-22001), push in a new oil seal.
| U j NOTE
Do not reuse old valve stem seals.
Incorrect installation o f the seal could result in oil leak­
age past the valve guides.
5)
Lightly tap the end of each valve stem two or
three times with the wooden handle of a hammer
to ensure proper seating of the valve and retainer
lock.
t
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on
wt
EDQF169A
EDQF167A
3)
Install the valve, valve spring and spring retainer.
U ) NOTE
Place valve springs so that the side coated with
enamel faces toward the valve spring retainer and
then installs the retainer.
EDQF168A
CYLINDER HEAD ASSEMBLY
2.
EMA -35
INSTALLATION
Install HLAs.
Check that the HLA rotates smoothly by hand.
E1F59CAC
U ) NOTE
• Thoroughly clean all parts to be assembled.
• Always use a new head and manifold gasket.
on
wt
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EDQF170A
u)wore
t
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Be careful o f the installation direction.
2.
Place the cylinder head quietly in order not to damage
the gasket with the bottom part of the end.
3.
Install cylinder head bolts.
Tightening torque
25Nm (250kgf.cm, 18lbf.ft) + 60° + 45°
1)
Apply a light coat if engine oil on the threads and
under the heads of the cylinder head bolts.
2)
Install the plate washer to the cylinder head bolt.
EMA -36
3)
ENGINE (G6BA - GSL 2.7)
Install and uniformly tighten the cylinder head
bolts on each cylinder head in several passes and
in the sequence shown, then repeat for the other
side, as shown.
5)
4.
Retighten the cylinder head bolts by 45° in the
numerical order shown.
Install the water pipe and water temperature control
assembly(A).
Tightening torque
Water temperature control
15 - 20Nm (150 - 200kgf.cm, 11 - 14lbf.ft)
wt
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on
EDQF166B
If only one of the cylinder head bolts dose not
meet the torque specification, replace the cylin­
der head bolt.
Torque : 25Nm (250kgf.cm, 18lbf.ft)
5.
EDQF058A
Install the timing belt rear cover(A).
t
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Tightening torque
Timing belt rear cover
10 ~ 12Nm (100 ~ 120kgf.cm, 7 ~ 9lbf.ft)
EDQF156A
4)
Retighten the cylinder head bolts by 60° in the
numerical order shown.
EDQF057A
CYLINDER HEAD ASSEMBLY
6.
EMA -37
Install the camshafts.
1)
3)
Align the camshaft timing chain with the intake
timing chain sprocket and exhaust timing chain
sprocket as shown.
Install the camshaft bearing caps(A).
Tightening torque
M6(38mm): 10 - 12Nm (100 - 120kgf.cm, 7 - 9lbf.ft)
M6(50mm): 14 - 16Nm (140 - 160kgf.cm, 10 - 12lbf.ft)
wt
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EDQF155A
Install the camshaft(A).
EDQF053A
on
2)
u] note
• Apply new engine oil to the thrust portion and
journal o f the camshafts.
• Apply a light coat o f engine oil on the threads and
under the heads o f the bearing cap bolts.
7.
t
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Using the SST (09214-21000), install the camshaft
bearing oil seal.
EDQF054A
EDQF052A
8.
Install the camshaft sprocket.
EMA -38
ENGINE (G6BA - GSL 2.7)
1)
Temporarily install the camshaft sprocket bolts.
2)
Hold the hexagonal head wrench portion of
the camshaft with a wrench, and tighten the
camshaft sprocket bolts.
3)
Install the cylinder head covers(A) with the
16bolts. Uniformly tighten the bolts in several
passes.
Tightening torque
8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~ 7.4lbf.ft)
Tightening torque
Camshaft sprocket bolt
90 ~ 110Nm (900 ~ HOOkgf.cm, 65 ~80lbf.ft)
Ne
9.
Install semi-circular packing.
10. Install the cylinder head cover.
1)
Install the cylinder head cover gasket(A) in the
groove of the cylinder head cover(B).
wt
EDQF050A
t
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on
EDQF171A
(U )
NOTE
• Before installing the head cover gasket, thor­
oughly clean the head cover gasket and the
groove.
• When installing, make sure the head cover gas­
ket is seated securely in the corners o f the re­
cesses with no gap.
2)
Apply liquid gasket to the head cover gasket at
the corners of the recess.
[iJ\N O T E
• Use liquid gasket, loctite No.5699.
• Check that the mating surfaces are clean and dry
before applying liquid gasket.
• After assembly, wait at least 30 minutes before
filling the engine with oil.
EDQF172A
11. Install the spark plug cable. (See EE group - ignition)
12. Install the timing belt. (See page EMA -17).
13. Install the exhaust manifold. (See page EMA - 91)
CYLINDER HEAD ASSEMBLY
14. Install the power steering pump.
power steering pump)
EMA -39
(See ST group -
19. Install the PCSV hose.
20. Install the fuel inlet hose(A).
15. Install the intake manifold. (See page EMA - 90)
16. Install the PCV hose(A).
wt
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EDQF014A
21. Install the engine wire harness connectors and wire
harness clamps to the cylinder head and the intake
manifold.
on
17. Install the accelerator cable.
EDQF025A
1)
Three fuel injector connectors(A).
18. Install the brake booster vacuum hose(A).
A
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EDQF028A
EDQF020A
2)
Oxygen sensor connector(D).
3)
Crankshaft position sensor connector(C).
EMA -40
ENGINE (G6BA - GSL 2.7)
4)
Ignition coil connector(B).
5)
ECT sensor connector(A).
22.
Install the heater hoses(A).
wt
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EDQF033A
CMP(Camshaft position sensor) connector(G).
7)
Knock sensor connector(F).
8)
Injector connector(E).
9)
PCSV(Purge Control Solenoid Valve) connector(C).
10) ISA connector(B).
11) TPS connedor(A).
23.
Install the upper radiator hose(A) and lower radiator
hose(B).
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on
6)
EDQF019A
24.
EDQF032A
EDQF037A
Install the intake air hose and air cleaner assembly.
1)
Install the intake air hose and air cleaner assem­
bly.
2)
Connect the breather hose from air cleaner hose.
3)
Connect the AFS connector.
CYLINDER HEAD ASSEMBLY
EMA -41
25. Install the engine cover.
26. Connect the negative terminal to the battery.
wt
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EOQF040A
27. Filll with engine coolant.
on
28. Start the engine and check for leaks.
29. Recheck engine coolant level and oil level.
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EMA -42
ENGINE (G6BA - GSL 2.7)
ENGINE AND TRANSAXLE
ASSEMBLY
REMOVAL
4.
Remove the intake air hose and air cleaner assembly.
1)
Disconnect the AFS connector.
2)
Disconnect the breather hose from air cleaner
hose.
3)
Remove the intake air hose and air cleaner as­
sembly.
E4AD264D
/ ! \ CAUTION
• Use fender covers to avoid damaging painted
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surfaces.
5.
• To avoid damage, unplug the wiring connec­
Remove the upper radiator hose(A) and lower radiator
hose(B).
tors carefully while holding the connector
portion.
j * j ) NOTE
1.
wt
• Mark all wiring and hoses to avoid misconnection.
• Inspection the timing belt before removing the
cylinder head.
• Turn the crankshaft pulley so that the No. 1 piston
is at top dead center. (See page EMA -13)
Disconnect the negative terminal from the battery.
on
6.
Remove the engine cover.
3.
Drain the engine coolant.
Remove the radiator cap to speed draining.
Remove the heater hoses(A).
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2.
EDQF037A
EDQF019A
ENGINE AND TRANSAXLE ASSEMBLY
7.
EMA -43
Remove the engine wire harness connectors and wire
harness clamps from the cylinder head and the intake
manifold.
TPS(Throttle Position Sensor) connector(A).
2)
ISA(ldle Speed Actuator) connector(B).
3)
PCSV(Purge Control Solenoid Valve) connec­
to r^ ).
Rear oxygen sensor connector(D).
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1)
10)
4)
Injector connedor(E).
5)
Knock sensor connector(F).
6)
CMP(Camshaft Position Sensor) connector(G).
11)
Three fuel injector connedors(A).
on
wt
EDQF033A
ECOF001A
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7)
ECT(Engine Coolant Temperature) sensor(A)
connector.
8)
Ignition coil connector(B).
9)
Crankshaft position sensor connector(C).
EDQF028A
EMA -44
8.
ENGINE (G6BA - GSL 2.7)
Disconnect front heated oxygen sensor(LH) connector(A), air compressor switch connector(B) and oil
pressure sensor connedor(C).
12. Remove the brake booster vacuum hose(A).
wt
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EDQF009A
9.
Disconnect rear heated oxygen sensor(RH) connec­
tor.
EDQF020A
13. Remove the accelerator cable by loosening the lock­
nut, then slip the cable end out of the throttle linkage.
14. Remove the power steering pump hose(A).
on
10. Remove the fuel inlet from delivery pipe(A).
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EDQF025A
11.
Remove the PCSV hose.
EDQF024A
ENGINE AND TRANSAXLE ASSEMBLY
EMA -45
d.
e.
Disconnect the output shaft speed connector(A).
Disconnect the vehicle speed sensor connec­
to r^ ).
wt
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EDQF021A
15. Remove the battery body bracket.
16. Disconnect the transaxle wire harness connector.
a. Disconnect the inhibitor switch connector(A).
b. Disconnect the transaxle range connector(B).
c. Disconnect the input shaft speed connector(C).
EDQF031A
17. Remove the control cable(A) transaxle range switch.
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on
EDQF035A
EDQF018A
EMA -46
ENGINE (G6BA - GSL 2.7)
18. Remove the transaxle oil cooler hoses(A/T)(A).
21. Disconnect the ABS wheel speed sensor(A) from both
front knuckles. (See DS group - front axle).
wt
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EDQF034A
19. Remove the under cover.
20. Remove the front exhaust pipe(A).
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on
EDQF001A
EDQF023A
ENGINE AND TRANSAXLE ASSEMBLY
EMA -47
23. Remove the caliper and hang the caliper assem­
b ly ^ ).
26. Remove the engine mounting bracket(A).
wt
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EDQF017A
ECKD612A
27. Remove the transaxle mounting bracket(A).
24. Remove the steering u-joint mounting bolt(A). (See
ST group - steering)
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on
ECKD616A
25. Install the jack for supporting engine and transaxle
assembly.
EDQF016A
EMA -48
ENGINE (G6BA - GSL 2.7)
INSTALLATION
28. Remove the sub frame mounting bolts and nuts.
Tightening torque
A : 160 - 180Nm (1600 - 1800kgf.cm, 118 - 133lbf.ft)
B : 70 - 90Nm (700 - 900kgf.cm, 52 - 66lbf.ft)
EFBF5C5C
Installation is in the reverse order of removal.
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on
wt
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ECOF002A
Perform the following :
• Adjust the shift cable.
• Adjust the throttle cable.
• Refill the engine with engine oil.
• Refill the transaxle with fluid.
• Refill 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 line, turn on the ignition
switch (do not operate the starter) so that the fuel
pump runs for approximately two seconds and fuel
line pressureizes.
Repeat this operation two or three times, then check
for fuel leakage at any point in the fuel line.
ECKD61BA
29. Jack up the vehicle.
ENGINE BLOCK
EMA -49
ENGINE BLOCK
COMPONENT
E75D75CB
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on
wt
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TORQUE : Nm (kgf.cm, Ibf.ft)
EDQF203A
EMA -50
ENGINE (G6BA - GSL 2.7)
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on
wt
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EDQF204A
ENGINE BLOCK
DISASSEMBLY
EMA -51
10. Remove knock sensors(A).
EB8FA3DB
1.
A/T : remove drive plate.
2.
Install engine to engine stand for disassembly(A).
3.
Remove timing belt. (See page EMA -1 3 )
4.
Remove cylinder head. (See page EMA - 23)
5.
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6.
7.
8.
Remove oil level gauge assembly.
Remove the alternator. (See EE group - alternator).
Remove the air compressor. (See HA group - air com­
pressor)
Remove the power steering pump bracket(A).
11. Remove the lower oil pan (A).
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on
wt
EDQF181A
EDQF061A
9.
Remove water pump. (See page EMA - 74)
EDQF065A
EMA -52
ENGINE (G6BA - GSL 2.7)
12. Remove oil screen.
Remove the 2bolts(B), oil screen(A) and gasket.
2)
Push the piston, connecting rod assembly and
upper bearing through the top of the cylinder
block.
( U NOTE
Ne
• Keep the bearings, connecting rod and cap to­
gether.
• Arrange the piston and connecting rod assem­
blies in the correct order.
17. Remove front case. (See page EMA - 80)
18. Remove oil seal case.
Remove the 3bolts(B) and oil seal case(A).
wt
EDQF066A
13. Remove the upper oil pan(A).
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on
EDQF174B
19. Check the crankshaft end play. (See page EMA - 58)
EDQF067A
14. Check the connecting rod end play. (See page EMA
-5 4 )
15. Remove the connecting rod caps and check oil clear­
ance. (See page EMA - 54)
16. Remove piston and connecting rod assemblies.
1)
Using a ridge reamer, remove all the carbon from
the top of the cylinder.
ENGINE BLOCK
EMA -53
20. Remove crankshaft bearing cap and check oil clear­
ance. (See page EMA - 56)
23. Remove piston rings.
1)
Using a piston ring expender, remove the 2 com­
pression rings.
2)
Remove the 2side rails and oil ring by hand.
[u J n o t e
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Arrange the piston rings in the correct order only.
24. Disconnect connecting rod from piston.
wt
EDQF072A
21.
Lift the crankshaft(A) out of the engine, being careful
not to damage journals.
on
( y ) NOTE
Arrange the main bearings and trust washers in the
correct order.
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EDQF074A
22. 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 set.
EMA -54
INSPECTION
ENGINE (G6BA - GSL 2.7)
EE99516D
7)
Remove the 2bolts, connecting rod cap and bear­
ing half.
8)
Measure the plastigage at its widest point.
CONNECTING ROD AND CRANKSHAFT
1.
Check the connecting rod end play.
Using a dial indicator, measure the end play while
moving the connecting rod back and forth.
Standard oil clearance
0.018 - 0.036mm(0.0007 - 0.0014in.)
on
wt
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Standard end play : 0.1- 0.25mm(0.004 - 0.01 Oin.)
Maximum end play : 0.4mm(0.016in.)
EDQF159A
9)
• If out-of-tolerance, replace the connecting rod as­
sembly.
• If still out-of-tolerance, replace the crankshaft.
Check the connecting road bearing oil clearance.
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.
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2.
EDQF175A
/ t \ CAUTION
1)
Check the matchmarks on the connecting rod
and cap are aligned to ensure correct reassem­
bly.
2)
Remove the 2 connecting rod cap bolts.
3)
Remove the connecting rod cap and bearing half.
4)
Clean the crank pin and bearing.
5)
Place plastigage across the crank pin.
6)
Reinstall the bearing half and cap, and torque the
bolts.
Tightening torque
16 - 20Nm (160 - 200kgf.cm, 12 - 15lbf.ft) + 90°
(Q j) NOTE
Do not turn the crankshaft.
Do not file, shim, or scrape the bearings or the
caps to adjust clearance.
10) If the plastigage shows the clearance is still in­
correct, try the next larger or smaller bearing (the
color listed above or below that one), and check
clearance again.
| U ] NOTE
If the proper clearance cannot be obtained by using
the appropriate larger or smaller bearings, replace the
crankshaft and start over.
A
CAUTION
If the marks are indecipherable because o f an ac­
cumulation o f dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with
solvent or detergent
ENGINE BLOCK
EMA -55
Connecting rod mark location
Discrimination of crankshaft
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CLSASS
MARK
OUTSIDE DIAMETER
OF PIN
I
A
47.994 - 48.000mm
(1 .8 8 9 5 - 1.8898in.)
II
B
47.988 - 47.994mm
(1.8893 - 1.8895in.)
III
C
47.982 - 47.988mm
(1.8890 - 1.8893in.)
Place of identification mark (Connecting rod
bearing)
wt
Discrimination of connecting rod
INSIDE DIAMETER
0
A
51.000 - 5 1 ,006mm
(2.0079 -2.0081 in.)
1
B
51.006 - 5 1 ,012mm
(2.0081 - 2.0083in.)
2
C
51.012 - 51.018mm
(2.0083 - 2.0086in.)
on
MARK
CLASS
Crankshaft pin mark location
eckd313a
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Discrimination of connecting rod bearing
EDQF176A
CLASS
MARK
THICKNESS OF
BEARING
A
BLUE
1.500 - 1.503mm
(0.0590-0.0591 in.)
B
BLACK
1.497 - 1,500mm
(0.0589 - 0.0590in.)
C
NONE
1.494 - 1.497mm
(0.0588 - 0.0589in.)
D
GREEN
1.491 - 1,494mm
(0.0587 - 0.0588in.)
E
YELLOW
1.488 - 1.491mm
(0.0586 - 0.0587in.)
EMA -56
ENGINE (G6BA - GSL 2.7)
11) Selection
CRANKSHAFT
INDENTIFICATION
MARK
I (A)
5)
CONNECT­
ING ROD
IDENTIFICA­
TION MARK
ASSEMBING
CLASSIFI­
CATION OF
BEARING
0 (A)
E (YELLOW)
1 (B)
D (GREEN)
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2 (C)
II (B)
III (C)
Standard oil clearance
0.004 - 0.022mm (0.00016 - 0.00087in.)
C (NONE)
0 (A)
D (GREEN)
1 (B)
C (NONE)
2 (C)
B (BLACK)
0 (A)
C (NONE)
1 (B)
B (BLACK)
2 (C)
A (BLUE)
wt
3.
Remove the cap and bearing again, and measure
the widest part of the plastigage.
Check the crankshaft bearing oil clearance.
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
bolts.
EDQF075A
on
1)
6)
J j ] NOTE
Do not turn the crankshaft.
/ ! \ CAUTION
Do not file, shim, or scrape the bearings or the
caps to adjust clearance.
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Tightening torque
M8
13 - 19Nm (130 - 190kgf.cm, 10 - 14lbf.ft) + 90°
M10
27 - 33Nm (270 ~ 330kgf.cm, 19.5 ~ 24lbf.ft) + 90°
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.
7)
If the plastigage shows the clearance is still in­
correct, try the next larger or smaller bearing (the
color listed above or below that one), and check
clearance again.
[ U ] NOTE
If the proper clearance cannot be obtained by using
the appropriate larger or smaller bearings, replace the
crankshaft and start over.
/ t \ CAUTION
If the marks are indecipherable because o f an ac­
cumulation o f dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with
solvent or detergent
ENGINE BLOCK
EMA -57
CONNECTING RODS
1.
2.
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.
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3.
Discrimination of cylinder block
MARK
INSIDE DIAMETER
a
A
66.000 - 66.006mm
(2.5984 - 2.5986in.)
b
B
66.006 - 66.012mm
(2.5986 - 2.5989in.)
c
C
66.012 - 66.018mm
(2.5989 -2.5991in.)
CLASS
Crankshaft journal mark location
Using a connecting rod aligning tool, check the rod for
bend and twist. If the measured value is close to the
repair limit, correct the rod by a press. Any connecting
rod that has been severely bent or distorted should be
replaced.
wt
Allowable bend of connecting rod
0.05mm / 100mm (0.0020 in./3.94 in.) or less
Allowable twist of connecting rod
0.1mm / 100mm (0.0039 in./3.94 in.) or less
Crankshaft bore mark location
on
Letters have been stamped on the end of the block as
a mark for the size of each of the 4 main journal bores.
Use them, and the numbers or bar stamped on the
crank (marks for main journal size), to choose the cor­
rect bearings.
EDQF176B
Discrimination of crankshaft
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EDQF078A
CLASS
MARK
OUTSIDE DIAMETER
OF JOURNAL
I
A
61.994 ~ 62.000mm
(2.4407 - 2.4409in.)
II
B
61.988 ~ 61.994mm
(2.4405 - 2.4407in.)
III
C
61.982 - 61.988mm
(2.4402 ~ 2.4405in.)
EMA -58
ENGINE (G6BA - GSL 2.7)
Place of identification mark (Crankshaft bearing)
Selection
CRANKSHAFT
IDENTIFICATION
MARK
I (A)
Ne
II (B)
III (C)
wt
ECKD31EA
Discrimination of crankshaft bearing
MARK
THICKNESS OF
BEARING
A
BLUE
2.007 - 2.010mm
(0.0790-0.0791 in.)
B
BLACK
2.004 - 2.007mm
(0.0789 - 0.0790in.)
C
NONE
2.001 - 2.004mm
(0.0788 - 0.0789in.)
D
GREEN
1 .9 9 8 - 2.001mm
(0.0787 - 0.788in.)
E
YELLOW
1.995 - 1,998mm
(0.0785 - 0.0787in.)
ASSEM­
BLING CLAS­
SIFICATION
OF BEARING
a (A)
E (YELLOW)
b (B)
D (GREEN)
c (C)
C (NONE)
a (A)
D (GREEN)
b (B)
C (NONE)
c (C)
B (BLACK)
a (A)
C (NONE)
b (B)
B (BLACK)
c (C)
A (BLUE)
Check crankshaft end play.
Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
screwdriver.
Standard end play
0.07 - 0.25mm (0.0027 - 0.0098in.)
Limit : 0.30mm (0.0118in.)
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on
CLASS
4.
CRANK­
SHAFT BORE
IDENTIFICA­
TION MARK
ECKD001B
If the end play is greater than maximum, replace the
thrust bearings as a set.
Thrust bearing thickness
1.925 ~ 1.965mm (0.076 ~ 0.077in.)
ENGINE BLOCK
5.
EMA -59
Inspect main journals and crank pins
Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter
61.982 - 62.000mm (2.4402 - 2.4409in.)
Crank pin diameter
47.982 ~ 48.000mm (1.8890 - 1.8898in.)
3.
Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge,
measure the surface contacting the cylinder head
gasket for warpage.
Flatness of cylinder block gasket surface
Standard : Less than 0.03mm(0.0012 in.)
Limit : 0.05 mm ( 0.0020 in.)
on
wt
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4.
Inspect cylinder bore diameter
Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder
liner.
ECKD001E
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CYLINDER BLOCK
1.
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.
EDQF154A
EMA -60
5.
ENGINE (G6BA - GSL 2.7)
Inspect cylinder bore diameter
Using a cylinder bore gauge, measure the cylinder
bore diameter at position A, B and C in the thrust and
axial directions.
7.
Check the piston size code(A) on the piston top face.
Standard diameter
86.70 ~ 86.73mm (3.4134 ~ 3.4145in.)
wt
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EDQF177A
fO )
no te
Stamp the grade mark o f basic diameter with rubber
stamp.
on
EDQF153A
6.
Check the cylinder bore size code(A) on the cylinder
block bottom face.
Size
code
Class
Piston diameter
A
86.68 ~86.69mm (3.4126 ~3.4130in.)
A
B
86.69 - 86.70mm (3.4130 - 3.4133in.)
None
C
86.70 ~ 86.71 mm (3.4133 ~ 3.4137in.)
C
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8.
Select the piston related to cylinder bore class.
Clearance : 0.01 - 0.03mm (0.0004 - 0.0012in.)
BORING CYLINDER
1.
Oversize pistons should be selected according to the
largest bore cylinder.
Identification Mark
Size
0.25
0.25mm (0.010in.)
0.50
0.50mm (0.0250in.)
EDQF078B
Class
Cylinder bore inner diameter
Size
code
A
86.70 ~ 86.71 mm (3.4133 ~ 3.4137in.)
A
B
86.71 - 86.72mm (3.4137-3.4141 in.)
B
C
86.72 - 86.73mm (3.4141 - 3.4145in.)
C
|UJ] NOTE
The size o f piston is stamped on top o f the piston.
Measure the outside diameter of the piston to be
used.
ENGINE BLOCK
3.
EMA -61
According to the measured O.D., calculate the new
bore size.
New bore size = Piston O.D + 0.01 to 0.03mm
(0.0004 to 0.0012 in.) (clearance between piston and
cylinder) - 0.01 mm (0.0004 in.) (honing margin.)
4.
2.
The standard measurement of the piston outside di­
ameter is taken 38.5mm (1,516in.) from the top land
of the piston.
Standard diameter
86.68 - 86.71mm (3.4126 - 3.4138in.)
Bore each of the cylinders to the calculated size.
Ne
,A \ CAUTION
To prevent distortion that may result from temper­
ature rise during honing, bore the cylinder holes
in the firing order.
5.
6.
Hone the cylinders, finishing them to the proper di­
mension (piston outside diameter + gap with cylinder).
Check the clearance between the piston and cylinder.
wt
Standard : 0.01 ~ 0.03mm (0.0004 - 0.0012 in.)
ITS) NOTE
When boring the cylinders, finish all o f the cylinders
to the same oversize. Do not bore only one cylinder
to the oversize.
1.
Clean piston
on
PISTON AND RINGS
3.
Using a gasket scraper, remove the carbon from
the piston top.
2)
Using a groove cleaning tool or broken ring, clean
the piston ring grooves.
3)
Using solvent and a brush, thoroughly clean the
piston.
Do not use a wire brush.
Calculate the difference between the cylinder bore di­
ameter and the piston diameter.
Piston-to-cylinder clearance
0.01 ~ 0.03mm(0.0004 - 0.0012in.)
t
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1)
[T jj| NOTE
ECKD001D
EMA -62
4.
ENGINE (G6BA - GSL 2.7)
Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between
new piston ring and the wall of the ring groove.
Ne
Piston ring side clearance
No. 1 : 0.04 - 0.08 mm (0.0016 ~ 0.0031 in.)
No. 2 : 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)
Limit
No. 1 : 0.1mm (0.004in.)
No. 2 : 0.1mm (0.004in.)
5.
Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston
ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing 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 - 60,
If the bore is over the service limit, the cylinder block
must be rebored.(see page EMA - 60).
Piston ring end gap
Standard
No.1 : 0.20 - 0.35mm (0.0079 ~ 0.0138in.)
No.2 : 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)
Limit
Oil ring : 0.2 - 0.7mm (0.0079 - 0.0276in.)
on
wt
ECKD001G
If the clearance is greater than maximum, replace the
piston.
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ECKD001K
ENGINE BLOCK
EMA -63
PISTON PINS
OIP PRESSURE SWITCH
1.
1.
Measure the diameter of the piston pin.
Piston pin diameter
21.001 - 21.007mm (0.8268 - 0.8270in.)
Check the continuity between the terminal and the
body with an ohmmeter.
If there is no continuity, replace the oil pressure
switch.
wt
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ECKD001W
ECKD001Z
on
2.
Measure the piston pin-to-piston clearance.
2.
Check the continuity between the terminal and the
body when the fine wire is pushed. If there is con­
tinuity even when the fine wire is pushed, replace the
switch.
3.
If there is no continuity when a 50kpa (7psi) vacuum
is applied throgh the oil hole, the switch is operaing
properly.
Check for air leakage. If air leaks, the diahragm is
broken. Replace it.
Piston pin-to-piston clearance
0.011 - 0.018mm (0.00043 - 0.00071 in.)
3.
Check the difference between the piston pin diameter
and the connecting rod small end diameter.
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Piston pin-to-connecting rod interference
0.016 ~ 0.033mm (0.00063 ~ 0.00130in.)
ECKD001Y
EMA -64
REASSEMBLY
ENGINE (G6BA - GSL 2.7)
3)
EF5F5963
Position the piston rings so that the ring ends are
as shown.
(gj) NOTE
• Thoroughly clean all parts to assembled.
• Before installing the parts, apply fresh engine oil
to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with
new parts.
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1.
Assemble piston and connecting rod.
1)
Use a hydraulic press for installation.
2)
The piston front mark(A) and the connecting rod
front mark(B) must face the timing belt side of the
engine.
3.
Install connecting rod bearings.
1)
on
wt
EDQF178A
2)
Align the bearing claw with the groove of the con­
necting rod or connecting rod cap.
Install the bearings in the connecting rod and
connecting rod cap.
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EDQF077A
2.
Install piston rings.
1)
Install the oil ring expander and 2 side rails by
hand.
2)
Using a piston ring expander, install the 2 com­
pression rings with the code mark facing upward.
ECKD322A
ENGINE BLOCK
4.
EMA -65
Install main bearings.
5.
[LlJ] note
Upper 1, 2, 3, 4 bearings have an oil groove o f oil
holes; Lower bearings do not.
1)
Install thrust bearings.
Install the 2 thrust bearings (A) under the No.3 jour­
nal position of the cylinder block with the oil grooves
facing outward.
Align the bearing claw with the claw groove of the
cylinder block, push in the 4upper bearings(A).
6.
Place crankshaft(A) on the cylinder block.
on
wt
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ECKD324A
EDQF076A
2)
Align the bearing claw with the claw groove of
the main bearing cap(A), and push in the 4lower
bearings(B).
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7.
EDQF079A
Place main bearing caps on cylinder block.
EDQF074A
EMA -66
8.
ENGINE (G6BA - GSL 2.7)
Install main bearing cap bolts.
3)
Retighten the bearing cap bolts by 90° - 94° in
the numerical order shown.
(gj) NOTE
• The main bearing cap bolts are tightened in 2
progressive steps.
• If any o f the bearing cap bolts in broken or de­
formed, replace it.
16______________ 12______________ 9_______________ 13
B
B8
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Tightening torque
Main bearing cap bolt
M8
13 - 19Nm (130 - 190kgf.cm, 10 - 14lbf.ft) + 90° - 94°
M10
27 ~ 33Nm (270 ~ 330kgf.cm, 1 9 .5 - 24lbf.ft) + 90° ~ 94°
Apply a light coat of engine oil on the threads and
under the bearing cap bolts.
2)
Install and uniformly tighten the 16bearing cap
bolts, in several passes, in the sequence shown.
wt
1)
3
2
6
11
e
10
©
7
B
O
5
B
B
B
B _________ EBJ__________S3
q
e
15
Tightening torque
M 8(A ): 13 - 19Nm (130 ~ 190kgf.cm, 10 - 14lbf.ft)
M 10(B): 27 - 33Nm (270 - 330kgf.cm, 19.5 - 24lbf.ft)
B
4
B
B1
B
14
EDQF198A
4)
9.
Check that the crankshaft turns smoothly.
Check crankshaft end play. (See page EMA - 58)
on
10. Install piston and connecting rod assemblies.
M NOTE
Before installing the pistons, apply a coat o f engine oil
to the ring grooves and cylinder bores.
1)
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Remove the connecting rod caps, and slip short
sections of rubber hose over the threaded ends
of the connecting rod bolts.
EDQF072A
2)
Install the ring compressor, check that the bear­
ing is securely in place, then position the piston in
the cylinder, and tap it in using the wooden han­
dle of a hammer.
3)
Stop after the ring compressor pops free, and
check the connecting rod-to-check journal align­
ment before pushing the piston into place.
ENGINE BLOCK
4)
EMA -67
Apply engine oil to the bolt threads. Install the
rod caps with bearings, and torque the bolts.
Tightening torque
16 ~ 20Nm (160 - 200kgf.cm, 12 - 15lbf.ft) + 90° - 94°
[
11. Apply liquid gasket to the oil seal case and install the
oil seal case(A).
Tightening torque
10 - 12Nm (100 - 120kgf.cm, 7.3 - 8.8lbf.ft)
0 NOTE
]
Maintain downward force on the ring compressor to
prevent the rings from expanding before entering the
cylinder bore.
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A
EDQF174A
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U jW O T E
• Use liquid gasket MS721-40A or equivalent
• Check that the mating surfaces are clean and dry.
ECKD001F
12.
Install rear oil seal.
1)
Apply engine oil to a new oil seal lip.
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EMA -68
2)
ENGINE (G6BA - GSL 2.7)
Using SST(09231-33000) and a hammer, tap in
the oil seal until its surface is flush with the rear
oil seal retainer edge.
2)
Install the oil pan(A) with the 17bolts.
Uniformly tighten the bolts in several passes.
Tightening torque
19 - 28Nm (190 - 280kgf.cm, 14 - 20lbf.ft): (1 - 15)
5 ~ 7Nm (50 ~ 70kgf.cm, 4 - 5 lb f.ft): (16,17)
wt
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EDQF179A
13. Install front case. (See page EMA - 83)
1)
on
14. Install the upper oil pan.
EDQF067A
Using a razor blade and gasket scraper, remove
all the old packing material from the gasket sur­
faces.
[TUj note
Check that the mating surfaces are clean and dry be­
fore applying liquid gasket.
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EDQF151A
\UJ\NOTE
• To prevent leakage o f oil, apply liquid gasket to
the inner threads o f the bolt holes.
• Do not install the parts if five minutes or more
have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the
residue.
ENGINE BLOCK
EMA -69
• After assembly, wait at least 30 minutes before
filling the engine with oil.
15.
Install oil screen.
Install a new gasket and oil screen(A) with 2bolts(B).
2)
Install the lower oil pan 10bolts.
Uniformly tighten the bolts serveral passes
Tightening torque
10 ~12Nm (100 - 120kgf.cm, 7.3 - 8.8lbf.ft)
Tightening torque
15 ~ 22Nm (150 - 220kgf.cm, 11 - 16lbf.ft)
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EDQF066A
16. Install the lower oil pan.
1)
Apply liquid gasket as an even bead, centered
between the edges of the mating surface.
Use liquid gasket MS 721-40A or equivalent.
17.
Install oil pressure sensor.
1)
Apply adhesive to 2 or 3 threads.
Adhesive: THREE BOND TB2403 or equivalent.
2)
Install the oil pressure sensor(A).
Tightening torque
15 ~ 22Nm (150 ~ 220kgf.cm, 11 ~ 16lbf.ft)
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|TlJ) NOTE
EDQF152A
• To prevent leakage o f oil, apply liquid gasket to
the inner threads o f the bolt holes.
• Do not install the parts if five minutes or more
have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the
residue.
• After assembly, wait at least 30 minutes before
filling the engine with oil.
EDQF180A
EMA -70
18.
ENGINE (G6BA - GSL 2.7)
Install knock sensor(A).
23. Install oil level gauge assembly.
Tightening torque
17 - 26Nm (170 - 260kgf.cm, 12.5 - 19lbf.ft)
1)
Install a new O-rlng on the oil level gauge.
2)
Apply engine oil on the O-ring.
3)
Install the oil level gauge assembly (A) with the
bolt.
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Tightening torque
12 - 15Nm (120 ~ 150kgf.cm, 9 ~ 111bf.ft)
24. Install cylinder head. (See page EMA - 35)
25. Install timing belt. (See page EMA -17)
26. Remove engine stand.
27. Install drive plate.
wt
Tightening torque
73 - 77Nm (730 - 770kgf.cm, 53 - 56lbf.ft)
EDQF181A
19. Install water pump. (See page EMA - 75)
on
20. Install the power steering pump bracket(A).
Tightening torque
35 ~ 55Nm (350 ~ 550kgf.cm, 25.8 ~ 40.6lbf.ft)
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EDQF061A
21. Install the air compressor. (See HA group - air com­
pressor)
22. Install the alternator. (See EE group - alternator)
EMA -71
COOLING SYSTEM
COOLING SYSTEM
COMPONENT
E9CB691B
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TO R Q U E : Nm (kgf.cm , Ibf.ft)
E D Q F 205A
EMA -72
ENGINE (G6BA - GSL 2.7)
ENGINE COOLANT REFILLING AND
BLEEDING EB5F0F42
o WARNING
Never remove the radiator cap when the engine is
hot. Serious scalding could be caused by hot fluid
under high pressure escaping from the radiator.
8.
Repeat 7 until the cooling fen 3 - 5times and bleed air
sufficiently out of the cooling system.
9.
Install the radiator cap and fill the reservoir tank to the
"MAX" line with coolant.
10. Run the vehicle under idle until the cooling fan oper­
ates 2 - 3 times.
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11. Stop the engine and allow coolant to cool.
, / j \ CAUTION
When pouring engine coolant, be sure to shut the
relay box lid and not to let coolant spill on the
electrical parts or the paint. If any coolant spills,
rinse it off immediately.
Slide the heater temperature control lever to maxi­
mum heat. Make sure the engine and radiator are
cool to the touch.
2.
Remove radiator cap.
3.
Loosen the drain plug, and drain the coolant.
4.
Tighten the radiator drain plug securely.
5.
Remove, drain and reinstall the reservoir. Fill the tank
halfway to the MAX mark with water, then up to the
MAX mark with antifreeze.
6.
Fill fluid mixture with coolant and water slowly through
the radiator cap. Gently squeeze the upper/lower
hoses of the radiator so as to bleed air easily.
Recheck the coolant level in the reservoir tank t b r 2 ~
3 days after replacing coolant.
on
\J \N O T E
/ t \ CAUTION
• Do
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• Use only genuine antifreeze/coolant.
• For best corrosion protection, the coolant con­
centration must be maintained year-round at 50%
minimum. Coolant concentrations less than 50%
may not provide sufficient protection against cor­
rosion or freezing.
• Coolant concentrations greater then 60% will im­
pair cooling efficiency and are not recommended.
not mix different brands o f antifreeze/coolants.
• Do not use additional rust inhibitors or anti­
rust products; they may not be compatible
with the coolant
7.
M note
wt
1.
12. Repeat steps 6 to 11 until the coolant level stays con­
stant and all air is bleed out of the cooling system.
Start the engine and allow coolant to circulates.
When the cooling fan operates and coolant circulates,
refill coolant through the radiator cap.
EMA -73
COOLING SYSTEM
CAP TESTING
TESTING
1.
1.
Wait until engine is cool, then carefully remove the
radiator cap and fill the radiator with engine coolant,
then install it on the pressure tester.
2.
Apply a pressure tester to the radiator and apply a
pressure of 93 - 123kPa (0.95 - 1.25kgf/cm2 14 19psi).
Remove the radiator cap, wet its seal with engine
coolant, then install it on the pressure tester.
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ECKD501X
Apply a pressure of 93 - 1 23kPa (0.95 - 1,25kgf/cm2,
14 - 19psi)
3.
Check for a drop in pressure.
4.
If the pressure drops, replace the cap.
on
2.
ECKD501Y
3.
Inspect for engine coolant leaks and a drop in pres­
sure.
4.
Remove the tester and reinstall the radiator cap.
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U | wore
Check for engine oil in the coolant and/or coolant in
the engine oil.
EMA -74
REMOVAL
ENGINE (G6BA - GSL 2.7)
THERMOSTAT
E6B7D6BE
WATER PUMP
1.
M NOTE
Removal o f the thermostat would have an adverse
effect, causing a lowering o f cooling efficiency. Do
not remove the thermostat, even if the engine tends
to overheat.
Drain the engine coolant.
o WARNING
1.
Remove the engine cover.
2.
Drain engine coolant so its level is below thermostat.
2.
Remove drive belts. (See page EMA -1 3 )
3.
Remove the lower hose.
3.
Remove the timing belt. (See page EMA -1 3 )
4.
Remove water inlet(A) and thermostat(B).
4.
Remove the timing belt idler. (See page EMA -16)
5.
Remove the water pump.
Remove the water pump(A) and gasket(B).
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System is under high pressure when the engine is
hot. To avoid danger of releasing scalding engine
coolant, remove the cap only when the engine is
cool.
B
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EDQF062A
EDQF183A
EMA -75
COOLING SYSTEM
INSPECTION
INSTALLATION
ED61C13B
WATER PUMP
WATER PUMP
1.
Check each part for cracks, damage or wear, and re­
place the coolant pump assembly if necessary.
1.
2.
Check the bearing for damage, abnormal noise and
sluggish rotation, and replace the coolant pump as­
sembly if necessary.
Tightening torque
15 - 22Nm (150 ~ 220kgf.cm, 11 - 16lbf.ft)
Check for coolant leakage. If coolant leaks from hole,
the seal is defective. Replace the coolant pump as­
sembly
(
0 NOTE
)
A small amount o f “ weeping'
is normal.
from the bleed hole
wt
THERMOSTAT
1.
Install the water pump(A) and a new gasket(B) with
the 8bolts.
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3.
EAD083BE
Immerse the thermostat in water and gradually heat
the water.
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on
ECKD503B
2.
Check the valve opening temperature.
Valve opening temperature : 82°C (177°F)
Full opening temperature : 95°C (205°F)
If the valve opening temperature is not as specified,
replace the thermostat.
3.
Check the valve lift.
Valve lift: 10mm(0.4in.) or more at 95°C (205°F)
If the valve lift is not as specified, replace the thermo­
stat.
EDQF190A
EMA -76
ENGINE (G6BA - GSL 2.7)
Bolt
Size
Number
x
x
x
x
4
2
1
1
8
8
8
8
A
B
C
D
25
30
32
40
Install the timing belt Idler. (See page EMA -1 7 )
3.
Install the timing belt. (See page EMA -1 7 )
4.
Install drive belt.
5.
Fill with engine coolant. (See page EMA - 72)
6.
Start engine and check for leaks.
7.
Recheck engine coolant level.
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2.
THERMOSTAT
wt
1.
Place thermostat in thermostat housing.
1)
Install the thermostat with the jiggle valve up­
ward.
2)
Install a new to the thermostat(B).
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EDQF183A
2.
Install water inlet(A).
Tightening torque
17 ~ 20Nm (170 ~ 200kgf.cm, 12.5 ~ 14lbf.ft)
3.
Install the lower hose.
4.
Fill with engine coolant.
5.
Start engine and check for leaks.
LUBRICATION SYSTEM
EMA -77
LUBRICATION SYSTEM
COMPONENT
E6B3C6EA
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EDQF206A
EMA -78
OIL AND FILTER
ENGINE (G6BA - GSL 2.7)
3.
E7FBE1A4
/ ! \ CAUTION
• Prolonged and repeated contact with mineral
wt
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oil will result in the removal o f natural fats
from the skin, leading to dryness, irritation
and dermatitis. In addition, used engine oil
contains potentially harmful contaminants
which may cause skin cancer.
• Exercise caution in order to minimize the
length and frequency o f contact o f your skin
to used oil. Wear protective clothing and
gloves. Wash your skin thoroughly with soap
and water, or use water-less hand cleaner,
to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
• In order to preserve the environment, used oil
and used oil filter must be disposed of only at
designated disposal sites.
1.
Drain engine oil.
a. Remove the oil filter cap.
b. Remove the oil drain plug(A), and drain the oil
into a container.
Tightening torque
35 ~ 45Nm (350 ~ 450kgf.cm, 26 ~ 33lbf.ft)
• Fill with fresh engine oil
Capacity
Drain and refill
W/Oil filter change : 4.5I (4.74U.S.qts, 3.95lmp qts)
W/O Oil filter change : 4.2I (4.30U.S.qts, 3.65lmp qts)
• Install the oil filter cap.
4.
Start engine and check for oil leaks.
5.
Recheck engine oil level.
INSPECTION
1.
J ).
Check engine oil level.
After warming up the engine and then 5 minutes after
the engine stop, oil level should be between th e " L
and ' F" marks on the dipstick.
If low, check for leakage and add oil up to the " F"
mark.
(U ) NOTE
Do not fill with engine oil above the
t
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k
Check engine oil quality
Check the oil for deterioration, entry of water, discol­
oring or thinning.
If the quality is visibly poor, replace the oil.
on
2.
EDQF022A
2.
Refill with engine oil filter.
• Clean and install the oil drain plug with a new
gasket.
Replace oil filter.
a. Remove the oil filter(B).
b. Check and clean the oil filter installation surface.
c. Check the part number of the new oil filter is as
same as old one.
d. Apply clean engine oil to the gasket of a new oil
filter.
e. Lightly screw the oil filter into place, and tighten
it until the gasket contacts the seat.
f.
Tighten it an additional 3/4 turn.
F” mark.
LUBRICATION SYSTEM
EMA -79
SELECTION OF ENGINE OIL
Recommended ILSAC classification : GF3 OR ABOVE
Recommended API classification : SJ / SL OR ABOVE
Recommended SAE viscosity grades :
Ne
Temperature range
anticipated before
next oil change
Recommended SAE viscosity number
°C
40
20
-
wt
10
-
-
■13
—
-18
—
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on
- 7
*1 : R e c o m m e n d e d r e g a r d le s s of environm ent.
If not av ailab le, refer to the re c o m m e n d e d S A E v isc o sity n u m b ers.
( S 3 NOTE
For best performance and maximum protection o f all
types o f operation, select only those lubricants which
3.
Satisfy the requirement of the API classification.
Have proper SAE grade number for expected am­
bient temperature range.
Lubricants that do not have both an SAE grade
number and API service classification on the con­
tainer should not be used.
t
1.
2.
LC8F002A
EMA -80
REMOVAL
ENGINE (G6BA - GSL 2.7)
1)
E0D7EC7F
Drain engine oil.
2.
Remove RH front wheel.
3.
Remove RH side cover.
4.
Remove the front exhaust pipe. (See page EMA - 46)
5.
Remove the alternator from engine. (See EE group alternator)
6.
Remove the drive belt. (See page EMA -1 3 )
7.
Turn the crankshaft and align the white groove on the
crankshaft pulley with the pointer on the lower cover.
(See page EMA -1 3 )
8.
Remove the timing belt. (See page EMA -1 3 )
9.
Remove the oil pan and oil screen.(See page EMA 51, 52)
wt
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1.
Remove the screws(B) from the pump housing,
then separate the housing and cover(A).
EDQF070A
10. Remove the oil pump case(A).
2)
Remove the inner and outer rotors.
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EDQF06BA
LUBRICATION SYSTEM
DISASSEMBLY
1.
EMA -81
INSPECTION
E1E5FFFC
Remove the relief plunger.
Remove the plug(A), spring(B) and relief plunger(C).
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o—
EC1BAD97
1.
Inspect relief plunger.
Coat the valve with engine oil and check that it falls
smoothly into the plunger hole by its own weight.
If it does not, replace the relief plunger. If necessary,
replace the front case.
2.
Inspect relief valve spring.
Inspect for distorted or broken relief valve spring.
Standard value
Free height : 43.8mm (91.724in.)
Load : 4.6kg/39.1mm (10lb/1.547in.)
3.
c
Inspect rotor side clearance.
Using a feeler gauge and precision straight edge,
measure the clearance between the rotors and
precision straight edge.
wt
Side clerance
0.040 - 0.095mm (0.0016 - 0.0037in.)
EDQF069A
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on
EDQF184A
If the side clearance is greater than maximum, replace
the rotors as a set. If necessary, replace the front
case.
EMA -82
4.
ENGINE (G6BA - GSL 2.7)
Inspect rotor body clearance.
Using a feeler gauge, measure the clearance between
the outer rotor and body.
Body clearance
0.100 ~ 0.181mm (0.0039 ~ 0.0071in.)
REASSEMBLY
1.
E27BB309
Install relief plunger.
Install relief plunger(C) and spring(B) into the front
case hole, and install the plug(A).
Tightening torque
40 - 50Nm (400 ~ 500kgf.cm, 30 ~ 37lb.ft)
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o—
C
V
EDQF186A
on
If the body clearance is greater than maximum, re­
place the rotors as a set. If necessary, replace the
front case.
EDQF069A
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LUBRICATION SYSTEM
INSTALLATION
1.
EMA -83
2)
ED7EB1F3
Apply liquid gasket to the oil pump as shown in
the illustration.
Use liquid gasket MS 721-40A.
Install oil pump.
1)
Place the inner and outer rotors into front case
with the marks facing the oil pump cover side.
2)
Install the oil pump cover(A) to front case with the
8screws(B).
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Tightening torque
8 - 12Nm (80 - 120kgf.cm, 6 - 8.8lbf.ft)
(OS)NOTE
• To prevent leakage o f oil, apply liquid gasket to
the inner threads o f the bolt holes.
• Do not install the parts i f five minutes or more
have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the
residue.
• After assembly, wait at least 30 minutes before
filling the engine with oil.
on
wt
EDQF187A
EDQF070A
Check that the oil pump turns freely.
3.
Install the oil pump on the cylinder block.
1)
3)
Place a new O-ring on the cylinder block.
4)
Engage the spline teeth of the oil pump drive gear
with large teeth of the crankshaft, and slide the oil
pump on the crankshaft.
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2.
Remove any old liquid gasket and be careful not
to drop any oil on the contact surfaces of the oil
pump and cylinder block.
• Using a razor blade and gasket scraper, re­
move all the old liquid gasket from the gasket
surfaces and sealing grooves.
• Using a non-residue solvent, clean both
sealing surfaces.
EMA -84
5)
ENGINE (G6BA - GSL 2.7)
Install the oil pump with 5bolts.
Uniformly tighten the bolts In several passes.
Tightening torque
12 - 15Nm (120 - 150kgf.cm, 8.8 - 11lbf.fi)
6.
Install the oil pan and oil screen. (See page EMA
69)
7.
Install the timing belt. (See page EMA -1 7 )
8.
Install the drive belt.
9.
Install the alternator. (See EE group - alternator)
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10. Install the front exhaust pipe. (See page EMA - 91)
11. Install the RH front wheel.
12. Fill engine with oil.
13. Start engine and check for leaks.
14. Recheck engine oil level.
wt
EDQF188A
Size
A
B
C
8 x 25
8 x 35
8 x 45
on
Bolt
Number
3
1
1
Apply a light coat of oil to the seal lip.
5.
Using the special tool(09214-33000), install the oil
seal.
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4.
EDQF189A
INTAKE AND EXHAUST SYSTEM____________________________________________ EMA -85
INTAKE AND EXHAUST
SYSTEM
COMPONENT
EC4F01D9
INTAKE MANIFOLD
0
0
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T : 4 ~ 6 (40 ~ 60, 3 ~ 4.5)
ECB9505E
EMA -86
ENGINE (G6BA - GSL 2.7)
EXHAUST MANIFOLD
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1 7 - 2 2 (1 7 0 - 220, 1 2 - 16)
TO R Q U E : Nm (kgf.cm , Ibf.ft)
EDQF209A
INTAKE AND EXHAUST SYSTEM
EMA -87
MUFFLER
Catalytic converter
Gasket
30 - 40
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Front exhaust pipe
TORQUE : Nm (kg-cm, Ib.ft)
EDOC160A
EMA -88
REMOVAL
ENGINE (G6BA - GSL 2.7)
4.
E0C67FDF
Remove the injector assembly(A).
INTAKE MANIFOLD
1.
Remove the engine cover.
2.
Remove air cleaner hose.
3.
Remove surge tank assembly.
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Disconnect the accelerator cable.
2)
Disconnect the TPS connector.
3)
Disconnect the ISA connector.
4)
Disconnect the injector connector.
5)
Disconnect the PCSV connector.
6)
Disconnect the PCSV hose.
7)
Disconnect the brake booster vacuum hose(A).
wt
1)
EDQF007A
5.
Remove the intake mani1bld(A) and gasket.
A
t
Ne
on
EDQF020A
8)
Disconnect the PCV hose.
9)
Disconnect the IAT sensor connector.
10) Remove the surge tank stay.
11) Remove the surge tank assembly.
EDQF063A
INTAKE AND EXHAUST SYSTEM
EMA -89
EXHAUST MANIFOLD
5.
1.
Remove the under cover.
2.
Remove the front exhaust pipe(A).
Remove the exhaust manifold(A) and gasket(B).
wt
Ne
EDQF001A
Disconnect the oxygen sensor connector.
4.
Remove the heat protector(A).
t
Ne
on
3.
EDQF003A
EDQF064A
EMA -90
INSTALLATION
ENGINE (G6BA - GSL 2.7)
10) Connector the ISA connector.
EE1ADD75
INTAKE MANIFOLD
11) Connector the TPS connector.
1.
12) Connector the actuator cable.
Install the intake manifold and gasket.
Tightening torque
19 - 21Nm (190 - 210kgf.cm, 14 - 15lbf.ft)
4.
Install the air cleaner hose.
5.
Install the engine cover.
on
wt
Ne
EDQF164A
2.
Install the injector assembly. (See FL group - injector)
3.
Install the surge tank assembly.
1)
Install the surge tank assembly.
2)
Install the surge tank stay.
Tightening torque
15 ~ 20Nm (150 ~ 200kgf.cm, 11 ~ 15lbf.ft)
3)
Install the ground cable.
4)
Connect the IAT sensor connector.
5)
Connect the PCV hose.
6)
Connect the brake booster vacuum hose.
7)
Connect the PCSV hose.
8)
Connect the PCSV connector.
9)
Connect the injector connector.
t
Ne
Tightening torque
15 - 20Nm (150 - 200kgf.cm, 11 - 15lbf.ft)
INTAKE AND EXHAUST SYSTEM
EMA -91
EXHAUST MANIFOLD
4.
Install the front exhaust pipe(A).
1. Install the exhaust mani1bld(A) and gasket(B).
-------------------------------------------------------------------------------Tightening torque
30 - 35Nm (300 - 350kgf.cm, 22 - 26lbf.ft)
Tightening torque
30 - 40Nm (300 ~ 400kgf.cm, 22 - 30lbf.ft)
---------------------------------------------------------------
on
wt
Ne
EDQF064A
2.
Install the heat protector(A).
Tightening torque
17 - 22Nm (170 ~ 220kgf.cm, 12 - 16lbf.ft)
t
Ne
EDQF003A
3.
Connect the oxygen sensor connector.
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