Manual PDF
Manual PDF
Manual PDF
SECTION
EM
CONTENTS
PRECAUTIONS ...............................................................5
Parts Requiring Angular Tightening.............................5
Liquid Gasket Application Procedure ..........................5
PREPARATION................................................................6
Special Service Tools ..................................................6
Commercial Service Tools .........................................10
QG
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ...................................................11
NVH Troubleshooting - Engine Noise .......................11
OUTER COMPONENT PARTS .....................................13
Removal and Installation ...........................................13
MEASUREMENT OF COMPRESSION PRESSURE ....16
OIL PAN .........................................................................17
Components...............................................................17
Removal.....................................................................17
Installation..................................................................18
TIMING CHAIN ..............................................................19
Components...............................................................19
Removal.....................................................................20
Inspection...................................................................24
Installation..................................................................24
OIL SEAL.......................................................................29
Replacement..............................................................29
VALVE OIL SEAL .....................................................29
FRONT OIL SEAL ....................................................29
REAR OIL SEAL ......................................................30
CYLINDER HEAD..........................................................31
Components...............................................................31
Removal.....................................................................32
Disassembly...............................................................34
Inspection...................................................................34
CYLINDER HEAD DISTORTION ...............................34
CAMSHAFT VISUAL CHECK ....................................34
CAMSHAFT RUNOUT ..............................................35
Valve Clearance.........................................................40
CHECKING .............................................................40
ADJUSTING ............................................................41
Assembly ...................................................................43
Installation..................................................................43
ENGINE REMOVAL.......................................................48
Removal and Installation ...........................................48
REMOVAL ...............................................................49
INSTALLATION ........................................................51
CYLINDER BLOCK .......................................................52
Components...............................................................52
Removal and Installation ...........................................53
Disassembly...............................................................53
PISTON AND CRANKSHAFT ....................................53
Inspection...................................................................54
PISTON AND PISTON PIN CLEARANCE...................54
PISTON RING SIDE CLEARANCE ............................54
PISTON RING END GAP ..........................................54
CONNECTING ROD BEND AND TORSION ...............55
CYLINDER BLOCK DISTORTION AND WEAR ...........55
PISTON-TO-BORE CLEARANCE ..............................56
CRANKSHAFT.........................................................57
BEARING CLEARANCE ...........................................57
CONNECTING ROD BUSHING CLEARANCE
(Small end) ..............................................................59
REPLACEMENT OF CONNECTING ROD
BUSHING (Small end) ..............................................60
FLYWHEEL/DRIVE PLATE RUNOUT .........................60
EM
CONTENTS
Assembly ...................................................................60
PISTON ..................................................................60
CRANKSHAFT.........................................................61
Inspection.................................................................110
PISTON AND PISTON PIN CLEARANCE.................110
PISTON RING SIDE CLEARANCE .......................... 111
PISTON RING END GAP ........................................ 111
CONNECTING ROD BEND AND TORSION ............. 111
CYLINDER BLOCK DISTORTION AND WEAR .........112
PISTON-TO-BORE CLEARANCE ............................112
CRANKSHAFT.......................................................113
BEARING CLEARANCE .........................................114
SR20DE
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING
........................................64
NVH Troubleshooting - Engine Noise .......................65
OUTER COMPONENT PARTS .....................................66
COMPRESSION PRESSURE........................................69
Measurement of Compression Pressure...................69
OIL PAN .........................................................................70
Removal.....................................................................70
Installation..................................................................73
TIMING CHAIN ..............................................................75
Components...............................................................75
Removal.....................................................................76
Inspection...................................................................79
Installation..................................................................79
OIL SEAL REPLACEMENT ..........................................84
VALVE OIL SEAL .....................................................84
FRONT OIL SEAL ....................................................84
REAR OIL SEAL ......................................................85
CYLINDER HEAD..........................................................86
Components...............................................................86
Removal.....................................................................87
Disassembly...............................................................89
Inspection...................................................................91
CYLINDER HEAD DISTORTION ...............................91
CAMSHAFT VISUAL CHECK ....................................91
CAMSHAFT RUNOUT ..............................................92
CAMSHAFT CAM HEIGHT .......................................92
CAMSHAFT JOURNAL CLEARANCE ........................92
CAMSHAFT END PLAY ............................................93
CAMSHAFT SPROCKET RUNOUT ...........................93
VALVE GUIDE CLEARANCE ....................................93
VALVE GUIDE REPLACEMENT ................................94
VALVE SEATS .........................................................95
REPLACING VALVE SEAT FOR SERVICE PARTS .....95
VALVE DIMENSIONS ...............................................95
VALVE SPRING .......................................................96
HYDRAULIC LASH ADJUSTER ................................96
ROCKER ARM, SHIM AND ROCKER ARM GUIDE .....97
Assembly ...................................................................97
Installation..................................................................99
ENGINE REMOVAL.....................................................106
Components.............................................................106
Removal...................................................................107
Installation................................................................108
CYLINDER BLOCK .....................................................109
Components.............................................................109
Disassembly.............................................................110
PISTON AND CRANKSHAFT ..................................110
(Contd)
Assembly .................................................................117
PISTON ................................................................117
CRANKSHAFT.......................................................118
CD20T
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING
.....................................121
NVH Troubleshooting Chart - Engine Noise ...........122
OUTER COMPONENT PARTS ...................................123
COMPRESSION PRESSURE......................................126
OIL PAN .......................................................................129
Removal...................................................................129
Installation................................................................129
TIMING BELT...............................................................131
Camshaft Timing Belt ..............................................131
REMOVAL .............................................................131
Inspection.................................................................133
Installation................................................................134
Injection Pump Timing Belt......................................135
REMOVAL .............................................................135
INSTALLATION ......................................................136
OIL SEAL REPLACEMENT ........................................138
VALVE OIL SEAL ...................................................138
CAMSHAFT AND CRANKSHAFT OIL SEAL
INSTALLING DIRECTION AND MANNER ................138
CAMSHAFT OIL SEALS .........................................138
CRANKSHAFT FRONT OIL SEAL ...........................139
CRANKSHAFT REAR OIL SEAL .............................139
CYLINDER HEAD........................................................140
Components.............................................................140
Removal...................................................................141
Disassembly.............................................................141
Inspection.................................................................142
CYLINDER HEAD DISTORTION .............................142
VALVE GUIDE CLEARANCE ..................................142
VALVE GUIDE REPLACEMENT ..............................142
VALVE SEATS .......................................................143
VALVE SEAT REPLACEMENT ................................143
EM-2
CONTENTS
VALVE DIMENSIONS .............................................144
VALVE SPRING SQUARENESS ..............................145
VALVE SPRING PRESSURE LOAD ........................145
VALVE LIFTER ......................................................145
COMBUSTION CHAMBER REPLACEMENT ............146
CAMSHAFT VISUAL CHECK ..................................147
CAMSHAFT END PLAY ..........................................147
CAMSHAFT RUNOUT ............................................147
CAMSHAFT CAM HEIGHT .....................................147
CAMSHAFT JOURNAL CLEARANCE ......................147
Assembly .................................................................175
PISTON ................................................................175
CRANKSHAFT.......................................................175
PISTON WITH CONNECTING ROD ........................176
FLYWHEEL RUNOUT.............................................177
(Contd)
QG
EM-3
CONTENTS
CAMSHAFT AND CAMSHAFT BEARING .................196
VALVE...................................................................197
VALVE LIFTER ......................................................198
AVAILABLE SHIMS ................................................198
VALVE CLEARANCE..............................................198
CYLINDER BLOCK ................................................199
EM-4
(Contd)
PISTON, PISTON RING AND PISTON PIN ..............199
CONNECTING ROD...............................................200
CRANKSHAFT.......................................................200
AVAILABLE MAIN BEARINGS .................................200
TURBOCHARGER .................................................201
MISCELLANEOUS COMPONENTS .........................201
PRECAUTIONS
Parts Requiring Angular Tightening
I
I
I
Some important engine parts are tightened using an angulartightening method rather than a torque setting method.
If these parts are tightened using a torque setting method,
dispersal of the tightening force (axial bolt force) will be two or
three times that of the dispersal produced by using the correct
angular-tightening method.
Although the torque setting values (described in this manual)
are equivalent to those used when bolts and nuts are tightened
with an angular-tightening method, they should be used for
reference only.
To assure the satisfactory maintenance of the engine, bolts
and nuts must be tightened using an angular-tightening
method.
Before tightening the bolts and nuts, ensure that the thread
and seating surfaces are clean and then coated with engine oil.
The bolts and nuts which require the angular-tightening
method are as follows:
(1) Cylinder head bolts ..... SR, CD, QG
(2) Main bearing cap bolts ..... SR
(3) Connecting rod cap nuts ..... SR, QG
b.
Groove
Bolt hole
SEM164F
c.
d.
Groove
Inner side
AEM080
EM-5
PREPARATION
Special Service Tools
Engine
application
Description
ST0501S000
Engine stand
assembly
1 ST05011000
p
Engine stand
2 ST05012000
p
Base
SR
CD
QG
NT042
KV10106500
Engine stand shaft
NT028
KV10115300
Engine sub-attachment
NT008
Engine attachment
assembly
1 KV10106500
p
Engine attachment
2 KV10113300
p
Sub-attachment
NT029
1 KV10108101
p
2
p
Engine attachment
KV10102500
Engine stand
shaft
NT366
ST10120000
Cylinder head bolt
wrench
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
NT583
EM-6
PREPARATION
Special Service Tools (Contd)
Tool number
Tool name
Engine
application
Description
KV10116200
Valve spring
compressor
1 KV10115900
p
Attachment
SR
CD
QG
NT022
KV101092S0
Valve spring
compressor
1 KV10109210
p
Compressor
2 KV10109220
p
Adapter
NT021
KV10115600
Valve oil seal drift
Side A
Side B
Side A
a: 20 (0.79)
b: 13 (0.51)
c: 10.3 (0.406)
d: 8 (0.31)
e: 10.7 (0.421)
f: 5 (0.20)
Side B
20 (0.79)
14.2 (0.559)
11 (0.43)
8 (0.31)
10.7 (0.421)
5 (0.20)
X
(Side
B)
X
(Side
A)
Unit: mm (in)
NT603
KV10107902
Valve oil seal
puller
1 KV10116100
p
Valve oil seal
puller adapter
NT605
KV10115700
Dial gauge stand
Adjusting shims
NT012
KV101151S0
Lifter stopper set
1 KV10115110
p
Camshaft
pliers
2 KV10115120
p
Lifter stopper
Changing shims
NT041
EM03470000
Piston ring compressor
NT044
EM-7
PREPARATION
Special Service Tools (Contd)
Tool number
Tool name
KV10107400
Piston pin press
stand
1 KV10107310
p
Center shaft
2 ST13040020
p
Stand
3 ST13040030
p
Spring
4
KV10107320
p
Cap
5 ST13040050
p
Drift
Engine
application
Description
SR
CD
QG
Disassembling and
assembling piston pin
NT013
KV10109300*
Pulley holder
a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.
NT628
ED19600000*
Compression
gauge set
NT626
KV11100300
Nozzle holder
socket
No. 2-4 injection
nozzle holder
socket
NT563
KV119E0030
No. 1 injection
nozzle holder
socket
NT648
KV10111100
Seal cutter
NT046
EM-8
PREPARATION
Special Service Tools (Contd)
Tool number
Tool name
Engine
application
Description
WS39930000
Tube presser
SR
CD
QG
NT052
KV10112100
Angle wrench
NT014
ST16610001*
Pilot bushing puller
NT045
KV11102900*
Pulley puller
NT647
KV101056S0*
Ring gear stopper
1 KV10105630
p
Adapter
2 KV10105620
p
Adapter
3
KV10105610
p
Plate assembly
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)
NT617
EM-9
PREPARATION
Commercial Service Tools
Engine
application
Description
SR
CD
QG
16 mm
(0.63 in)
NT047
NT048
NT030
NT015
2
p
SR
d1 =
d2 =
QG
d1 =
d2 =
NT016
NT049
NT049
EM-10
QG
NCEM0005S01
Use the chart below to help you find the cause of the symptom.
1. 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.
Operating condition of engine
Location of
noise
Type of
noise
Top of
Engine
Rocker
Cover Cylinder Head
Crankshaft
Pulley
Cylinder
block (Side
of Engine)
Oil pan
Source of
noise
Reference
page
Before After
warm- warmup
up
When
starting
When
idling
When While
racing driving
Ticking or
click
Tappet
noise
Valve clearance
EM-40
Rattle
Camshaft
bearing
noise
EM-35
Slap or
knock
Piston pin
noise
EM-54, 59
Slap or
rap
Piston slap
noise
Knock
Connecting
rod-bearing
noise
EM-58, 59
Knock
EM-57
Front of
Tapping or A
Engine Tim- ticking
ing Chain
Cover
Timing
chain and
chain tensioner noise
EM-24
Front of
Engine
Squeak or A
fizzing
Other drive
belts (sticking or slipping)
Creaking
Other drive
belts (slipping)
MA Section
(Checking
Drive Belts,
Engine
Maintenance)
Squall or
creak
A: Closely related
B: Related
C: Sometimes related
: Not related
EM-11
Check item
LC Section
(Water
Pump
Inspection,
Engine
Cooling
System)
QG
Tappet noise
Timing chain
and chain
tensioner noise
VALVE MECHANISM
Valve
TIMING CHAIN
ROTATION
MECHANISM
DRIVE BELT
Connecting rod
bearing noise
Piston slap noise
EM-12
QG
NCEM0006
YEM026
1.
2.
3.
4.
5.
6.
7.
8.
Intake manifold
Intake manifold upper support
Intake manifold rear supports
Oil filter
*: If so equipped
EM-13
9. Thermostat
10. Water pump
11. Water pump pulley
QG
Gasket
Clip
.
2.9 - 3.8
(0.30 - 0.39,
26.0 - 33.9)
O-ring
O-ring
Gasket
6.9 - 9.5
(0.70 - 0.97,
60.8 - 84.2)
Gasket
3.0 - 4.0
(0.31 - 0.41, 26.9 - 35.6)
3.0 - 4.0
(0.31 - 0.41, 26.9 - 35.6)
: Nm (kg-m, ft-lb)
: Nm (kg-m, in-lb)
: Do not re-use.
Intake manifold bolts and nuts tightening order
Engine
front
Tighten in numerical order.
1.
2.
3.
4.
5.
6.
Injector
Injector tube
Pressure regulator
EM-14
7.
8.
Intake manifold
Canister purge control valve
QG
13
p
20 - 26
(2.0 - 2.7, 14 - 20)
20 - 29
(2.0 - 3.0, 14 - 22)
Washer
20 - 29
(2.0 - 3.0, 14 - 22)
30 - 40
(3.1 - 4.0, 23 - 29)
40 - 60
(4.1 - 6.1,
30 - 44)
58.8 - 78.4
(6.0 - 8.0, 43 - 58)
29 - 34
(3.0 - 3.5,
22 - 25)
6.3 - 8.3
(0.64 - 0.85,
55.6 - 73.8)
34.3 - 44.1
(3.50 - 4.50,
25.3 - 32.5)
Washer
26 - 29
(2.7 - 3.0,
20 - 22)
6.3 - 8.3
(0.64 - 0.85,
55.6 - 73.8)
29 - 34
(3.0 - 3.5,
22 - 25)
Exhaust manifold nuts
tightening order
6.3 - 8.3
(0.64 - 0.83,
55.6 - 72.0)
33 - 46
(3.4 - 4.7,
25 - 34)
16 - 21
(1.6 - 2.1,
12 - 15)
: Nm (kg-m, in-lb)
33 - 46
(3.4 - 4.7,
25 - 34)
: Nm (kg-m, ft-lb)
Engine
front
6.3 - 8.3
(0.64 - 0.83,
55.6 - 72.0)
16 - 21
(1.6 - 2.1,
12 - 15)
: Do not re-use.
Tighten in
numerical order.
1.
2.
3.
4.
5.
Crankshaft pulley
Engine coolant temperature
Gasket
Exhaust manifold
Exhaust manifold cover
6.
7.
8.
9.
Thermal transmitter
Water drain plug
Heated oxygen sensor
Three way catalyst
EM-15
10.
11.
12.
13.
Converter cap
Converter cover
Ignition coil
Spark plug
Warm up engine.
Turn ignition switch OFF.
Release fuel pressure.
Refer to Releasing Fuel Pressure in EC section.
Remove ignition coils.
Remove spark plugs.
Clean area around plug with compressed air before removing
the spark plug.
6.
7.
SEM973E
AEM308
QG
EM-16
QG
OIL PAN
Components
Components
NCEM0008
Gasket
Oil pan
Oil pan side
Oil strainer
6.3 - 8.3
(0.64 - 0.85,
55.6 - 73.8)
Washer
Drain plug
29.4 - 39.2
(3.00 - 4.00, 21.69 - 28.91)
6.28 - 8.34
(0.641 - 0.851,
55.6 - 73.8)
6.28 - 8.34
(0.641 - 0.851, 55.6 - 73.8)
: Nm (kg-m, in-lb)
: Nm (kg-m, ft-lb)
SEM867F
Removal
1.
2.
3.
Centre member
NCEM0009
5.
6.
4.
SEM067F
Drain plug
Lower rear engine plate
Gusset
.
SEM071FA
EM-17
OIL PAN
QG
Removal (Contd)
7.
a.
1)
b.
SEM365EB
Installation
1.
I
NCEM0010
Scraper
SEM295C
2.
Cut here.
7 mm (0.28 in)
I
I
I
Liquid gasket
Inner
side
Groove
Bolt hole
SEM015E
Tube presser
3.
I
I
4.
SEM296CB
Engine front
SEM072F
EM-18
QG
TIMING CHAIN
Components
Components
NCEM0011
108 - 118
(11.0 - 12.0, 80 - 87)
7.2 - 10.8
(0.73 - 1.10, 63.4 - 95.5)
6.9 - 9.5
(0.70 - 0.97, 60.8 - 84.2)
O-ring
98 - 128
(10.0 - 13.1, 72 - 95)
6.9 - 9.5
(0.70 - 0.97,
60.8 - 84.2)
17 - 24
(1.7 - 2.4, 12 - 17)
6.3 - 8.3
(0.64 - 0.85, 55.6 - 73.8)
17 - 24
(1.7 - 2.4, 12 - 17)
6.9 - 9.5
(0.70 - 0.97, 60.8 - 84.2)
6.9 - 9.5
(0.70 - 0.97, 60.8 - 84.2)
16 - 21
(1.6 - 2.1, 12 - 15)
: Nm (kg-m, in-lb)
: Nm (kg-m, ft-lb)
6.9 - 9.5
(0.70 - 0.97, 60.8 - 84.2)
132 - 152
(13.5 - 15.5, 98 - 112)
1.
2.
3.
4.
5.
6.
Chain tensioner
Camshaft sprocket (Intake)
Camshaft sprocket (Exhaust)
O-ring
Slack side timing chain guide
Timing chain tension guide
7.
8.
9.
10.
11.
12.
Timing chain
Crankshaft sprocket
Oil pump drive spacer
Front cover
O-ring
Oil seal
EM-19
TIMING CHAIN
QG
Components (Contd)
CAUTION:
I After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
I When installing chain tensioner, oil seals, or other sliding
parts, lubricate contacting surfaces with new engine oil.
I Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprocket and crankshaft pulley.
I When removing oil pump assembly, remove camshaft
position sensor (PHASE), then remove timing chain from
engine.
I Be careful not to damage sensor edges.
Removal
Drain plug
1.
2.
SEM869F
3.
I
I
4.
5.
6.
7.
8.
NCEM0012
Ignition coil
Engine front
SEM870F
EM-20
QG
TIMING CHAIN
Removal (Contd)
SEM872F
Mating mark
(INT)
RH camshaft
sprocket
Mating mark
(EXH)
LH camshaft
sprocket
SEM873F
Cylinder head
front cover
O-ring
Camshaft position
sensor (PHASE)
SEM874F
Chain guide
Stopper pin
Chain tensioner
SEM875F
Mating mark
SEM876F
EM-21
TIMING CHAIN
QG
Removal (Contd)
Engine front
SEM008G
23.
24.
25.
26.
Oil strainer
SEM879F
27. Remove starter motor, and set ring gear stopper using mounting bolt holes.
SEM880F
Crankshaft pulley
SEM881F
SEM079FA
EM-22
QG
TIMING CHAIN
Removal (Contd)
SEM882F
SEM883F
Timing
chain
Chain
guides
O-rings
34.
35.
36.
37.
38.
Remove
Remove
Remove
Remove
Remove
timing chain.
oil pump drive spacer.
chain guides.
crankshaft sprocket.
O-rings from cylinder block and front cover.
Crankshaft
sprocket
Oil pump
drive spacer
SEM884F
O-rings
SEM897F
39. Remove cylinder block dowels by using locking pliers for easyto-install front cover.
I Do not hit dowels because cylinder block may be cracked.
Locking pliers
SEM944F
EM-23
TIMING CHAIN
QG
Inspection
Inspection
NCEM0013
Crack
Wear
SEM885F
Crankshaft sprocket
Crankshaft
side
Installation
NCEM0014
1.
I
2.
3.
Install slack side timing chain guide and timing chain tension
guide.
4.
I
Engine front
Mating mark
SEM886F
Crankshaft key
SEM890F
Slack side
timing chain
guide
Timing chain
tension guide
SEM891F
Crankshaft sprocket
Timing chain
EM-24
QG
TIMING CHAIN
Installation (Contd)
5.
6.
O-rings
SEM893F
Scraper
SEM894F
7.
I
I
I
Liquid
gasket
Front cover
2.0 - 3.0 mm
(0.079 0.118 in) dia.
SEM895F
8.
Tightening torque
Nm (kg-m, in-lb)
mm (in)
a.
20 (0.79)
b.
40 (1.57)
c.
70 (2.76)
d.
72.8 (2.866)
e.
12 (0.47)
SEM896F
*: 12 - 17 ft-lb
I
I
O-rings
SEM897F
EM-25
TIMING CHAIN
QG
Installation (Contd)
9.
I
Engine front
SEM009G
Point mark
SEM945F
Cylinder block
dowels
SEM946F
Engine front
mounting bracket
SEM898F
Mating
mark
Mating
mark
Camshaft sprocket
(INT)
Camshaft sprocket
(EXH)
SEM905F
EM-26
QG
TIMING CHAIN
Installation (Contd)
SEM906F
Chain guide
Chain tensioner
Stopper pin
SEM907F
2.0 - 3.0 mm
(0.079 0.118 in) dia.
SEM887F
Camshaft position
sensor (PHASE)
SEM889F
26. Before installing rocker cover, apply a continuous bead of liquid gasket to mating surface of cylinder head.
Liquid gasket
Cylinder head
Cylinder head front cover
SEM888F
EM-27
TIMING CHAIN
QG
Installation (Contd)
EM-28
OIL SEAL
QG
Replacement
Replacement
VALVE OIL SEAL
NCEM0015
NCEM0015S01
KV10107902
SEM909F
5.
13.5
0.3 mm
(0.531
0.012 in)
Apply new engine oil to new valve oil seal and install it with
Tool.
KV10115600
SEM910F
NCEM0015S02
1.
I
I
I
I
2.
I
3.
Apply new engine oil to new oil seal and install it using a suitable tool.
Install new oil seal in the direction shown.
SEM911F
I
Engine
inside
Engine
outside
SEM715A
Suitable tool
SEM912F
EM-29
OIL SEAL
QG
Replacement (Contd)
NCEM0015S03
1.
2.
I
3.
Apply new engine oil to new oil seal and install it using a suitable tool.
Install new oil seal in the direction shown.
SEM096F
I
Engine
inside
Engine
outside
SEM715A
Suitable tool
SEM097F
EM-30
QG
CYLINDER HEAD
Components
Components
NCEM0016
To intake manifold
Refer to Installation in
TIMING CHAIN.
9
p
4
p
Refer to Installation in
TIMING CHAIN.
24.5 - 34.3
(2.5 - 3.5,
18 - 25)
O-ring
: Nm (kg-m, in-lb)
6.3 - 8.3
(0.64 - 0.85,
55.6 - 73.8)
: Nm (kg-m, ft-lb)
: Use Genuine Liquid Gasket
or equivalent.
: Lubricate with new engine oil.
: Do not re-use.
SEM913F
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
EM-31
15.
16.
17.
18.
19.
20.
21.
CYLINDER HEAD
QG
Components (Contd)
CAUTION:
I When installing camshaft and oil seal, lubricate contacting
surfaces with new engine oil.
I When tightening cylinder head bolts, camshaft sprocket
bolts and camshaft bracket bolts, lubricate bolt threads
and seat surfaces with new engine oil.
I Attach tags to valve lifters so as not to mix them up.
Removal
Drain plug
1.
2.
3.
4.
5.
NCEM0017
SEM869F
6.
7.
Ignition coil
Engine front
SEM870F
8.
SEM872F
EM-32
QG
CYLINDER HEAD
Removal (Contd)
Mating mark
(INT)
RH camshaft
sprocket
Mating mark
(EXH)
LH camshaft
sprocket
SEM873F
Cylinder head
front cover
O-ring
Camshaft position
sensor (PHASE)
SEM874F
Chain guide
Stopper pin
Chain tensioner
SEM875F
Mating mark
SEM876F
Engine front
877F
EM-33
CYLINDER HEAD
QG
Removal (Contd)
Engine front
SEM878F
Disassembly
1.
2.
KV10109220
NCEM0018
KV10116200
SEM914F
Inspection
Straightedge
Feeler gauge
SEM915F
NCEM0019
NCEM0019S01
EM-34
NCEM0019S02
QG
CYLINDER HEAD
Inspection (Contd)
CAMSHAFT RUNOUT
1.
2.
NCEM0019S03
SEM154D
Micrometer
SEM916F
2.
Inside
micrometer
1.
2.
NCEM0019S04
NCEM0019S05
SEM917F
3.
4.
SEM156D
EM-35
CYLINDER HEAD
QG
Inspection (Contd)
Dial guage
1.
2.
SEM918F
3.
I
3.
NCEM0019S06
NCEM0019S07
SEM919F
NCEM0019S08
SEM345D
EM-36
QG
CYLINDER HEAD
Inspection (Contd)
Micrometer
2.
a.
b.
c.
SEM938C
Standard
Limit
Intake
0.020 - 0.050
(0.0008 - 0.0020)
0.1 (0.004)
Exhaust
0.040 - 0.070
(0.0016 - 0.0028)
0.1 (0.004)
I
I
Oil
NCEM0019S09
1.
2.
SEM008A
SEM931C
EM-37
CYLINDER HEAD
QG
Inspection (Contd)
3.
4.
5.
Suitable reamer
SEM932C
MEM096A
Suitable reamer
SEM932C
VALVE SEATS
NCEM0019S10
SEM934C
1.
Recess diameter
SEM795A
NCEM0019S11
Bore out old seat until it collapses. Set machine depth stop so
that boring cannot contact the bottom face of seat recess in
cylinder head.
2. Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 in)]:
Refer to SDS, EM-182.
Use the valve guide center for reaming to ensure valve seat
will have the correct fit.
EM-38
QG
CYLINDER HEAD
Inspection (Contd)
Oil
3.
4.
5.
SEM008A
6.
7.
SEM892B
8.
AEM343
VALVE DIMENSIONS
T (Margin thickness)
NCEM0019S12
SEM188A
S (Out-of-square)
VALVE SPRING
Squareness
1.
2.
Measure dimension S.
Out-of-square S:
Less than 1.75 mm (0.0689 in)
If it exceeds the limit, replace spring.
SEM288A
EM-39
NCEM0019S13
NCEM0019S1301
QG
CYLINDER HEAD
Inspection (Contd)
Pressure
EM113
NCEM0019S1302
NCEM0019S16
1.
2.
SEM160D
SEM161D
SEM920F
Valve Clearance
CHECKING
Pointer
NCEM0041
NCEM0041S01
Timing
mark
Crankshaft pulley
SEM921F
EM-40
QG
CYLINDER HEAD
INT
No. 1
No. 2
No. 3
4.
No. 4
EXH
Engine front
SEM922F
SEM139D
5.
INT
No. 1
No. 2
No. 3
No. 4
6.
I
7.
I
I
EXH
Turn crankshaft one revolution (360) and align mark on crankshaft pulley with pointer.
Check only those valves shown in the figure.
Use the same procedure as mentioned in step 4.
If all valve clearances are within specification, install the following parts:
Rocker cover
All spark plugs
Engine front
SEM923F
ADJUSTING
NCEM0041S02
Notch
SEM941F
EM-41
CYLINDER HEAD
QG
3.
Tool (A)
KV10115110
SEM924F
4.
Tool (B)
KV10115120
Tool (A)
Place Tool (B) between camshaft and valve lifter to retain valve
lifter.
CAUTION:
I Tool (B) must be placed as close to camshaft bracket as
possible.
I Be careful not to damage cam surface with Tool (B).
5. Remove Tool (A).
SEM925F
Magnetic
finger
6.
Tool (B)
SEM144D
SEM145D
Shim
Indicate
T1 = 2.800 mm
(0.1102 in)
AEM236
EM-42
QG
CYLINDER HEAD
8.
I
Tool (B)
Suitable tool
SEM146D
Tool (B)
Tool (A)
Unit: mm (in)
For adjusting
For checking
Hot
Cold* (reference
data)
Hot
Intake
0.32 - 0.40
(0.013 - 0.016)
0.25 - 0.33
(0.010 - 0.013)
0.21 - 0.49
(0.008 - 0.019)
Exhaust
0.37 - 0.45
(0.015 - 0.018)
0.32 - 0.40
(0.013 - 0.016)
0.30 - 0.58
(0.012 - 0.023)
SEM147D
Assembly
1.
I
I
I
Narrow pitch
Wide pitch
Narrow pitch
NCEM0020
AEM293
Installation
Liquid gasket
1.
2.0 - 3.0 mm
(0.079 - 0.118 in) dia.
2.
I
Engine
front
NCEM0021
SEM899F
EM-43
QG
CYLINDER HEAD
Installation (Contd)
3.
I
Cylinder head bolt washer
I
I
SEM877A
Engine front
Tightening procedure
Tighten bolts to 29 Nm (3 kg-m, 22 ft-lb).
Tighten bolts to 59 Nm (6 kg-m, 43 ft-lb).
Loosen bolts completely.
Tighten bolts to 29 Nm (3 kg-m, 22 ft-lb).
Turn bolts 50 to 55 degrees clockwise or if angle
wrench is not available, tighten bolts to 594.9 Nm (60.5
kg-m, 433.6 ft-lb).
f Tightening bolts (11 - 14) to 6.3 to 8.3 Nm (0.64 to 0.85
p
kg-m, 55.8 to 73.5 in-lb).
a
p
b
p
c
p
d
p
e
p
Tightening torque
Nm (kg-m, ft-lb)
59 (6, 43)
Bolts
(1 - 10)
29
(3, 22)
59
(6, 43)
0
(0, 0)
e, f
29
(3, 22)
50 - 55
degrees or
594.9
(60.5,
433.6
ft-lb)
6.3 - 8.3
(0.64 0.85, 55.8 73.5 in-lb)
29 (3, 22)
Bolts
(11 - 14)
SEM614EC
Intake
4.
Install camshaft.
Exhaust
SEM901F
Intake
Knock pin
Exhaust
Knock pin
SEM902F
EM-44
CYLINDER HEAD
QG
Installation (Contd)
No.
Front mark
Intake side
5.
I
I
I
Intake
mark
No.
Engine front
Exhaust side
Front
mark
Exhaust
mark
SEM903F
Engine front
I
Tighten in numerical order.
Mating
mark
Camshaft sprocket
(INT)
SEM904F
6.
I
7.
I
Mating
mark
Camshaft sprocket
(EXH)
SEM905F
SEM906F
EM-45
CYLINDER HEAD
QG
Installation (Contd)
8.
I
Chain guide
I
9.
Chain tensioner
Stopper pin
SEM907F
2.0 3.0 mm
(0.079 0.118 in) dia.
SEM887F
Camshaft position
sensor (PHASE)
SEM889F
12. Before installing rocker cover, apply a continuous bead of liquid gasket to mating surface of cylinder head.
Liquid gasket
Cylinder head
Cylinder head front cover
SEM888F
EM-46
CYLINDER HEAD
QG
Installation (Contd)
EM-47
QG
ENGINE REMOVAL
Removal and Installation
NCEM0022
1
p
2
p
30 - 40
(3.1 - 4.0, 23 - 29)
p
5
64 - 74
(6.6 - 7.5, 48 - 54)
62 - 78
(6.4 - 7.9,
46 - 57)
.
22 - 28
(2.3 - 2.8,
17 - 20)
60 - 70
(6.2 - 7.1,
45 - 51)
64 - 74
(6.6 - 7.5, 48 - 54)
3
p
43 - 55
(4.4 - 5.6,
32 - 41)
43 - 55
(4.4 - 5.6,
32 - 40)
64 - 74
(6.6 - 7.5,
48 - 54)
43 - 55
(4.4 - 5.6,
32 - 40)
6
p
4
p
7
p
8
p
62 - 78
(6.4 - 7.9, 46 - 57)
60 - 70
(6.2 - 7.1, 45 - 51)
9
p
77 - 98
(7.9 - 9.9,
57 - 72)
: Nm (kg-m, ft-lb)
NEM372
1.
2.
3.
4.
5.
6.
LH engine mounting
Engine rear mounting bracket
Engine rear mounting
EM-48
7.
8.
9.
Center member
Front mounting bracket
Front mounting
ENGINE REMOVAL
QG
Removal and Installation (Contd)
WARNING:
I Position vehicle on a flat and solid surface.
I Place chocks at front and back of rear wheels.
I Do not remove engine until exhaust system has completely cooled off, otherwise, you may burn yourself
and/or fire may break out in fuel line.
I Before disconnecting fuel hose, release pressure.
Refer to EC section (Fuel Pressure Release, BASIC
SERVICE PROCEDURE).
I Be sure to lift engine and transaxle in a safe manner.
I For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
I When lifting engine, be sure to clear surrounding parts.
Use special care near accelerator wire casing, brake lines
and brake master cylinder.
I When lifting the engine, always use engine slingers in a
safe manner.
I When removing drive shaft, be careful not to damage
grease seal of transaxle.
I Before separating engine and transaxle, remove crankshaft position sensor (POS) from the cylinder block
assembly.
I Always be extra careful not to damage edge of crankshaft
position sensor (POS), or signal plate teeth.
Engine cannot be removed separately from transaxle. Remove
engine with transaxle as an assembly.
REMOVAL
1.
NCEM0022S01
EM-49
ENGINE REMOVAL
QG
8.
I
I
I
I
I
SEM174D
I
I
I
I
I
Center member
Front exhaust tube
Stabilizer bar
Cooling fan
Radiator
NEM330
SEM875DA
I
I
EM-50
QG
ENGINE REMOVAL
Wooden
block
Jack
SEM420D
INSTALLATION
I
EM-51
NCEM0022S02
QG
CYLINDER BLOCK
Components
Components
83.4 - 93.2 (8.5 - 9.5, 61 - 69)
6.28 - 8.34
(0.64 - 0.85, 55.6 - 73.8)
34.3 - 44.1
(3.50 - 4.50, 25.3 - 32.5)
: Nm (kg-m, in-lb)
: Nm (kg-m, ft-lb)
: Use Genuine Liquid Gasket or equivalent.
: Lubricate with new engine oil.
: Do not re-use.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
2nd ring
Oil ring
Piston
Snap ring
Piston pin
Connecting rod
Connecting rod bearing
Connecting rod cap
EM-52
18.
19.
20.
21.
22.
23.
24.
25.
Key
Main bearing
Thrust bearing
Crankshaft
Main bearing cap
Knock sensor
Crankshaft position sensor (POS)
Signal plate
CYLINDER BLOCK
QG
Removal and Installation
NCEM0024
CAUTION:
I When installing sliding parts such as bearings and
pistons, apply engine oil on the sliding surfaces.
I Place removed parts, such as bearings and bearing caps,
in their proper order and direction.
I When installing connecting rod nuts and main bearing cap
bolts, apply new engine oil to threads and seating surfaces.
I Do not allow any magnetic materials to contact the signal
plate teeth of flywheel or drive plate, and rear plate.
I Remove the crankshaft position sensor (POS).
I Be careful not to damage sensor edges and single plate
teeth.
Disassembly
KV10106500
KV10113300
NCEM0025
NCEM0025S01
ST0501S000
SEM927F
Piston heater
Oil
4.
I
SEM877B
5.
Front
6.
I
I
SEM165DB
EM-53
CYLINDER BLOCK
QG
Disassembly (Contd)
7.
Crankshaft
Signal plate
SEM928F
Inspection
PISTON AND PISTON PIN CLEARANCE
NCEM0026
NCEM0026S01
1.
2.
AEM023
3.
Micrometer
AEM024
NCEM0026S02
Side clearance:
Refer to SDS, EM-185
Max. limit of side clearance:
Refer to SDS, EM-185
If out of specification, replace piston and/or piston ring assembly.
Feeler
gauge
OK
Feeler gauge
Ring
SEM024AA
Piston
Press-fit
Feeler
gauge
Ring
End gap:
Refer to SDS, EM-185
Max. limit of ring gap:
Refer to SDS, EM-185
Ring
AEM096
EM-54
NCEM0026S03
QG
CYLINDER BLOCK
Inspection (Contd)
Feeler gauge
NCEM0026S04
Bend:
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.3 mm (0.012 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
SEM150B
Torsion
Feeler gauge
SEM003F
Straightedge
Feeler gauge
213.95 - 214.05 mm
(8.4232 - 8.4271 in)
SEM486C
NCEM0026S05
SEM102F
EM-55
CYLINDER BLOCK
QG
Inspection (Contd)
20 (0.79)
60 (2.36)
100 (3.94)
PISTON-TO-BORE CLEARANCE
1.
Unit: mm (in)
SEM166D
Front
Cylinder bore
grade number
(1, 2, 3)
2.
I
No.2 No.4
No.1
No.3
Cylinder
block
NCEM0026S06
Using a bore gauge, measure cylinder bore for wear, out-ofround and taper.
Standard inner diameter:
Refer to SDS, EM-184
Wear limit:
0.2 mm (0.008 in)
Out-of-round (X Y) standard:
Less than 0.015 mm (0.0006 in)
Taper (A B) standard:
Less than 0.01 mm (0.0004 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
Check for score and seizure. If seizure is found, hone it.
If cylinder block or piston is replaced, match piston grade
with grade number on cylinder block lower surface.
SEM929F
3.
SEM258C
EM-56
CYLINDER BLOCK
QG
Inspection (Contd)
CRANKSHAFT
1.
2.
Taper:
Out-of-round:
NCEM0026S07
SEM316A
3.
SEM346D
BEARING CLEARANCE
I
NCEM0026S08
Oil hole
Main bearing
1.
NCEM0026S0801
Oil groove
Front
SEM366E
Bore gauge
AEM153
4.
5.
AEM026
EM-57
QG
CYLINDER BLOCK
Inspection (Contd)
Main journal and pin journal
I
I
SEM588A
6.
Front
a.
Main journal
grade number
(0, 1, 2)
Cylinder block
SEM930F
b.
Crankshaft journal
grade number
No. 1
No. 5
AEM172
Oil hole
Black
Red
Green
Red
Green
Yellow
Green
Yellow
Blue
For example:
Cylinder block main journal grade number: 1
Crankshaft main journal grade number: 2
Main bearing grade number = 1 + 2 = Yellow
Oil groove
Front
Identification colour
SEM194C
NCEM0026S0802
Inside micrometer
AEM027
EM-58
QG
CYLINDER BLOCK
Inspection (Contd)
4.
5.
AEM028
I
Crankshaft pin journal
grade number
No. 1
No. 4
Brown
Green
SEM437CA
EM142
AEM029
2.
3.
Micrometer
AEM030
EM-59
CYLINDER BLOCK
QG
Inspection (Contd)
Align.
SEM062A
NCEM0026S12
Assembly
PISTON
NCEM0027
NCEM0027S01
1.
2.
SEM166B
Piston pin
grade number
Piston grade
number
Oil hole
Cylinder
number
Front mark
I
I
I
Front
SEM932F
Punchmark side up
(if mark is present.)
3.
CAUTION:
I When piston rings are not replaced, make sure that piston
rings are mounted in their original position.
I Install new piston rings either side up if there is no punch
mark.
SEM965E
EM-60
CYLINDER BLOCK
QG
Assembly (Contd)
Oil ring
expander
Top ring
Oil ring
upper rail
Engine
front
Oil ring
lower rail
2nd ring
SEM160B
CRANKSHAFT
1.
2.
Signal plate
Duel pin
I
I
NCEM0027S02
Crankshaft
SEM934F
Oil hole
Oil groove
Front
SEM366E
Identification No.
Cap
Engine front
SEM420C
3.
Engine
front
I
I
I
I
Tighten in numerical order.
SEM933F
EM-61
CYLINDER BLOCK
QG
Assembly (Contd)
4.
SEM116F
5.
I
I
I
Install connecting rod bearings in connecting rods and connecting rod caps.
Confirm that correct bearings are used. Refer to EM-58.
Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing.
Apply new engine oil to bolt threads and bearing surfaces.
SEM168D
6.
a.
I
I
I
I
SEM942F
b.
KV10112100
I
I
SEM943F
7.
Feeler gauge
SEM935F
EM-62
CYLINDER BLOCK
QG
Assembly (Contd)
8.
a.
b.
2.0 - 3.0 mm
(0.079 - 0.118 in) dia.
I
I
9.
AEM248
Engine front
SEM936F
EM-63
Rocker noise
Timing chain
and chain
tensioner noise
VALVE MECHANISM
TIMING CHAIN
Valve
Piston
slap noise
Connecting rod
bearing noise
EM-64
Top of
Engine
rocker
cover
Cylinder
head
Type of
noise
When
starting
When
idling
When While
racing driving
Source of
noise
Front of
engine
Timing
chain cover
Front of
Engine
Reference
page
Rocker
noise
EM-96
Rattle
Camshaft
bearing
noise
EM-92
Piston pin
noise
EM-110, 116
Piston slap
noise
Piston-to-bore clearance
Piston ring side clearance
EM-111, 112
Piston ring end gap
Connecting rod bend and
torsion
Connecting rod bearing
clearance (Big end)
Connecting rod bushing
clearance (Small end)
EM-115, 116
EM-113, 114
Slap or
rap
Cylinder
block (Side
of Engine)
Oil pan
Check item
Ticking or
clicking
Slap or
knock
Crankshaft
Pulley
Before After
warm- warmup
up
Knock
Connecting
rod-bearing
noise
Knock
Timing
chain and
Timing chain cracks and
chain tenwear
sioner noise
Tapping or
ticking
Squeak or
fizzing
Other drive
belts (sticking or slipping)
Creaking
Other drive
belts (slipping)
Squall or
creak
A: Closely related
B: Related
C: Sometimes related
: Not related
EM-65
Water pump
Water pump operation
noise
EM-132
MA Section
(Checking
Drive Belts,
ENGINE
MAINTENANCE)
LC Section
(Water Pump
Inspection,
ENGINE
COOLING
SYSTEM)
SR20DE
Refer to Installation
in TIMING CHAIN.
Washer
16 - 21
(1.6 - 2.1,
12 - 15)
6.3 - 8.3
(0.64 - 0.85, 55.6 - 73.8)
Insulator
Gasket
Gasket
Gasket
6.3 - 8.3
(0.64 - 0.85, 55.6 - 73.8)
16 - 22
(1.6 - 2.2,
12 - 16)
.
41 - 52
(4.2 - 5.3,
30 - 38)
18 - 21
(1.8 - 2.1,
13 - 15)
21 - 26
(2.1 - 2.7,
15 - 20)
16 - 21
(1.6 - 2.1,
12 - 15)
45 - 60
(4.6 - 6.1,
33 - 44)
16 - 21
(1.6 - 2.1, 12 - 15)
16 - 21
(1.6 - 2.1, 12 - 15)
16 - 22
(1.6 - 2.2, 12 - 16)
6.3 - 8.3
(0.64 - 0.85,
55.6 - 73.8)
15 - 21
(1.5 - 2.1,
11 - 15)
16 - 19
(1.6 - 1.9, 12 - 14)
Oil seal
3.7 - 5.0
(0.38 - 0.51, 33.0 - 44.3)
Nm (kg-m, ft-lb)
Nm (kg-m, in-lb)
1
p
2
p
3
p
4
p
5
p
6
p
7
p
8
p
9
p
10
p
11
p
: Refer to LC section.
(Thermostat, ENGINE COOLING SYSTEM).
Knock sensor
Oil filter bracket
Oil catcher
Oil filter
Water pipe assembly
Thermostat housing
EM-66
12
p
13
p
14
p
15
p
16
p
17
p
NEM373
SR20DE
O-ring
6.9 - 9.5
(0.70 - 0.97, 60.8 - 84.2)
6.9 - 9.5
(0.70 - 0.97,
60.8 - 84.2)
O-ring
Clip
6.9 - 9.5
(0.70 - 0.97,
60.8 - 84.2)
Gasket
6.9 - 9.5
(0.70 - 0.97, 60.8 - 84.2)
Gasket
Gasket
2.0 - 2.5
(0.20 - 0.26,
17.4 - 22.6)
Gasket
18 - 21
(1.9 - 2.2,
13.3 - 15.4)
: Nm (kg-m, ft-lb)
: Nm (kg-m, in-lb)
: Do not re-use
Tighten in
numerical order.
NEM337
1
p
2
p
3
p
Injector
Pressure regulator
IACV-AAC valve
4
p
5
p
6
p
EM-67
7
p
8
p
SR20DE
Gasket
5.1 - 6.5
(0.52 - 0.66,
45.1 - 57.3)
8 - 12
(0.8 - 1.2, 64 - 104)
40 - 50
(4.1 - 5.1,
30.0 - 36.8)
6.3 - 8.3
(0.64 - 0.85,
55.6 - 73.8)
45 - 60
(4.6 - 6.1, 33 - 44)
37 - 48
(7.8 - 4.9, 27.3 - 35.4)
45 - 60
(4.6 - 6.1, 33 - 44)
44 - 52
(4.5 - 5.3, 32.5 - 38.3)
16 - 22
(1.6 - 2.2,
12 - 16)
16 - 22
(1.6 - 2.2, 12 - 16)
39 - 46
(4.0 - 4.7, 28.8 - 33.9)
16 - 22
(1.6 - 2.2, 12 - 16)
45 - 60
(4.6 - 6.1, 33 - 44)
: Nm (kg-m, in-lb)
: Nm (kg-m, ft-lb)
: Apply liquid gasket.
16 - 22
(1.6 - 2.2, 12 - 16)
: Do not re-use
1
p
2
p
3
p
4
p
NEM339
5
p
6
p
7
p
8
p
Water outlet
Drain plug
Exhaust manifold
Heated oxygen sensor
EM-68
9
p
10
p
11
p
SR20DE
COMPRESSION PRESSURE
6.
7.
8.
9.
I
Warm up engine.
Turn ignition switch off.
Release fuel pressure.
Refer to Releasing Fuel Pressure in EC-section.
Remove all spark plugs.
Disconnect distributor center cable.
Compression pressure:
kPa (bar, kg/cm2, psi)/300 rpm
SEM968C
Standard
Minimum
NEM118
EM-69
SR20DE
OIL PAN
Removal
SEC. 110
Refer to Installation.
1
p
Refer to Installation.
p
2
5
p
3
p
1
Aluminum oil pan
p
2
Rear cover plate
p
3
Drain plug
p
4
Steel oil pan
p
5
p Baffle plate
: Nm (kg-m, in-lb)
: Nm (kg-m, ft-lb)
: Apply liquid gasket.
Washer
: Do not re-use
4
p
NEM217
Removal
9
p
11
p
3.
4.
a.
I
I
7
p
4
p
Engine
front
1.
2.
3
p
2
p
1
p
8
6
p
p
10
p
5
p
NEM218
SEM602E
EM-70
OIL PAN
SR20DE
Removal (Contd)
b.
c.
d.
5.
6.
7.
8.
9.
SEM603E
Engine
front
Baffle plate
NEM219
Center
member
Transmission jack
SEM045D
Front compressor
gusset
Compressor bracket
Rear compressor .
SEM048D
gusset
SEM043D
EM-71
OIL PAN
SR20DE
Removal (Contd)
Engine
front
SEM044D
11. Remove the two engine-to-transaxle bolts and install them into
open bolt holes shown. Tighten the bolts to release aluminum
oil pan from cylinder block.
SEM783E
12.
a.
I
I
b.
SEM046D
SEM047D
SEM223D
EM-72
OIL PAN
SR20DE
Installation
Installation
1.
a.
I
SEM050D
b.
Cut here.
I
I
7 mm (0.28 in)
Liquid gasket
Groove
Bolt hole
SEM357E
c.
I
2.
4.0 - 5.0 mm
(0.157 - 0.197 in)
Tube presser
Liquid gasket
SEM065D
Engine
front
3.
Install
Install
SEM224D
EM-73
OIL PAN
SR20DE
Installation (Contd)
Front compressor
gusset
4.
5.
6.
7.
Install
Install
Install
Install
compressor gussets.
center member.
front exhaust tube.
baffle plate.
8.
a.
Compressor bracket
Rear compressor
gusset
SEM363D
Tighten in numerical order.
NEM220
b.
Cut here.
7 mm (0.28 in)
I
I
Liquid gasket
Inner
side
Groove
Bolt hole
SEM015E
Liquid gasket
4.0 - 5.0 mm
(0.157 0.197 in)
NEM221
5
p
8
p
Engine
front
c.
I
1
p
3
p
9
p
10
p
11
p
6
p
4
p
2
p
7
p
NEM222
EM-74
SR20DE
TIMING CHAIN
Components
Components
SEM718EC
1
p
2
p
3
p
4
p
Cylinder block
Upper chain guide
Intake camshaft sprocket
Chain tensioner
5
p
6
p
7
p
8
p
Chain guide
Front cover
Crank pulley
Oil pump spacer
EM-75
9
p
10
p
11
p
12
p
Crankshaft sprocket
Chain guide
Timing chain
Exhaust camshaft sprocket
TIMING CHAIN
SR20DE
Components (Contd)
CAUTION:
I After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
I When installing chain tensioner, oil seals, or other sliding
parts, lubricate contacting surfaces with new engine oil.
I Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprocket and crankshaft pulley.
Removal
1.
2.
3.
Rocker cover
4.
5.
I
I
I
I
6.
7.
8.
Engine
front
NLEM0126
SEM029G
Front cover
SEM287G
EM-76
SR20DE
TIMING CHAIN
Removal (Contd)
9.
SEM983C
SEM695DA
SEM038G
13.
14.
15.
16.
17.
Suitable puller
SEM980C
EM-77
TIMING CHAIN
SR20DE
Removal (Contd)
Engine
front
Transmission
jack
SEM039G
RH engine mounting
SEM040G
Water pump
SEM041G
Chain
tensioner
SEM032G
EM-78
TIMING CHAIN
SR20DE
Removal (Contd)
SEM982CA
SEM034G
Inspection
NLEM0127
SEM984C
Installation
Engine
front
NLEM0128
1.
I
2.
Crankshaft
side
Crankshaft sprocket
SEM470E
SEM985C
EM-79
TIMING CHAIN
SR20DE
Installation (Contd)
20 rollers
3.
4.
Mating mark
Mating mark
56 rollers
48 rollers
SEM982CA
Mating mark
Mating mark
Mating mark
Mating mark
RH camshaft sprocket
LH camshaft sprocket
SEM048G
SEM049G
EM-80
TIMING CHAIN
SR20DE
Installation (Contd)
SEM990C
SEM991C
6.
I
SCL491A
7.
2.0 - 3.0 mm
8.
9.
BEM010
SEM721E
EM-81
TIMING CHAIN
Installation (Contd)
Front cover
SEM287G
RH engine mounting
SEM040G
Crankshaft pulley
SEM073D
SEM038G
EM-82
SR20DE
TIMING CHAIN
SR20DE
Installation (Contd)
(0.39)
Engine
front
Unit: mm (in)
18. Remove old liquid gasket from mating surfaces of rocker cover
and cylinder head.
19. Apply a continuous bead of liquid gasket to rocker cover gasket and cylinder head as shown in the illustrations.
I Use Genuine RTV silicone sealant Part No. 999MP-A7007
or equivalent.
(0.39)
3 (0.12)
BEM006
3 mm
(0.12 in) dia.
SEM051G
Rocker cover
Engine
front
SEM052G
EM-83
SR20DE
SEM077D
6.
Attachment
Compressor assembly
SEM604E
8.
9.
Apply engine oil to new valve oil seal and install it with Tool.
10.7 mm
(0.421 in)
SEM994C
KV10115600
SEM358E
SEM997C
EM-84
Engine
inside
SR20DE
3.
Apply engine oil to new oil seal and install it using a suitable
tool.
Engine
outside
SEM715A
SEM998C
4.
Apply engine oil to new oil seal and install it using a suitable
tool.
SEM999C
Engine
inside
Engine
outside
SEM715A
Suitable tool
SEM001D
EM-85
SR20DE
CYLINDER HEAD
Components
Components
.
NLEM0130
SEC. 111130
Refer to Installation in
CYLINDER HEAD.
Washer
Intake side
Rocker cover
gasket
Refer to
Installation in
CYLINDER HEAD.
Exhaust side
Gasket
6.3 - 8.3
(0.64 - 0.85, 55.6 - 73.8)
O-ring
Refer to LC section (Water
Outlet, ENGINE COOLING
SYSTEM).
Gasket
6.3 - 8.3
(0.64 - 0.85, 55.6 - 73.8)
9.0 - 11.8
(0.92 - 1.2,
79.9 - 104.2)
Nm (kg-m, in-lb)
Nm (kg-m, ft-lb)
Apply Genuine RTV Silicone SEALANT Part No. 999
MP-A7007 or equivalent.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Camshaft sprocket
Camshaft
Camshaft bracket
Water outlet
Cylinder head
Valve
EM-86
14.
15.
16.
17.
18.
19.
NEM355
CYLINDER HEAD
SR20DE
Removal
Removal
1.
2.
3.
4.
5.
6.
7.
I
I
I
I
I
I
8.
Rocker cover
Engine
front
SEM029G
SEM030G
Intake
manifold
NLEM0131
SEM065G
EM-87
CYLINDER HEAD
SR20DE
Removal (Contd)
SEM983C
Mating mark
Mating mark
LH camshaft sprocket
RH camshaft sprocket
SEM031G
Chain
tensioner
SEM032G
Rotor head position
(No. 1 cylinder at TDC)
SEM033G
SEM034G
EM-88
CYLINDER HEAD
SR20DE
Removal (Contd)
RH camshaft
Camshaft bracket
Engine
front
LH camshaft
Loosen in numerical order.
SEM035G
18.
19.
I
I
SEM036G
Water outlet
SEM037G
SEM978C
Disassembly
OK
NG
SEM878CA
CAUTION:
I When installing camshafts, chain tensioners, oil seals or
other sliding parts, lubricate contacting surfaces with new
engine oil.
I When tightening cylinder head bolts, camshaft sprocket
bolts, cramshaft pulley bolt and seat surfaces, lubricate
with new engine oil.
I If a hydraulic lash adjuster is kept on its side, there is a
risk of air entering it. After removal, always set hydraulic
EM-89
CYLINDER HEAD
SR20DE
Disassembly (Contd)
SEM202D
2.
3.
4.
5.
6.
Water
outlet
SEM082D
SEM061G
Thermostat
housing
Water pipe
NEM215
EM-90
CYLINDER HEAD
SR20DE
Inspection
7.
8.
Attachment
Compressor assembly
SEM604E
SEM994C
Inspection
CYLINDER HEAD DISTORTION
SEM925C
EM-91
CYLINDER HEAD
SR20DE
Inspection (Contd)
CAMSHAFT RUNOUT
1.
2.
SEM926C
SEM549A
2.
SEM927C
3.
4.
SEM012A
EM-92
SR20DE
CYLINDER HEAD
Inspection (Contd)
SEM002D
3.
SEM929C
2.
a.
b.
SEM003D
Micrometer
SEM938C
c.
EM-93
CYLINDER HEAD
SR20DE
Inspection (Contd)
Oil
2.
3.
4.
5.
SEM008A
SEM931C
Suitable reamer
SEM932C
SEM083D
Suitable reamer
SEM932C
EM-94
CYLINDER HEAD
SR20DE
Inspection (Contd)
VALVE SEATS
Check valve seats for any evidence of pitting at valve contact surface. Reset or replace if it has worn out excessively.
I Before repairing valve seats, check valve and valve guide
for wear. If they have worn, replace them. Then correct
valve seat.
I Use both hands to cut uniformly.
SEM934C
1.
Recess diameter
SEM795A
Oil
Bore out old seat until it collapses. Boring should not continue
beyond the bottom face of the seat recess in cylinder head. Set
the machine depth stop to ensure this.
2. Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 in)]:
Intake 35.500 - 35.516 mm (1.3976 - 1.3983 in)
Exhaust 31.500 - 31.516 mm (1.2402 - 1.2408 in)
Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly.
3. Heat cylinder head to 110 to 130C (230 to 266F).
4. Press fit valve seat until it seats on the bottom.
SEM008A
5.
6.
7.
SEM892B
VALVE DIMENSIONS
T (Margin thickness)
SEM188A
EM-95
CYLINDER HEAD
SR20DE
Inspection (Contd)
S (Out-of-square)
VALVE SPRING
Squareness
1.
2.
Measure S dimension.
Out-of-square:
Less than 2.2 mm (0.087 in)
If it exceeds the limit, replace spring.
Free height
Check free height: 49.36 mm (1.9433 in)
SEM288A
Pressure
Check valve spring pressure.
Pressure: N (kg, lb) at height mm (in)
Standard
519 - 571 (52.9 - 58.2, 116.6 - 128.3) at 27 (1.063)
Limit
Replace if load is less than 501 (51.1 - 112.7) at
27 (1.063)
EM113
2.
3.
SEM935C
SEM936C
SEM084D
EM-96
CYLINDER HEAD
SR20DE
Assembly
Rocker arm
Shim
NEM144
Assembly
1.
2.
I
1)
2)
3)
4)
3.
4.
5.
a.
SEM064G
Thermostat
housing
Water pipe
NEM216
I
2.0 - 3.0 mm
(0.079 - 0.118 in)
Liquid gasket
SEM086D
b.
I
6.
I
EM-97
CYLINDER HEAD
SR20DE
Assembly (Contd)
I
I
I
Wide pitch
I
Narrow pitch
Paint mark
SEM085D
7.
a.
Push
NEM146
b.
Rod
Engine oil
NEM147
8.
SEM202D
9.
Shim
Rocker arm guide
Valve collet
a.
I
Valve spring
retainer
Valve spring
EM-98
CYLINDER HEAD
SR20DE
Assembly (Contd)
Dial gauge
b.
c.
Rod
SEM365DA
SEM899D
d.
Make sure that the following parts are installed to the cylinder
head: Valve, valve spring, collet, retainer and rocker arm guide
(except shim). Measure difference (T1) between sliding surface
of rocker arm guide and valve stem end on shim side.
When measuring, lightly pull dial indicator rod toward you to
eliminate play in Tool (KV10115700).
e.
Shim
Indicate
T = 2.800 mm
(0.1102 in)
SEM096D
Installation
1.
2.0 - 3.0 mm
(0.079 - 0.118 in)
dia.
NLEM0136
Liquid gasket
AEM250
EM-99
CYLINDER HEAD
SR20DE
Installation (Contd)
2.
SEM390G
SEM877A
3.
a.
b.
c.
d.
SEM986C
e.
Method A
degrees
degrees
SEM043G
Method B
Method A:
Turn all bolts 90 to 95 degrees clockwise with Tool or
suitable angle wrench.
Method B:
If an angle wrench is not available, mark all cylinder head
bolts on the side facing engine front. Then, turn each cylinder head bolt 90 to 95 degrees clockwise.
f. Turn all bolts another 90 to 95 degrees clockwise.
g. Ensure that paint mark on each bolt faces the rear of the
engine. (Method B only)
Do not turn any bolt 180 to 190 degrees clockwise all at once.
degrees
degrees
Engine
front
Paint mark
SEM044G
EM-100
SR20DE
CYLINDER HEAD
Installation (Contd)
Nm (kg-m, ft-lb)
118
(12, 87)
Plastic zone
78
(8, 58)
Elastic zone
39
(4, 29)
AEM113
Water inlet
Water outlet
a.
39 (4.0, 29)
b.
78 (8.0, 58)
c.
0 (0, 0)
d.
39 (4.0, 29)
e.
f.
4.
5.
I
I
Install
Install
Water
Water
6.
7.
SEM037G
SEM036G
I
8.
I
9.
I
I
I
RH camshaft key
LH camshaft key
SEM045G
EM-101
CYLINDER HEAD
SR20DE
Installation (Contd)
Tightening procedure
STEP 1:
RH camshaft
Tighten bolts 9 - 10 in that order then tighten
bolts 1 - 8 in numerical order.
: 2 Nm (0.2 kg-m, 17 in-lb)
LH camshaft
Tighten bolts 11 - 12 in that order then tighten
bolts 1 - 10 in numerical order.
: 2 Nm (0.2 kg-m, 17 in-lb)
STEP 2:
Tighten bolts in numerical order.
: 6 Nm (0.6 kg-m, 52 in-lb)
STEP 3:
Tighten bolts in numerical order.
Bolt type A B
: 9.8 - 11.8 Nm (1.0 - 1.2 kg-m, 7.2 - 8.7 ft-lb)
Bolt type C
: 18 - 25 Nm (1.8 - 2.6 kg-m, 13 - 19 ft-lb)
End bracket
RH camshaft
bracket
End bracket
Engine
front
No. 1 to 4
brackets
No. 1 to 4 brackets
LH camshaft
bracket
SEM098DA
Engine
front
Bolt type
SEM046G
RH camshaft
Engine
front
LH camshaft
Tighten in numerical order.
SEM047G
Engine
front
Bolt type
SEM046G
Mating mark
Mating mark
Mating mark
Mating mark
RH camshaft sprocket
LH camshaft sprocket
SEM048G
EM-102
CYLINDER HEAD
SR20DE
Installation (Contd)
SEM049G
SEM050G
Rotor head position
(No. 1 cylinder at TDC)
Make sure that No. 1 piston is set at TDC and that distributor rotor is set at No. 1 cylinder spark position.
SEM033G
SEM990C
SEM991C
EM-103
CYLINDER HEAD
SR20DE
Installation (Contd)
6.3 - 8.3
(0.64 - 0.85,
56 - 73)
16 - 20
(1.6 - 2.1,
12 - 15)
6.3 - 8.3
(0.64 - 0.85,
56 - 73)
16 - 20
(1.6 - 2.1, 12 - 15)
Nm (kg-m, in-lb)
Nm (kg-m, ft-lb)
SEM066G
SEM030G
(0.39)
Engine
front
Unit: mm (in)
15. Remove old liquid gasket from mating surfaces of rocker cover
and cylinder head.
16. Apply a continuous bead of liquid gasket to rocker cover gasket and cylinder head as shown in the illustrations.
I Use Genuine RTV silicone sealant Part No. 999MP-A7007
or equivalent.
(0.39)
3 (0.12)
BEM006
3 mm
(0.12 in) dia.
SEM051G
EM-104
CYLINDER HEAD
SR20DE
Installation (Contd)
Rocker cover
Engine
front
SEM052G
EM-105
SR20DE
ENGINE REMOVAL
Components
Components
SEC. 112
Rear engine slinger
Front engine slinger
20.6 - 26.5
(2.1 - 2.7,
15 - 20)
20.6 - 26.5
(2.1 - 2.7, 15 - 20)
43 - 55
(4.9 - 5.6, 32 - 41)
43 - 55
(4.4 - 5.6,
32 - 41)
49 - 59
(5.0 - 6.0,
36 - 44)
43 - 55
(4.4 - 5.6,
32 - 41)
Front engine
mounting
Rear engine mounting
Mounting
bracket
CVT models
.
43 - 55
(4.4 - 5.6, 32 - 41)
49 - 59
(5.0 - 6.0,
36 - 44)
64 - 74
(6.5 - 7.5, 47 - 54)
43 - 55
(4.4 - 5.6, 32 - 41)
43 - 55
(4.4 - 5.6,
32 - 41)
43 - 55
(4.4 - 5.6, 32 - 41)
64 - 74
(6.5 - 7.5, 47 - 54)
62 - 78
(6.3 - 8.0, 46 - 58)
55 - 65
(5.6 - 6.6, 41 - 48)
64 - 74
(6.5 - 7.5, 47 - 54)
Front mounting
bracket
49 - 59
(5.0 - 6.0, 36 - 44)
Rear insulator
Insulator
Center member
77 - 98
(7.9 - 100, 57 - 72)
: Nm (kg-m, ft-lb)
NEM340
EM-106
ENGINE REMOVAL
SR20DE
Components (Contd)
WARNING:
I Position vehicle on a flat and solid surface.
I Place chocks at front and back of rear wheels.
I Do not remove engine until exhaust system has completely cooled;
Otherwise, you may burn yourself and/or fire may break
out in fuel line.
I Before disconnecting fuel hose, release fuel pressure
from fuel line.
Refer to Releasing Fuel Pressure in EC section.
I Be sure to hoist engine and transaxle in a safe manner.
I For engines not equipped with engine slingers, attach
slingers and bolts described in PARTS CATALOG.
CAUTION:
I When lifting engine, be sure to clear surrounding parts.
Use special care for accelerator cable, brake lines and
brake master cylinder.
I In hoisting the engine, always use engine slingers in a
safe manner.
I When removing drive shaft, be careful not to damage
grease seal of transaxle.
Removal
1.
2.
3.
4.
5.
6.
7.
8.
9.
Transmission jack
SEM092D
EM-107
ENGINE REMOVAL
SR20DE
Removal (Contd)
11. Remove engine mounting bolts from both sides and then
slowly lower transmission jack.
Front engine
mounting
SEM597D
SEM195F
Installation
1. Install engine mounting bracket and fixing bolts.
Be sure that insulators are correctly positioned on the brackets.
2. Carefully lower the engine onto engine mounting insulators.
Rubber seat
Insulator
SEM312D
EM-108
SR20DE
CYLINDER BLOCK
Components
Components
SEC. 110120150
16 - 21 (1.6 - 2.1, 12 - 15)
4
p
1
p
2
p
p
3
6.3 - 8.3
(0.64 - 0.85, 55.8 - 73.5)
5
p
Gasket
16 - 19 (1.6 - 1.9, 12 - 14)
24
p
pp p
23
22
21
7
p
8
p
9
p
10
p
20
p
p
12
p
11
Snap ring
Refer to Assembly
13
p
Refer to Assembly
16
p
6.4 - 7.5
: Refer to LC section.
(0.65 - 0.76, 56.6 - 66.0)
: Refer to Installation in
OIL PAN.
17
29 - 39
p
(3.0 - 4.0, 22 - 29)
: Nm (kg-m, in-lb)
: Nm (kg-m, ft-lb)
: Apply liquid gasket.
: Lubricate with new engine oil.
: Do not re-use
14
p
15
p
19
p
Washer
6.4 - 7.5
(0.65 - 0.76,
56.6 - 66.4)
18
p
NEM225
1
p
2
p
3
p
4
p
5
p
6
p
7
p
8
p
9
p
10
p
11
p
12
p
13
p
14
p
15
p
16
p
EM-109
17
p
18
p
19
p
20
p
21
p
22
p
23
p
24
p
Drain plug
Steel oil pan
Baffle plate
Main bearing cap
Flywheel
Pilot bushing
Rear plate
Main bearing
CYLINDER BLOCK
SR20DE
Components (Contd)
CAUTION:
I When installing sliding parts (bearings, pistons, etc.),
apply new engine oil to the sliding surfaces.
I Place removed parts such as bearings and bearing caps
in their correct order and direction.
I When installing connecting rod nuts and main bearing cap
bolts, apply new engine oil to threads and seating surfaces.
I Do not allow any magnetic materials to contact the ring
gear teeth of flywheel/drive plate.
Disassembly
: Nm (kg-m, ft-lb)
3.
4.
25 - 34
(2.5 - 3.5, 18 - 25)
SEM141FA
5.
I
Piston heater
Oil
6.
SEM877B
7.
Front
4
p
8
p
10
p
6
p
2
p
3
p
7
p
9
p
5
p
1
p
NEM150
Inspection
PISTON AND PISTON PIN CLEARANCE
1.
AEM023
EM-110
CYLINDER BLOCK
SR20DE
Inspection (Contd)
2.
3.
Micrometer
AEM024
Side clearance:
Top ring 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Max. limit of side clearance:
0.2 mm (0.008 in)
If out of specification, replace piston and/or piston ring assembly.
Feeler
gauge
OK
Feeler gauge
Ring
SEM024AA
SEM822B
Bend
Feeler gauge
End gap:
Top ring 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd ring 0.35 - 0.50 mm (0.0138 - 0.0197 in)
Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 in)
Max. limit of ring gap:
1.0 mm (0.039 in)
If out of specification, replace piston ring. If gap still exceeds the
limit even with a new ring, do the following. Rebore cylinder and
use over-sized piston and piston rings.
Refer to SDS (EM-193).
I When replacing the piston, inspect cylinder block surface for
scratches or seizure. If scratches or seizure are found, hone
or replace the cylinder block.
SEM038F
Torsion
Feeler gauge
Bend:
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.30 mm (0.0118 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
SEM003F
EM-111
CYLINDER BLOCK
SR20DE
Inspection (Contd)
Straightedge
1.
2.
Feeler gauge
SEM123C
211.25 - 211.35 mm
(8.3169 - 8.3208 in)
PISTON-TO-BORE CLEARANCE
100 (3.94)
60 (2.36)
10 (0.39)
1.
SEM363E
2.
I
Using a bore gauge, measure cylinder bore for wear, out-ofround and taper.
Standard inner diameter:
86.000 - 86.030 mm (3.3858 - 3.3870 in)
Wear limit: 0.20 mm (0.0079 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
Out-of-round (X Y) standard:
Less than 0.015 mm (0.0006 in)
Taper (A B and A C) standard:
Less than 0.010 mm (0.0004 in)
Check for scratches and seizure. If seizure is found, hone it.
When replacing both cylinder block and piston with new
ones, select piston making sure of grade numbers. Piston
grade number should be the same as the grade number
punched on cylinder block upper surface.
SEM011D
3.
SEM012D
EM-112
CYLINDER BLOCK
SR20DE
Inspection (Contd)
6.
CRANKSHAFT
1.
2.
Taper:
Out-of-round:
SEM316A
3.
SEM434
EM-113
CYLINDER BLOCK
SR20DE
Inspection (Contd)
BEARING CLEARANCE
I
SEM685D
SEM100D
4.
5.
6.
7.
AEM026
a.
b.
SEM964
8.
Main journal grade number
No. 5
a.
No. 1
Engine
front
SEM313D
EM-114
SR20DE
CYLINDER BLOCK
Inspection (Contd)
Type I
b.
c.
No. 1
No. 4
Crankshaft
front view
Type II
SEM013D
0
(A, Black)
1
(B, Red)
2
(C, Green)
3
(D, Yellow)
1
(B, Red)
2
(C, Green)
3
(D, Yellow)
4
(E, Blue)
2
(C, Green)
3
(D, Yellow)
4
(E, Blue)
5
(F, Pink)
3
(D, Yellow)
4
(E, Blue)
5
(F, Pink)
6
(G, White)
No. 5 journal
Crankshaft
front view
For example:
Main journal grade number: 1
Crankshaft journal grade number: 2
Main bearing grade number = 1 + 2
= 3 (D, Yellow)
SEM203D
Inside micrometer
AEM027
4.
5.
6.
7.
AEM028
EM-115
SR20DE
CYLINDER BLOCK
Inspection (Contd)
Type I
8.
No. 1
No. 4
Crankshaft
front view
SEM013D
Identification color:
Grade 0; Black or Yellow
Grade 1; Brown or Red
Grade 2; Green or Blue
Type II
No. 3
No. 2
No. 4 cylinder
Grade 0
Grade 1
No. 1
Grade 2
Pin journal
grade number
Crankshaft
rear view
SEM204D
2.
3.
AEM029
Micrometer
AEM030
EM-116
SR20DE
CYLINDER BLOCK
Inspection (Contd)
Align.
SEM062A
2.
SEM916AB
Crankshaft side
M/T
CVT
SEM163B
SEM901E
Assembly
PISTON
1.
SEM166B
EM-117
CYLINDER BLOCK
SR20DE
Assembly (Contd)
2.
I
I
I
SEM946C
Punchmark side up
(if mark is present.)
SEM965E
Oil ring
expander
Top ring
Oil ring
upper rail
Engine
front
2nd ring
Oil ring
lower rail
NEM336
CRANKSHAFT
1.
I
I
SEM685D
EM-118
CYLINDER BLOCK
SR20DE
Assembly (Contd)
2.
Front
7
p
8
p
3
p
1
p
4
p
2
p
5
p
6
p
9
p
10
p
NEM151
I
I
I
a.
b.
I
KV10112100
NEM152
3.
4.
Install connecting rod bearings in connecting rods and connecting rod caps.
Confirm that correct bearings are used. Refer to Inspection.
Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing.
Apply new engine oil to bolt threads and bearing surfaces.
Feeler gauge
NEM153
Align oil hole.
I
I
I
SEM159B
5.
a.
I
I
I
EM03470000
or suitable tool
SEM554EA
EM-119
CYLINDER BLOCK
SR20DE
Assembly (Contd)
b.
6.
7.
a.
Engine
front
NEM154
Feeler gauge
NEM153
SEM218D
b.
Liquid
gasket
2.0 - 3.0 mm
(0.079 0.118 in)
SEM219D
EM-120
Camshaft
bearing noise
CD20T
Tappet noise
Belt tensioner
noise
Valve mechanism
Timing belt
Belt tensioner
noise
Water pump
Rotation
mechanism
Piston pin noise
Drive belt
Piston
slap noise
Connecting rod
bearing noise
EM-121
CD20T
Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil pan
Type of
noise
When
starting
When
idling
When
racing
While
driving
Source of
noise
Check item
Reference
page
Ticking or
clicking
Tappet
noise
Valve clearance
Rattle
Camshaft
bearing
noise
EM-147
Slap or
knock
Piston pin
noise
EM-168,
171
EM-168,
169, 172,
174
Slap or rap
Piston slap
noise
Piston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend and
torsion
Knock
Connecting
rod bearing
noise
EM-170,
171
Knock
EM-169,
172
Timing belt
noise (too
tight)
EM-135
Whine or
Camshaft
and injection hissing
pump
Timing belt
Clatter
cover
Squeaking
or fizzing
Front of
engine
Before
After
warm-up warm-up
Timing belt
noise (too
loose)
Other drive
belts
(Sticking or
slipping)
Creaking
Other drive
belts (Slipping)
Squall
Creak
Water pump
noise
EM-122
*1
*2
CD20T
49 - 59 (5.0 - 6.0,
36 - 43)
31 - 42
(3.2 - 4.3, 23 - 31)
: Nm (kg-m, ft-lb)
: Do not re-use
NEM240
1
p
2
p
3
p
4
p
5
p
6
p
7
p
Starter motor
Injection pump
Injection tube
Thermostat housing
Injection nozzle
Spill hose
Water outlet
8
p
9
p
10
p
11
p
12
p
13
p
14
p
Belt cover
Timing belt
Injection pump sprocket
Rear camshaft sprocket
Tensioner
Vacuum pump
Rear back cover
EM-123
15
p
16
p
17
p
18
p
19
p
Oil cooler
Gasket
Bracket
Power steering oil pump
adjusting bar
Gasket
CD20T
3 - 5 (0.3 - 0.5,
27 - 44)
37 - 50
(3.8 - 5.1,
27 - 37)
6.3 - 8.3
(0.64 - 0.85,
55.8- 73.5)
11
p
16
p
9
p
1
p
21 - 26
(2.1 - 2.7,
15 - 20)
10
p
8
p
12
p
6.4 - 8.4
(0.65 - 0.86,
56.6 - 74.3)
13
p
18 - 22
(1.8 - 2.2,
13 - 16)
2
p
8
p
3
p
8
p
7
p
3-5
(0.3 - 0.5,
26 - 44)
4
p
21 - 26
(2.1 - 2.7,
15 - 20)
14
39 - 49
(4.0 - 5.0, 29 - 36)
18 - 22
(1.8 - 2.2,
13 - 16)
.
142 - 152
(14.5 - 15.5, 105 - 112)
6
p
18 - 22
(1.8 - 2.2, 13 - 16)
17
p
20 - 31
(2.0 - 3.2,
14 - 23)
15
p
4-5
(0.4 - 0.5,
35 - 44)
5
p
16 - 21 (1.6 - 2.1,
12 - 15)
: Nm (kg-m, ft-lb)
: Do not re-use
1
p
2
p
3
p
4
p
5
p
6
p
7
p
8
p
9
p
10
p
EM-124
11
p
12
p
13
p
14
p
15
p
16
p
17
p
NEM197
EGR valve
Air inlet
Air inlet hose
EGR tube
Exhaust manifold cover
Blow-by gas control valve
Turbocharger oil return hose
CD20T
2
p
12
p
13
p
3
p
4
p
5.1 - 6.5
(0.52 - 0.66,
45.1 - 57.5)
1
p
6
p
5
p
5.1 - 6.5
(0.52 - 0.66,
45.1 - 57.5)
8
p
3
p
14
p
9
p
13 - 19
(1.3 - 1.9,
9 - 14)
.
10
p
7.2 - 9.6
(0.73 - 0.98,
63.7 - 85.0)
20 - 31
(2.0 - 3.2, 14 - 23)
15
p
: Nm (kg-m, ft-lb)
: Do not re-use
15
p
6.3 - 8.3
(0.64 - 0.85, 55.8 - 73.5)
11
p
NEM375
1
p
2
p
3
p
4
p
5
p
Turbocharger assembly
Exhaust manifold
Gasket
Air inlet hose
Air hose
6
p
7
p
8
p
9
p
10
p
Lock plate
Exhaust outlet
Exhaust outlet cover
Turbocharger oil return pipe
Turbocharger oil return hose
EM-125
11
p
12
p
13
p
14
p
15
p
Insulator
Turbocharger oil feed tube
Turbocharger water feed tube
Turbocharger water return tube
Bracket
COMPRESSION PRESSURE
CD20T
1.
2.
3.
NEM241
SEM501D
4.
5.
6.
NEM242
NEM243
SEM505D
EM-126
CD20T
COMPRESSION PRESSURE
7.
8.
Trouble diagnosis
EM-127
COMPRESSION PRESSURE
Nozzle side
CD20T
Combustion
chamber side
NEM244
SEM501D
NEM242
NEM241
EM-128
OIL PAN
CD20T
Removal
Removal
1.
2.
1)
I
I
Drain oil.
Remove oil pan using tool as illustrated.
Insert Tool between oil pan and cylinder block.
Do not drive seal cutter into oil pump or rear oil seal
retainer portion, or aluminum mating surfaces will be
damaged.
Do not insert screwdriver, or oil pan flange will be
deformed.
SEM230D
2)
SEM231D
Installation
1.
Scraper
Before installing oil pan, remove all traces of liquid gasket from
mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of
cylinder block.
SEM350B
SLC906
2.
SEM909B
EM-129
OIL PAN
CD20T
Installation (Contd)
3.
Apply liquid gasket to oil pan front oil seal and rear oil seal.
4.
SEM894BA
Tube presser
SEM351B
5.
Install oil pan and tighten bolts in the order shown in the figure.
Wait at least 30 minutes before refilling engine oil.
Oil pan bolts:
: 6.3 - 8.3 Nm (0.64 - 0.85 kg-m, 55.8 - 73.5 in-lb)
Engine
front
SEM369D
EM-130
CD20T
TIMING BELT
5.3 - 7.3
(0.54 - 0.74,
46.9 - 64.6)
3-5
(0.3 - 0.5, 27 - 44)
32 - 40
(3.3 - 4.1, 24 - 30)
32 - 40
(3.3 - 4.1, 24 - 30)
43 - 58 (4.4 - 5.9, 32 - 43)
142 - 152
(14.5 - 15.5,
105 - 112)
: Do not re-use
Lubricate with new engine oil.
Nm (kg-m, in-lb)
Nm (kg-m, ft-lb)
6.4 - 8.4
(0.65 - 0.86, 56.6 - 74.3)
Locking sealant
SEM368FA
1
p
2
p
3
p
4
p
5
p
6
p
7
p
8
p
9
p
10
p
REMOVAL
1.
2.
3.
EM-131
TIMING BELT
CD20T
4.
5.
SEM369F
6.
7.
8.
SEM681D
Tighten
Loosen
SEM520D
SEM515D
SMA398A
EM-132
CD20T
TIMING BELT
Inspection
Inspection
Timing belt
Visually check the condition of timing belt.
Replace if any abnormality is found.
Item to check
Problem
Cause
I Camshaft jamming
I Damaged camshaft/crankshaft oil seal
SEM394A
I Tensioner jamming
I Overheated engine
I Interference with belt cover
SEM395A
SEM396A
I
I
I
I
Rotating direction
EM-133
TIMING BELT
CD20T
Inspection (Contd)
SEM558
SEM516D
Installation
1.
SEM517D
SEM518D
Mark
Align
4.
a.
43 cogs
b.
5.
Align
SEM519DA
EM-134
CD20T
TIMING BELT
Installation (Contd)
6.
1)
2)
Tighten
3)
Loosen
SEM520D
SEC. 130135
31 - 37 (3.2 - 3.8, 23 - 27)
3-5
(0.3 - 0.5,
27 - 44)
17 - 21
(1.7 - 2.1,
12 - 15)
59 - 69
(6.0 - 7.0, 43 - 51)
Engine front
Nm (kg-m, in-lb)
Nm (kg-m, ft-lb)
Lubricate with new engine oil
16 - 21 (1.6 - 2.1, 12 - 15)
SEM349F
1
p
2
p
3
p
Timing belt
Tensioner spring
Tensioner
4
p
5
p
6
p
7
p
8
p
REMOVAL
1.
2.
3.
4.
5.
EM-135
TIMING BELT
CD20T
6.
7.
SEM369F
Alignment
mark
Alignment
mark
SEM350F
Front mark
Alignment
mark
Alignment mark
SEM351F
8.
Loosen tensioner mounting nut. Using a screwdriver, turn tensioner in direction of arrow to release belt tension.
9. Remove vacuum pump.
10. Remove timing belt.
Tensioner
SEM352F
INSTALLATION
1.
I
SEM370F
EM-136
TIMING BELT
CD20T
Injection Pump Timing Belt (Contd)
Front mark
Alignment
mark
2.
1)
2)
3)
3.
1)
I
Alignment mark
SEM351F
Alignment
mark
Alignment
mark
SEM350F
SEM353F
EM-137
CD20T
SEM888
KV10107902
NEM200
12.2 0.3 mm
(0.480 0.012 in)
3)
4)
5)
6)
7)
Install new valve oil seals for No. 1 and No. 4 cylinders as
illustrated. Reinstall valve springs. (Narrow pitch side toward
cylinder head)
Install valve spring retainers on intake valves and valve rotators on exhaust valves, and remount valve assembly.
Set No. 2 cylinder at TDC.
Replace valve oil seals for No. 2 and No. 3 cylinders according to steps 2) and 3).
Install valve lifters in original positions.
NEM201
Engine
outside
Engine
inside
SEM715A
Tape
SEM887
EM-138
CD20T
Rear
Front
SEM240D
3.
Apply engine oil to new oil seal and install oil seal using a
suitable tool.
SEM889
SEM241D
SEM891
1.
Apply engine oil to new oil seal and install oil seal using a
suitable tool.
SEM242D
EM-139
CD20T
CYLINDER HEAD
Components
Components
SEM356F
1
p
2
p
3
p
4
p
5
p
6
p
7
p
8
p
Camshaft
Front oil seal
Collar
Grommet
Front back cover
Front camshaft sprocket plate
Front camshaft sprocket
Spring
9
p
10
p
11
p
12
p
13
p
14
p
15
p
EM-140
16
p
17
p
18
p
19
p
20
p
21
p
22
p
23
p
CYLINDER HEAD
CD20T
Removal
Removal
1.
2.
3.
4.
5.
Drain plug
(cylinder block)
SEM373D
SEM682D
Disassembly
1.
SEM864
Remove front camshaft sprocket plate, front and rear sprockets using special service tool or a suitable tool, and front back
cover.
2. Remove camshaft brackets in order from outside to inside.
I Loosen camshaft bracket nuts in two or three stages.
3. Remove camshaft and oil seals.
4. Remove valve lifters.
For valve lifter
I Attach tags to valve lifters for identification.
5.
I
6.
SEM716B
SEM745BA
EM-141
CYLINDER HEAD
CD20T
Inspection
Inspection
CYLINDER HEAD DISTORTION
1.
2.
Warpage of surface:
Less than 0.1 mm (0.004 in)
SEM595A
2.
a)
SEM870
Micrometer
b)
c)
Top
Center
Bottom
Valve guide Valve
SEM244D
SEM871
EM-142
CD20T
CYLINDER HEAD
Inspection (Contd)
3.
4.
SEM245D
10.3 mm
(0.406 in)
5.
SEM246DA
VALVE SEATS
1.
SEM722BA
2.
SEM795A
EM-143
CYLINDER HEAD
CD20T
Inspection (Contd)
3.
5.
SEM876
6.
7.
SEM877
W: Refer to SDS.
SEM635AA
VALVE DIMENSIONS
T (Margin thickness)
1.
2.
SEM188A
EM-144
CYLINDER HEAD
CD20T
Inspection (Contd)
3.
EM111
SEM333
Check valve spring for squareness using a steel square and flat
surface plate.
If spring is out of square S more than specified limit, replace with
new one.
Out-of-square:
Outer
Less than 1.8 mm (0.071 in) Intake
Less than 2.2 mm (0.087 in) Exhaust
Inner
Less than 1.6 mm (0.063 in) Intake
Less than 1.8 mm (0.071 in) Exhaust
EM113
VALVE LIFTER
1.
SEM723B
EM-145
CYLINDER HEAD
CD20T
Inspection (Contd)
2.
3.
SEM724B
SEM725B
SEM720B
4.
a.
b.
SEM721B
EM-146
CD20T
CYLINDER HEAD
Inspection (Contd)
CAMSHAFT RUNOUT
1.
2.
SEM155
2.
.
Intake
Exhaust
SEM730B
SEM727B
2.
SEM728B
EM-147
CYLINDER HEAD
CD20T
Inspection (Contd)
Using plastigage
1.
2.
3.
Wipe off oil from camshaft journal bracket caps and brackets.
Install camshaft in journal bracket caps and put plastigage on
each camshaft journal.
Install cam bracket caps and tighten cam bracket cap nuts in
the correct order to the specified torque.
: 18 - 22 Nm (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
SEM879
4.
5.
I
SEM880
Valve clearance
Checking
Check valve clearance while engine is warm and not running.
1. Remove rocker cover.
2. Set No. 1 cylinder at TDC on its compression stroke.
I Align pointer with TDC mark on crankshaft pulley.
1 and p
2 are loose and valve
I Check that valve lifters No. p
lifters No. p
7 and p
8 are tight.
SEM369F
3.
SMA406A
EM-148
1 , p
2 , p
4
p
and
CYLINDER HEAD
CD20T
Checking (Contd)
I
I
Feeler gauge
SEM634F
3.
4.
I
5.
I
SMA406A
Adjusting
Notch
.
SEM636F
Tool (B)
KV10115120
Tool (A)
KV10115110
SEM637F
EM-149
CD20T
CYLINDER HEAD
Adjusting (Contd)
6.
7.
Small screwdriver
I
I
Magnetic finger
SEM638F
HOT
COLD
SEM145D
Shim
Intake
0.30 (0.012)
Exhaust
Intake
Exhaust
0.44 (0.017)
0.25 (0.010)
0.38 (0.015)
Intake:
N = R + [M S]
Exhaust:
N = R + [M S]
Shims are available in 15 sizes from 2.20 mm (0.0866 in) to 2.90
mm (0.1142 in), in steps of 0.05 mm (0.0020 in).
I Select the closest size shim to the calculated thickness.
Refer to chart in SDS, EM-198.
Indicate
T1 = 2.800 mm
(0.1102 in)
AEM236
8.
I
Intake
Exhaust
For adjusting
Hot
Cold* (reference data)
0.25 - 0.35
0.20 - 0.30
(0.010 - 0.014)
(0.008 - 0.012)
0.39 - 0.49
0.33 - 0.43
(0.015 - 0.019)
(0.013 - 0.017)
EM-150
CYLINDER HEAD
CD20T
Assembly
Assembly
Painted side
Cylinder
head side
Narrow
pitch
Wide pitch
SEM202
SEM731BA
2.
Grade number
Tightening sequence
I
I
I
I
17.5 (0.689)
13.0 (0.512)
Installation
Cylinder head bolt
Cylinder head
1.
I
I
I
Washer
SEM675D
2.
EM-151
CYLINDER HEAD
CD20T
Installation (Contd)
CAUTION:
The cylinder head bolts can be reused providing dimension
A is not exceeded.
Dimension A:
118.7 mm (4.6732 in)
NEM328
EM-152
CD20T
CYLINDER HEAD
Installation (Contd)
Tightening procedure
Engine front
SEM672D
SEM848F
Marking
NEM211
3.
I
SEM678D
Apply sealant.
SEM677D
EM-153
CD20T
CYLINDER HEAD
Installation (Contd)
SEM593A
25
25
(0.98) (0.98)
30
30
(1.18) (1.18)
Unit: mm (in)
SEM529D
Notch
Average value of
piston projections
mm (in)
SEM530D
Gasket thickness
mm (in)
Grade
(Number of
notches)
New parts
In assembly
1.30 (0.0512)
1.150.05
(0.04530.0020)
0.505 - 0.555
(0.0199 - 0.0219)
1.35 (0.0531)
1.200.05
(0.04720.0020)
1.40 (0.0551)
1.250.05
(0.04920.0020)
Step 6
Check if the average value of each projection obtained from step
2 is larger than the max. value of the standard projection (of
selected gasket) incremented by 0.05 mm (0.0020 in).
If so, use gasket that is 1 grade thicker. If not, use gasket as
selected in step 4.
EM-154
CD20T
CYLINDER HEAD
Installation (Contd)
Example
Unit: mm (in)
Cylinder No.
Step
Item
1.
Measured
value
2.
Average value
of each piston
3.
Average value
of all pistons
4.
Round off
value
5.
Determined
gasket thickness (Temporarily)
1
M1
M2
2
M3
M4
M1
M2
3
M3
M4
M1
M2
4
M3
M4
M1
M2
M3
M4
0.53
0.56
0.53
0.56
0.59
0.55
0.59
0.55
0.53
0.58
0.57
0.54
0.58
0.51
0.52
0.57
(0.0209) (0.0220) (0.0209) (0.0220) (0.0232) (0.0217) (0.0232) (0.0217) (0.0209) (0.0228) (0.0224) (0.0213) (0.0228) (0.0201) (0.0205) (0.0224)
0.545
(0.0215)
0.570
(0.0224)
0.555
(0.0219)
0.545
(0.0215)
0.55375 (0.02180)
0.554 (0.0218)*1
X: Maximum value of standard projection of selected gasket . . . 0.555 (0.0219) (in chart A) + 0.05 (0.0020) = 0.605 (0.0238)
6. Y: Maximum value in step 2 = 0.57 (0.0224)
The relationship between X and Y is X > Y. *2
Determined
7. gasket thickness (Finally)
*1: If the average value of projections for all pistons is, for example, 0.553 (7) 5, as shown in the table above, it should be rounded off as follows:
If the digit in the fourth decimal place (which is enclosed by a circle in this case) is smaller than 5, the average value should be regarded
as 0.553 mm (0.0218 in); if it is larger than 5, the average value should be regarded as 0.554 mm (0.0218 in).
*2: If X < Y, then the thicker grade 3 gasket must be used.
EM-155
TURBOCHARGER
CD20T
Removal
Removal
Turbocharger water
return tube
1.
2.
3.
4.
5.
6.
7.
8.
9.
Turbocharger water
feed tube
Turbocharger oil
feed tube
NEM204
EGR
tube
Air inlet
hose
Exhaust
manifold
cover
Insulator
NEM202
Turbocharger
oil return hose
Oil pan
.
NEM203
3
p
1
p
4
p
2
p
EM-156
CD20T
TURBOCHARGER
Removal (Contd)
Exhaust
manifold
Turbocharger
NEM206
Disassembly
Turbocharger
water
feed tube
1.
Remove oil tubes and water tubes. Before removing tubes, put
mating marks on tube connectors and turbocharger.
2.
3.
Remove exhaust outlet cover, exhaust outlet, and heat insulator brackets.
4.
Turbocharger
water return
tube
Turbocharger
oil feed tube
Turbocharger
oil return tube
NEM207
Turbocharger side
SEM367F
SEM026F
NEM208
EM-157
CD20T
TURBOCHARGER
Inspection
Inspection
Perform the following checks. If NG, replace turbocharger unit.
Compressor wheel
Wastegate valve
Compressor housing
Center housing
Turbine housing
SEM366F
SEM029F
ROTOR SHAFT
1.
SEM030F
EM-158
CD20T
TURBOCHARGER
Inspection (Contd)
2.
3.
4.
Rotor shaft
SEM031F
SEM032F
SEM827D
TURBINE WHEEL
Check turbine wheel for the following:
I Oil
I Carbon deposits
I Deformed fins
I Contact with turbine housing
SEM828D
COMPRESSOR WHEEL
Check compressor wheel for the following:
I Oil
I Deformed fins
I Contact with compressor housing
SEM829D
EM-159
TURBOCHARGER
CD20T
Inspection (Contd)
WASTEGATE VALVE
Remove rod pin and check wastegate valve for cracks, deformation and smooth movement. Check valve seat surface for smoothness.
SEM830D
SEM831D
Assembly
NEM228
I
Exhaust manifold side
Turbocharger side
SEM367F
Installation
1.
2
p
4
p
1
p
3
p
EM-160
TURBOCHARGER
CD20T
Installation (Contd)
2.
I
Turbocharger
water
feed tube
Turbocharger
water return
tube
Turbocharger
oil feed tube
Turbocharger
oil return tube
NEM207
EM-161
CD20T
ENGINE REMOVAL
43 - 55 (4.4 - 5.6, 32 - 41)
SEC. 112
43 - 55
(4.4 - 5.6,
32 - 41)
Rear engine
mounting
64 - 74
(6.5 - 7.5,
47 - 54)
Insulator
49 - 59
(5.0 - 6.0,
36 - 44)
43 - 55
(4.4 - 5.6,
32 - 41)
: Nm (kg-m, ft-lb)
NEM226
EM-162
ENGINE REMOVAL
CD20T
WARNING:
I Situate vehicle on a flat and solid surface.
I Place chocks at front and back of rear wheels.
I Do not remove engine until exhaust system has completely cooled down.
I For safety during subsequent steps, the tension of wires
should be slackened against the engine.
I Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI section for lifting points and towing.
I Be sure to hoist engine and transaxle in a safe manner.
I For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG
or Eurofast.
CAUTION:
I When lifting engine, be careful not to strike adjacent parts,
especially accelerator wire casing, brake lines, and brake
master cylinder.
I Always use engine slingers when hoisting the engine.
I When removing drive shaft, be careful not to damage transaxle oil seal.
1.
2.
3.
4.
5.
6.
7.
SEM531D
8.
9.
10.
11.
12.
13.
14.
15. Remove brake caliper mounting bolts and bind caliper properly
to vehicle LH & RH.
SEM532D
EM-163
ENGINE REMOVAL
16.
17.
18.
1)
2)
CD20T
Disconnect tie rod ball joints and lower ball joints (LH & RH).
Remove stabilizer.
Remove drive shafts from transaxle.
RH: Split drive shaft center thrust bearing.
RH & LH: Remove hub mounting bolts and remove drive shaft
carefully from transaxle.
SEM534D
SEM535D
SEM536D
EM-164
ENGINE REMOVAL
23. Remove center member fixing bolts from chassis.
SEM538D
SEM247D
EM-165
CD20T
CD20T
CYLINDER BLOCK
Components
Components
SEC. 110120
30 - 40 (3.1 - 4.1, 266 - 354)
83 - 93
(8.5 - 9.5,
61 - 69)
30 - 40
(3.1 - 4.1, 22 - 30)
: Do not re-use.
: Nm (kg-m, in-lb)
: Nm (kg-m, ft-lb)
1
p
2
p
3
p
4
p
5
p
6
p
7
p
Piston ring
Piston
Piston pin
Connecting rod bearing
Connecting rod
Main bearing cap
Rear plate
Refer to
Assembly
NEM376
8
p
9
p
10
p
11
p
12
p
13
p
14
p
Flywheel
Rear oil seal
Rear oil seal retainer
Gusset
Cylinder block
Main bearing
Crankshaft
EM-166
15
p
16
p
17
p
18
p
19
p
20
p
Main bearing
Gusset
Drain plug
Pilot bushing
Plate
Oil jet
CD20T
CYLINDER BLOCK
Preparation
Preparation
I
SEM707D
Disassembly
PISTON AND CRANKSHAFT
SEM895
Heater
SEM360D
Engine front
1.
2.
3.
4.
5.
6.
7.
SEM359F
9.
SEM291
EM-167
CD20T
CYLINDER BLOCK
Inspection
Inspection
PISTON AND PISTON PIN CLEARANCE
1.
Side clearance:
Unit: mm (in)
Feeler
gauge
OK
Feeler gauge
Ring
Standard
Limit
Top ring
0.020 - 0.040
(0.0008 - 0.0016)
0.10 (0.0039)
2nd ring
0.050 - 0.085
(0.0020 - 0.0033)
0.10 (0.0039)
Oil ring
0.030 - 0.070
(0.0012 - 0.0028)
0.10 (0.0039)
SEM024AA
EM-168
CD20T
CYLINDER BLOCK
Inspection (Contd)
Piston
Press-fit
End gap:
Feeler
gauge
Unit: mm (in)
Ring
Ring
SEM599A
Standard
Limit
Top ring
Bore grade 1, 2, 3
0.22 - 0.32 (0.0087 - 0.0126)
Bore grade 4, 5
0.12 - 0.22 (0.0047 - 0.0087)
1.0 (0.039)
2nd ring
0.7 (0.028)
Oil ring
0.6 (0.024)
If out of specification, replace piston ring. If gap exceeds maximum limit with new ring, rebore cylinder and use oversize piston and piston rings.
Refer to SDS (EM-199).
I When replacing the piston, check the cylinder block surface for
scratches or evidence of seizure. If scratches or evidence of
seizure is found, hone or replace the cylinder block.
SEM360F
4.
5.
SEM506A
EM-169
CD20T
CYLINDER BLOCK
Inspection (Contd)
I
I
Counter weight
Main journal
SEM566B
0
1
2
Identification color:
Grade 0
Yellow
Grade 1
Green
Grade 2
Brown
Grade 3
Black
Grade 4
Blue
SEM706DA
For example:
Main journal grade number: 1
Crankshaft journal grade number: 2
Main bearing grade number = 1 + 2 = 3
Main bearing thickness:
Refer to SDS (EM-200).
SEM706A
Inside micrometer
AEM027
EM-170
CD20T
CYLINDER BLOCK
Inspection (Contd)
4.
5.
Counter weight
Pin journal
I
I
I
I
SEM705D
Identification color
Grade 0: Black
Grade 1: Yellow
Grade 2: Blue
Clearance (D d):
0.025 - 0.044 mm (0.0010 - 0.0017 in)
If clearance exceeds the specifications, replace the bearing.
Clearance = D d
SEM575B
EM-171
CYLINDER BLOCK
CD20T
Inspection (Contd)
Bearing replacement
I Remove bearing with a suitable tool.
Do not scratch inner surface of connecting rod.
SEM906
1.
2.
SEM907
EM133
CRANKSHAFT
1.
2.
Taper:
Out-of-round:
SEM316A
3.
SEM601A
EM-172
CD20T
CYLINDER BLOCK
Inspection (Contd)
Measuring points
Warpage of surface:
Less than 0.1 mm (0.004 in)
SEM655A
H = 227.75-227.85 mm
(8.9665-8.9705 in)
NEM210
CYLINDER BORE
1.
2.
0.2 (0.008)
Out-of-round (X Y) standard
0.015 (0.0006)
Taper (A B) standard
0.010 (0.0004)
SEM704DA
EM-173
CYLINDER BLOCK
CD20T
Inspection (Contd)
Front
SEM176B
Reboring
1.
SEM904-A
PISTON-TO-BORE CLEARANCE
Using micrometer
1.
2.
EM-174
CD20T
CYLINDER BLOCK
Inspection (Contd)
SEM550
Assembly
PISTON
I
I
I
SEM703D
I
I
EM156
Teflon tube
set position
1, 2, 3
4, 5
No mark
SEM251D
CRANKSHAFT
1.
I
I
I
Front
SEM617
EM-175
CYLINDER BLOCK
CD20T
Assembly (Contd)
Bearing No.
2.
3.
4.
I
I
Engine
front
NEM377
I
I
Engine front
SEM362F
5.
Feeler gauge
SEM363F
1.
SEM909
EM-176
CD20T
CYLINDER BLOCK
Assembly (Contd)
2.
I
I
I
I
SEM620-A
3.
I
KV10112100
SEM364F
Feeler gauge
SEM365F
FLYWHEEL RUNOUT
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in)
EM426
EM-177
QG
General Specifications
Engine
NCEM0028
QG16DE
QG18DE
Classification
Gasoline
Cylinder arrangement
4, in-line
Displacement
cm3 (cu in)
1,596 (97.39)
1,769 (107.94)
Bore stroke
mm (in)
Valve arrangement
DOHC
Firing order
1-3-4-2
Compression
Oil
Compression ratio
9.5
EM120
QG16DE
222
228
-4 (16)
52 (32)
44
QG18DE
222
236
0 (20)
56 (36)
44
Valve timing
Compression Pressure
NJEM0029
Minimum
Cylinder Head
NCEM0030
Unit: mm (in)
Standard
Limit
0.1 (0.004)
EM-178
QG
Valve
Valve
NCEM0031
VALVE
NCEM0031S01
Unit: mm (in)
T (Margin thickness)
SEM188A
Intake
Exhaust
Exhaust
Intake
Exhaust
Valve length L
4515 - 4545
0.2 (0.008)
VALVE SPRING
NCEM0031S02
Free height
mm (in)
40.0 (1.575)
Standard
Limit
VALVE LIFTER
NCEM0031S10
Unit: mm (in)
Valve lifter outside diameter
VALVE CLEARANCE
NCEM0031S11
Unit: mm (in)
For adjusting
For checking
Hot
Hot
Intake
Exhaust
EM-179
QG
VALVE GUIDE
NCEM0031S04
Unit: mm (in)
MEM096A
Intake
Outer diameter
Exhaust
Standard
Service
Standard
Service
Valve guide
Inner diameter
[Finished size]
0.027 - 0.059 (0.0011 - 0.027 - 0.049 (0.0011 - 0.027 - 0.059 (0.0011 - 0.027 - 0.049 (0.0011 0.0023)
0.0019)
0.0023)
0.0019)
Projection length L
AVAILABLE SHIMS
NCEM0031S07
Thickness mm (in)
Identification mark
2.00 (0.0787)
2.00
2.02 (0.0795)
2.02
2.04 (0.0803)
2.04
2.06 (0.0811)
2.06
2.08 (0.0819)
2.08
2.10 (0.0827)
2.10
2.12 (0.0835)
2.12
2.14 (0.0843)
2.14
2.16 (0.0850)
2.16
2.18 (0.0858)
2.18
2.20 (0.0866)
2.20
2.22 (0.0874)
2.22
2.24 (0.0882)
2.24
2.26 (0.0890)
2.26
2.28 (0.0898)
2.28
2.30 (0.0906)
2.30
2.32 (0.0913)
2.32
EM-180
QG
Valve (Contd)
Thickness mm (in)
Identification mark
2.34 (0.0921)
2.34
2.36 (0.0929)
2.36
2.38 (0.0937)
2.38
2.40 (0.0945)
2.40
2.42 (0.0953)
2.42
2.44 (0.0961)
2.44
2.46 (0.0969)
2.46
2.48 (0.0976)
2.48
2.50 (0.0984)
2.50
2.52 (0.0992)
2.52
2.54 (0.1000)
2.54
2.56 (0.1008)
2.56
2.58 (0.1016)
2.58
2.60 (0.1024)
2.60
2.62 (0.1031)
2.62
2.64 (0.1039)
2.64
2.66 (0.1047)
2.66
2.68 (0.1055)
2.68
2.70 (0.1063)
2.70
2.72 (0.1071)
2.72
2.74 (0.1079)
2.74
2.76 (0.1087)
2.76
2.78 (0.1094)
2.78
2.80 (0.1102)
2.80
2.82 (0.1110)
2.82
2.84 (0.1118)
2.84
2.86 (0.1126)
2.86
2.88 (0.1134)
2.88
2.90 (0.1142)
2.90
2.92 (0.1150)
2.92
2.94 (0.1157)
2.94
2.96 (0.1165)
2.96
2.98 (0.1173)
2.98
EM-181
QG
Indicate
T1 = 2.800 mm
(0.1102 in)
Shim
AEM236
VALVE SEAT
NCEM0031S05
Unit: mm (in)
INTAKE
Standard
EXHAUST
Standard
1.20 - 1.68
(0.0472 - 0.0661)
1.06 - 1.34
(0.0417 - 0.0528)
5.9 (0.232)
5.65 (0.2224)
Oversize
1.20 - 1.68
(0.0472 - 0.0661)
Oversize
1.06 - 1.34
(0.0417 - 0.0528)
5.65 (0.2224)
5.9 (0.232)
SEM574DA
SEM573DA
Dia.
QG
Dia.
QG
EM-182
QG
Valve (Contd)
NCEM0031S08
Unit: mm (in)
AEM343
Intake
Exhaust
Depth (L)
NCEM0032
Unit: mm (in)
Engine model
Intake
QG16DE
QG18DE
Cam height A
Exhaust
0.20 (0.0079)
EM671
Standard
Limit
0.15 (0.0059)
Inner diameter of
camshaft bearing
No. 1
No. 2 to No. 5
Outer diameter of
camshaft journal
No. 1
No. 2 to No. 5
0.1 (0.004)
0.20 (0.0079)
EM-183
QG
Cylinder Block
NCEM0033
100 (3.94)
60 (2.36)
20 (0.79)
Unit: mm (in)
Crankshaft center
SEM171D
QG16DE
QG18DE
Limit
Standard
Surface flatness
Height H (nominal)
Cylinder bore
inner diameter
Standard
0.1 (0.004)
Grade No. 1
76.000 - 76.0610
(2.9921 - 2.9925)
80.000 - 80.010
(3.1496 - 3.1500)
Grade No. 2
76.010 - 76.020
(2.7957 - 2.7961)
80.010 - 80.020
(3.1500 - 3.1504)
Grade No. 3
76.020 - 76.030
(2.7961 - 2.9933)
80.020 - 80.030
(3.1504 - 3.1508)
0.2 (0.008)
Out-of-round (X Y)
Taper (A B)
0.05 (0.0020)
0.2 (0.008)
EM-184
QG
NCEM0034
PISTON
NCEM0034S01
Unit: mm (in)
SEM882E
QG16DE
QG18DE
Grade No. 1
75.975 - 75.985
(2.9911 - 2.9915)
79.965 - 79.975
(3.1482 - 3.1486)
Grade No. 2
75.985 - 75.995
(2.9915 - 2.9919)
79.975 - 79.985
(3.1486 - 3.1490)
Grade No. 3
75.995 - 76.005
(2.9919 - 2.9923)
79.985 - 79.995
(3.1490 - 3.1494)
76.475 - 76.505
(3.0108 - 3.0120)
80.215 - 80.245
(3.1581 - 3.1592)
76.975 - 77.005
(3.0305 - 3.0317)
80.465 - 80.495
(3.1679 - 3.1691)
44.5 (1.7520)
42.3 (1.665)
18.987 - 18.999
(0.7475 - 0.7080)
18.993 - 19.005
(0.7478 - 0.7482)
0.015 - 0.035
(0.0006 - 0.0014)
0.025 - 0.045
(0.0010 - 0.0018)
Standard
a dimension
PISTON RING
NCEM0034S02
Unit: mm (in)
QG16DE
QG18DE
Limit
Standard
Top
Side clearance
2nd
Oil
2nd
0.110 (0.0043)
Top
End gap
0.100 (0.0039)
Oil
0.53 (0.0209)
0.98 (0.0386)
0.95 (0.0374)
PISTON PIN
NCEM0034S03
Unit: mm (in)
QG16DE
Piston pin outer diameter
Piston pin to piston clearance
Piston pin to connecting rod bushing
clearance
QG18DE
Limit
0.023 (0.0009)
EM-185
QG
Connecting Rod
Connecting Rod
NCEM0035
Unit: mm (in)
Center distance
0.15 (0.0059)
0.3 (0.012)
Side clearance
Limit
0.5 (0.020)
Crankshaft
NCEM0036
Unit: mm (in)
Grade No. 0
Grade No. 1
Grade No. 2
Grade No. 0
Grade No. 1
Grade No. 2
Center distance r
Limit
Standard
Limit
Standard
Limit
Out-of-round (X Y)
Taper (A B)
Runout [TIR*]
Standard
0.3 (0.012)
Main Bearing
NCEM0037
STANDARD
NCEM0037S01
Grade No.
Thickness T mm (in)
Identification color
Black
Red
Green
Yellow
Blue
UNDERSIZE
NCEM0037S02
Unit: mm (in)
Thickness T
0.25 (0.0098)
0.50 (0.0197)
EM-186
QG
NCEM0038
STANDARD SIZE
NCEM0038S01
Unit: mm (in)
Grade No.
Thickness
Brown
Green
UNDERSIZE
NCEM0038S02
Unit: mm (in)
Grade No.
Thickness
0.08 (0.0031)
0.12 (0.0047)
0.25 (0.0098)
Bearing Clearance
NCEM0039
Unit: mm (in)
Standard
0.1 (0.004)
Standard
0.1 (0.004)
Miscellaneous Components
NCEM0040
Unit: mm (in)
Flywheel runout [TIR*]
EM-187
SR20DE
General Specifications
Cylinder arrangement
cm3 (cu in)
Displacement
Valve timing
In-line 4
mm (in)
1,998 (121.92)
86 x 86 (3.39 x 3.39)
Valve arrangement
DOHC
Firing order
1-3-4-2
Oil
Compression ratio
10.0
EM120
Unit: degree
SR20DE
232
240
54
49
1,275
(12.75, 13.0, 185)
Minimum
1,079
(10.79, 11.0, 156)
98
(0.98, 1.0, 14)
CYLINDER HEAD
Unit: mm (in)
Standard
Limit
Less than
0.03 (0.0012)
0.1 (0.004)
EM-188
SR20DE
VALVE
Unit: mm (in)
HLA outer diameter
16.980 - 16.993
(0.6685 - 0.6690)
17.000 - 17.020
(0.6693 - 0.6701)
0.007 - 0.040
(0.0003 - 0.0016)
Valve guide
Unit: mm (in)
SEM188
Exhaust
Valve length L
Intake
Exhaust
Exhaust
NEM032
Intake
4515 - 4545
Exhaust
Intake
10.023 - 10.034
(0.3946 - 0.3950)
10.223 - 10.234
(0.4025 - 0.4029)
Exhaust
10.023 - 10.034
(0.3946 - 0.3950)
10.223 - 10.234
(0.4025 - 0.4029)
Outer
diameter
Valve margin T
Intake
1.3 (0.051)
Exhaust
1.6 (0.063)
Valve guide
Inner diam- Intake
eter (Finished size) Exhaust
Cylinder head
valve guide
hole diameter
Valve clearance
Intake
0 (0)
Exhaust
0 (0)
mm (in)
49.36 (1.9433)
569.00 - 641.57
(58.02 - 65.42, 127.93 - 144.25)
at 30.0 (1.181)
Standard
mm (in)
10.175 - 10.196
(0.4006 - 0.4014)
Exhaust
9.975 - 9.996
(0.3927 - 0.3935)
10.175 - 10.196
(0.4006 - 0.4014)
Limit
Intake
0.020 - 0.053
(0.0008 - 0.0021)
0.08 (0.0031)
Exhaust
0.040 - 0.073
(0.0016 - 0.0029)
0.1 (0.004)
0.2 (0.008)
Projection length L
Limit
Intake
Stem to guide
clearance
Pressure
N (kg, lb) at height mm (in)
6.000 - 6.018
(0.2362 - 0.2369)
9.975 - 9.996
(0.3927 - 0.3935)
Valve spring
Out-of-square
Service
Valve guide
Free height
Standard
EM-189
SR20DE
Valve seat
SR20DE engine
Unit: mm (in)
Cylinder head
INTAKE
EXHAUST
Standard
Standard
*29.35 - 29.65
(1.1555 - 1.1673)
*4453 - 4507
*33.6 - 33.8
(1.323 - 1.331)
Contacting width (W): 1.385 - 1.401
(0.0545 - 0.0552)
*4453 - 4507
Oversize
Oversize
*4453 - 4507
*33.6 - 33.8
(1.323 - 1.331)
Contacting width (W): 1.385 - 1.401
(0.0545 - 0.0552)
:* Machining data
*4453 - 4507
Standard
NEM212
Service
In.
Ex.
Ex.
Ex.
6.25 (0.2461)
Ex.
6.25 (0.2461)
Depth (H)
Height (h)
EM-190
SR20DE
Valve clearance
Intake
0 (0)
Exhaust
0 (0)
Valve clearance T
T10.025 (0.001)
Valve
Available shim
Valve
SEM095D
Thickness mm (in)
Identification mark
2.800 (0.1102)
28
00
2.825 (0.1112)
28
25
2.850 (0.1122)
28
50
2.875 (0.1132)
28
75
2.900 (0.1142)
29
00
2.925 (0.1152)
29
25
2.950 (0.1161)
29
50
2.975 (0.1171)
29
75
3.000 (0.1181)
30
00
3.025 (0.1191)
30
25
3.050 (0.1201)
30
50
3.075 (0.1211)
30
75
3.100 (0.1220)
31
00
3.125 (0.1230)
31
25
3.150 (0.1240)
31
50
3.175 (0.1250)
31
75
3.200 (0.1260)
32
00
Shim
Indicate
T = 2.800 mm
(0.1102 in)
SEM096D
EM-191
SR20DE
CYLINDER BLOCK
Unit: mm (in)
Limit
0.030 - 0.071
(0.0012 - 0.0028)
0.15 (0.0059)
Inner diameter of
camshaft bearing
28.000 - 28.021
(1.1024 - 1.1032)
Outer diameter of
camshaft journal
27.950 - 27.970
(1.1004 - 1.1012)
Less than
0.02 (0.0008)
0.1 (0.004)
Camshaft sprocket
runout [TIR*]
Less than
0.25 (0.0098)
0.055 - 0.139
(0.0022 - 0.0055)
0.20 (0.0079)
211.25 - 211.35
(8.3169 - 8.3208)
Standard
Camshaft journal to
bearing clearance
Unit: mm (in)
100 (3.94)
60 (2.36)
10 (0.39)
SEM008D
EM671
SR20DE
SEM010D
Surface flatness
Cam height A
Standard
Intake
37.775 (1.4872)
Exhaust
37.404 (1.4726)
Limit
Cylinder bore
0.2 (0.008)
Inner diameter
Standard
Grade No. 1
Grade No. 2
Grade No. 3
Wear limit
0.20 (0.0079)
Out-of-round (X Y)
Taper (A B C)
EM-192
Grade No. 0
Grade No. 1
Grade No. 2
Grade No. 3
SR20DE
Piston pin
Unit: mm (in)
Available piston
Unit: mm (in)
CONNECTING ROD
SEM750C
Center distance
Standard
85.980 - 85.990 (3.3850 - 3.3854)
Grade No. 2
Grade No. 3
a dimension
Piston clearance to cylinder
block
Piston pin hole diameter
136.30 (5.3661)
Grade No. 1
0.20 (0.0079)
oversize (Service)
Unit: mm (in)
Limit
0.15 (0.0059)
0.3 (0.0012)
Side clearance
Standard
Piston ring
Limit
Unit: mm (in)
Side clearance
Top
Standard
Limit
2nd
Standard
Limit
Oil ring
Ring gap
Top
Standard
Limit
2nd
Standard
Limit
Oil
Standard
Limit
EM-193
SR20DE
CRANKSHAFT
Grade No. 1
Grade No. 2
Grade No. 3
Grade No. 1
Grade No. 2
Center distance r
SEM021D
Out-of-round (X Y)
Pin journal: Less than 0.0025 (0.0001)
Main journal: Less than 0.005 (0.0002)
Standard
Taper (A B)
Pin journal: Less than 0.0025 (0.0001)
Main journal: Less than 0.005 (0.0002)
Standard
Grade
number
Thickness T
1.977 - 1.980
(0.0778 - 0.0780)
Black (A)
1.980 - 1.983
(0.0780 - 0.0781)
Red (B)
1.983 - 1.986
(0.0781 - 0.0782)
Green (C)
1.986 - 1.989
(0.0782 - 0.0783)
1.989 - 1.992
(0.0783 - 0.0784)
Blue (E)
1.992 - 1.995
(0.0784 - 0.0785)
Pink (F)
1.995 - 1.998
(0.0785 - 0.0787)
White (G)
Runout [TIR]
Standard
Limit
Limit
0.30 (0.0118)
Identification
color (mark)
Width W
18.9 - 19.1
(0.744 - 0.752)
Yellow (D)
Out-of-round X - Y
Taper
A-B
A
EM715
EM-194
Undersize
Thickness T
Main journal
diameter Dm
0.25 (0.0098)
2.109 - 2.117
(0.0830 - 0.0833)
SR20DE
Bearing clearance
Unit: mm (in)
Standard size
Standard
Unit: mm (in)
Grade
number
Thickness T
1.500 - 1.503
(0.0591 - 0.0592)
1.503 - 1.506
(0.0592 - 0.0593)
1.506 - 1.509
(0.0593 - 0.0594)
Width W
Limit
Identification
color (mark)
0.05 (0.0020)
Black or Yellow
Limit
16.9 - 17.1
(0.665 - 0.673)
0.065 (0.00256)
Brown or Red
Green or Blue
MISCELLANEOUS COMPONENTS
Unit: mm (in)
Undersize
Unit: mm (in)
Undersize
Thickness T
0.08 (0.0031)
1.541 - 1.549
(0.0607 - 0.0610)
0.12 (0.0047)
1.561 - 1.569
(0.0615 - 0.0618)
0.25 (0.0098)
1.626 - 1.634
(0.0640 - 0.0643)
0.25 (0.0098)
0.15 (0.0059)
EM-195
0.2 (0.008)
CD20T
General Specifications
Cylinder arrangement
Displacement
In-line 4
3
cm (cu in)
mm (in)
Valve timing
1,974 (120.45)
84.5 88.0 (3.329 3.465)
Valve arrangement
OHC
Firing order
1-3-4-2
Oil
Compression ratio
22.2
EM120
Unit: degree
a
248
232
14
38
12
56
Limit
Difference limit
between cylinders
CYLINDER HEAD
Unit: mm (in)
Unit: mm (in)
Standard
Max. tolerance
Camshaft journal
clearance
0.045 - 0.086
(0.0018 - 0.0034)
0.1 (0.004)
Inner diameter of
camshaft bearing
30.000 - 30.021
(1.1811 - 1.1819)
Outer diameter of
camshaft journal
29.935 - 29.955
(1.1785 - 1.1793)
Camshaft runout
Less than
0.02 (0.0008)
0.05 (0.0020)
0.115 - 0.188
(0.0045 - 0.0074)
EM671
Cam height A
EM-196
Intake
Exhaust
CD20T
VALVE
Valve spring
Unit: mm (in)
Inner
Free height
Outer
mm (in)
Intake
36.57 (1.4398)
42.25 (1.6634)
Exhaust
41.27 (1.6248)
49.35 (1.9429)
Intake
233.21
(23.78, 52.43)
at 22.2 (0.874)
437.69
(44.63, 98.41)
at 25.7 (1.012)
Exhaust
233.4
(23.8, 52.5)
at 22.2 (0.874)
437.4
(44.6, 98.3)
at 25.7 (1.012)
Intake
208.01
(21.21, 46.77)
at 22.2 (0.874)
392.28
(40.00, 88.20)
at 25.7 (1.012)
Exhaust
208.69
(21.28, 46.92)
at 22.2 (0.874)
390.42
(39.81, 87.78)
at 25.7 (1.012)
Pressure
N (kg, lb)
at height
mm (in)
Standard
SEM188
Exhaust
Valve length L
Intake
99.53 - 99.97
(3.9185 - 3.9358)
Exhaust
99.38 - 99.82
(3.9126 - 3.9299)
Limit
Out-of-square
mm (in)
Intake
6.965 - 6.980
(0.2742 - 0.2748)
Intake
Exhaust
6.945 - 6.960
(0.2734 - 0.2740)
Exhaust
4530
0.5 (0.020)
0.5 (0.020)
Valve guide
Unit: mm (in)
Standard
Service
11.023 - 11.034
(0.4340 - 0.4344)
11.223 - 11.234
(0.4418 - 0.4423)
Valve guide
Outer diameter
Valve guide
Inner diameter
(Finished size)
7.000 - 7.015
(0.2756 - 0.2762)
10.985 - 10.996
(0.4325 - 0.4329)
0.027 - 0.049
(0.0011 - 0.0019)
11.185 - 11.196
(0.4404 - 0.4408)
Standard
Max. tolerance
Intake
0.020 - 0.050
(0.0008 - 0.0020)
0.10 (0.0039)
Exhaust
0.040 - 0.070
(0.0016 - 0.0028)
0.10 (0.0039)
EM-197
0.1 (0.004)
CD20T
Unit: mm (in)
VALVE LIFTER
Unit: mm (in)
Valve lifter outer diameter
34.959 - 34.975
(1.3763 - 1.3770)
Standard
Cylinder head valve lifter hole
diameter
34.998 - 35.018
(1.3779 - 1.3787)
Clearance
0.023 - 0.059
(0.0009 - 0.0023)
Standard
Limit
0.1 (0.004)
AVAILABLE SHIMS
Thickness mm (in)
Identification mark
2.20 (0.0866)
220
2.25 (0.0886)
225
2.30 (0.0906)
230
2.35 (0.0925)
235
2.40 (0.0945)
240
2.45 (0.0965)
245
2.50 (0.0984)
250
2.55 (0.1004)
255
2.60 (0.1024)
260
2.65 (0.1043)
265
2.70 (0.1063)
270
2.75 (0.1083)
275
2.80 (0.1102)
280
2.85 (0.1122)
285
2.90 (0.1142)
290
SEM917-B
VALVE CLEARANCE
Unit: mm (in)
For adjusting
Hot
Intake
Exhaust
0.25
(0.010
0.39
(0.015
0.35
0.014)
0.49
0.019)
Cold*
(reference data)
0.20 - 0.30
(0.008 - 0.012)
0.33 - 0.43
(0.013 - 0.017)
SEM113FA
EM-198
CD20T
CYLINDER BLOCK
Unit: mm (in)
Standard
Piston
skirt
diameter
Grade No. 1
84.460 - 84.470
(3.3252 - 3.3256)
Grade No. 2
84.470 - 84.480
(3.3256 - 3.3260)
Grade No. 3
84.480 - 84.490
(3.3260 - 3.3264)
Grade No. 4
84.490 - 84.500
(3.3264 - 3.3268)
Grade No. 5
84.500 - 84.510
(3.3268 - 3.3272)
0.25 (0.0098)
84.710 - 84.760
(3.3350 - 3.3370)
0.5 (0.020)
84.960 - 85.010
(3.3449 - 3.3468)
Oversize
Surface flatness
Standard
Limit
0.10 (0.0039)
62 (2.44)
27.991 - 27.999
(1.1020 - 1.1023)
Grade No. 1
84.500 - 84.510
(3.3268 - 3.3272)
Piston ring
Grade No. 2
Unit: mm (in)
84.510 - 84.520
(3.3272 - 3.3276)
Inner
diameter
Cylinder
bore
Grade No. 3
84.520 - 84.530
(3.3276 - 3.3279)
Side clearance
0.2
(0.008)
Top
Standard
Grade No. 4
Limit
84.530 - 84.540
(3.3279 - 3.3283)
Standard
Grade No. 5
Limit
Oil
Out-ofround
(X Y)
0.04 (0.0016)
Taper
(A B)
0.04 (0.0016)
0.030 - 0.050
(0.0012 - 0.0020)
Standard
End gap
Top
Standard
Grade No. 0
56.654 - 56.663
(2.2305 - 2.2308)
Main journal inner
diameter
0.10 (0.0039)
2nd
84.540 - 84.550
(3.3283 - 3.3287)
Bore grade 4, 5
Limit
Grade No. 1
56.663 - 56.672
(2.2308 - 2.2312)
Bore grade 1, 2, 3
1.0 (0.039)
2nd
Standard
Grade No. 2
Limit
56.672 - 56.680
(2.2312 - 2.2315)
Oil
Standard
Limit
EM-199
CD20T
Piston pin
CRANKSHAFT
Unit: mm (in)
Unit: mm (in)
27.994 - 28.000
(1.1021 - 1.1024)
Grade No. 0
52.967 - 52.975
(2.0853 - 2.0856)
Grade No. 1
52.959 - 52.967
(2.0850 - 2.0853)
Grade No. 2
52.951 - 52.959
(2.0847 - 2.0850)
Grade No. 0
49.968 - 49.974
(1.9672 - 1.9675)
Grade No. 1
49.961 - 49.968
(1.9670 - 1.9672)
Grade No. 2
49.954 - 49.961
(1.9667 - 1.9670)
0.004 to 0 (0.0002 to 0)
0.025 - 0.044
(0.0010 - 0.0017)
CONNECTING ROD
Unit: mm (in)
Bend [per 100 mm (3.94 in)]
Standard
Torsion
Standard
28.025 - 28.038
(1.1033 - 1.1039)
Standard
0.3 (0.012)
Standard
Limit
0.3 (0.012)
Width W mm (in)
Identification color
Thickness T mm (in)
Yellow
Green
Black
Blue
20.0 (0.787)
17.8 (0.701)*
Brown
*: Contacting width
Thickness T mm (in)
Width W mm (in)
Yellow
Green
Black
Blue
27.95 (1.1004)
21.35 (0.8405)*
*: Contacting width
EM-200
Identification color
Brown
CD20T
Bearing clearance
Unit: mm (in)
Crank journal diameter
STD
52.951 - 52.975
(2.0847 - 2.0856)
52.701 - 52.725
(2.0748 - 2.0758)
Unit: mm (in)
Main bearing clearance
0.039 - 0.065
(0.0015 - 0.0026)
Standard
Connecting rod bearing clearance
Standard
0.031 - 0.055
(0.0012 - 0.0022)
TURBOCHARGER
Unit: mm (in)
Grade 1
Grade 2
Black
49.968 - 49.974
(1.9672 - 1.9675)
Yellow
49.961 - 49.968
(1.9670 - 1.9672)
Blue
49.954 - 49.961
(1.9667 - 1.9670)
49.874 - 49.894*
(1.9635 - 1.9643)
49.834 - 49.854*
(1.9620 - 1.9628)
49.704 - 49.724*
(1.9568 - 1.9576)
*: Reference value
Rotor shaft
Runout [TIR*]
End play
MISCELLANEOUS COMPONENTS
Unit: mm (in)
Flywheel
Runout [TIR*]
*: Total indicator reading
EM-201
EM-202
CD20T