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SERVICE DATA AND SPECIFICATIONS (SDS)
EM-215
[HR]
C
D
E
F
G
H
I
J
K
L
M
A
EM
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
Standard and Limit
BBS002PC
GENERAL SPECIFICATIONS
DRIVE BELT
Belt Deflection:
*: When engine is cold.
EXHAUST MANIFOLD
Unit: mm (in)
SPARK PLUG (PLATINUM-TIPPED TYPE)
Unit: mm (in)
CYLINDER HEAD
Unit: mm (in)
Engine type HR16DE
Cylinder arrangement In-line 4
Displacement
cm
3
(cu in)
1,598 (97.51)
Bore and stroke mm (in) 78.0 x 83.6 (3.070 x 3.291)
Valve arrangement DOHC
Firing order 1-3-4-2
Number of piston rings
Compression 2
Oil 1
Compression ratio 9.8
Compression pressure
kPa (bar, kg/cm
2
,psi)/200rpm
Standard 1,510 (15.1, 15.4, 219)
Minimum 1,265 (12.69, 12.9, 183)
Differential limit between cylinders 981 (9.81, 10.0, 142)
Location
Deflection adjustment * Unit: mm (in)
Used belt
New belt
Limit After adjusted
Drive belt With A/C models 7.9 (0.31) 4.8 - 5.3 (0.19 - 0.21) 4.2 - 4.5 (0.17 - 0.18)
Without A/C models 7.1 (0.28) 4.3 - 4.7 (0.17 - 0.19) 3.6 - 3.9 (0.14 - 0.15)
Applied pushing force 98 N (10 kg, 22lb)
Items Limit
Surface distortion 0.3 (0.012)
Make NGK
Standard type PLZKAR6A-11
Hot type PLZKAR5A-11
Cold type PLZKAR7A-11
Spark plug gap Standard 1.1 (0.043)
Items Limit
Head surface distortion 0.1 (0.004)
Содержание
- B engine 1
- Contents 1
- Engine mechanical 1
- Sectio 1
- Parts requiring angle tightening 7
- Precautions 7
- Precautions for assembling and installing 7
- Precautions for disconnecting fuel piping 7
- Precautions for draining coolant 7
- Precautions for inspections repairs and replacement 7
- Precautions for removal and disassembly 7
- Liquid gasket application procedure 8
- Precautions 8
- Precautions for liquid gasket 8
- Removal of liquid gasket sealing 8
- Preparation 9
- Special service tools 9
- Preparation 10
- Commercial service tools 11
- Preparation 11
- Locate the area where noise occurs 2 confirm the type of noise 3 specify the operating condition of engine 4 check specified noise source if necessary repair or replace these parts 13
- Noise vibration and harshness nvh troubleshooting 13
- Use the chart below to help you find the cause of the symptom 13
- Caution when measuring belt tension immediately after the belt is installed first set the tension to the stan dard rotate the crankshaft for more than two turns in order to eliminate variance in the belt tension between pulleys then measure and adjust tension to the standard again 14
- Checking drive belts 14
- Drive belts 14
- Inspection should be done only when engine is cold or over 30 minutes after the engine is stopped 14
- Tension adjustment 14
- Turn the crankshaft pulley two times clockwise and make sure tension on all pulleys is equal before doing the test 14
- Visually check the belts for wear damage and cracks on inside and edges 14
- When measuring deflection apply 98 n 10 kg 22lb at the marked point 14
- Alternator and a c compressor belt with a c models 15
- Alternator belt without a c models 15
- Drive belts 15
- Drive belts 16
- Installation 16
- Removal 16
- Removal and installation 16
- Removal and installation of drive belt idler pulley 16
- Water pump belt 16
- Drive belts 17
- Installation 17
- Removal 17
- Air cleaner and air duct 18
- Handle manifold absolute pressure sensor with care avoid impacts 18
- Make sure no foreign matter is attached to the sensor oils chemicals etc 2 remove the harness connector and vacuum hose and then the evap canister purge volume control sole noid valve caution handle evap canister purge volume control solenoid valve with care avoid impacts 3 remove air duct 18
- Note the steps 1 to 2 can be skipped moving straight to the step 3 separation of harnesses and hoses etc can not be skipped 1 remove the harness connector and then the manifold absolute pressure sensor caution 18
- Removal 18
- Removal and installation 18
- Air cleaner and air duct 19
- Installation 19
- Air cleaner and air duct 20
- Air cleaner and air duct 21
- Changing air cleaner filter 21
- Installation 21
- Removal 21
- Intake manifold 22
- Removal 22
- Removal and installation 22
- Attachment of the intake manifold 23
- Check for damage or foreign material on the mounting surfaces 23
- Install in the reverse order of removal paying attention to the following 23
- Installation 23
- Intake manifold 23
- Tighten nuts and bolts in numerical order shown in figure note no 6 in the figure shows the 2nd tightening of no 1 bolt 23
- When installing support bracket refer to em 22 removal and installation 23
- Exhaust manifold and three way catalyst 24
- Removal 24
- Removal and installation 24
- Exhaust manifold and three way catalyst 25
- Inspection after removal surface distortion 25
- Installation 25
- Installation of exhaust manifold and three way catalyst 25
- Installation of heated oxygen sensor 1 25
- Oil pan and oil strainer 26
- Removal 26
- Removal and installation 26
- Installation 27
- Oil pan and oil strainer 27
- Inspection after installation 28
- Oil pan and oil strainer 28
- Do not disassemble 29
- Handle ignition coil with care avoid impacts 29
- Ignition coil 29
- Install in the reverse order of removal 29
- Installation 29
- Removal 29
- Removal and installation 29
- Remove air duct and air cleaner case assembly refer to em 18 air cleaner and air duct 2 disconnect harness connector from the ignition coil 3 remove ignition coil caution 29
- Inspection after removal 30
- Removal 30
- Removal and installation 30
- Spark plug platinum tipped type 30
- 19 29 n m 2 3 kg m 15 21 ft lb 31
- Checking and adjusting plug gap is not required between change intervals 31
- Install in the reverse order of removal 31
- Installation 31
- Spark plug 31
- Spark plug platinum tipped type 31
- Fuel injector and fuel tube 32
- Removal 32
- Removal and installation 32
- Fuel injector and fuel tube 33
- Installation 33
- Fuel injector and fuel tube 34
- Inspection after installation 34
- Removal 35
- Removal and installation 35
- Rocker cover 35
- Installation 36
- Rocker cover 36
- Rocker cover 37
- Camshaft 38
- Removal 38
- Removal and installation 38
- Camshaft 39
- Camshaft 40
- Camshaft 41
- Installation 41
- Camshaft 42
- Camshaft 43
- Camshaft 44
- Inspection after removal camshaft runout 44
- Camshaft 45
- Camshaft cam height 45
- Camshaft journal clearance 45
- Camshaft 46
- Camshaft end play 46
- Camshaft sprocket runout 46
- Valve lifter 46
- Valve lifter clearance 46
- Camshaft 47
- Inspection 47
- Inspection after installation inspection of camshaft sprocket int oil groove 47
- Valve clearance 47
- Camshaft 48
- Adjustment 49
- Camshaft 49
- Removal and installation 50
- Timing chain 50
- Removal operation description 51
- Timing chain 51
- Timing chain 52
- Inspection after removal 53
- Installation 53
- Timing chain 53
- Timing chain 54
- Timing chain 55
- Inspection after installation 56
- Timing chain 56
- Installation 57
- Oil seal 57
- Removal 57
- Removal and installation of front oil seal 57
- Removal and installation of valve oil seal 57
- Installation 58
- Oil seal 58
- Removal 58
- Removal and installation of rear oil seal 58
- Oil seal 59
- Press rear oil seal 2 into rear oil seal retainer 3 so that it does not project from the end 59
- Reinstall removed parts in reverse order of removal 59
- Compression pressure inspection 60
- Cylinder head 60
- On vehicle inspection 60
- Cylinder head 61
- Removal 61
- Removal and installation 61
- Cylinder head 62
- Inspection after removal cylinder head bolt outer diameter 62
- Installation 62
- Check tightening angle indicated on the angle wrench indica tor plate 63
- Cylinder head 63
- Disassembly and assembly 63
- Reinstall removed parts in reverse order of removal 63
- Tighten auxiliary bolts 11 to 13 in the numerical order shown in the figure 63
- Assembly 64
- Cylinder head 64
- Disassembly 64
- Cylinder head 65
- Inspection after disassembly cylinder head distortion 65
- Valve dimensions 65
- Cylinder head 66
- Valve guide clearance 66
- Valve guide replacement 66
- Cylinder head 67
- Replacement of valve seat 67
- Valve seat contact 67
- Cylinder head 68
- Cylinder head 69
- Valve spring dimensions and valve spring pressure load 69
- Valve spring squareness 69
- Always be careful to work safely avoid forceful or uninstructed operations 70
- Always use the support point specified for lifting 70
- Caution 70
- Do not start working until exhaust system and engine coolant are cool enough 70
- Engine assembly 70
- For engines not equipped with engine slingers attach proper slingers and bolts described in parts catalog 70
- For supporting points for lifting and jacking point at rear axle refer to gi 40 garage jack safety stand and 2 pole lift 70
- If items or work required are not covered by the engine main body section refer to the applicable sections 70
- Place chocks at front and back of rear wheels 70
- Removal and installation 70
- Situate vehicle on a flat and solid surface 70
- Use either 2 pole lift type or separate type lift as best you can if board on type is used for unavoidable reasons support at the rear axle jacking point with transmission jack or similar tool before starting work in preparation for the backward shift of center of gravity 70
- Warning 70
- Engine assembly 71
- Removal 71
- Engine assembly 72
- Engine assembly 73
- Inspection after installation 73
- Installation 73
- And installation 75
- Caution make sure signal plate 1 are not damaged or deformed note figure shows the drive plate c remove rear plate 75
- Cylinder block 75
- D lift engine using a hoist and mount it on an engine stand 1 75
- Disassembly 75
- For installation of engine slingers refer to em 70 removal 75
- Remove engine and transaxle assembly from the vehicle and separate transaxle from the vehicle refer to em 70 removal and installation 2 install engine to engine stand in the following procedure note we will use as an example the engine stand commercial service tool specified to support the cylinder block rear transaxle mounting surface a remove clutch cover and clutch disc refer to cl 11 clutch disc clutch cover and fly wheel b remove the flywheel 75
- Using a ring gear stopper special service tool secure the crankshaft loosen the bolts diagonally and remove 75
- Cylinder block 76
- Assembly 77
- Cylinder block 77
- Cylinder block 78
- Cylinder block 79
- Cylinder block 80
- Cylinder block 81
- Caution make sure signal plate 4 are not damaged or deformed 82
- Cylinder block 82
- Description 82
- For details of the measurement method of each part the reuse standards and the selection method of the selective fitting parts refer to the text 82
- For reused or repaired parts measure the dimension accurately determine the grade by comparing the measurement with the values of each selection table 82
- How to select piston and bearing 82
- Install by aligning the dowel pin hole 6 with the dowel pin 5 on the back of the crankshaft 82
- Install so that signal plate 4 is towards the back of the engine 82
- Install the flywheel 1 82
- Reinstall removed parts remained in reverse order of removal 82
- The identification grade stamped on each part is the grade for the dimension measured in new condition this grade cannot apply to reused parts 82
- Using a ring gear stopper special service tool secure the crankshaft and tighten the bolts diagonally 82
- Check cylinder bore grade 1 2 or 3 on cylinder block bottom rear surface and select piston of the same grade 83
- Cr14de 83
- Cylinder block 83
- How to select piston when new cylinder block is used 83
- Measure cylinder bore inner diameter 2 determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the piston selection table 3 select the piston of the same grade 83
- Note the piston head shape varies from engine to engine as do their positions shown in figure 83
- Piston selection table 83
- When cylinder block is reused 83
- Apply journal diameter grade 0 1 2 or 3 stamped on crank shaft front side to column in main bearing selection table 3 select main bearing std 1 to 7 at the point where selected row and column meet in the following selection table 84
- Cylinder block 84
- How to select main bearing when new cylinder block and crankshaft are used 84
- Main bearing selection table 84
- Main bearing selection table rows correspond to bearing housing grade 0 1 2 or 3 on cylinder block bottom rear sur face 84
- Measure inner diameter of cylinder block main bearing housing and outer diameter of crankshaft journal 2 find measured dimension in cylinder block bearing housing inner diameter row of main bearing selec tion table 3 find the measured dimension in crankshaft main journal diameter column in the following selection table 4 select main bearing std 1 to 7 at the point where selected row and column meet in the following selec tion table 84
- When cylinder block and crankshaft are reused 84
- Connecting rod side clearance 85
- Crankshaft side clearance 85
- Cylinder block 85
- Inspection after disassembly 85
- Piston and piston pin clearance inner diameter of piston pin 85
- Undersize bearing usage guide 85
- Cylinder block 86
- Outer diameter of piston pin 86
- Piston and piston pin clearance 86
- Piston ring end gap 86
- Piston ring side clearance 86
- Connecting rod bearing housing diameter big end 87
- Connecting rod bend and torsion 87
- Connecting rod bushing oil clearance diameter small end inner diameter of connecting rod bushing small end 87
- Cylinder block 87
- Connecting rod bushing oil clearance small end 88
- Cylinder block 88
- Cylinder block distortion 88
- Inner diameter of main bearing housing 88
- Outer diameter of piston pin 88
- Cylinder block 89
- Outer diameter of piston 89
- Piston to cylinder bore clearance 89
- Piston to cylinder bore clearance inner diameter of cylinder bore 89
- Cylinder block 90
- Out of round and teper of crankshaft 90
- Outer diameter of crankshaft journal 90
- Outer diameter of crankshaft pin 90
- Reboring cylinder bore 90
- Crankshaft runout 91
- Cylinder block 91
- Method of using plastigage 91
- Oil clearance of connecting rod bearing method of measurement 91
- Undersize bearing usage guide 91
- Crush height of main bearing or connecting rod bearing 92
- Cylinder block 92
- Method of using plastigage 92
- Oil clearance of main bearing method of measurement 92
- Cylinder block 93
- Flywheel limit 0 5 mm 0 059 in 93
- Flywheel runout 93
- The runout of the clutch contact surface of the flywheel should be measured using a dial gauge 1 total indicator reading 93
- General specifications 94
- Intake manifold and exhaust manifold 94
- Service data and specifications sds 94
- Standard and limit 94
- Cylinder head 95
- Drive belts 95
- Service data and specifications sds 95
- Spark plug 95
- Service data and specifications sds 96
- Valve clearance 96
- Valve guide 96
- Valve valve dimensions 96
- Available valve lifter 97
- Service data and specifications sds 97
- Valve lifter 97
- Valve seat 97
- Valve spring 97
- Service data and specifications sds 98
- Camshaft and camshaft bearing 99
- Cylinder block 99
- Service data and specifications sds 99
- Em 100 100
- Piston pin 100
- Piston piston ring and piston pin available piston 100
- Piston ring 100
- Service data and specifications sds 100
- Connecting rod 101
- Crankshaft 101
- Em 101 101
- Main bearing standard size 101
- Service data and specifications sds 101
- Bearing clearance 102
- Connecting rod bearing standard size 102
- Em 102 102
- Miscellaneous components 102
- Service data and specifications sds 102
- Undersize 102
- 1 parts to be tightened in particular orders 1 order of tightening when tightening two or more steps separately 103
- Em 103 103
- Service data and specifications sds 103
- Tightening torque 103
- Em 104 104
- Service data and specifications sds 104
- Em 105 105
- Parts requiring angle tightening 105
- Precautions 105
- Precautions for assembly and installation 105
- Precautions for disconnecting fuel piping 105
- Precautions for draining engine coolant 105
- Precautions for inspection repair and replacement 105
- Precautions for procedures without cowl top cover 105
- Precautions for removal and disassembly 105
- Em 106 106
- Liquid gasket application procedure 106
- Precautions 106
- Precautions for liquid gasket 106
- Removal of liquid gasket 106
- As for the bolt holes normally apply the liquid gasket inside the holes occasionally it should be applied outside the holes make sure to read the text of service manual 107
- Caution if there are specific instructions in this manual observe them 107
- Do not retighten mounting bolts or nut after the installation 107
- Em 107 107
- If the liquid gasket protrudes wipe it off immediately 107
- Precautions 107
- Wait 30 minutes or more after installation before refilling engine oil and engine coolant 107
- Within 5 minutes of liquid gasket application install the mating component 107
- Em 108 108
- Preparation 108
- Special service tools 108
- Em 109 109
- Preparation 109
- Commercial service tools 110
- Em 110 110
- Preparation 110
- Em 111 111
- Preparation 111
- Em 113 113
- Locate the area where noise occurs 2 confirm the type of noise 3 specify the operating condition of engine 4 check specified noise source if necessary repair or replace these parts 113
- Noise vibration and harshness nvh troubleshooting 113
- Use the chart below to help you find the cause of the symptom 113
- Belt deflection 114
- Caution 114
- Checking drive belts 114
- Do not allow oil or engine coolant to get on the belt 114
- Do not twist or bend the belt strongly 1 remove front fender protector rh refer to ei 14 fender protector 114
- Drive belts 114
- Em 114 114
- Inspection should be done only when engine is cold or over 30 minutes after the engine is stopped 114
- Measure the belt tension and frequency with acoustic tension gauge commercial service tool at the marked point 114
- Tension adjustment 114
- Turn crankshaft pulley two time clockwise and make sure tension on all pulleys is equal before doing the test 114
- Visually check belts for wear damage and cracks on inside and edges 114
- When belt is replaced with new one adjust belt tension to the value for new belt because new belt will not fully seat in the pulley groove 114
- When checking immediately after installation first adjust it to the specified value then after turn ing crankshaft two turns or more re adjust to the specified value to avoid variation in deflection between pulleys 114
- When installing a belt make sure it is correctly engaged with the pulley groove 114
- When measuring deflection apply 98 n 10 kg 22 lb at the marked point 114
- When tension of the belt being used exceeds limit adjust it to the value for after adjusted 114
- When the tension and frequency are measured the acoustic tension gauge should be used 114
- 34 n m 3 kg m 26 ft lb 115
- 4 n m 0 5 kg m 39 in lb 115
- Caution 115
- Drive belts 115
- Em 115 115
- Installation 115
- Loosen the idler pulley lock nut a from the tightening position with the specified torque by 45 degrees 115
- Pull the idler pulley in the loosening direction and then tempo rarily tighten the lock nut a to the following torque 115
- Put a matching mark on the lock nut a and check turning angle with a protractor do not visu ally check the tightening angle 3 adjust the belt tension by turning the adjusting bolt b refer to em 114 checking drive belts caution 115
- Removal 115
- Removal and installation 115
- Remove drive belt 115
- Remove front fender protector rh refer to ei 14 fender protector 2 loosen the lock nut a and then adjust the belt tension by turn ing the adjusting bolt b 115
- When checking immediately after installation first adjust it to the specified value then after turning crankshaft two turns or more re adjust to the specified value to avoid variation in deflection between pulleys 115
- When the lock nut is loosened excessively the idler pul ley tilts and the correct tension adjustment cannot be performed do not loosen it excessively more than 45 degrees 115
- When the tension adjustment is performed the lock nut should be in the condition at step 2 if the tension adjustment is performed when the lock nut is loosened more than the standard the idler pulley tilts and the correct tension adjustment cannot be performed 4 tighten the lock nut a 115
- Drive belts 116
- Em 116 116
- Removal 116
- Removal and installation of drive belt idler pulley 116
- Drive belts 117
- Em 117 117
- Installation 117
- Air cleaner and air duct 118
- Components 118
- Em 118 118
- Removal 118
- Removal and installation 118
- Air cleaner and air duct 119
- Changing air cleaner filter 119
- Em 119 119
- Inspection after removal 119
- Installation 119
- Removal 119
- Components 120
- Em 120 120
- Intake manifold 120
- Refer to gi 11 components for symbol marks in the figure 120
- Em 121 121
- Intake manifold 121
- Removal 121
- Removal and installation 121
- Em 122 122
- Installation 122
- Intake manifold 122
- Electric throttle control actuator 123
- Em 123 123
- Intake manifold 123
- Components 124
- Em 124 124
- Exhaust manifold 124
- Refer to gi 11 components for symbol marks in the figure 124
- Em 125 125
- Exhaust manifold 125
- Removal 125
- Removal and installation 125
- Em 126 126
- Exhaust manifold 126
- Inspection after removal mounting surface distortion 126
- Installation 126
- Components 127
- Em 127 127
- Note the oil strainer and oil pump are included in the oil pan upper individual disassembly is prohibited 127
- Note when removing oil pan lower only steps 2 and 3 are not necessary perform step 5 after completing step 4 1 remove engine undercover 2 remove engine and transaxle assembly from the vehicle and then separate engine and transaxle refer to em 184 engine assembly 3 install engine assembly to widely use engine stand refer to em 189 cylinder block 4 drain engine oil refer to lu 16 engine oil 5 remove the oil pan lower with the following procedure 127
- Oil pan and oil strainer 127
- Refer to gi 11 components for symbol marks in the figure 127
- Removal 127
- Removal and installation 127
- Em 128 128
- Installation 128
- Oil pan and oil strainer 128
- Em 129 129
- Oil pan and oil strainer 129
- Em 130 130
- Oil pan and oil strainer 130
- Em 131 131
- Inspection after installation 131
- Oil pan and oil strainer 131
- Components 132
- Em 132 132
- Ignition coil 132
- Installation 132
- Removal 132
- Removal and installation 132
- Components 133
- Em 133 133
- Inspection after removal 133
- Removal 133
- Removal and installation 133
- Spark plug platinum tipped type 133
- Em 134 134
- Installation 134
- Spark plug platinum tipped type 134
- Components 135
- Em 135 135
- Fuel injector and fuel tube 135
- Removal 135
- Removal and installation 135
- Em 136 136
- Fuel injector and fuel tube 136
- Em 137 137
- Fuel injector and fuel tube 137
- Installation 137
- Em 138 138
- Fuel injector and fuel tube 138
- Em 139 139
- Fuel injector and fuel tube 139
- Inspection after installation check on fuel leaks 139
- Components 140
- Em 140 140
- Removal 140
- Removal and installation 140
- Rocker cover 140
- Em 141 141
- Installation 141
- Rocker cover 141
- Components 142
- Em 142 142
- Refer to gi 11 components for symbol marks in the figure 142
- Timing chain 142
- Em 143 143
- Removal 143
- Removal and installation 143
- Timing chain 143
- Em 144 144
- Timing chain 144
- Em 145 145
- Timing chain 145
- B hold the top of the oil pump shaft using the torx socket size e8 and then loosen the oil pump sprocket nuts and remove them c remove the crankshaft sprocket 1 the oil pump drive chain 2 and the oil pump sprocket 3 at the same time 146
- Check timing chain for cracks a and any excessive wear b at the roller links of timing chain replace timing chain if necessary 146
- Em 146 146
- Inspection after removal timing chain 146
- Install the crankshaft sprocket and the oil pump drive related parts with the following procedure 146
- Installation 146
- Note the figure shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket with the components installed 146
- Timing chain 146
- Em 147 147
- Timing chain 147
- Em 148 148
- Timing chain 148
- Em 149 149
- Timing chain 149
- Em 150 150
- Inspection after installation inspection for leaks 150
- Timing chain 150
- Camshaft 151
- Caution the rotation direction indicated in the text indicates all directions seen from the engine front direction 151
- Components 151
- Em 151 151
- Note this section describes the procedure for removal and installation of camshaft with front cover if the front cover is removed first change the following procedure 151
- Refer to gi 11 components for symbol marks in the figure 151
- Removal 151
- Removal and installation 151
- Step 8 after camshaft sprocket is removed remove the camshaft brackets no 2 to 5 step 9 the camshaft exh can be removed simultaneously with the camshaft int step 10 when the camshaft sprocket int mounting bolt is removed the lifting up of cam shaft is not necessary 151
- Support the bottom surface of engine using a transmission jack and then remove the engine mounting bracket and insulator rh refer to em 184 engine assembly 151
- Camshaft 152
- Em 152 152
- Camshaft 153
- Em 153 153
- Camshaft 154
- Em 154 154
- Camshaft 155
- Em 155 155
- Camshaft 156
- Em 156 156
- Camshaft 157
- Em 157 157
- Inspection after removal oil filter 157
- Camshaft 158
- Camshaft cam height 158
- Camshaft journal oil clearance 158
- Camshaft runout 158
- Em 158 158
- Camshaft 159
- Camshaft end play 159
- Camshaft sprocket runout 159
- Em 159 159
- Camshaft 160
- Em 160 160
- Valve lifter 160
- Valve lifter clearance 160
- Camshaft 161
- Em 161 161
- Installation 161
- Camshaft 162
- Em 162 162
- Camshaft 163
- Em 163 163
- Camshaft 164
- Em 164 164
- Camshaft 165
- Em 165 165
- Inspection after installation inspection for leaks 165
- Camshaft 166
- Em 166 166
- Inspection 166
- Inspection of camshaft sprocket int oil groove 166
- Valve clearance 166
- At the same time make sure that both intake and exhaust cam noses of no 1 cylinder face outside as shown in the fig ure 167
- B use a feeler gauge measure the clearance between valve lifter and camshaft 167
- By referring to the figure measure the valve clearances at locations marked as shown in the table below locations indicated with black arrow in the figure with a feeler gauge 167
- Camshaft 167
- Em 167 167
- If they do not face outside rotate crankshaft pulley once more 360 degrees and align as shown in the figure 167
- Remove rocker cover refer to em 140 rocker cover 2 measure the valve clearance with the following procedure a set no 1 cylinder at tdc of its compression stroke 167
- Rotate crankshaft pulley 2 clockwise and align tdc mark without paint mark a to timing indicator 1 on front cover 167
- Valve clearance 167
- Adjustment 168
- Camshaft 168
- Em 168 168
- Camshaft 169
- Em 169 169
- Em 170 170
- Installation 170
- Oil seal 170
- Removal 170
- Removal and installation of valve oil seal 170
- Em 171 171
- Installation 171
- Oil seal 171
- Removal 171
- Removal and installation of front oil seal 171
- Em 172 172
- Installation 172
- Oil seal 172
- Removal 172
- Removal and installation of rear oil seal 172
- Checking compression pressure 173
- Cylinder head 173
- Em 173 173
- On vehicle service 173
- Components 174
- Cylinder head 174
- Em 174 174
- Removal 174
- Removal and installation 174
- Cylinder head 175
- Cylinder head distortion 175
- Em 175 175
- Inspection after removal cylinder head bolts outer diameter 175
- Cylinder head 176
- Em 176 176
- Inspection after installation inspection for leaks 176
- Installation 176
- After cooling down engine again check oil fluid levels including engine oil and engine coolant refill to the specified level if necessary 177
- Bleed air from lines and hoses of applicable lines such as in cooling system 177
- Components 177
- Cylinder head 177
- Em 177 177
- Refer to gi 11 components for symbol marks in the figure 177
- Summary of the inspection items 177
- Assembly 178
- Cylinder head 178
- Disassembly 178
- Disassembly and assembly 178
- Em 178 178
- Cylinder head 179
- Em 179 179
- Inspection after disassembly 179
- Valve dimensions 179
- Valve guide clearance 179
- Valve guide clearance valve stem diameter 179
- Valve guide inner diameter 179
- Cylinder head 180
- Em 180 180
- Valve guide replacement 180
- Cylinder head 181
- Em 181 181
- Valve seat contact 181
- Valve seat replacement 181
- Cylinder head 182
- Em 182 182
- Valve spring dimensions and valve spring pressure load 182
- Valve spring squareness 182
- Cylinder head 183
- Em 183 183
- If the installation load or load with valve open is out of the standard replace valve spring 183
- Standard 183
- Always be careful to work safely avoid forceful or uninstructed operations 184
- Attach proper slingers and bolts described in parts catalog if engine slingers are not equipped 184
- Caution 184
- Components 184
- Do not start working until exhaust system and coolant are cool enough 184
- Em 184 184
- Engine assembly 184
- Place chocks at front and back of rear wheels 184
- Refer to gi 11 components for symbol marks in the figure 184
- Removal and installation 184
- Situate the vehicle on a flat and solid surface 184
- Warning 184
- Em 185 185
- Engine assembly 185
- Engine room lh 185
- Engine room rh 185
- Preparation 185
- Removal outline 185
- Em 186 186
- Engine assembly 186
- Removal 186
- Vehicle underbody 186
- Em 187 187
- Engine assembly 187
- Installation 187
- Separation 187
- After cooling down engine again check oil fluid levels including engine oil and engine coolant refill to the specified level if necessary 188
- Before starting engine check oil fluid levels including engine coolant and engine oil if less than required quantity fill to the specified level refer to ma 24 recommended fluids and lubricants 188
- Bleed air from lines and hoses of applicable lines such as in cooling system 188
- Em 188 188
- Engine assembly 188
- Inspection after installation inspection for leaks 188
- Run engine to check for unusual noise and vibration 188
- Start engine with engine speed increased check again for fuel leakage at connection points 188
- Summary of the inspection items 188
- The following are procedures for checking fluids leak lubricates leak and exhaust gases leak 188
- Tighten engine mounting insulator rh bolts in the numerical order shown in the figure 188
- Turn ignition switch on with engine stopped with fuel pressure applied to fuel piping check for fuel leakage at connection points 188
- Use procedure below to check for fuel leakage 188
- Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gases or any oil fluids including engine oil and engine coolant 188
- Components 189
- Cylinder block 189
- Em 189 189
- Cylinder block 190
- Disassembly 190
- Disassembly and assembly 190
- Em 190 190
- Exhaust manifold refer to em 124 exhaust manifold 190
- If the load capacity of stand is not adequate remove the following parts beforehand to reduce the potential risk of overturning stand 190
- Intake manifolds refer to em 120 intake manifold 190
- Lift the engine with a hoist to install it onto widely use engine stand caution 190
- Note explained here is how to disassemble with an engine stand supporting mating surface of transaxle when using different type of engine stand note with difference in steps and etc 1 remove the engine and the transaxle assembly from the vehicle and separate the transaxle from the engine refer to em 184 engine assembly 2 remove clutch cover and clutch disc refer to cl 11 clutch disc clutch cover and fly wheel 3 remove flywheel m t models or drive plate a t models 190
- Refer to gi 11 for symbol marks in the figure 190
- Rocker cover refer to em 140 rocker cover 190
- Secure flywheel or drive plate with a stopper plate sst kv11105210 a and remove mounting bolts 190
- Use the engine stand that has a load capacity approximately 150 kg 331 lb or more large enough for supporting the engine weight 190
- Using torx socket size e20 loosen mounting bolts caution be careful not to damage or scratch drive plate a t mod els and contact surface for clutch disc of flywheel 190
- Cylinder block 191
- Em 191 191
- Cylinder block 192
- Em 192 192
- Assembly 193
- Cylinder block 193
- Em 193 193
- B after positioning crankshaft and signal plate with positioning dowel pin tighten bolt note dowel pin of crankshaft and signal plate is provided as a set for each c remove dowel pin 194
- B install thrust bearings to the both sides of the no 3 journal hous ing b on cylinder block 194
- Before installing main bearings apply new engine oil to the bearing surface inside do not apply engine oil to the back surface but thoroughly clean it 194
- C install the main bearings 1 paying attention to the direction 194
- Caution dimension l1 of journal no 3 is the distance from the housing base end surface bulk it is not the distance from the thrust bearing mounting end surface 4 install signal plate to crankshaft if removed a set the signal plate 1 with the flange facing toward the counter weight side engine front side to the crankshaft rear surface 194
- Cylinder block 194
- Em 194 194
- Ensure the oil holes on cylinder block and those on the corre sponding bearing are aligned 194
- Install the main bearing in the position shown in the figure 194
- Install the one with oil holes a onto cylinder block and the one without oil holes onto main bearing cap 194
- Install thrust bearings with the oil groove a facing crankshaft arm outside 194
- Note install the main bearing in the center position with the follow ing dimension for service operation the center position can be checked visually 194
- Cylinder block 195
- Em 195 195
- Cylinder block 196
- Em 196 196
- Cylinder block 197
- Em 197 197
- Cylinder block 198
- Em 198 198
- Apply connecting rod big end diameter grade stamped c on connecting rod side face to the row in the connecting rod bearing selection table 199
- Assemble in the reverse order of disassembly after this step 199
- Cylinder block 199
- Description 199
- Em 199 199
- For details of the measurement method of each part the reuse standards and the selection method of the selective fitting parts refer to the text 199
- For reused or repaired parts measure the dimension accurately determine the grade by comparing the measurement with the values of each selection table 199
- How to select connecting rod bearing when new connecting rod and crankshaft are used 199
- How to select piston and bearing 199
- The identification grade stamped on each part is the grade for the dimension measured in new condition this grade cannot apply to reused parts 199
- Tighten bolts with it seated completely 20 for the oil level gauge guide 1 fix the position b shown in the figure to the water inlet clip a after inserting to the cylinder block side 199
- Cylinder block 200
- Em 200 200
- When crankshaft and connecting rod are reused 200
- Connecting rod bearing selection table 201
- Cylinder block 201
- Em 201 201
- Bearing undersize table 202
- Caution in grinding crankshaft pin to use undersize bearings keep the fillet r a 0 1 mm 0 31 0 47 in 202
- Connecting rod bearing grade table 202
- Cylinder block 202
- Em 202 202
- How to select main bearing when new cylinder block and crankshaft are used 202
- If there is a corrected stamp mark b on cylinder block use it as a correct reference 202
- Main bearing selection table rows correspond to main bearing housing grade on left side of cylinder block 202
- Undersize bearings usage guide 202
- When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings use undersize us bearings 202
- When using undersize us bearing measure the connecting rod bearing inner diameter with bearing installed and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the stan dard 202
- Cylinder block 203
- Em 203 203
- When cylinder block and crankshaft are reused 203
- Bearing undersize table 205
- Caution in grinding crankshaft main journal to use undersize bearings keep fillet r a 0 1 mm 0 31 0 47 in 205
- Cylinder block 205
- Em 205 205
- Main bearing grade table 205
- Use undersize bearing usage guide 205
- When the specified main bearing oil clearance is not obtained with standard size main bearings use undersize us bearing 205
- When using undersize us bearing measure the main bearing inner diameter with bearing installed and grind main journal so that the main bearing oil clearance satisfies the standard 205
- Connecting rod side clearance 206
- Crankshaft end play 206
- Cylinder block 206
- Em 206 206
- Inspection after disassembly 206
- Piston pin outer diameter 206
- Piston to piston pin oil clearance 206
- Piston to piston pin oil clearance piston pin hole diameter 206
- Cylinder block 207
- Em 207 207
- Piston ring end gap 207
- Piston ring side clearance 207
- Connecting rod bend and torsion 208
- Connecting rod big end diameter 208
- Connecting rod bushing oil clearance connecting rod bushing inner diameter 208
- Cylinder block 208
- Em 208 208
- Connecting rod bushing oil clearance 209
- Cylinder block 209
- Cylinder block distortion 209
- Em 209 209
- Main bearing housing inner diameter 209
- Piston pin outer diameter 209
- Cylinder block 210
- Em 210 210
- Piston skirt diameter 210
- Piston to cylinder bore clearance 210
- Piston to cylinder bore clearance cylinder bore inner diameter 210
- Connecting rod bearing oil clearance method by calculation 211
- Crankshaft main journal diameter 211
- Crankshaft pin journal diameter 211
- Crankshaft runout 211
- Cylinder block 211
- Em 211 211
- Out of round and taper of crankshaft 211
- Cylinder block 212
- Em 212 212
- Main bearing oil clearance method by calculation 212
- Method of using plastigage 212
- Connecting rod bearing crush height 213
- Cylinder block 213
- Em 213 213
- Main bearing cap bolt outer diameter 213
- Main bearing crush height 213
- Connecting rod bolt outer diameter 214
- Cylinder block 214
- Em 214 214
- Flywheel deflection 214
- Belt deflection 215
- Cylinder head 215
- Drive belt 215
- Em 215 215
- Exhaust manifold 215
- General specifications 215
- Service data and specifications sds 215
- Spark plug platinum tipped type 215
- Standard and limit 215
- Em 216 216
- Service data and specifications sds 216
- Valve clearance 216
- Valve dimensions 216
- Valve valve timing 216
- Available valve lifter 217
- Em 217 217
- Service data and specifications sds 217
- Em 218 218
- Service data and specifications sds 218
- Standard 218
- Valve guide 218
- Valve lifter 218
- Valve spring 218
- Em 219 219
- Service data and specifications sds 219
- Valve seat 219
- Camshaft and camshaft bearing 220
- Cylinder block 220
- Em 220 220
- Service data and specifications sds 220
- Em 221 221
- Piston pin 221
- Piston piston ring and piston pin available piston 221
- Piston ring 221
- Service data and specifications sds 221
- Connecting rod 222
- Crankshaft 222
- Em 222 222
- Service data and specifications sds 222
- Em 223 223
- Service data and specifications sds 223
- Bearing oil clearance 224
- Em 224 224
- Main bearing 224
- Service data and specifications sds 224
- Undersize 224
- Bearing oil clearance 225
- Connecting rod bearing 225
- Em 225 225
- Service data and specifications sds 225
- Undersize 225
- Application notice 226
- Confirm k9k engine type with model written on identification plate refer to gi 45 identification infor mation then refer to service information in em section 226
- Em 226 226
- How to check vehicle type 226
- Em 227 227
- Parts requiring angular tightening 227
- Precautions 227
- Precautions for assembly and installation 227
- Precautions for disconnecting fuel piping 227
- Precautions for drain coolant 227
- Precautions for inspection repair and replacement 227
- Precautions for removal and disassembly 227
- Em 228 228
- Liquid gasket application procedure 228
- Precautions 228
- Precautions for liquid gasket 228
- Removal of liquid gasket 228
- Cleanliness 229
- Em 229 229
- Precautions 229
- Precautions for diesel equipment 229
- Em 230 230
- Precautions 230
- Em 231 231
- Precautions 231
- Special features 231
- Em 232 232
- Precautions 232
- Em 233 233
- Preparation 233
- Special service tools 233
- Em 234 234
- Preparation 234
- Em 235 235
- Preparation 235
- Commercial service tools 236
- Em 236 236
- Preparation 236
- Em 237 237
- Preparation 237
- A engine type 238
- B engine type approval letter 238
- D code 238
- E engine suffix 238
- Em 238 238
- Engine identification 238
- F engine serial number 238
- G engine assembly plant 238
- Identification information 238
- Identification is by means of an engraved plate on the cylinder block which carries 238
- Em 239 239
- Noise vibration and harshness nvh troubleshooting 239
- Nvh troubleshooting engine noise 239
- Em 240 240
- Locate the area where noise occurs 2 confirm the type of noise 3 specify the operating condition of engine 4 check specified noise source if necessary repair or replace these parts 240
- Noise vibration and harshness nvh troubleshooting 240
- Use the chart below to help you find the cause of the symptom 240
- Caution do not damage or scratch cover when installing or removing 241
- Em 241 241
- Engine room cover 241
- Install in the reverse order of removal note press engine room cover until hearing the click 241
- Installation 241
- Removal 241
- Removal and installation 241
- Remove engine room cover from engine room cover bracket 241
- Checking drive belts 242
- Drive belts 242
- Em 242 242
- Models with a c compressor 242
- Models without a c compressor 242
- Tension adjustment 242
- Drive belts 243
- Em 243 243
- Installation 243
- Removal 243
- Removal and installation 243
- Drive belts 244
- Em 244 244
- Air cleaner and air duct 245
- Em 245 245
- Installation 245
- Removal 245
- Removal and installation 245
- Air cleaner and air duct 246
- Changing air cleaner filter 246
- Em 246 246
- Installation 246
- Removal 246
- Charge air cooler 247
- Em 247 247
- Removal 247
- Removal and installation for 50kw 247
- Remove air inlet hose and tube between inlet pipe assembly and charge air cooler 2 remove engine undercover 3 remove bumper undercover refer to ei 4 front bumper 247
- Charge air cooler 248
- Em 248 248
- Inspection after removal 248
- Installation 248
- Charge air cooler 249
- Em 249 249
- Removal 249
- Removal and installation for 65kw 249
- Remove air inlet hose and tube between inlet pipe assembly and charge air cooler 2 remove engine undercover 3 remove bumper undercover refer to ei 4 front bumper 249
- Charge air cooler 250
- Em 250 250
- Inspection after removal 250
- Installation 250
- Egr unit 251
- Em 251 251
- Removal 251
- Removal and installation 251
- Egr unit 252
- Em 252 252
- Installation 252
- Em 253 253
- Exhaust manifold turbocharger catalyst 253
- Removal 253
- Removal and installation 253
- Em 254 254
- Exhaust manifold turbocharger catalyst 254
- Inspection after installation 254
- Installation 254
- After applying penetrative lubricant to the mounting nuts check for the penetration of the lubricant and then loosen the nuts to remove caution do not disassemble or adjust the turbocharger body 255
- Caution when the compressor wheel turbine wheel or rotor shaft is damaged remove all the fragments and foreign matter left in the following passages in order to prevent a secondary failure 255
- Disassembly 255
- Disassembly and assembly 255
- Em 255 255
- Exhaust manifold turbocharger catalyst 255
- Inspection after disassembly turbocharger 255
- Suction side between turbocharger and air cleaner exhaust side between turbocharger and catalyst 255
- Assembly 256
- Em 256 256
- Exhaust manifold turbocharger catalyst 256
- Caution to avoid the danger of being scalded never drain the engine oil when the engine is hot 257
- Em 257 257
- Oil pan 257
- Removal 257
- Removal and installation 257
- Remove engine undercover 2 remove rh front wheel 3 remove right side splash cover 4 remove center bearing bracket as shown 257
- Em 258 258
- Oil pan 258
- Em 259 259
- Inspection after installation 259
- Inspection after removal 259
- Installation 259
- Oil pan 259
- Em 260 260
- Glow plug 260
- Installation 260
- Removal 260
- Removal and installation 260
- Em 261 261
- Inspection before removal 261
- Installation 261
- Removal 261
- Removal and installation 261
- Vacuum pump 261
- Em 262 262
- High pressure pipes 262
- Removal 262
- Removal and installation 262
- Em 263 263
- High pressure pipes 263
- Installation 263
- Em 264 264
- High pressure pipes 264
- Em 265 265
- High pressure pipes 265
- Em 266 266
- Fuel injector 266
- Installation 266
- Removal 266
- Removal and installation 266
- Em 267 267
- Injector rail 267
- Installation 267
- Removal 267
- Removal and installation 267
- Em 268 268
- High pressure pump 268
- Removal 268
- Removal and installation 268
- Em 269 269
- High pressure pump 269
- Installation 269
- Em 270 270
- Removal 270
- Removal and installation 270
- Rocker cover 270
- 10 n m 1 2 kg m 7 ft lb 271
- Apply liquid gasket on locations shown in the figure 271
- Em 271 271
- Install in the reverse order of removal after this steps 271
- Installation 271
- Rocker cover 271
- Tighten holding bolts in the numerical order as shown in the fig ure 271
- Use genuine liquid gasket or equivalent 271
- Em 272 272
- Removal 272
- Removal and installation 272
- Timing belt 272
- Em 273 273
- Remove rh engine mounting support bracket rh engine mounting insulator and reservoir tank 10 remove upper timing cover camshaft position sensor and cylin der head suspended mounting bracket 273
- Remove rh engine torque rod 8 remove rh engine mounting 273
- Remove timing belt lower cover 12 remove the tdc pin bolt 273
- Set the engine support bar commercial service tool or suitable tool and secure the engine in position 273
- Timing belt 273
- Em 274 274
- Timing belt 274
- Em 275 275
- Install in the reverse order of removal paying attention to the following 275
- Installation 275
- Refer to em 316 timing adjustment 275
- Slacken the timing belt by loosening the bolt of tensioner then remove timing belt 275
- Timing belt 275
- Cylinder head 276
- Em 276 276
- Removal 276
- Removal and installation 276
- Cylinder head 277
- Cylinder head bolts 277
- Disassembly 277
- Disassembly and assembly 277
- Em 277 277
- Inspection after disassembly 277
- Installation 277
- Assembly 278
- Cylinder head 278
- Em 278 278
- Always be careful to work safely avoid forceful or uninstructed operations 279
- Always use the support point specified for lifting 279
- Caution 279
- Do not start working until exhaust system and coolant are cool enough 279
- Em 279 279
- Engine assembly 279
- For engines not equipped with engine slingers attach proper slingers and bolts described in parts catalog 279
- For supporting points for lifting and jacking point at rear axle refer to gi 40 lifting point 279
- If items or work required are not covered by the engine main body section refer to the applicable sections 279
- Place chocks at front and back of rear wheels 279
- Removal and installation 279
- Situate vehicle on a flat and solid surface 279
- Use either 2 pole lift type or separate type lift as best you can if board on type is used for unavoidable reasons support at the rear axle jacking point with transmission jack or similar tool before starting work in preparation for the backward shift of center of gravity 279
- Warning 279
- Em 280 280
- Engine assembly 280
- Removal 280
- Em 281 281
- Engine assembly 281
- Inspection after installation 281
- Installation 281
- Bottom engine 282
- Em 282 282
- Overhaul 282
- Tightening torques 282
- Upper engine 282
- Em 283 283
- Overhaul 283
- Preparing used engine 283
- Standard replacement 283
- Disassembly 284
- Em 284 284
- Overhaul 284
- Removing the upper engine 284
- Em 285 285
- Overhaul 285
- Position the hole a of the camshaft pulley almost opposite the hole b of the cylinder head 285
- Positioning the belt at the timing point 285
- Remove the cylinder head suspended mounting bracket 285
- Remove the tdc pin cap 285
- Screw in the tool kv113b0130 mot 1489 285
- Em 286 286
- Overhaul 286
- Em 287 287
- Overhaul 287
- Remove air cleaner case refer to em 245 air cleaner and air duct 11 remove the clamp oil vapor rebreathing pipe and turbocharger oil supply pipe on the cylinder head side 287
- Remove the timing belt tensioner and inner timing cover 287
- Slacken the timing belt by loosening the bolt of the tensioner then remove the timing belt 287
- Disassembly of the cylinder head 288
- Em 288 288
- Overhaul 288
- Em 289 289
- Overhaul 289
- Em 290 290
- Overhaul 290
- Camshaft end play 291
- Cleaning 291
- Em 291 291
- Gasket face 291
- Inspection 291
- Overhaul 291
- Checking and adjusting the valve clearance 292
- Em 292 292
- Overhaul 292
- Valve clearance 292
- Assembly 293
- Assembly of the cylinder head 293
- Em 293 293
- New valve stem seals 293
- Overhaul 293
- Em 294 294
- Overhaul 294
- Camshaft seal 295
- Em 295 295
- Overhaul 295
- Em 296 296
- Overhaul 296
- Disassembly of the bottom engine 297
- Em 297 297
- Overhaul 297
- Removal 297
- Em 298 298
- Overhaul 298
- Em 299 299
- Overhaul 299
- Em 300 300
- Overhaul 300
- Replacement of the oil jets 300
- Assembly 301
- Em 301 301
- Installation of oil jets 301
- Installation of the oil jets for no 1 and no 3 cylinders 301
- Overhaul 301
- Em 302 302
- Installation of the oil jets for no 1 and no 4 cylinders 302
- Method for installing the oil cooler and oil filter 302
- Orientation of the oil jets see diagram below 302
- Overhaul 302
- Removing the piston pins 302
- Connecting rod bearing 303
- Em 303 303
- On the connecting rod body 303
- Overhaul 303
- Em 304 304
- On the connecting rod cap 304
- Overhaul 304
- Em 305 305
- Overhaul 305
- Em 306 306
- Installation of main bearing 306
- On the cylinder block 306
- Overhaul 306
- Em 307 307
- On the bearing caps 307
- Overhaul 307
- Connecting rods piston assembly 308
- Direction for installation the snap rings on the piston 308
- Direction of installation of the connecting rod in relation to the piston 308
- Em 308 308
- Installation of no 1 bearing 308
- Installation of the snap rings 308
- Overhaul 308
- Checking piston protrusion 309
- Em 309 309
- Orientation of the piston rings in the piston 309
- Overhaul 309
- Em 310 310
- Installation of rear oil seal retainer and oil pump 310
- Overhaul 310
- Em 311 311
- Installation of the crankshaft seal gaskets 311
- Overhaul 311
- Em 312 312
- Overhaul 312
- Crankshaft elastomer seal flywheel side 9 install tool kv113b0210 mot 1585 on the crankshaft securing it with bolts f 313
- Em 313 313
- Install the cover g and nut h putting the threaded part i of the nut on the side away from the engine of tool kv113b0210 mot 1585 313
- Overhaul 313
- Put the protector complete with the seal on tool kv113b0210 mot 1585 being careful not to touch the seal 313
- Remove the nut the cover the protector and the threaded rod 313
- Tighten the nut until the cover touches the cylinder block 313
- Em 314 314
- Overhaul 314
- Em 315 315
- Installation of the cylinder head 315
- Overhaul 315
- Em 316 316
- Overhaul 316
- Timing adjustment 316
- Em 317 317
- Overhaul 317
- Em 318 318
- Overhaul 318
- Em 319 319
- Install the alternator bracket tighten the bolts to a torque of 44 n m 4 kg m 32 ft lb 319
- Install the upper timing cover 18 remove the engine from the tool kv113b0070 mot 792 03 319
- Install the water pipe tighten the bolt to a torque of 22 n m 2 kg m 16 ft lb 20 install the two water hoses 319
- Overhaul 319
- Em 320 320
- Models with a c compressor 320
- Models without a c compressor 320
- Overhaul 320
- Basic inspection 321
- Cylinder head 321
- Cylinder head tightening procedure 321
- Em 321 321
- Inspection of the piston protrusion 321
- Thickness of the cylinder head gasket 321
- Basic inspection 322
- Em 322 322
- Valve guide 322
- Valve seat 322
- Valve valve dimensions 322
- Basic inspection 323
- Em 323 323
- Basic inspection 324
- Em 324 324
- Inspection of valve clearance 324
- Piston 324
- Valve spring 324
- Basic inspection 325
- Camshaft 325
- Em 325 325
- Basic inspection 326
- Em 326 326
- If the engine is installed with a k class piston an l class piston must be installed as a replace ment 326
- If the engine is installed with a p class piston an n class piston must be installed as a replace ment 326
- Install the piston pin in the connecting rod and in the piston 326
- Measuring the piston diameter 326
- Piston 326
- Piston diameter 75 33 75 47 mm 2 895 2 900 in piston pin length 59 60 mm 2 50 2 74 in outer diameter 24 25 mm 0 76 0 92 in inner diameter 13 5 13 5 mm 0 335 0 492 in 326
- Piston marking 326
- Table of piston pin height 326
- The piston diameter must be measured at height a 56 mm 2 0 in 326
- The piston pin is retained by circlips 326
- The tolerance on the piston pin heights is 0 2 mm 0 008 the different piston pin heights are exclusively reserved for the engine assembly plant the service parts will only supply piston classes height l m n note 326
- Basic inspection 327
- Connecting rod 327
- Em 327 327
- Piston ring 327
- Piston ring end gap 327
- Basic inspection 328
- Crankshaft 328
- Direction for installation the snap rings on the piston 328
- Direction of installation of the connecting rod in relation to the piston 328
- Em 328 328
- Basic inspection 329
- Cylinder block 329
- Detail of the marking a number of journals 329
- Em 329 329
- Note the marking zone includes 329
- Table of cylinder block main bearing housing inner diameters 329
- Table of journal diameter classes 329
- The diameters of the bearings a of the cylinder block are marked by a hole on the block b located above the oil filter 329
- Working out the class of main bearing original fitment marking a on the crankshaft 329
- Basic inspection 330
- Em 330 330
- For direction of installation on the bearing caps install non grooved main bearing 330
- For direction of installation on the cylinder block install grooved main bearing on all the bearings 330
- Main bearing 330
- Main bearing and cap 330
- Matching the main bearing 330
- Note the service parts will only supply class c2 blue 330
- The engine is installed with main bearing without a locator notch 1 the main bearings are installed on the cylinder block and on the bearings using tool kv113b0160 mot 1493 01 330
- X y gives the diameter class of bearings a or b 330
- Basic inspection 331
- Connecting rod bearing 331
- Em 331 331
- Preparing the engine to be on the stand 331
- Basic inspection 332
- Em 332 332
- Parts to be replaced after removal 332
- Basic inspection 333
- Em 333 333
- Installation of thread inserts 333
- Oil jets 333
- Pipe plugs 333
- Threaded holes on all engine component parts can be repaired by using thread inserts 333
- Timing belt tension wheel 333
- Turbocharger plastic pipes 333
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