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Engine Mechanical System

Specifications
Description Specifications Limit
General
Type V-type, DOHC
Number of cylinders 6
Bore 96mm (3.7795 in.)
Stroke 87mm (3.4252 in.)
Total displacement 3,778cc (230.55 cu.In.)
Compression ratio 11.5 : 1
Firing order 1-2-3-4-5-6
Valve timing
Open BTDC 40° ~ ATDC 10° (3.8)
Intake
Close ABDC 74° ~ ABDC 24° (3.8)
Open BBDC 52° ~ BBDC 2°
Exhaust
Close ATDC 0° ~ ATDC 50°
Cylinder Head
Less than 0.05 mm (0.0019 in.)
Flatness of gasket surface
[Less than 0.02 mm (0.0008 in.) / 150 x 150]
Less than 0.1 mm ( 0.0039 in.)
Intake
Flatness of manifold [Less than 0.03 mm (0.001 in.) / 110 x 110]
mounting Less than 0.1 mm (0.0039 in.)
Exhaust
[Less than 0.03 mm (0.001 in.) / 110 x 110]
Camshaft
LH Intake 47.2 mm (1.8582 in.)
Camshaft Exhaust 45.8 mm (1.8031 in.)
Cam height
RH Intake 47.2 mm (1.8582 in.)
Camshaft Exhaust 45.8 mm (1.8031 in.)
No.1: 27.964 ~ 27.978 mm (1.1009 ~ 1.1015 in.)
Intake
LH No.2,3,4: 23.954 ~ 23.970 mm (0.9430 ~ 0.9437 in.)
Camshaft No.1: 27.964 ~ 27.978 mm (1.1009 ~ 1.1015 in.)
Exhaust
No.2,3,4: 23.954 ~ 23.970 mm (0.9430 ~ 0.9437 in.)
Journal outer diameter
No.1: 27.964 ~ 27.978 mm (1.1009 ~ 1.1015 in.)
Intake
RH No.2,3,4: 23.954 ~ 23.970 mm (0.9430 ~ 0.9437 in.)
Camshaft No.1: 27.964 ~ 27.978 mm (1.1009 ~ 1.1015 in.)
Exhaust
No.2,3,4: 23.954 ~ 23.970 mm (0.9430 ~ 0.9437 in.)
No.1: 0.027 ~ 0.057 mm (0.0011 ~ 0.0022 in.)
Intake
LH, RH No.2,3,4: 0.030 ~ 0.067 mm (0.0012 ~ 0.0026 in.)
Bearing oil clearance
camshaft No.1: 0.027 ~ 0.057 mm (0.0011 ~ 0.0022 in.)
Exhaust
No.2,3,4: 0.030 ~ 0.067 mm (0.0012 ~ 0.0026 in.)
End play 0.02 ~ 0.18 mm (0.0008 ~ 0.0071 in.)
Valve
Intake 105.27 mm (4.1445 in.)
Valve length
Exhaust 105.50 mm (4.1535 in.)
Intake 5.465 ~ 5.480 mm (0.2151 ~ 0.2157 in.)
Stem outer diameter
Exhaust 5.458 ~ 5.470 mm (0.2149 ~ 0.2153 in.)
Face angle 45.25° ~ 45.75°
Thickness of valve head Intake 1.56 ~ 1.86 mm (0.06142 ~ 0.07323 in.)
(margin) Exhaust 1.73 ~ 2.03 mm (0.06811 ~ 0.07992 in.)
Less than. 0.07 mm (0.00275
Intake 0.020 ~ 0.047 mm (0.00078 ~ 0.00185 in.)
Valve stem to valve guide in.)
clearance Less than. 0.09 mm (0.00354
Exhaust 0.030 ~ 0.054 mm (0.00118 ~ 0.00212 in.)
in.)
Valve guide
Intake 5.500 ~ 5.512 mm (0.2165 ~ 0.2170 in.)
Inner diameter
Exhaust 5.500 ~ 5.512 mm (0.2165 ~ 0.2170 in.)
Intake 41.8 ~ 42.2 mm (1.6457 ~ 1.6614 in.)
Length
Exhaust 41.8 ~ 42.2 mm (1.6457 ~ 1.6614 in.)
Valve seat
Intake 1.15 ~ 1.45 mm (0.05118 ~ 0.05709 in.)
Width of seat contact
Exhaust 1.35 ~ 1.65 mm (0.05315 ~ 0.06496 in.)
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Intake 44.75° ~ 45.20°
Seat angle
Exhaust 44.75° ~ 45.20°
Valve spring
Free length 46.2 mm (1.8189 in.)
When mounting height 34mm
19.3 ± 0.8 kg (42.5 ± 1.816)
(1.3385 in)
Load
When mounting height 23.8mm
38.5 ± 1.2 kg (84.9 ± 2.618)
(0.9370 in)
Out of squareness Less than 1.5° (Max)
MLA
Intake 34.964 ~ 34.980 mm (1.3765 ~ 1.3772 in.)
MLA outer diameter
Exhaust 34.964 ~ 34.980 mm (1.3765 ~ 1.3772 in.)
Cylinder head tappet Intake 35.000 ~ 35.025 mm (1.3779 ~ 1.3789 in.)
bore inner diameter Exhaust 35.000 ~ 35.025 mm (1.3779 ~ 1.3789 in.)
Less than. 0.07 mm (0.0027
Intake 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in.)
MLA to tappet bore in.)
clearance Less than. 0.07 mm (0.0027
Exhaust 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in.)
in.)
Valve clearance
0.10 ~ 0.30 mm
Intake 0.17 ~ 0.23 mm (0.0067 ~ 0.0090 in.)
(0.0039 ~ 0.0118 in.)
0.20 ~ 0.40 mm
Exhaust 0.27 ~ 0.33 mm (0.0106 ~ 0.0129 in.)
(0.0078 ~ 0.0157 in.)
Cylinder block
Cylinder bore 96.00 ~ 96.03mm (3.7795 ~ 3.7807 in)
Less than 0.05 mm (0.0019 in.)
Flatness of gasket surface
[Less than 0.02 mm (0.0008 in.) / 150 x 150]
Piston
Piston outer diameter 95.96 ~ 95.99mm (3.7779 ~ 3.7791 in)
Piston to cylinder clearance 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in.)
No. 1 ring groove 1.25 ~ 1.26mm (0.0492 ~ 0.0496 in)
Ring groove width No. 2 ring groove 1.23 ~ 1.25 mm (0.0484 ~ 0.0492 in.)
Oil ring groove 2.01 ~ 2.03 mm (0.0791 ~ 0.0799 in.)
Piston ring
No. 1 ring 0.04 ~ 0.08 mm (0.0016 ~ 0.0032 in.) 0.1 mm (0.004 in.)
Side clearance No. 2 ring 0.04 ~ 0.08 mm (0.0016 ~ 0.0032 in.) 0.1 mm (0.004 in.)
Oil ring 0.02 ~ 0.065mm (0.00079 ~ 0.00256 in) 0.2 mm (0.008 in.)
No. 1 ring 0.17 ~ 0.32 mm (0.0067 ~ 0.0126 in.) 0.6 mm (0.0236 in.)
End gap No. 2 ring 0.32 ~ 0.47mm (0.0125 ~ 0.0185 in) 0.7 mm (0.0275 in.)
Oil ring 0.2 ~ 0.5mm (0.0078 ~ 0.0196 in) 0.8 mm (0.0315 in.)
Piston pin
Piston pin outer diameter 21.097 ~ 22.000 mm (0.8306 ~ 0.8661 in.)
Piston pin hole inner diameter 22.004 ~ 22.010 mm (0.8662 ~ 0.8665 in.)
Piston pin hole clearance 0.004 ~ 0.013 mm (0.00016 ~ 0.00051 in.)
Connecting rod small end inner diameter 22.005 ~ 22.016 mm (0.8663 ~ 0.8667 in.)
Connecting rod small end hole clearance 0.005 ~ 0.019 mm (0.0002 ~ 0.0007 in.)
Connecting rod
Connecting rod big end inner diameter 58.000 ~ 58.018 mm (2.2834 ~2.2842 in.)
Connecting rod bearing oil clearance 0.028 ~ 0.046 mm (0.0011 ~ 0.0018 in.)
Side clearance 0.1 ~ 0.25 mm (0.0039 ~ 0.0098 in.)
Crankshaft
Main journal outer diameter 68.942 ~ 68.960 mm (2.7142 ~ 2.7149 in.)
Pin journal outer diameter 54.954 ~ 54.972 mm (2.1635 ~ 2.1642 in.)
Main bearing oil clearance 0.022 ~ 0.040 mm (0.0008 ~ 0.0016 in.)
End play 0.10 ~ 0.28 mm (0.0039 ~ 0.0110 in.)
Oil pump
Pressure regulating outer ring 3.8 ~ 4.2 bar
Engine oil
Total 7.3L (7.71 U.S qt., 6.42 lmp.qt., 1.92 U.S gal.)
Oil quantity Oil pan 6.8L (7.18 U.S qt., 5.98 lmp.qt., 1.79 U.S gal.)
Drain and refill 6.9L (7.29 U.S qt., 6.06 lmp.qt., 1.82 U.S gal.) Including oil filter
Oil grade Recommended 5W-30 / A5
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Allowed ACEA A3, A5 or above Meet at least one grade or
For information on SAE viscosity grades based on ambient more
temperatures, refer to the “Lubrication System”.
Oil temperature (oil pan):
Oil pressure (at 1000rpm) 108kPa(1.10kgf/cm², 15.65 psi)
110±2°C
Cooling system
Cooling method Forced circulation with water pump
Coolant quantity 8.4 L (8.87 U.S.qt., 7.38 lmp.qt., 2.21 U.S.gal.)
Type Wax pellet type
Opening temperature 88 ± 2°C
Thermostat
Fully opened temperature 100°C
Full lift 10 mm (0.3937 in.) More than
93.16 ~ 122.58 kPa
Main valve opening pressure
(0.95 ~ 1.25 kg/cm², 13.51 ~ 17.78 psi)
Radiator cap
0 ~ 6.86 kPa
Vacuum valve opening pressure
(0 ~ 0.07 kg/cm², 0 ~ 0.99 psi)
Water temperature sensor
Type Thermistor type
20°C (68°F) 2.31 ~ 2.59 KΩ
Resistance
80°C (176°F) 0.3222 KΩ

Liquid Gasket
Description Specifications
Cylinder head and cylinder block between gap
Timing chain cover
Cylinder head cover
TB1217H
Cylinder head
(Hyundai Gray RTV)
Oil seal case
Lower oil pan
Upper oil pan

Tightening Torques
Item N.m kgf.m Ib-ft
Engine Mounting
Engine support bracket bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Engine mounting insulator to engine support bracket fixing nut 63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5
Timing system
Drive belt idler bolt 44.1 ~ 53.9 4.5 ~ 5.5 32.5 ~ 39.8
Drive belt auto tensioner bolt(M12) 81.4 ~ 85.3 8.3 ~ 8.7 60.0 ~ 62.9
Drive belt auto tensioner bolt(M8) 17.7 ~ 21.6 1.8 ~ 2.2 13.0 ~ 15.9
Crankshaft pulley mounting bolt 284.5 ~ 304.1 29.0 ~ 31.0 209.8 ~ 224.2
Timing chain cover bolt A 18.6 ~ 21.6 1.9 ~ 2.2 13.7 ~ 15.9
Timing chain cover bolt B 24.5 ~ 26.5 2.5 ~ 2.7 18.1 ~ 19.5
Timing chain cover bolt C 58.8 ~ 68.6 6.0 ~ 7.0 43.4 ~ 50.6
Timing chain cover bolt D 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain auto tensioner bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain auto tensioner nut 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain auto tensioner arm bolt 18.6 ~ 21.6 1.9 ~ 2.2 13.7 ~ 15.9
Timing chain guide bolt 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Timing chain cam to cam guide bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Cylinder head
Cylinder head cover bolt (LH/RH) [4.9 ~ 5.9] + [9.8 ~ 11.8] [0.5 ~ 0.6] + [1.0 ~ 1.2] [3.6 ~ 4.3] + [7.2 ~ 8.7]
CVVT bolt (LH/RH) 64.7 ~ 76.5 6.6 ~ 7.8 47.7 ~ 56.4
Camshaft bearing cap bolt (LH/RH) [5.8] + [9.8 ~ 11.8] [0.6] + [1.0 ~ 1.2] [4.3] + [7.2 ~ 8.7]
[37.3 ~ 41.2] + [118 ~ 122°] + [3.8 ~ 4.2] + [118 ~ 122°] + [27.5 ~ 30.4] + [118 ~ 122°] + [88
Cylinder head bolt (LH/RH)
[88 ~ 92°] [88 ~ 92°] ~ 92°]
Cylinder head bolt (RH rear) 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Engine hanger bolt (LH) 44.1 ~ 53.6 4.5 ~ 5.5 32.5 ~ 39.8
Engine hanger bolt (RH) 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Exhaust OCV(oil control valve) bolt (LH/RH) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
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Intake OCV(oil control valve) bolt (LH/RH) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
high-pressure fuel pump bracket bolts 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
High-pressure fuel pump bolts 12.7 ~ 14.7 1.3 ~ 1.5 9.4 ~ 10.8
Cylinder block
Connecting rod bolt [27.5 ~ 31.3] + [68 ~ 72°] [2.8 ~ 3.2] + [68 ~ 72°] [20.2 ~ 23.1] + [68 ~ 72°]
Main bearing cap inner bolt(M11) [49.0] + [90°] [5.0] + [90°] [36.2] + [90°]
Main bearing cap outer bolt(M8) [19.6] + [120°] [2.0] + [120°] [14.5] + [120°]
Main bearing cap side bolt(M8) 29.4 ~ 31.4 3.0 ~ 3.2 21.7 ~ 23.1
Plug bolt 83.4 ~ 103.0 8.5 ~ 10.5 61.5 ~ 76.0
Oil jet bolt 27.5 ~ 31.3 2.8 ~ 3.2 20.2 ~ 23.1
Rear oil seal case bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Baffle plate bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Knock sensor (LH / RH) bolt 15.7 ~ 23.5 1.6 ~ 2.4 11.6 ~ 17.4
Drive plate bolt 71.5 ~ 75.5 7.3 ~ 7.7 52.8 ~ 55.7
Upper oil pan long bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Upper oil pan short bolt 20.6 ~ 22.6 2.1 ~ 2.3 15.2 ~ 16.6
Lubrication system
Oil drain bolt 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil pump bolt 20.6 ~ 22.6 2.1 ~ 2.3 20.6 ~ 22.6
Oil filter body bolt 20.6 ~ 22.6 2.1 ~ 2.3 15.2 ~ 16.6
Oil filter cap 31.4 ~ 38.2 3.2 ~ 3.9 23.1 ~ 28.2
Oil level gauge & water inlet pipe bolt 18.6 ~ 22.6 1.9 ~ 2.3 13.7 ~ 16.6
Lower oil pan bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pump chain cover bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pump chain tensioner bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pump chain sprocket bolt 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Cooling system
Water pump bolt A 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt B 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt C 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5
Water pump bolt D 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt E 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt F 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt G 21.6 ~ 23.5 2.2 ~ 2.4 15.9 ~ 17.4
Water pump pulley bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Water temp. control nut 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4
Water temp. control bolt 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4
Water center pipe bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water outlet pipe bolt 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4
Water in/outlet pipe to water temp. control bolt 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4
Thermostat housing bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Radiator reservoir tank screw 2.7 ~ 3.2 0.28 ~ 0.33 2.0 ~ 2.4
Cooling fan bolt 2.7 ~ 3.2 0.28 ~ 0.33 2.0 ~ 2.4
Cooling fan shroud bolt 4.9 ~ 7.8 0.5 ~ 0.8 3.6 ~ 5.8
Cooling fan motor bolt 8.8 ~ 10.8 0.9 ~ 1.1 6.4 ~ 8.0
Cooling fan controller (PWM) nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Intake and exhaust system
Air duct bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Intake air hose clamp bolt 2.9 ~ 4.9 0.3 ~ 0.5 2.2 ~ 3.6
Air cleaner assembly bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Surge tank bolt [3.9 ~ 5.9] + [9.8 ~ 11.8] [0.4 ~ 0.6] + [1.0 ~ 1.2] [2.9 ~ 4.3] + [7.2 ~ 8.7]
Surge tank nut [3.9 ~ 5.9] + [9.8 ~ 11.8] [0.4 ~ 0.6] + [1.0 ~ 1.2] [2.9 ~ 4.3] + [7.2 ~ 8.7]
VIS actuator bolt 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Intake manifold bolts [3.9 ~ 5.9] + [26.5 ~ 31.4] [0.4 ~ 0.6] + [2.7 ~ 3.2] [2.9 ~ 4.3] + [19.5 ~ 23.1]
Exhaust manifold nut (LH/RH) 49.0 ~ 53.9 5.0 ~ 5.5 36.2 ~ 39.8
Exhaust manifold stay bolt 34.3 ~ 41.2 3.5 ~ 4.2 25.3 ~ 30.4
Front muffler nut 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Center muffler nut 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Rear muffler nut 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
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Torque-to-yield cylinder head, connecting rod cap and crankshaft main bearing cap bolts must be replaced after they are removed because the bolts are
designed to be permanently elongated beyond the state of elasticity when torqued.
If the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
Engine Mechanical System

Inspection
Compression Pressure

In case of lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1. Warm up engine until the normal operating temperature (80~95°C(176-203°F)).
2. Remove the surge tank.
(Refer to Intake And Exhaust System - "Surge Tank")
3. Remove the LH/RH ignition coils and connectors.
(Refer to Engine Electrical System - "Ignition Coil")
4. Using the plug wrench (16mm), remove all the six spark plugs.
(Refer to Engine Electrical System - "Spark Plug")
5. Check cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole.
(2) Fully open the throttle.
(3) Crank the engine over 7 times to measure compression pressure.

Always use a fully charged battery to obtain engine speed of 250 rpm or more.
(4) Repeat step 1) though 3) for each cylinder.

This measurement must be done in as short a time as possible.

Compression pressure :
1,029 kPa (10.5 kgf/cm², 149 psi) (250 ~ 400 rpm)
Minimum pressure :
882 kPa (9.0 kgf/cm², 128 psi)
Difference between each cylinder :
98 kPa (1.0 kg/cm², 14 psi) or less
(5) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat step
1) through 3) for cylinders with low compression.
A. If adding oil helps the compression rise, it is likely that the piston rings and/or cylinder bore are worn or damaged.
B. If pressure stays low, a valve may be sticking or seating is improper, or there may be a gas leak through the gasket.
C. Low compression pressure in two adjacent cylinders may indicate that the head gasket is damaged.
6. Reinstall the spark plugs.
7. Install the ignition coils and ignition connectors.
8. Install the surge tank.
(Refer to Intake And Exhaust System - "Surge Tank")
Engine Mechanical System

Troubleshooting
Symptom Suspect area Remedy
Engine misfire with abnormal internal lower engine Oil short or oil plethora bearing wear Replace the crankshaft and bearings as required.
noises. Loose or damaged engine drive plate. Repair or replace the drive plate as required.
Worn piston rings. Inspect the cylinder for a loss of compression.
(Oil consumption may or may not cause the engine Repair or replace as required.
to misfire.)
Worn crankshaft thrust bearings Replace the crankshaft and bearings as required.
Bad valve clearance Check the valve clearance and adjust if necessary
Engine misfire with abnormal valve train noise. Stuck valves. Repair or replace as required.
(Carbon buildup on the valve stem)
Excessive worn or mis-aligned timing chain. Replace the timing chain and sprocket as required.
Worn camshaft lobes. Replace the camshaft and valve lifters.
Bad valve clearance Check the valve clearance and adjust if necessary
Engine misfire with coolant consumption. • Faulty cylinder head gasket and/or cranking or • Inspect the cylinder head and engine block for
other damage to the cylinder head and engine damage to the coolant passages and/or a faulty
block cooling system head gasket.
• Coolant consumption may or may not cause the • Repair or replace as required.
engine to overheat.
Engine misfire with excessive oil consumption. Worn valves, guides and/or valve stem oil seals. Repair or replace as required.
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Worn piston rings. • Inspect the cylinder for a loss of compression.
(Oil consumption may or may not cause the engine • Repair or replace as required.
to misfire)
Engine noise on start-up, but only lasting a few Incorrect oil viscosity. Proper oil change
seconds. Worn crankshaft thrust bearing. • Inspect the thrust bearing and crankshaft.
• Repair or replace as required.
Upper engine noise, regardless of engine speed. Low oil pressure. Repair or replace as required.
Broken valve spring. Replace the valve spring.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain and/or damaged Replace the timing chain and sprockets.
sprocket teeth.
Worn timing chain tensioner, if applicable. Replace the timing chain tensioner as required.
Worn camshaft lobes. • Inspect the camshaft lobes.
• Replace the timing camshaft and valve lifters as
required.
Worn valve guides or valve stems. Inspect the valves and valve guides, then repair as
required.
Stuck valves. Carbon on the valve stem or valve seat Inspect the valves and valve guides, then repair as
may cause the valve to stay open. required.
Worn drive belt, idler, tensioner and bearing. Necessary and related parts replacement belt
replacement
Lower engine noise, regardless of engine speed. Low oil pressure. Repair as required.
Loose or damaged drive plate. Repair or replace the drive plate.
Damaged oil pan, contacting the oil pump screen. • Inspect the oil pan.
• Inspect the oil pump screen.
• Repair or replace as required.
Oil pump screen loose, damaged or restricted. • Inspect the oil pump screen.
• Repair or replace as required.
Excessive piston-to-cylinder bore clearance. • Inspect the piston, piston pin and cylinder bore.
• Repair as required.
Excessive piston pin-to-piston clearance. • Inspect the piston, piston pin and the connecting
rod.
• Repair or replace as required.
Excessive connecting rod bearing clearance Inspect the following components and repair as
required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft pin journals.
Excessive crankshaft bearing clearance. Inspect the following components, and repair as
required.
• The crankshaft bearings.
• The crankshaft main journals.
• The cylinder block.
Incorrect piston, piston pin and connecting rod • Verify the piston pins and connecting rods are
installation installed correctly.
• Repair as required.
Engine noise under load. Low oil pressure Repair or replace as required.
Excessive connecting rod bearing clearance . Inspect the following components and repair as
required :
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components, and repair as
required.
• The crankshaft bearings.
• The crankshaft main journals.
• The cylinder block.
Engine will not crank-crankshaft will not rotate. Hydraulically locked cylinder. 1. Remove spark plugs and check for fluid.
• Coolant/antifreeze in cylinder. 2. Inspect for broken head gasket.
• Oil in cylinder. 3. Inspect for cracked engine block or cylinder head.
• Fuel in cylinder. 4. Inspect for a sticking fuel injector and/or leaking
fuel regulator.
Broken timing chain and/or timing chain and/or 1. Inspect timing chain and gears.
timing chain gears. 2. Repair as required.
Material in cylinder. 1. Inspect cylinder for damaged components and/or
• Broken valve foreign materials.
2.
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• Piston material Repair or replace as required.
• Foreign material
Seized crankshaft or connecting rod bearings. 1. Inspect crankshaft and connecting rod bearing.
2. Repair as required.
Bent or broken connecting rod. 1. Inspect connecting rods.
2. Repair as required.
Broken crankshaft. 1. Inspect crankshaft.
2. Repair as required.

Engine Mechanical System

Special Service Tools

Tool Name / Number Illustration Description
Crankshaft front oil seal installer Front oil seal mounting
09231-3C100

Crankshaft pulley fixing tool Remove the crankshaft damper pulley and mounting bolts
(09231-1S100) A : 09231-1S100
Crankshaft pulley fixed tool handle B : 09231-2J210
(09231-2J210)

Torque angle adapter Used for tightening torque-to-yield fasteners to a specified

09221-4A000 angle

Valve stem seal remover

09222-29000

Valve stem seal installer Mounting of the valve stem seals

09222-2W100

Valve spring compressor Used for removing / installing intake or exhaust valve
A : 09222-3K000 (Compressor)
B : 09222-3K100 (Holder)

Crankshaft rear oil seal installer Mounting of the crankshaft rear oil seal
A : 09231-3C200
B : 09231-H1100

Oil pan remover Remove the oil pan

09215-3C000
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Engine Mechanical System

Removal and Installation

Engine Cover
1. Remove the engine cover (A).

• Lift up the lower end of the engine cover to remove the fixing part, and then alternately remove both the left and right side parts.
• When installing, confirm that the mounting rubber insulators has been installed.
2. To install, reverse the removal procedure.

Engine Room Cover

1. Remove the engine room cover (A).

2. To install, reverse the removal procedure.

Engine Mechanical System

Components
[2WD]
 Page 9 of 169

1. Front under cover 3. LH side cover

2. Rear under cover 4. RH side cover

[AWD]
 Page 10 of 169

1. Front under cover 3. LH side cover

2. Rear under cover 4. RH side cover

Engine Mechanical System

Removal and Installation

1. Remove the front under cover (A). Remove the rear under cover(B).
Tightening torque:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 Ib-ft)

2. Remove the RH/LH side cover (A).

 Page 11 of 169

3. To install, reverse the removal procedure.

Engine Mechanical System

Components
[2WD]

1. Engine mounting insulator assembly 3. Engine support bracket RH

2. Engine support bracket LH 4. Transmission mounting insulator

[AWD]
 Page 12 of 169

1. Engine mounting insulator assembly 4. Transmission support bracket

2. Engine support bracket LH 5. Transmission mounting insulator
3. Engine support bracket RH

Engine Mechanical System

Removal and Installation

LH Engine Mounting Insulator
1. Disconnect the negative (-) battery terminal from the trunk room.
2. Remove the engine cover.
3. Remove the engine under cover.
4. Remove the engine room cover and radiator grille upper cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
5. Remove the steering joint mounting bolts (A).
(Refer to Steering System - "Steering Column and Shaft")
 Page 13 of 169

6. Remove the engine oil level gauge.

(Refer to Lubrication System - "Oil Level Gauge & Pipe")
7. Remove the water inlet pipe .
(Refer to Cooling System - Water Temperature Control Assembly")
8. Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "Exhaust Manifold")
9. Engine jack oil pan (A) to be installed .

Insert the rubber block between jack and upper oil pan.
10. Remove the upper nut (A) of the LH engine mounting insulator, and then remove the mounting support bracket (B).
Tightening torque :
63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 Ib-ft)

11. Remove the engine mounting insulator (A).

Tightening torque :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 Ib-ft)

12. To install, reverse the removal procedure.

 Page 14 of 169
RH Engine Mounting Insulator
1. Disconnect the negative (-) battery terminal from the trunk room.
2. Remove the engine cover.
3. Remove the engine room cover and the radiator grill upper cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
4. Remove the air cleaner.
(Refer to Intake And Exhaust System - "Air Cleaner")
5. Remove the engine under cover.
6. Remove the water outlet pipe.
(Refer to Cooling System - Water Temperature Control Assembly")
7. Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "Exhaust Manifold")
8. Engine jack oil pan (A) to be installed.

Insert the rubber block between jack and upper oil pan.
9. Remove the upper nut (A) of the RH engine mounting insulator, and then remove the mounting support bracket (B).
Tightening torque :
63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 Ib-ft)

10. Remove the RH engine mounting insulator (A).

Tightening torque :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 Ib-ft)

11. To install, reverse the removal procedure.

Transmission Mounting Insulator

1. Disconnect the negative (-) battery terminal from the trunk room.
2. Remove the engine under cover.
3. Using a jack support the transmission assembly.
 Page 15 of 169
4. Remove the transmission mounting bracket (A).
Tightening torque :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 Ib-ft)

5. Remove the transmission mounting insulator (A).

Tightening torque :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 Ib-ft)

6. To install, reverse the removal procedure.

Engine Mechanical System

Removal

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring and hoses to avoid misconnection.

• Start the engine to release the pressure inside the fuel line. Then, remove the fuel pump relay.
When the engine runs out of fuel in the fuel line and stops, turn the ignition switch to OFF.
1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine cover.
3. Remove the engine room cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
4. Remove the under cover.
5. Loosen the drain plug and drain the engine coolant.
(Refer to Cooling System - "Coolant")
6. After recovering refrigerant, remove the high & low pressure pipe.
(Refer to Heating, Ventilation, Air Conditioning - "Compressor")
7. Remove the air intake hose and air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
8. Remove the front wheel.
9. Disconnect the radiator upper hose (A) and lower hose (B).
 Page 16 of 169

When installing radiator hoses, install as shown in illustrations.

10. Disconnect the heater inlet & outlet hose (A).

When installing radiator hoses, install as shown in illustrations.

 Page 17 of 169

11. Remove the strut bar cover (A).

12. Disconnect the engine wiring harness.

(1) ECM Connector (A)
(2) TCM connector (B)
(3) IDB connector (C)
(4) Earth cable (D)

13. Remove the fuse & relay box cover (A).

 Page 18 of 169

14. Disconnect the fuse & relay box wirings.

(1) Front control connector (A).
(2) Alternator extension wiring (B).

15. Disconnect the fuel hose (A), PCSV hose (B) brake vacuum hose (C).

16. Disconnect the engine earth cable (A).

17. Remove the Steering U-joint mounting bolts (A).

(Refer to Steering System - "Steering Column and Shaft")
 Page 19 of 169

18. Remove the MDPS connector (A).

19. Remove the front muffler.

(Refer to Intake and Exhaust System - "Muffler")
20. Remove the front knuckle assembly.
(Refer to Drive Shaft and Axle - "Front Hub / Knuckle")
21. Remove the transmission Inhibitor cable (A), and the ground (B).

22. Remove the left and right subframe Bracket (A).

23. Remove the propeller shaft.

(Refer to Drive Shaft and Axle - "Propeller Shaft")
24. Support the sub frame (A) securely with a floor jack, and then remove the sub frame mounting bolts and the Transmission mounting bolts (B).
Tightening torque :
Sub frame : 137.3 ~ 156.9 N.m (14.0 ~ 16.0 kgf.m, 101.3 ~ 115.7 lb-ft)
Transmission mounting : 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

• After removing the sub frame mounting bolt, the engine and transaxle assembly may fall down, Support them securely with a floor jack.
• Check that all the cables, harness connector and hoses are disconnected from the engine and transaxle assembly.
 Page 20 of 169

25. Remove the engine assembly and sub frame by lifting vehicle.

When removing the engine and transmission assembly, be careful not to damage any surrounding parts or body components.

Installation
To install, reverse the removal procedure.
Perform the following procedures :
• Adjust a shift cable.
• Refill engine with engine oil.
• Refill a transaxle with fluid.
• Refill power steering fluid.
• Refill a radiator and a reservoir tank with engine coolant.
• Inspect for fuel leakage.
- After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and that the
fuel line is pressurized.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
• Place a heater control knob on "HOT" position.
• Bleed air from the cooling system.
- Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.
• Clean the battery terminals, cable terminals by using sandpaper and assemble them, and apply grease to prevent a corrosion.
Engine Mechanical System

Components
 Page 21 of 169

1. Drive belt 5. Idler

2. Drive belt tensioner 6. Cylinder head cover
3. Crankshaft pulley 7. Exhaust camshaft OCV cap
4. Water pump pulley
 Page 22 of 169

1. Timing chain cover 8. RH Timing chain tensioner arm 15. LH Timing chain
2. Oil pump sprocket 9. RH Timing chain 16. LH cam to cam guide
3. Oil pump chain 10. RH cam to cam guide 17. LH Timing chain guide
4. Oil pump tensioner assembly 11. RH Timing chain guide 18. Tensioner adapter
5. Crankshaft oil pump sprocket 12. LH Timing chain auto tensioner 19. Gasket
6. Crankshaft RH chain sprocket 13. LH Timing chain tensioner arm
7. RH Timing chain auto tensioner 14. Crankshaft LH chain sprocket

Engine Mechanical System

Removal and Installation

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
3. Remove the engine room cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
4. Turn the tensioner (B) clockwise and loosen it, then remove the drive belt (A).
 Page 23 of 169

When installing the drive belt, follow the order below.

crankshaft pulley → A/C compressor pulley → Idler Pulley → alternator pulley → water pump pulley → drive belt auto tensioner pulley.
Rotate the auto tensioner arm by turning the auto tensioner arm boss (B) counterclockwise using a wrench.
5. To install, reverse the removal procedure.

Inspection
Inspect Drive Belt
Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.

Drive belt, Idler, Belt tensioner pulley

1. Check the idler for excessive oil leakage, abnormal rotation or vibration. Replace the idler if necessary.
2. Check the belt tensioner for excessive dust, crack, and damage and inspect it Replace if necessary.
3. Check the belt replacement cycle, and inspect the belt for the abnormal wear of v-ripped part and uneven wear if necessary.
4. Check the crankshaft pulley, auxiliary pulley for vibration when rotating, and V-ribbed part for foreign materials or uneven contact. Replace the components if
necessary.
Engine Mechanical System

Components
 Page 24 of 169

1. Idler

Engine Mechanical System

Removal and Installation

1. Remove the drive belt.
(Refer to Timing System - "Drive Belt")
2. Remove the drive belt idler (A).
Tightening torque :
44.1 ~ 53.9 N.m (4.5 ~ 5.5 kgf.m, 32.5 ~ 39.8 lb-ft)

3. To install, reverse the removal procedure.

Inspection
 Page 25 of 169
Drive belt, Idler, Belt tensioner pulley
1. Check the idler for excessive oil leakage, abnormal rotation or vibration. Replace if necessary.
2. Check the belt tensioner for excessive dust, crack, and damage. Replace if necessary.
3. Check belt for maintenance and abnormal wear of V-ribbed part. Replace if necessary.
4. Check the pulleys for vibration in rotation, oil or dust deposit of V-ribbed part. Replace if necessary.
Engine Mechanical System

Components

1. Drive belt tensioner

Engine Mechanical System

Removal and Installation

1. Remove the drive belt.
(Refer to Timing System - "Drive Belt")
2. Remove the drive belt auto tensioner (A).
Tightening torque
Bolt (B) :
81.4 ~ 85.3 N.m (8.3 ~ 8.7 kgf.m, 60.0 ~ 62.9 lb-ft)
Bolt (C) :
17.7 ~ 21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 b-ft)
 Page 26 of 169

3. To install, reverse the removal procedure.

Inspection
Drive belt, Idler, Belt tensioner pulley
1. Check the idler for excessive oil leakage, abnormal rotation or vibration. Replace if necessary.
2. Check the belt tensioner for excessive dust, crack, and damage. Replace if necessary.
3. Check belt for maintenance and abnormal wear of V-ribbed part. Replace if necessary.
4. Check the pulleys for vibration in rotation, oil or dust deposit of V-ribbed part. Replace if necessary.
Engine Mechanical System

Components

1. Crankshaft pulley
 Page 27 of 169
Engine Mechanical System

Removal and Installation

1. Remove the drive belt.
(Refer to Timing System - "Drive Belt")
2. Remove the engine under cover.
3. Remove the crankshaft pulley (A).
Tightening torque :
284.5 ~ 304.1 N.m (29 ~ 31 kgf.m, 209.8 ~ 224.2 lb-ft)

To fix the pulley to the crankshaft, special tools (09231-1S100, 09231-2J210) are used.

4. To install, reverse the removal procedure.

Inspection
Drive belt, Idler, Belt tensioner pulley
1. Check the idler for excessive oil leakage, abnormal rotation or vibration. Replace if necessary.
2. Check the belt tensioner for excessive dust, crack, and damage. Replace if necessary.
3. Check belt for maintenance and abnormal wear of V-ribbed part. Replace if necessary.
4. Check the pulleys for vibration in rotation, oil or dust deposit of V-ribbed part. Replace if necessary.
Engine Mechanical System

Components
 Page 28 of 169

1. Front oil seal

Engine Mechanical System

Removal
1. Remove the crankshaft pulley.
(Refer to Timing System - "Crankshaft Pulley")
2. Remove the timing chain cover oil seal (A).

Installation
1. Using SST (09231-3C100), install timing chain cover oil seal.
 Page 29 of 169

Always use a new oil seal.

2. Install the crankshaft damper pulley.
(Refer to Timing System - "Crankshaft Pulley")
Engine Mechanical System

Components

1. Timing chain cover 2. Gasket

Engine Mechanical System

Removal
1. Remove the lower oil pan.
(Refer to Lubrication System - "Oil Pan")
 Page 30 of 169
2. Drain the coolant.
(Refer to Cooling System - "Coolant")
3. Remove the air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
4. Remove the surge tank.
(Refer to Intake And Exhaust System - "Surge Tank")
5. Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
6. Remove the LH/RH cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
7. Remove the drive belt.
(Refer to Timing System - "Drive Belt")
8. Remove the idler.
(Refer to Timing System - "Idler")
9. Remove the drive belt auto tensioner.
(Refer to Timing System - "Drive Belt Tensioner")
10. Remove the oil filter body.
(Refer to Lubrication System - "Oil Filter Body")
11. Remove the crankshaft damper pulley.
(Refer to Timing System - "Crankshaft Damper Pulley")
12. Remove the water pump.
(Refer to Cooling System - "Water Pump")
13. Remove the timing chain cover (A).

Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.

Installation
1. Install the timing chain cover.
(1) The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and etc.
(2) Before assembling the timing chain cover, the liquid sealant THREE BOND 1217H should be applied on the gap between cylinder head and cylinder
block. The part must be assembled within 5 minutes after sealant was applied.
Bead width :2.5 mm (0.1 in.)

(3) Apply liquid sealant THREE BOND1217H on timing chain cover. The part must be assembled within 5 minutes after sealant was applied. Sealant should
be applied without discontinuity.
 Page 31 of 169

• Fill the T-joint area (6EA *) with sealant.

• Apply sealant all around the dowel pin hole (2EA).
(4) Install the new gasket (A) to the timing chain cover.
Always use a new gasket.

During timing cover installation, be careful not to take off applied sealant on the timing cover by contacting other parts.
(5) The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be
in the exact position.
Tightening torque
A (19EA) :
18.6 ~ 21.6 N.m (1.9 ~ 2.2 kgf.m, 13.7 ~ 15.9 lb-ft)
B (2EA) :
24.5 ~ 26.5 N.m (2.5 ~ 2.7 kgf.m, 18.1 ~ 19.5 lb-ft)
C (2EA) :
58.8 ~ 68.8 N.m (6.0 ~ 7.0 kgf.m, 43.4 ~ 50.6 lb-ft)
D (3EA) :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

(6) Install the water vent hose to the timing chain cover.
(7) The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
2. Install the water pump.
(Refer to Cooling System - "Water Pump")
3. Install the crankshaft damper pulley.
(Refer to Timing System - "Crankshaft Damper Pulley")
4. Install the oil filter body.
(Refer to Lubrication System - "Oil Filter Body")
5. Install the drive belt auto tensioner.
 Page 32 of 169
(Refer to Timing System - "Drive Belt Tensioner")
6. Install the idler.
(Refer to Timing System - "Idler")
7. Install the drive belt.
(Refer to Timing System - "Drive Belt")
8. Install the LH/RH cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
9. Install the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
10. Install the surge tank.
(Refer to Intake And Exhaust System - "Surge Tank")
11. Install the air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
12. Refill the coolant.
(Refer to Cooling System - "Coolant")
13. Install the lower oil pan.
(Refer to Lubrication System - "Oil Pan")

• Refill engine oil.

• Refill radiator and reservoir tank with engine coolant.
• Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn Off the engine and let it cool down. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the
cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.
• Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.
• Inspect for fuel leakage.
- After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and
that the fuel line is pressurized.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.
Engine Mechanical System

Components
 Page 33 of 169

1. Oil pump sprocket 7. RH timing chain tensioner arm 13. Crankshaft LH chain sprocket
2. Oil pump chain 8. RH timing chain 14. LH timing chain
3. Oil pump tensioner assembly 9. RH cam to cam guide 15. LH cam to cam guide
4. Crankshaft oil pump sprocket 10. RH timing chain guide 16. LH timing chain guide
5. Crankshaft RH chain sprocket 11. LH timing chain auto tensioner 17. tensioner adapter
6. RH timing chain auto tensioner 12. LH timing chain tensioner arm

Engine Mechanical System

Removal
1. Set No.1 cylinder to top dead center (TDC)/compression.
(1) Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the lower timing chain cover.

(2) Check that the mark (A) of the camshaft timing sprockets is in the straight line on the cylinder head surface as shown in the illustration. If not, turn the
crankshaft clockwise, making one revolution (360°).
 Page 34 of 169

Do not rotate engine counterclockwise.

2. Remove the timing chain cover.
(Refer to Timing System - "Timing Chain Cover")

Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification
mark on the chain for TDC can be erased.
 Page 35 of 169

3. Lower the tensioner link (A), compress the piston of the RH timing chain tensioner, and fix the tensioner with a fixing pin.

4. Remove the RH timing chain cam to cam guide (A).

5. Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).

6. Remove the RH timing chain guide (A).

 Page 36 of 169
7. Remove the RH timing chain (A).

8. Remove the oil pump chain tensioner assembly (A).

9. Remove the RH crankshaft chain sprocket (A).

10. Remove the oil pump chain sprocket (A) and oil pump chain (B).

11. Remove the crankshaft sprocket (A). (O/P & RH camshaft drive)
 Page 37 of 169

12. Install a set pin after compressing the LH timing chain tensioner.

13. Remove the LH timing chain cam to cam guide (A).

14. Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).

15. Remove the LH timing chain guide (A).

 Page 38 of 169
16. Remove the LH timing chain (A).

17. Remove the crankshaft sprocket (A). (LH camshaft drive)

18. Remove the timing chain auto tensioner assembly adapter (A).

Inspection
Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary
2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary.
3. Check that the chain tensioner piston moves smoothly and that the ratchet operates normally. Replace as necessary.

Installation
1. The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a result of this, the piston of No.1 cylinder is placed at the top
dead center on compression stroke.

2. Install the timing chain auto tensioner assembly adapter (A).

 Page 39 of 169

3. Install the crankshaft sprocket (A). (LH camshaft drive).

4. Install the LH timing chain (A).

To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below.
Crankshaft sprocket →Exhaust camshaft sprocket → Intake camshaft sprocket.
The timing mark of each sprocket should be matched with timing mark (color link) of timing chain when installing timing chain.
5. Install the LH timing chain guide (A).
Tightening torque :
19.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.5 ~ 18.1 lb-ft)
 Page 40 of 169

6. Install the LH timing chain tensioner arm (B) and LH timing chain auto tensioner (A).
Tightening torque :
A : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
B : 18.6 ~ 21.6 N.m (1.9 ~ 2.2 kgf.m, 13.7 ~ 15.9 lb-ft)

7. Install the timing chain cam to cam guide (A).

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

8. Remove the LH timing chain auto tensioner stopper pin (A).

9. Install the crankshaft sprocket (A).

 Page 41 of 169

10. Install the oil pump chain sprocket (A) and oil pump chain (B).
Tightening torque :
19.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.5 ~ 18.1 lb-ft)

11. Install the oil pump chain tensioner assembly (A).

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

12. Install the RH timing chain (A).

 Page 42 of 169

To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below.
Crankshaft sprocket →Intake camshaft sprocket → Exhaust camshaft sprocket.
The timing mark of each sprocket should be matched with timing mark (color link) of timing chain when installing timing chain.
13. Install the RH timing chain guide (A).
Tightening torque :
19.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.5 ~ 18.1 lb-ft)

14. Install the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).
Tightening torque
A : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
B : 18.6 ~ 21.6 N.m (1.9 ~ 2.2 kgf.m, 13.7 ~ 15.9 lb-ft)

15. Install the RH timing chain cam to cam guide (A).

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

16. Remove the RH timing chain auto tensioner stopper pin (A).
 Page 43 of 169

17. After rotating the crankshaft two times in regular direction (clockwise viewed from front), confirm the timing mark.

Always turn the crankshaft clockwise.

Turning the crankshaft counter clockwise before building up oil pressure in the hydraulic timing chain tensioner may result in the chain disengaging
from the sprocket teeth.
18. Install the timing chain cover.
(Refer to Timing System - "Timing Chain Cover")

• Refill engine oil.

• Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.
• Inspect for fuel leakage.
- After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and that
the fuel line is pressurized.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.
• Refill radiator and reservoir tank with engine coolant.
• Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.
Engine Mechanical System

Components
 Page 44 of 169

1. RH cylinder head 4. LH cylinder head gasket

2. RH cylinder head gasket 5. Cylinder block
3. LH cylinder head
 Page 45 of 169

1. Camshaft bearing cap 9. Retainer 17. LH exhaust camshaft OCV

2. Camshaft thrust bearing cap 10. Valve spring 18. Fuel pump bracket
3. RH exhaust camshaft 11. Valve stem seal 19. LH intake camshaft
4. RH intake camshaft 12. Valve 20. LH exhaust camshaft
5. RH exhaust CVVT assembly 13. RH intake camshaft OCV 21. LH intake CVVT assembly
6. RH intake CVVT assembly 14. RH exhaust camshaft OCV 22. LH exhaust CVVT assembly
7. Mechanical lash adjuster (MLA) 15. RH cylinder head 23. LH cylinder head
8. Retainer lock 16. LH intake camshaft OCV

Engine Mechanical System

Components
 Page 46 of 169

1. LH cylinder head cover 4. RH cylinder head cover

2. LH cylinder head cover gasket 5. RH cylinder head cover gasket
3. LH exhaust CVVT OCV cap 6. RH exhaust CVVT OCV cap

Engine Mechanical System

Removal
LH Cylinder Head Cover
1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the surge tank.
(Refer to Intake And Exhaust System - "Surge Tank")
3. Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
4. Remove the high-pressure fuel pipe.
(Refer to Fuel system - "delivery pipe")
5. Remove the LH ignition coil and wiring.
(Refer to Engine Electrical System - "Ignition Coil")
6. Remove the high pressure fuel pump.
(Refer to Engine Control / Fuel System - "High Pressure Fuel Pump")
7. Remove the LH cylinder head cover.
(1) Remove the LH exhaust CVVT oil control valve (OCV) cap (A).
(2) Remove the LH cylinder head cover (B).
 Page 47 of 169

Cover the cylinder head with a piece of clean cloth or vinyl cover to prevent foreign materials from entering the cylinder head.

RH Cylinder Head Cover

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the surge tank.
(Refer to Intake And Exhaust System - "Surge Tank")
3. Remove the RH ignition coil and wiring.
(Refer to Engine Electrical System - "Ignition Coil")
4. Remove the RH exhaust CMP sensor connector (A).

5. Remove the RH cylinder head cover.

(1) Remove the RH exhaust CVVT oil control valve (OCV) cap (A).
(2) Remove the RH cylinder head cover (B).

Cover the cylinder head with a piece of clean cloth or vinyl cover to prevent foreign materials from entering the cylinder head.

Installation
LH Cylinder Head Cover
1. Install the LH cylinder head cover.

• Install the cylinder head cover under the exhaust oil control valve (OCV) cap
• To prevent engine oil leakage, surely install the exhaust OCV cap after installing the cylinder head cover.
(1) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head
cover.
(2) After applying THREE BOND 1217H sealant, it should be assembled within 5 minutes.
Bead width :2.5 mm (0.1 in.)
 Page 48 of 169

(3) The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
(4) Install the cylinder head cover bolts as following method.
Tightening torque
1st step :
4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)
2nd step :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Do not reuse a cylinder head cover gasket.

(5) Install the LH exhaust CVVT oil control valve cap.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Always use a new exhaust CVVT oil control valve cap.

2. To install the other parts, reverse the removal procedure.

RH Cylinder Head Cover

1. Install the RH cylinder head cover.

• Install the cylinder head cover under the exhaust oil control valve (OCV) cap
• To prevent engine oil leakage, surely install the exhaust OCV cap after installing the cylinder head cover.
(1) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head
cover.
(2) After applying THREE BOND 1217H sealant, it should be assembled within 5 minutes.
Bead width :2.5 mm (0.1 in.)

(3) The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover is assembled.
 Page 49 of 169
(4) Install the RH cylinder head cover bolts as following method.
Tightening torque
1st step :
4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)
2nd step :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Do not reuse the cylinder head cover gasket.

(5) Install the RH exhaust CVVT oil control valve cap.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Always use a new exhaust CVVT oil control valve cap.

2. To install the other parts, reverse the removal procedure.
Engine Mechanical System

Components
 Page 50 of 169

1. RH exhaust CVVT 3. LH intake CVVT

2. RH intake CVVT 4. LH exhaust CVVT

Engine Mechanical System

Description
Continuous Variable Valve Timing (CVVT) system advances or retards the valve timing of the intake and exhaust valve in accordance with the ECM control
signal which is calculated by the engine speed and load.
By controlling CVVT, the valve over-lap or under-lap occurs, which makes better fuel economy and reduces exhaust gases (NOx, HC). CVVT improves engine
performance through reduction of pump loss, internal EGR effect, improvement of combustion stability, improvement of volumetric efficiency, and increase of
expansion work.
This system consists of
- the CVVT Oil Control Valve (OCV) which supplies the engine oil to the cam phaser or drains the engine oil from the cam phaser in accordance with the ECM
PWM (Pulse With Modulation) control signal,
- the CVVT Oil Temperature Sensor (OTS) which measures the engine oil temperature,
- and the Cam Phaser which changes the cam phase by using the hydraulic force of the engine oil.
The engine oil released out of the CVVT oil control valve changes the cam phase in the direction (Intake Advance/Exhaust Retard) or opposite direction (Intake
Retard/Exhaust Advance) of the engine rotation by rotating the rotor connected with the camshaft inside the cam phaser.
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Operation Principle
The CVVT has the mechanism rotating the rotor vane with hydraulic force generated by the engine oil supplied to the advance or retard chamber in accordance
with the CVVT oil control valve control.

[CVVT System Mode]

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(1) Low Speed / Low Load (2) Part Load

(3) Low Speed / High Load (4) High Speed / High Load

Exhaust Valve Intake Valve

Driving
Valve Valve
Condition Effect Effect
Timing Timing
(1) Low Speed Completely * Valve Under-lap Completely * Valve Under-lap
/Low Load Advance * Improvement of combustion stability Retard * Improvement of combustion stability
* Increase of expansion work
(2) Part Load Retard * Reduction of pumping loss Retard * Reduction of pumping loss
* Reduction of HC
(3) Low Speed * Prevention of intake back flow (Improvement of
Retard * Increase of expansion work Advance
/High Load volumetric efficiency)
(4) High Speed
Advance * Reduction of pumping loss Retard * Improvement of volumetric efficiency
/High Load

Engine Mechanical System

Removal
Continuous Variable Valve Timing (CVVT)
1. Remove the timing chain.
(Refer to Timing System - "Timing Chain")
2. Remove the CVVT assembly.
A. A: LH exhaust CVVT
B. B: LH intake CVVT
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C. C: RH intake CVVT
D. D: RH exhaust CVVT

When removing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position (A).

Inspection
Continuously variable valve timing (CVVT) Assembly
1. Clamp the camshaft using a vise. Be careful not to damage the cam lobes and journals while using the vise.
2. Check that the CVVT is locked by turning it clockwise or counterclockwise. It is normal that the CVVT does not rotate.
3. Intake CVVT : Seal one of the two advance holes in the camshaft journal with tape.
Exhaust CVVT : Seal one of the two retard holes in the camshaft journal with tape.
[Intake]

[Exhaust]
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4. Intake CVVT : Apply approx. 150 kPa (1.5 kgf/cm², 21 psi ) of compressed air into the unsealed advance hole to release the lock.
Exhaust CVVT : Apply approx. 150 kPa (1.5 kgf/cm², 21 psi ) of compressed air into the unsealed retard hole to release the lock.

Cover the oil paths with a piece of cloth when applying compressed air to prevent oil from spraying.
5. Intake CVVT : With compressed air applied, rotate the CVVT into the advance direction (counterclockwise) within its phasing range and check that the CVVT
turns smoothly.
Exhaust CVVT : With compressed air applied, rotate the CVVT into the retard direction (clockwise) and check that the CVVT turns smoothly.
CVVT phasing range
Intake : 25°±0°30’ (from the most retarded position to the most advanced position)
Exhaust : 25°±0°30’ (from the most advanced position to the most retarded position)

6. Intake CVVT : Rotate the CVVT into the most retarded position (clockwise) and then check that the CVVT is locked.
Exhaust CVVT : Rotate the CVVT into the most advanced position (counterclockwise) and then check that the CVVT is locked.

Installation
Continuous Variable Valve Timing (CVVT)
1. Install the continuous variable valve timing (CVVT) assembly.
Tightening torque :
64.7 ~ 76.5 N.m (6.6 ~ 7.8 kgf.m, 47.7 ~ 56.4 lb-ft)

• Install the dowel pin of CVVT assembly to the camshaft-inlet.

Then, be careful not to install the pin on the oil hole.
• Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly.
• After connecting the dowel pin of the CVVT to the camshaft or tightening the CVVT bolt, turn the housing of the CVVT assembly counterclockwise
by hand to put the lock pin of the CVVT assembly in the correct position.
• After connecting the CVVT assembly to the camshaft, ensure that the camshaft is immobilized without exerting any constraining force n the housing
or sprocket of the CVVT assembly.
•
 Page 55 of 169
After connecting the CVVT assembly to the camshaft, ensure that the CVVT assembly is not press-fit too forcefully.
• Do not rotate CVVT assembly when camshaft is installed to dowel pin of CVVT assembly.
A. A: LH exhaust CVVT
B. B: LH intake CVVT

C. C: RH intake CVVT
D. D: RH exhaust CVVT

When installing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position (A).

2. Install the timing chain.

(Refer to Timing System - "Timing Chain")
Engine Mechanical System

Components
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1. RH Exhaust camshaft 3. LH Intake camshaft

2. RH Intake camshaft 4. LH Exhaust camshaft

Engine Mechanical System

Removal
LH Intake and Exhaust camshaft
1. Remove the timing chain.
(Refer to Timing System - "Timing Chain")
2. Remove the fuel pump bracket (A).

3. Remove the LH exhaust camshaft oil control valve (OCV) (A).

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4. Remove the LH camshaft bearing cap (A) and thrust bearing cap (B).

5. Remove the LH camshaft assembly (A).

RH Intake and Exhaust camshaft

1. Remove the timing chain.
(Refer to Timing System - "Timing Chain")
2. Remove the RH exhaust camshaft oil control valve (OCV) (A).

3. Remove the RH camshaft bearing cap (A) and thrust bearing cap (B).
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4. Remove the RH camshaft assembly (A).

Inspection
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 47.2 mm (1.8582 in.)
Exhaust : 45.8 mm (1.8031 in.)

If the cam lobe height is less than standard, replace the camshaft.
2. Check the surface of the camshaft journal for wear.
If the journal is worn excessively, replace the camshaft.
3. Inspect the camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journals.

(4) Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
 Page 59 of 169
Tightening torque :
1st step : 5.8 N.m (0.6 kgf.m, 4.3 lb-ft)
2nd step :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Do not turn the camshaft.

• Do not turn the camshaft.
• Be careful not to mistake the thrust bearing cap (B) bolt for a common bearing cap (A) bolt.
(5) Remove the bearing caps.
(6) Measure the width of the plastigage at its widest point.
Bearing oil clearance
[Standard value]
Intake
No.1 journal : 0.027 ~ 0.057 mm (0.0010 ~ 0.0022 in.)
No.2,3,4 journal :
0.030 ~ 0.067 mm (0.0012 ~ 0.0026 in.)
Exhaust
No.1 journal : 0.027 ~ 0.057 mm (0.0010 ~ 0.0022 in.)
No.2,3,4 journal :
0.030 ~ 0.067 mm (0.0012 ~ 0.0026 in.)

A. If the oil clearance is greater than specification, replace the camshaft.

B. If the oil clearance is still greater than specification after camshaft replacement, replace the bearing caps and cylinder head a set .
(7) Completely remove the plastigage.
(8) Remove the camshafts.
4. Inspect the camshaft end play.
(1) Install the camshafts.
(2) Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
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Tightening torque :
1st step : 5.8 N.m (0.6 kgf.m, 4.31 lb-ft)
2st step : 9.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

• Do not turn the camshaft.

• Be careful not to mistake the thrust bearing cap (B) bolt for a common bearing cap (A) bolt.
(3) Using a dial gauge, measure the end play while moving the camshaft back and forth.
Camshaft end play
[Standard value] :
0.02 ~ 0.18 mm (0.0008 ~ 0.0071 in.)

A. If the end play is greater than specification, replace the camshaft.

B. If the end play is still greater than specification after camshaft replacement, replace the bearing caps and cylinder head as a set.
(4) Remove the camshafts.

Installation
 Page 61 of 169

• Be careful when assembling the right/left bank, intake/exhaust side.

• Assemble the key groove of camshaft rear side to the same level of head top surface.
• Apply a light coat of engine oil on camshaft journals.
[Intake camshaft]

As for camshaft identification, refer to the table below.

Displacement Left Bank Right Bank
A : 27mm (1.0630in.) A : 27mm (1.0630in.)
B : 27mm (1.0630in.) B : 27mm (1.0630in.)
3.8L C : 30mm (1.1811in.) C : 30mm (1.1811in.)
D : 30mm (1.1811in.) D : 27mm (1.0630in.)
E : 27mm (1.0630in.) E : 30mm (1.1811in.)

[Exhaust Camshaft]

As for camshaft identification, refer to the table below.

Displacement Left Bank Right Bank
A:- A : 27mm (1.0630in.)
B:- B : 27mm (1.0630in.)
3.8L C:- C : 30mm (1.1811in.)
D:- D : 30mm (1.1811in.)
E : 31mm (1.2205in.) E:-

LH Intake and Exhaust camshaft

1. Install the LH camshaft assembly (A).

2. Install the LH camshaft bearing cap (A) and thrust bearing cap (B).
Tightening torque
 Page 62 of 169
1st step : 5.8 N.m (0.6 kgf.m, 4.3 lb-ft)
2nd step :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Be sure to install the thrust bearing cap bolts and the bearing cap bolts in the correct place.

Be careful when assembling the right/left bank, intake/exhaust side.

A : L(LH),R(RH)
B : I(Intake), E(Exhaust)
C : Journal number
D : Front mark

When assembling the camshaft bearing cap, rotate the crankshaft to locate the pistons at the center of the cylinder block in order to avoid unnecessary
contact between the valves and pistons.
3. Install the LH exhaust camshaft oil control valve (OCV) (A).
(Refer to Engine Control/Fuel System - "CVVT Oil Control Valve (OCV)")
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

4. Install the fuel pump bracket (A).

Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
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5. Install the timing chain.

(Refer to Timing System - "Timing Chain")

RH Intake and Exhaust camshaft

1. Install the RH camshaft assembly (A).

2. Install the RH camshaft bearing cap (A) and thrust bearing cap (B).
Tightening torque
1st step : 5.8 N.m (0.6 kgf.m, 4.3 lb-ft)
2nd step :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Be sure to install the thrust bearing cap bolts and the bearing cap bolts in the correct place.

Install the bearing caps in their correct position, being careful of the mark shown below.

A : L(LH),R(RH)
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B : I(Intake), E(Exhaust)
C : Journal number
D : Front mark

When assembling the camshaft bearing cap, rotate the crankshaft to locate the pistons at the center of the cylinder block in order to avoid unnecessary
contact between the valves and pistons.
3. Install the RH exhaust camshaft oil control valve (OCV) (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

4. Install the timing chain.

(Refer to Timing System - "Timing Chain")
Engine Mechanical System

Components
 Page 65 of 169
1. RH intake camshaft OCV 10. LH exhaust camshaft 18. RH cylinder head gasket
2. Camshaft thrust bearing cap 11. LH intake camshaft CVVT assembly 19. LH cylinder head gasket
3. Camshaft bearing cap 12. LH exhaust camshaft CVVT assembly 20. MLA
4. RH exhaust camshaft 13. RH exhaust camshaft OCV 21. Retainer lock
5. RH intake camshaft 14. LH intake camshaft OCV 22. Retainer
6. RH exhaust camshaft CVVT assembly 15. RH cylinder head 23. Valve spring
7. RH intake camshaft CVVT assembly 16. Fuel pump bracket 24. Valve stem seal
8. LH exhaust camshaft OCV 17. LH cylinder head 25. Valve
9. LH intake camshaft

Engine Mechanical System

Removal

• Use fender covers to avoid damaging painted surfaces.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) before removing it.
• When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring and hoses to avoid misconnection.

• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

LH Cylinder Head
1. Remove the LH exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
2. Remove the LH camshaft.
(Refer to Cylinder Head Assembly - "Camshaft")
3. Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
4. Remove the fuel delivery pipe.
(Refer to Engine Control / Fuel System - "Fuel Delivery System")
5. Remove the alternator.
(Refer to Engine Electrical System - "Alternator")
6. Remove the LH cylinder heads assembly.
(1) When removing the cylinder head bolts, do not completely loosen the bolts at a time. Loosen them in two or three steps according to the sequence shown
below.

Head warpage or cracking could result from removing bolts in an incorrect order.
(2) Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.
 Page 66 of 169

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
(3) Remove the cylinder head gasket.

RH Cylinder Head
1. Remove the RH exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
2. Remove the RH camshaft.
(Refer to Cylinder Head Assembly - "Camshaft")
3. Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
4. Remove the fuel delivery pipe.
(Refer to Engine Control / Fuel System - "Fuel Delivery System")
5. Remove the RH cylinder head assembly.
(1) Remove the RH cylinder head rear bolt (A).
[3.8L]

(2) When removing the cylinder head bolts, do not completely loosen the bolts at a time. Loosen them in two or three steps according to the sequence shown
below.

Head warpage or cracking could result from removing bolts in an incorrect order.
(3) Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.
 Page 67 of 169

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
(4) Remove the cylinder head gaskets.

Disassembly

Identify MLA, valves and valve springs as they are removed so that each item can be reinstalled in its original position.
1. Remove the mechanical lash adjusters (MLA) (A).

2. Remove the valves.

(1) Using the SST (09222-3K000, 09222-3K100), compress the valve spring and remove retainer lock.

(2) Remove the spring retainer.

(3) Remove the valve spring.
(4) Remove the valve.
(5) Using the SST (09222-29000), remove the valve stem seal.
 Page 68 of 169
Do not reuse old valve stem seals.

3. Remove the LH/RH intake camshaft oil control valve (OCV) (A).

Inspection
Cylinder Head
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the flatness of the surface where the cylinder block contacts the manifold.
Flatness of cylinder head gasket surface
Standard : Less than 0.05 mm (0.002 in.)
[Less than 0.02 mm (0.0008 in.) / 150x150]
Flatness of manifold gasket surface
Standard : Less than 0.01 mm (0.0004 in)
[Less than 0.03 mm (0.001 in.) / 110x110]

2. Inspect for cracks.

Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracks are found, replace the cylinder head.
 Page 69 of 169
Valve and Valve Spring
1. Inspect valve stems and valve guides.
(1) Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide I.D.
Intake / Exhaust : 5.500 ~ 5.512 mm (0.216 ~ 0.217 in.)

(2) Using a micrometer, measure the diameter of the valve stem.

Valve stem O.D.
Intake : 5.465 ~ 5.480 mm (0.2151 ~ 0.2157 in.)
Exhaust : 5.458 ~ 5.470 mm (0.2149 ~ 0.2153 in.)

(3) To measure the valve stem-to-guide clearance, subtract the valve guide inside diameter from the valve stem diameter.
Valve stem-to-guide clearance
[Standard]
Intake : 0.020 ~ 0.047 mm (0.0008 ~ 0.0018 in.)
Exhaust : 0.030 ~ 0.054 mm (0.0012 ~ 0.0021 in.)
[Limit]
Intake : 0.07 mm (0.0027 in.)
Exhaust : 0.09 mm (0.0035 in.)
2. Inspect valves.
(1) Check the valve face angle with the ground.
(2) Check that the surface of the valve for wear.
If the wear is excessive, replace the valve.
(3) Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
[Standard]
Intake : 1.56 ~ 1.86 mm (0.06142 ~ 0.07323 in.)
Exhaust : 1.73 ~ 2.03 mm (0.06811 ~ 0.07992 in.)
 Page 70 of 169
(4) Check the valve length.
Length
Intake : 105.27 mm (4.1445 in)
Exhaust : 105.50 mm (4.1535 in)
(5) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect valve seats
(1) Check the valve seat for evidence of overheating and improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace the cylinder head.
(3) Recondition the valve seat with a valve seat grinder or cutter.
The valve seat contact width should be within specifications and centered on the valve face.
4. Inspect valve springs.
(1) Using a steel square, measure the out-of-square of the valve spring.
(2) Using vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 46.2 mm (1.8189 in.)
Out-of-square : MAX, 1.5°

Mechanical Lash Adjuster (MLA)

1. Inspect MLAs.
Using a micrometer, measure the MLA outside diameter.
MLA O.D.
Intake/Exhaust :
34.964 ~ 34.980 mm (1.3765 ~ 1.3771 in.)
2. Using a caliper gauge, measure MLA tappet bore inner diameter of the cylinder head.
Tappet bore I.D.
Intake/Exhaust :
35.000 ~ 35.025 mm (1.3779 ~ 1.3789 in.)
3. Subtract MLA outside diameter measurement from tappet bore inside diameter measurement.
MLA to tappet bore clearance
[Standard]
Intake/Exhaust :
0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in.)
[Limit]
Intake/Exhaust : 0.07 mm (0.0027 in.)

Reassembly

• Thoroughly clean all parts to be assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace the valve stem seals with new ones.
1. Install the valves.
(1) Using the SST (09222-3C100), push in a new oil seal.

• Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage through the valve guides.
• Assemble the valve stem seal so that it fully covers the surface of the head.
 Page 71 of 169

(2) After applying engine oil to each end of the valves, install the valve, valve spring and spring retainer.

When installing the valve spring, place the enamel-coated part to face the valve spring retainer.
(3) Using the SST (09222 - 3K000, 09222-3K100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks
are correctly in place before releasing the valve spring compressor.

(4) Lightly tap the end of each valve stem two or three times with a soft hammer or the wooden handle of a hammer to ensure proper seating of the valve
and retainer lock.
2. Install the mechanical lash adjusters (MLA).
Check that the MLA rotates smoothly by hand.

MLA can be reinstalled in its original position.

However, the valve lash clearances must be rechecked and adjusted accordingly before the cylinder head is installed onto the cylinder block.
Refer to General information in EM section for Valve Clearance checking and adjustment procedure.
3. Install the LH/RH intake camshaft oil control valve (OCV) (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
 Page 72 of 169

• Install OCV with gray colored connector into RH bank.

• Install OCV with black colored connector into LH bank.

• In case of dropping the OCV, do not reuse it.

• Keep the OCV clean.
• Do not hold the OCV sleeve during servicing.
• When installing the OCV in the engine, do not move the engine while holding the OCV yoke.

Installation
LH Cylinder Head

• Thoroughly clean all parts to be assembled.

• Always use a new head and manifold gasket.
• Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity
when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
• The cylinder head gasket is a metal gasket. Take care not to bend it.
• Rotate the crankshaft, set the No.1 piston at top dead center (TDC).
1. Install the LH cylinder head.
A. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.
B. Apply sealant on cylinder block top face before assembling cylinder head gaskets.
The assembly must be done within 5 minutes after the sealant is applied.

Refer to the illustration below to apply the sealant.

Bead width :
2.0 ~ 3.0 mm (0.078 ~ 0.118 in.)
Sealant locations :
1.0 ~ 1.5 mm (0.039 ~ 0.059 in.) from block surface
Recommended sealant :Liquid sealant THREE BOND 1217H
 Page 73 of 169

C. Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The assembly must be done within 5 minutes after the sealant is applied.

Be careful of the installation direction.

D. Install the LH cylinder head.

Remove the extruded sealant after assembling cylinder heads.

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2. Install the LH cylinder head bolts.

(1) Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
(2) Using SST (09221-4A000), When installing the cylinder head bolts, do not completely tighten the bolts at a time. Tighten them in two or three steps
according to the sequence shown below.

Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of
elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
Tightening torque
Head bolt:
37.3 ~ 41.2 N.m (3.8 ~ 4.2 kgf.m, 27.5 ~ 30.4 lb-ft) + (118 ~ 122°) + (88 ~ 92°)

3. Install the alternator.

(Refer to Engine Electrical System - "Alternator")
4. Install the fuel delivery pipe.
(Refer to Engine Control / Fuel System - "Fuel Delivery System")
5. Install the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
6. Install the LH camshaft.
(Refer to Cylinder Head Assembly - "Camshaft")
7. Install the LH exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")

RH Cylinder Head
1. Install the RH cylinder head.
A. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.
B. Apply TB 1217H sealant on cylinder block top face before assembling cylinder head gaskets.
The assembly must be done within 5 minutes after the sealant is applied.
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Refer to the illustration below to apply the sealant.

Bead width :
2.0 ~ 3.0 mm (0.078 ~ 0.118 in.)
Sealant locations :
1.0 ~ 1.5 mm (0.039 ~ 0.059 in.) from block surface
Recommended sealant :Liquid sealant THREE BOND 1217H

C. Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The assembly must be done within 5 minutes after the sealant is applied.
 Page 76 of 169

Be careful of the installation direction.

D. Install the RH cylinder head.

Remove the extruded sealant after assembling cylinder heads.

2. Install the RH cylinder head bolts.

(1) Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
(2) When installing the cylinder head bolts and plate washers, tighten them in two or three steps according to the sequence shown below.

Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of
elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
Tightening torque
Head bolt:
37.3 ~ 41.2 N.m (3.8 ~ 4.2 kgf.m, 27.5 ~ 30.4 lb-ft) + (118 ~ 122°) + (88 ~ 92°)
Bolt (A):
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
 Page 77 of 169

[3.8L]

Using SST (09221-4A000), When installing the cylinder head bolts and plate washers, tighten them in two or three steps according to the sequence
shown below.

3. Install the fuel delivery pipe.

(Refer to Engine Control / Fuel System - "Fuel Delivery System")
4. Install the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
5. Install the RH camshaft.
(Refer to Cylinder Head Assembly - "Camshaft")
6. Install the RH exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
Engine Mechanical System

Components
 Page 78 of 169

1. Piston ring 6. Connecting rod lower bearing 11. Snap ring

2. Piston 7. Connecting rod bearing cap 12. Water jacket separator 1#
3. Connecting rod 8. Baffle plate 13. Water jacket separator 2#
4. Connecting rod upper bearing 9. Upper oil pan
5. Piston pin 10. Cylinder block
 Page 79 of 169

1. Plug bolt 6. Drive plate 11. Main bearing cap

2. Washer gasket 7. Rear oil seal 12. Oil cover
3. Crankshaft upper bearing 8. Rear oil seal case 13. Oil cover gasket
4. Thrust bearing 9. Crankshaft 14. Crankshaft adapter
5. Adapter plate 10. Crankshaft lower bearing

Engine Mechanical System

Components
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1. Water jacket separator 1# 3. Cylinder block

2. Water jacket separator 2#

Engine Mechanical System

Removal
1. Remove the LH/RH cylinder head assembly.
(Refer to Cylinder Head Assembly - "Cylinder Head")
2. Remove the water jacket separator 1# (A) and 2# (B).

Installation
1. Install the water jacket separator 1# (A) and 2# (B).
 Page 81 of 169

Insert the separator align with block inner side protrusion, and it must be located under the cylinder head installing surface.

2. Install the LH/RH cylinder head.

(Refer to Cylinder Head Assembly - "Cylinder Head")
Engine Mechanical System

Components
 Page 82 of 169

1. Drive plate 3. Crankshaft adapter

2. Adapter plate

Engine Mechanical System

Removal and Installation

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the automatic transaxle .
(Refer to Automatic Transaxle System - "Automatic Transaxle")
3. Remove the adapter plate (B) and the drive plate (A).
Tightening torque :
71.6 ~ 75.5 N.m (7.3 ~ 7.7 kgf.m, 52.8 ~ 55.7 lb-ft)

4. To install, reverse the removal procedure.

 Page 83 of 169
Engine Mechanical System

Components

1. Rear oil seal 2. Rear oil seal case

Engine Mechanical System

Removal
1. Remove the drive plate and adapter plate.
(Refer to Cylinder Block - "Drive Plate")
2. Remove the rear oil seal (A).

Installation
 Page 84 of 169
1. Using SST(09231-3C200, 09231-H1100), install the rear oil seal.

Always use a new oil seal.

2. Install the drive plate and adapter plate.
(Refer to Cylinder Block - "Drive Plate")
Engine Mechanical System

Components

1. Piston ring 5. Connecting rod

2. Piston pin 6. Connecting rod upper bearing
 Page 85 of 169
3. Snap ring 7. Connecting rod lower bearing
4. Piston 8. Connecting rod bearing cap

Engine Mechanical System

Disassembly

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring and hoses to avoid misconnection.

• Inspect the timing chain before removing the cylinder head.
• Turn the crankshaft pulley so that the No.1 piston is at top dead center.
1. Remove the engine assembly from the vehicle.
(Refer to Engine And Transaxle Assembly - "Engine And Transaxle Assembly")
2. Remove the drive plate and adapter plate.
(Refer to Cylinder Block - "Drive Plate")
3. Attach the engine to engine stand for disassembly.
4. Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
5. Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
6. Remove the timing chain.
(Refer to Timing System - "Timing Chain")
7. Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
8. Remove the cylinder head.
(Refer to Cylinder Head Assembly - "Cylinder Head")
9. Remove the oil pump.
(Refer to Lubrication System - "Oil Pump")
10. Remove the oil cover (A) and the gasket (B).

11. Remove the water jacket separator.

(Refer to Cylinder Block - "Water Jacket Separator")
12. Remove the knock sensor.
 Page 86 of 169

13. Remove the upper oil pan.

(Refer to Lubrication System - "Oil Pan")
14. Remove the baffle plate (A).

15. Remove the rear oil seal case (A).

16. Remove the plug bolt (A) and a washer gasket (B).

17. Check the connecting rod cap oil clearance.

18. Remove the piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

• Keep the bearings, connecting rod and cap together.

• Arrange the piston and connecting rod assemblies in the correct order.
19. Remove the crankshaft bearing cap and check oil clearance.
20. Check the crankshaft end play.
21. Remove the crankshaft (A).
 Page 87 of 169

Arrange the main bearings and thrust bearings in the correct order.
22. Remove the oil jets (A).

23. Disassemble the piston rings.

(1) Using a piston ring expander, remove the 2 compression rings (A).
(2) Remove the oil ring and coil spring (B) by hand.

Arrange the piston rings in the correct order only

24. Remove the snap rings at both ends of the piston pin, and push the piston pin to disconnect the connecting rod.

Inspection
Connecting Rod
1. Check the connecting rod side clearance.
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
Standard end play :0.1 ~ 0.25 mm (0.004 ~ 0.010 in.)

A. If the side clearance is out of tolerance, install a new connecting rod.

B. If the crankshaft is still out of tolerance after connecting rod replacement, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and bearing half.
(4) Clean the crankshaft pin journal and bearing.
(5) Place plastigage across the crank pin.
(6) Reinstall the bearing half and cap, and tighten the bolts with the specified torque.
Tightening torque:
[27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)] + [68 ~ 72°]
 Page 88 of 169

Do not turn the crankshaft.

(7) Remove the connecting rod cap again.
(8) Measure the plastigage at its widest point.
Standard oil clearance:
0.028 ~ 0.046 mm (0.0011 ~ 0.0018 in.)

(9) If the plastigage measurement is too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark
(select the color as shown in the next column), and recheck the clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above orbelow that one), and check
clearance again.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with
solvent or detergent.

Connecting Rod Mark Location

Identification of Connecting Rod

Class Mark Inside Diameter
58.000 ~ 58.006 mm
0 a
(2.2834 ~ 2.2837 in.)
58.006 ~ 58.012 mm
1 b
(2.2837 ~ 2.2839 in.)
58.012 ~ 58.018 mm
2 c
(2.2839 ~ 2.2842 in.)
 Page 89 of 169

Crankshaft Pin Mark Location

Identification of Crankshaft

Discrimination of Crankshaft
Class Mark Outside Diameter Of Pin
54.966 ~ 54.972 mm
I 1 or A
(2.1640 ~ 2.1642 in.)
54.960 ~ 54.966 mm
II 2 or B
(2.1638 ~ 2.1640 in.)
54.954 ~ 54.960 mm
III 3 or C
(2.1635 ~ 2.1638 in.)

Place of Identification Mark (Connecting Rod Bearing)

Identification of Connecting Rod Bearing

Class Mark Thickness Of Bearing
1.509 ~ 1.512
E BLUE
(0.05941 ~ 0.05953 in)
1.506 ~ 1.509
D BLACK
(0.05929 ~ 0.05941 in)
1.503 ~ 1.506
C RED
(0.05917 ~ 0.05929 in)
1.500 ~ 1.503
B GREEN
(0.05906 ~ 0.05917 in)
1.497 ~ 1.500
A YELLOW
(0.05894 ~ 0.05906 in)

(11) Selection
Connecting Rod Identification Mark
0(a) 1(b) 2(c)
A B C
1 or A
(YELLOW) (GREEN) (RED)
Crankshaft Indentification B C D
2 or B
Mark (GREEN) (RED) (BLACK)
C D E
3 or C
(RED) (BLACK) (BLUE)

3. Check the connecting rod.

 Page 90 of 169
(1) When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing a new connecting rod, the notches for bearing fixing
on the connecting rods and caps should face the same direction.
(2) If one or both edge of the connecting rod thrust surface is damaged, replace the rod. If the inner surface of the rod is damaged or rough, also replace it.
(3) Using a connecting rod aligner, measure the degree of bending or torsion of the rod. If the measured value is not within the specification, adjust the rod
with a press. If the rod is bent or twisted excessively, replace it.
Allowable bend of connecting rod:
0.05 mm/100 mm (0.0020 in./3.9370 in.)
Allowable twist of connecting rod:
0.1 mm/100 mm (0.0039 in./3.9370 in.)

When assembling the rod without a bearing, there should be no difference.

Piston
1. Clean piston
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.

Do not use a wire brush.

2. Check the piston-to-cylinder clearance by calculating the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston-to-cylinder clearance :
0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in)
(1) Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
Standard diameter :
96.00 ~ 96.03 mm (3.7795 ~ 3.7807 in.)

(2) Measure the piston outside diameter at 3.8L : 16 mm (0.6299 in.) from bottom land of the piston.
Standard diameter :
95.96 ~ 95.99 mm (3.7779 ~ 3.7791 in.)

3. Select the piston matching with cylinder bore class.

Piston-to-cylinder clearance :
0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in.)
(1) Check the cylinder bore size mark code on the cylinder block side surface.
 Page 91 of 169

Discrimination of Cylinder Bore Size

Class Size code Cylinder bore inner diameter
A A 96.00 ~ 96.01 mm (3.7795 ~ 3.7799 in.)
B B 96.01 ~ 96.02 mm (3.7799 ~ 3.7803 in.)
C C 96.02 ~ 96.03 mm (3.7803 ~ 3.7807 in.)

(2) Check the piston size code (A) and the front mark (B) on the piston top face.

Discrimination of Piston Outer Diameter

Class Mark 3.8L
A A 95.96 ~ 95.97 mm (3.7779 ~ 3.7783 in.)
B B 95.97 ~ 95.98 mm (3.7783 ~ 3.7787 in.)
C C 95.98 ~ 95.99 mm (3.7787 ~ 3.7791 in.)

Piston Rings
1. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.
Piston ring side clearance
Standard
No.1 : 0.06 ~ 0.09 mm (0.0024 ~ 0.0035 in.)
No.2 : 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.)
Oil ring : 0.02 ~ 0.065 mm (0.0008 ~ 0.0026 in.)
Limit
No.1 : 0.1 mm (0.0039 in.)
No.2 : 0.1 mm (0.0039 in.)
Oil ring : 0.2 mm (0.0079 in.)

If the clearance is greater than the maximum limit, replace the piston.
2. Inspect piston ring end gap.
 Page 92 of 169
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at the right angle to the cylinder wall by gently pressing it
down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the
cylinder bore diameter against the wear limits. If the bore is over the service limit, the cylinder block must be replaced.
Piston ring end gap
Standard
No.1 : 0.17 ~ 0.32mm (0.0067 ~ 0.0126in.)
No.2 : 0.32 ~ 0.47mm (0.0126 ~ 0.0185 in.)
Oil ring : 0.2 ~ 0.5mm (0.0079 ~ 0.0197in.)
Limit
No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)

Piston Pins
1. Measure the external diameter of the piston pin.
Piston pin diameter :
21.097 ~ 22.000mm (0.8306 ~ 0.8661 in.)

2. Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance :
0.004 ~ 0.013 mm (0.0002 ~ 0.0005 in.)
3. Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod interference :
0.005 ~ 0.019 mm (0.0002 ~ -0.0007 in.)

Reassembly

• Thoroughly clean all parts to be assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble the piston and the connecting rod.
 Page 93 of 169
(1) Install the piston pin with snap ring 2EA and check the snap ring assembly thoroughly.
(2) The piston front mark (A) and the connecting rod front mark (B) must face the timing belt side of the engine.

2. Install the piston rings.

(1) Install the coil spring and oil ring by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Install the piston rings to ensure the ring ends are positioned as shown below.

3. Install the connecting rod bearings.

(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings(A) in the connecting rod and connecting rod cap(B).

When reassembling the connecting rods and the caps, make sure that each connecting rod and connecting cap are placed in their original position.
4. Install the piston and connecting rod assemblies.

Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
(1) Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a
hammer.
(2) Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place.
(3) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque :
[27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)] + [68 ~ 72°]

• Always use new connecting rod cap bolts. Connecting rod cap bolts are torque-to-yield bolts designed to be permanently elongated beyond the
state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
• Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
 Page 94 of 169

Use SST (09221-4A000), install connecting rod bearing cap bolts.

5. Install the connecting rod caps and check oil clearance.

6. Check the connecting rod end play.
7. Install the rear oil seal.
(Refer to Cylinder Block - "Rear Oil Seal")
8. Install the baffle plate.
When installing the baffle plate bolts, tighten the bolts in two or three steps according to the sequence shown below.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

9. Assemble the other parts in the reverse order of disassembly.

Engine Mechanical System

Components
 Page 95 of 169

1. Crank shaft upper bearing 4. Crankshaft lower bearing

2. Thrust bearing 5. Main bearing cap
3. Crankshaft

Engine Mechanical System

Disassembly

• Use fender covers to avoid damaging painted surfaces.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) before removing it.
• When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring and hoses to avoid misconnection.

• Inspect the timing chain before removing the cylinder head.
• Turn the crankshaft pulley so that the No.1 piston is at top dead center.
1. Remove the engine assembly from the vehicle.
(Refer to Engine And Transaxle Assembly - "Engine And Transaxle Assembly")
2. Remove the drive plate and adapter plate.
(Refer to Cylinder Block - "Drive Plate")
 Page 96 of 169
3. Attach the engine to engine stand for disassembly.
4. Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
5. Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
6. Remove the timing chain.
(Refer to Timing System - "Timing Chain")
7. Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
8. Remove the cylinder head.
(Refer to Cylinder Head Assembly - "Cylinder Head")
9. Remove the oil pump.
(Refer to Lubrication System - "Oil Pump")
10. Remove the water jacket separator
(Refer to Cylinder Block - "Water Jacket Separator")
11. Remove the upper oil pan.
(Refer to Lubrication System - "Oil Pan")
12. Remove the baffle plate (A).

13. Remove the rear oil seal case (A).

14. Check the connecting rod side clearance

(Refer to Cylinder Block - "Piston and Connecting Rod")
15. Check the connecting rod bearing cap oil clearance.
(Refer to Cylinder Block - "Piston and Connecting Rod")
16. Remove the piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting Rod")
17. Remove the crankshaft main bearing cap and check oil clearance.
18. Check the crankshaft end play.
19. Remove the crankshaft.
Lift the crankshaft (A) out of engine, being careful not to damage journals.
 Page 97 of 169

Arrange the main bearings and thrust bearings in the correct order.

Inspection
1. Check the crankshaft bearing oil clearance.
(1) To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves.
(2) Clean each main journal and bearing half with clean cloth.
(3) Place a piece of plastigage in the axial direction of each main journal.
(4) Reinstall the bearings and caps, then torque the bolts.
Tightening torque
No.1~8 : 49.0 N.m (5.0 kgf.m, 36.2 lb-ft) + 90°
No.9~16 : 19.6 N.m (2.0 kgf.m, 14.5 lb-ft)+ 120°
No.17~24 :
29.4 ~ 31.4 N.m (3.0 ~ 3.2 kgf.m, 21.7 ~ 23.1 lb-ft)

• Always use new crankshaft main bearing cap bolts. Crankshaft main bearing cap bolts are torque-to-yield bolts designed to be permanently
elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain
clamping force.
• Do not turn the crankshaft.
(5) Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance :
0.024 ~ 0.042 mm (0.00094 ~ 0.0017 in.)

(6) If the plastigage measuring value is too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color
mark (select the color as shown in the next column), and recheck the clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (refer to the crankshaft bearing selection table), and check
clearance again.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with
solvent or detergent.
Crankshaft bore mark location
Letters have been stamped on the block as a mark for the size of each of the 4 main journal bores.
To choose correct bearings, check the size marks of both the journal bore and the journal outer diameter, stamped on the block and crankshaft,
respectively.
 Page 98 of 169

Discrimination of Cylinder Block

Class Mark Inside Diameter
73.500 ~ 73.506 mm
a A
(2.8937 ~ 2.8939 in.)
73.506 ~ 73.512 mm
b B
(2.8939 ~ 2.8942 in.)
73.512 ~ 73.518 mm
c C
(2.8942 ~ 2.8944 in.)

Crankshaft Journal Mark Location

Discrimination of Crankshaft

Discrimination of Crankshaft
Class Mark Outside Diameter Of Journal
68.954 ~ 68.960 mm
I 1 or A
(2.7147 ~ 2.7150 in.)
68.948 ~ 68.954 mm
II 2 or B
(2.7145 ~ 2.7147 in.)
68.942 ~ 68.948 mm
III 3 or C
(2.7142 ~ 2.7145 in.)

Place of Identification Mark (Crankshaft Bearing)

 Page 99 of 169

Discrimination of Crankshaft
Class Mark Thickness Of Bearing
2.276 ~ 2.279 mm
E BLUE
(0.0896 ~ 0.0897 in.)
2.273 ~ 2.276 mm
D BLACK
(0.0895 ~ 0.0896 in.)
2.270 ~ 2.273 mm
C RED
(0.0894 ~ 0.0895 in.)
2.267 ~ 2.270 mm
B GREEN
(0.0893 ~ 0.0894 in.)
2.264 ~ 2.267 mm
A YELLOW
(0.0891 ~ 0.0893 in.)

Selection
Crankshaft Bore Identification Mark
a(A) b(B) c(C)
A B C
1 or A
(YELLOW) (GREEN) (RED)
Crankshaft B C D
2 or B
Identification Mark (GREEN) (RED) (BLACK)
C D E
3 or C
(RED) (BLACK) (BLUE)

2. Check crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard end play :
0.10 ~ 0.28 mm (0.0039 ~ 0.0110 in.)

If the end play is greater than the maximum limit, replace the thrust bearings as a set.
Thrust bearing thickness :
2.41 ~ 2.45 mm (0.0949 ~ 0.0964 in.)
3. Inspect main journals and crank pins
Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter :
68.942 ~ 68.960 mm (2.7142 ~ 2.7149 in.)
Crank pin diameter :
54.954 ~ 54.972 mm (2.1635 ~ 2.1642 in.)
 Page 100 of 169

Reassembly

• Thoroughly clean all parts to be assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new ones.
1. Install the main bearings.

Upper bearings have an oil groove of oil holes; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings(A).

(2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.
2. Install the thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.

3. Place the crankshaft (A) on the cylinder block.

 Page 101 of 169

4. Place the main bearing caps on the cylinder block.

5. Install the main bearing cap bolts.
(1) Install and uniformly tighten the bearing cap bolts, When installing the bearing cap bolts, tighten the bolts in two or three steps according to the sequence
shown below, in the sequence shown.
Tightening torque
Main bearing cap bolt
No.1~8 : 49.0 N.m (5.0 kgf.m, 36.2 lb-ft) + 90°
No.9~16 : 19.6 N.m (2.0 kgf.m, 14.5 lb-ft) + 120°
No.17~24 :
29.4 ~ 31.4 N.m (3.0 ~ 3.2 kgf.m, 21.7 ~ 23.1 lb-ft)

• Always use new crankshaft main bearing cap bolts. Crankshaft main bearing cap bolts are torque-to-yield bolts designed to be permanently
elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain
clamping force.
• If any of the bearing cap bolts are broken or deformed, replace it.
Use the SST( 09221-4A000 ), install main bearing cap bolts.

(2) Check that the crankshaft turns smoothly.

6. Check crankshaft end play.
7. Install the piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting rod")
8. Install the connecting rod caps and check oil clearance.
(Refer to Cylinder Block - " Piston and Connecting Rod")
9. Check the connecting rod end play.
(Refer to Cylinder Block - "Piston and Connecting Rod")
10. Install the rear oil seal case (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
 Page 102 of 169

• Clean the sealing face before assembling two parts.

• Remove harmful foreign materials on the sealing face before applying sealant
• Before assembling rear oil seal case, the liquid sealant THREE BOND 1217H should be applied to the rear oil seal case.
• The assembly must be done within 5 minutes after the sealant is applied.
• Apply sealant to the inner threads of the bolt holes.

11. Install the rear oil seal.

(Refer to Cylinder Block - "Rear Oil Seal")
12. Install the baffle plate.
When installing the baffle plate bolts, tighten the bolts in two or three steps according to the sequence shown below.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

13. Install the upper oil pan.

(Refer to Lubrication System - "Oil Pan")
14. Assemble the other parts in the reverse order of disassembly.

In case the crankshaft is replaced with a new one, select the proper connecting rod bearing according to the pin journal mark on the crankshaft.
• Connecting rod bearing selection
(Refer to Cylinder Block - "Piston and Connecting Rod")
Engine Mechanical System

Components
 Page 103 of 169

1. Water jacket separator 1# 5. Oil cover gasket

2. Water jacket separator 2# 6. Plug bolt
3. Cylinder block 7. Washer gasket
4. Oil cover

Engine Mechanical System

Disassembly

• Use fender covers to avoid damaging painted surfaces.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) before removing it.
• When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring and hoses to avoid misconnection.

• Inspect the timing chain before removing the cylinder head.
• Turn the crankshaft pulley so that the No.1 piston is at top dead center.
1. Remove the engine assembly from the vehicle.
(Refer to Engine And Transaxle Assembly - "Engine And Transaxle Assembly")
2. Remove the drive plate and adapter plate.
(Refer to Cylinder Block - "Drive Plate")
3. Attach the engine to engine stand for disassembly.
 Page 104 of 169
4. Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
5. Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
6. Remove the timing chain.
(Refer to Timing System - "Timing Chain")
7. Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
8. Remove the cylinder head.
(Refer to Cylinder Head Assembly - "Cylinder Head")
9. Remove the oil pump.
(Refer to Lubrication System - "Oil Pump")
10. Remove the oil cover (A) and gasket (B).

11. Remove the water jacket separator.

(Refer to Cylinder Block - "Water Jacket Separator")
12. Remove the knock sensor (A).

13. Remove the upper oil pan.

(Refer to Lubrication System - "Oil Pan")
14. Remove the baffle plate (A).
 Page 105 of 169

15. Remove the rear oil seal case (A).

16. Remove the oil drain cover (A) and gasket (B).

17. Check the connecting rod side clearance.

(Refer to Cylinder Block - "Piston and Connecting Rod")
18. Check the connecting rod bearing cap oil clearance.
(Refer to Cylinder Block - "Piston and Connecting Rod")
19. Remove the piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

• Keep the bearings, connecting rod and cap together.

• Arrange the piston and connecting rod assemblies in the correct order.
20. Remove the crankshaft main bearing cap and check oil clearance.
(Refer to Cylinder Block - "Crankshaft")
21. Check the crankshaft end play.
(Refer to Cylinder Block - "Crankshaft")
22. Remove the crankshaft.
(Refer to Cylinder Block - "Crankshaft")
 Page 106 of 169

Arrange the main bearings and thrust bearings in the correct order.
23. Remove the oil jets (A).

24. Disassemble the piston rings.

(1) Using a piston ring expander, remove the 2 compression rings (A).
(2) Remove the oil ring and coil spring (B) by hand.

Arrange the piston rings in the correct order only.

25. Remove the snap rings at both ends of the piston pin, and push the piston pin to disconnect the connecting rod.

Inspection
Cylinder Block
1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of the cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Standard : Less than 0.05 mm (0.0020 in.),
Less than 0.02 mm (0.0008 in.) / 150 x 150

4. Inspect cylinder bore diameter.

Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
5. Inspect cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter in the thrust and axial directions
Standard diameter :
 Page 107 of 169
96.00 ~ 96.03 mm (3.7795 ~ 3.7807 in.)

Measuring direction : axial direction, Thrust direction

6. Check the cylinder bore size code on the cylinder block.

Class Mark 3.8L

96.00 ~ 96.01 mm
A A
(3.7795 ~ 3.7799 in.)
96.01 ~ 96.02 mm
B B
(3.7799 ~ 3.7803 in.)
96.02 ~ 96.03 mm
C C
(3.7803 ~ 3.7807 in.)

The maximum allowable size

96.28 mm (3.7905 in.)

Cylinder boring
1. Oversize pistons should be selected according to the largest bore cylinder.
Identification Mark Size
0.1 0.1 mm (0.004 in)
0.25 0.25 mm (0.010 in)

The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.
 Page 108 of 169
3. According to the measured O.D(Outer Diameter), calculate the new bore size.
New bore size = piston O.D + 0.03 to 0.05 mm (0.0012 to 0.0020 in) (clearance between piston and cylinder) -
0.01 mm (0.0004 in) (honing margin.)
4. Bore each of the cylinders to the calculated size.

To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order.
5. Hone the cylinders for the proper clearance (between the cylinder and piston).
6. Check the clearance between the piston and cylinder.
Standard :0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in)

When boring the cylinders, finish all of the cylinders to the same new bore size. Do not bore only one cylinder to the new bore size.

Reassembly
1. Install the oil jets (A).
Tightening torque
27.5 ~ 31.3 N.m (2.8 ~ 3.2kgf.m, 20.2 ~ 23.1lb-ft)

2. Install the crankshaft.

(Refer to Cylinder Block - "Crankshaft")
3. Install the crankshaft main bearing cap and check oil clearance.
(Refer to Cylinder Block - "Crankshaft")
4. Check the crankshaft end play.
(Refer to Cylinder Block - "Crankshaft")
5. Install the piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting rod")
6. Check the connecting rod end play.
(Refer to Cylinder Block - Piston and Connecting Rod")
7. Install the plug bolt (A) and the washer gasket (B).
Tightening torque :
83.4 ~ 102.9N.m (8.5 ~ 10.5kgf.m, 61.5 ~ 75.9lb-ft)

8. Install the rear oil seal case (A).

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
 Page 109 of 169

• Clean the sealing face before assembling two parts.

• Remove harmful foreign materials on the sealing face before applying sealant
• Before assembling rear oil seal case, the liquid sealant THREE BOND 1217H should be applied to the rear oil seal case.
• The assembly must be done within 5 minutes after the sealant is applied.
• Apply sealant to the inner threads of the bolt holes.

9. Install the rear oil seal.

(Refer to Cylinder Block - "Rear Oil Seal")
10. Install the baffle plate.
When installing the baffle plate bolts, tighten the bolts in two or three steps according to the sequence shown below.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

11. Install the upper oil pan.

(Refer to Lubrication System - "Oil Pan")
12. Install the knock sensor #1 and #2.
(Refer to Engine Control / Fuel System - "Knock Sensor")
13. Install the water jacket separator.
(Refer to Cylinder Block - "Water Jacket Separator")
14. Install the oil cover (A) and gasket (B).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
 Page 110 of 169

15. Assemble the other parts in the reverse order of disassembly.

In case the cylinder block is replaced with a new one, select the proper crankshaft main bearing and the piston according to the crankshaft journal bore
mark and the cylinder bore mark on the cylinder block.
• Crankshaft main bearing selection
(Refer to Cylinder Block - "Crankshaft")
• Piston selection
(Refer to Cylinder Block - "Piston and Connecting Rod")
Engine Mechanical System

Components

1. Water pump pulley 5. Water inlet pipe

2. Water pump 6. Water outlet pipe
 Page 111 of 169
3. Water pump gasket 7. Water temperature control assembly
4. Water center pipe 8. Thermostat

Engine Mechanical System

Replacement and Air Bleeding

Never remove the radiator cap when the engine is hot. A serious scalding could be caused by high-pressure hot fluid escaping from the radiator.

When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint. If any coolant spills, rinse it off
immediately.
1. Make sure the engine and radiator are cool to touch.
2. Remove the radiator cap (A).

3. Loosen the drain plug (A), and drain the coolant with the radiator cap still being open for smooth draining.
Tightening torque :
0.78 ~ 1.57 N.m (0.08 ~ 0.16 kgf.m, 0.58 ~ 1.161 lb-ft)

4. Tighten the radiator drain plug securely.

5. Remove, drain and reinstall the reservoir.
(Refer to Cooling System - "Reservoir Tank")
Fill the tank halfway to the F mark with water, then up to the F mark with antifreeze.
6. Fill the radiator with water through the radiator cap and tighten the cap.

To bleed air in the most effective way, pour the water slowly and press on the upper / lower radiator hoses.
7. Start the engine and allow it to come to normal operating temperature. Wait for the cooling fans to turn on several times.
Accelerate the engine to aid in purging trapped air. Shut engine off.
8. Wait until the engine is cool.
9. Repeat steps 1 to 8 until the drained water runs clear.
10. Fill fluid mixture with coolant and water (45~60%) (except for North America, Europe and China : 45~50%) slowly through the radiator cap.
Push the upper/lower hoses of the radiator so as to bleed air easily.

• Use only genuine antifreeze/coolant.

• For best corrosion protection, the coolant concentration must be maintained year-round at a minimum of 45 to 50%
Coolant concentration less than 45 to 60% may not provide sufficient protection against corrosion or freezing.
• Coolant concentration greater than 60% will impair cooling efficiency and is not recommended.

• Do not mix different brands of antifreeze/coolants.

• Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
11. Start the engine and let the coolant circulate.
 Page 112 of 169
When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
12. Repeat the step 11 until the cooling fan operates three to five times in order to sufficiently bleed air out of the cooling system.
13. Install the radiator cap and fill the reservoir tank to the "MAX"(or "F") line with coolant.
14. Let the vehicle idle until the cooling fan operates two to three times.
15. Stop the engine and wait until coolant gets cool.
16. Repeat step 10 to 15 until the coolant level doesn't fall any more, bleed air out of the cooling system.

As bleeding air out of the cooling system and refilling coolant are optimized when coolant gets cool completely, recheck the coolant level in the
reservoir tank for 2 ~ 3 days after replacing coolant.
Coolant capacity :
for Europe : 8.8 L (9.30 U.S.qt., 7.74 lmp.qt., 2.32 U.S.gal.)
except Europe : 8.4 L (8.87 U.S.qt., 7.38 lmp.qt., 2.21 U.S.gal.)
Engine Mechanical System

Components

1. Cooling fan shroud 4. Cooling far rear cover

2. Cooing fan 5. Cooling fan controller (PWM)
3. Cooling fan motor 6. Reservoir tank

Engine Mechanical System

Description
The cooling fan controlsx the cooling fan motor voltage depending on the duty output from the ECU (Freq.: 300Hz).
[Signal from the ECU to the PWM (SI: 300Hz)]
 Page 113 of 169

SI Duty Motor Voltage (V) Variation (V)

10% 0
30% 4.1
±0.5
60% 8.2
70% 9.57
90% more than 12.5 -

[Operating condition of the cooling fan]

Vehicle speed Water Temperature
A/C switch A/C pressure [kgf/cm² G (psi G)] Duty (%)
[km/h (mph)] [°C (°F)]
V < 45 (28) 98 (208.4) or above 35 or above
OFF ㅡ 45 (28) ≤ V < 80 (49.7) 101 (213.8) or above 40 or above
80 (49.7) ≤ V 105 (221) or above 80 or above
A/C pressure < 6 (85.3) All 105 (221) or above 90 or above
V < 45 (28) 82 (179.6) or above 30 or above
6 (85.3) ≤ A/C pressure < 12 (170.7) 45 (28) ≤ V < 80 (49.7) 96 (204.8) or above 40 or above
80 (49.7) ≤ V 96 (204.8) or above 60 or above
ON V < 45 (28) 101 (213.8) or above 70 or above
12 (170.7) ≤ A/C pressure < 15.5 (120.5) 45 (28) ≤ V < 80 (49.7) - 30 (- 22) or above 40 or above
80 (49.7) ≤ V 82 (179.6) or above 60 or above
V=0 - 30 (- 22) or above 70 or above
15.5 (120.5) ≤ A/C Pressure
0<V - 30 (- 22) or above 90 or above

Engine Mechanical System

Specifications
[Cooling fan control (PWM)]
Items Performance spec
MAX, load current consumption (12V) 23.3 + 10% A
Communication frequency 300 ± 5%
Duty 10, 30 ~ 90 %
Input
HI more than 0.7 V
Voltage level
LOW 0 ~ 1.9 V

Engine Mechanical System

Cooling Circuit Diagram

Page 114 of 169
 Page 115 of 169

Engine Mechanical System

Removal And Installation

Cooling fan
1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
3. Disconnect the over flow hose (A) and cooling fan motor connector (B).

4. Loosen the cooling fan mounting bolts and then remove the cooling fan (A).
Tightening torque :
4.9 ~ 7.8 N.m (0.5 ~ 0.8 kgf.m, 3.6 ~ 5.8 lb-ft)
 Page 116 of 169

5. To install, reverse the removal procedure.

Cooling fan controller (PWM)

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
3. Disconnect the cooling fan motor connector (A).

4. Remove the cooling fan controller (PWM) (A).

Tightening torque :
4.9 ~ 8.3 N.m (0.50 ~ 0.85 kgf.m, 3.6 ~ 6.1 Ib-ft)

5. To install, reverse the removal procedure.

Disassembly
1. Remove the cooling fan rear cover (A).
Tightening torque :
1.8 ~ 2.4 N.m (0.18 ~ 0.25 kgf.m, 1.3 ~ 1.8 lb-ft)
 Page 117 of 169
2. Remove the fan (B) from cooling fan assembly (A).
Tightening torque:
2.8 ~ 3.2 N.m (0.28 ~ 0.33 kgf.m, 2.0 ~ 2.4 lb-ft)

3. Remove the cooling fan motor (A).

Tightening torque:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

4. To install, reverse the removal procedure.

Engine Mechanical System

Troubleshooting
Symptoms Remedy
If the cooling fan is not functioning under normal operating conditions • Check the connector
• Check the voltage of the battery (#1).
Check the fuse if the voltage is not applied.
• Check the wires in the motor for short circuits.
If the cooling fan functions excessively under non-operational conditions Check the SI terminal for short circuits (connectors, wires).

※ Must measure the SI waveform with the PWM connected so that it can locate the ON/OFF signals.
Engine Mechanical System

Components
 Page 118 of 169

1. Radiator assembly 5. Radiator lower hose

2. Radiator upper mounting bracket 6. Radiator upper hose
3. Radiator lower mounting insulator 7. Clamp
4. Radiator cap

Engine Mechanical System

Removal and Installation

1. Disconnect the battery "-" terminal from the trunk room.
2. Loosen the drain plug and drain the engine coolant.
(Refer to Cooling System - "Coolant")
3. Remove the cooling fan.
(Refer to Cooling System - "Cooling fan")
4. Disconnect the radiator upper hose (A) and lower hose (B).
 Page 119 of 169

When installing radiator hoses, install as shown in illustrations.

5. Remove the radiator upper mounting bracket.

6. Remove the fixing bolts (A) between the radiator assembly and the A/C condenser, and then remove the radiator (A) from the vehicle.
Tightening torque :
4.9 ~ 7.8 N.m (0.5 ~ 0.8 kgf.m, 3.6 ~ 5.8 Ib-ft)

7. To install, reverse the removal procedure.

Fill the radiator with coolant and check for leaks.

Inspection
Radiator Cap Testing
1. Remove the radiator cap, apply engine coolant to the seal, and then install a pressure tester on it.
 Page 120 of 169

2. Apply a pressure of 93.16 ~ 122.58 kPa (0.95 ~ 1.25 kg/cm², 13.51 ~ 17.78 psi).
3. Check the pressure for any changes.
4. If the pressure drops, replace the cap.

Radiator Leakage Test

1. Wait for the engine to cool down, then carefully remove the radiator cap and fill the radiator with engine coolant, then install the pressure tester.

2. Apply a pressure tester to the radiator and apply a pressure of 93.16~122.58 kPa (0.95~1.25 kg/cm², 13.51~17.78 psi).
3. Inspect for engine coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the radiator cap.

Check whether the engine oil is mixed with the coolant.

Engine Mechanical System

Removal and Installation

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine cover.
3. Remove the engine room cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
4. Remove the reservoir tank (A) after loosening the mounting bolts from cooling fan. and then disconnect the over flow hose (B).
Tightening torque :
4.9 ~ 8.3 N.m (0.50 ~ 0.85 kgf.m, 3.6 ~ 6.1 lb-ft)
 Page 121 of 169

5. To install, reverse the removal procedure.

Engine Mechanical System

Components

1. Water temperature control assembly 4. Water center pipe

2. O-ring 5. Water inlet pipe
3. Water outlet pipe

Engine Mechanical System

Removal and Installation

Water Temperature Control Assembly
1. Disconnect the battery "-" terminal from the trunk room.
 Page 122 of 169
2. Remove the engine room under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
3. Drain the coolant.
(Refer to Cooling System - "Coolant")
4. Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "Air cleaner")
5. Disconnect the radiator lower hose (A).

When installing radiator hoses, follow the illustration below.

6. Remove the water inlet pipe (A).

Tightening torque :
19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 Ib-ft)

7. Disconnect the radiator upper hose (A).

When installing radiator hoses, follow the illustration below.

 Page 123 of 169

8. Disconnect the engine wiring harness.

(1) ECM Connector (A)
(2) TCM connector (B)
(3) IDB Connector (C)
(4) Earth cable (D)
Tightening torque
Earth cable (D) :
10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 Ib-ft)

9. Remove the oil level gauge.

10. Remove the water outlet pipe & hose (B) and then oil level gauge (A).
Tightening torque :
19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 Ib-ft)

11. Remove the surge tank.

(Refer to Intake And Exhaust System - "Surge Tank")
12. Remove the cowl top cover.
13. Remove the engine room bulkhead (A).
 Page 124 of 169
14. Disconnect the heater inlet & outlet hose (A).

When installing the heater hoses, follow the illustration below.

15. Remove the ATF cooler hose (A), heater hose (B).

16. Remove the water temperature control assembly (A) and th the gaskets.
Tightening torque
bolts and nuts :
19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 Ib-ft)
 Page 125 of 169

• Clean the surface of gasket before installing the water temperature control assembly.
• Do not reuse the gasket.
17. To install, reverse the removal procedure.
18. Fill the radiator with coolant and check for leaks.
(Refer to Cooling System - "Coolant")

Water Inlet Pipe

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine room under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
3. Drain the coolant.
(Refer to Cooling System - "Coolant")
4. Remove the air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
5. Disconnect the radiator lower hose (B).

When installing radiator hoses, follow the illustration below.

6. Remove the oxygen sensor bracket (A), and sensor bracket (B).
 Page 126 of 169

7. Remove the water inlet pipe (A).

Tightening torque:
19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 Ib-ft)

Do not reuse the water pipe o-ring.

8. To install, reverse the removal procedure.

Water Outlet Pipe

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine room under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
3. Disconnect the radiator upper hose (A).

When installing radiator hoses, follow the illustration below.

 Page 127 of 169

4. Remove the engine room cover and the radiator grill upper cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
5. Disconnect the engine wiring harness.
(1) ECM Connector (A)
(2) TCM connector (B)
(3) IDB connector (C)
(4) Earth cable (D)
Tightening torque
Earth cable (D) :
10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 Ib-ft)

6. Remove the oil level gauge.

7. Remove the water outlet pipe & hose (B) and then oil level gauge load (A).
Tightening torque
19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 Ib-ft)

• When installing, apply engine oil to the O-ring and take care not to damage the O-ring.
• Do not reuse the oil level gauge O-ring.
• Do not reuse the water pipe o-ring.
8. To install, reverse the removal procedure.
9. Recheck the coolant level.
(Refer to Cooling System - "Coolant")

Water Center Pipe

1. Remove the water outlet pipe.
(Refer to Cooling System - "Water Temperature Control Assembly")
2. Remove the Water inlet pipe.
(Refer to Cooling System - "Water Temperature Control Assembly")
 Page 128 of 169
3. Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
4. Remove the delivery pipe and injector.
(Refer to Engine Control / Fuel System - "Fuel Delivery System")
5. Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
6. Remove the water center pipe (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 Ib-ft)

Do not reuse the water pipe o-ring.

7. To install, reverse the removal procedure.
Engine Mechanical System

Components
 Page 129 of 169

1. Water pump pulley 3. Water pump gasket

2. Water pump

Engine Mechanical System

Removal and Installation

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine room under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
3. Drain the engine coolant.
(Refer to Cooling System - "Coolant")
4. Remove the drive belt.
(Refer to Timing System - "Drive Belt")
5. Remove the water pump pulley (A).
Tightening torque :
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
 Page 130 of 169

6. Remove the water pump (A) and gaskets (B).

• Clean the contact face before assembly.

• Always use a new gasket.
• Always use a new seal bolt (Bolt C)
Tightening torque
A(3EA) :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
B(1EA) :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
C(1EA) :
21.6 ~ 26.5 N.m (2.2 ~ 2.7 kgf.m, 15.9 ~ 19.5lb-ft)
D(1EA) :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
E(1EA) :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
F(1EA) :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
G(4EA) :
21.6 ~ 23.5 N.m (2.2 ~ 2.4 kgf.m, 15.9 ~ 17.4lb-ft)
 Page 131 of 169

7. To install, reverse the removal procedure.

8. Fill the radiator with coolant and check for leaks.
(Refer to Cooling System - "Coolant")

Inspection
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly.

A small amount of "weeping" from the bleed hole is normal.

Engine Mechanical System

Troubleshooting
Symptoms Possible Causes Remedy
Coolant leakage • From the bleed hole of the Visually check • Check leaks after about ten- • If coolant still leaks, replace a water
water pump minute warming up. pump.
• If leakage stops, reuse the water pump
(Do not replace the pump with a new
one).
• From gaskets or bolts • Check the tightening of the water • Retighten the mounting bolts.
pump mounting bolts.
• Check damage of gaskets or • Replace the gasket and clean dust off.
inflow of dust.
• From outer surface of • Check the material or any cracks • Poor material. If any crack found, replace
water pump of the water pump. the water pump.
Noise • From bearings Inspection with a • After starting the engine, check • If there is no noise, reuse the water pump
• From mechanical seals stethoscope noise with a stethoscope. (do not replace it).
• Impeller interference • If there is any noise from the water pump,
remove the drive belt and recheck.
Inspection after removing • After removing a water pump and • If there is noise, reuse the water pump.
a drive belt a drive belt, check noise again. Check other drive line parts.
• If there is no noise, replace the water
pump with a new one.
Inspection after removing • After removing a water pump and • If there is any interference between them,
a water pump a drive belt, check noise again. replace the water pump with a new one.
Overheating • Damaged impeller Loosened impeller • Corrosion of the impeller wing • Check engine coolant.
• Loosened impeller • Poor coolant quality / Maintenance check
• Impeller separation from the shaft • Replace the water pump.

Engine Mechanical System

Components
 Page 132 of 169

1. Water temperature control Assembly 3. Coolant inlet fitting

2. Thermostat

Engine Mechanical System

Removal and Installation

Removal of the thermostat will have an adverse effect, leading to lowered cooling efficiency.
Do not remove the thermostat, even if the engine tends to overheat.
1. Disconnect the battery "-" terminal from the trunk room.
2. Drain engine coolant so its level is below thermostat.
(Refer to Cooling System - "Coolant")
3. Remove the water inlet pipe.
(Refer to Cooling System - "Water Temperature Control Assembly")
4. Remove the coolant inlet fitting (A).
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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5. Remove the thermostat (A).

Install the thermostat with the jiggle valve facing upward.

6. To install, reverse the removal procedure.

Inspection
1. Immerse the thermostat in water and gradually heat the water.

2. Check the valve opening temperature.

Valve opening temperature:88 ± 2°C (190.4±3.6°F)
Full opening temperature:100°C (212°F)
If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift.
Valve lift :10 mm (0.3937 in.) or more at 100°C (212°F)
If the valve lift is not as specified, replace the thermostat.
Engine Mechanical System

Troubleshooting
Symptoms Possible Causes Remedy
Coolant leakage • From the thermostat gasket Check the mounting bolts • Check the torque of the mounting • Retighten the bolts and check
bolts leakage again.
Check the gasket for • Check gasket or seal for damage • Replace gaskets and reuse the
damage thermostat.
Cooled excessively • Low heater performance Visually check after • Insufficient coolant or leakage. • After refilling coolant, recheck.
(cool air blowed-out) removing the radiator cap.
• Thermogauge indicates GDS check & Starting • Check DTCs • Check the engine coolant sensor,
'LOW' engine • Check connection of the fan clutch wiring and connectors.
or the fan motor. • Replace the components.
 Page 134 of 169
※ If the fan clutch is always connected,
there will be a noise at idle.
Remove the thermostat and • Check if there are dusts or chips in • Clean the thermostat valve and
inspect the thermostat valve. reuse the thermostat.
• Check adherence of the thermostat. • Replace the thermostat, if it doesn't
work properly.
Heated excessively • Engine overheated Visually check after • Insufficient coolant or leakage. • After refilling coolant, recheck.
• Thermogauge indicates 'HI' removing the radiator cap. ※ Be careful when removing a • Check the cylinder head gaskets for
radiator cap of the overheated damage and the tightening torque
vehicle. of the mounting bolts.
• Check air in cooling system.
GDS check & Starting • Check DTCs • Check the engine coolant sensor,
engine • Check the fan motor performance wiring and connectors.
as temperature varies. • Check the fan motor, the relay and
• Check if the fan clutch slips. the connector.
• Check the water pump adherence or • Replace the fan clutch, if it doesn't
impeller damaged. work properly.
• Replace the water pump, if it
doesn't work properly.
Immerse the thermostat in • After removing the thermostat, • Replace the thermostat, if it doesn't
boiling water and check it works properly. work properly.
inspection. ※ Check the thermostat opens at
the valve opening temperature.

Engine Mechanical System

Description
The AAF (Active Air Flap) is located between radiator grille and radiator, and consists of an actuator and 6 air flaps. The system receives information from EMS,
FATC, TCU, MCU and LDC via CAN communication . With this information, the AAF controls the motor properly and then the air flaps adjust air flow from the
radiator grille.
During high speed driving, it will reduce the air resistance by closing the air flaps. This improves the fuel efficiency and enhances the driving stability. If the
engine is overheated, the system will open the air flaps to drop the temperature.
During the A/C operation, the system will open the air flaps to maintain the refrigerant pressure. The system will close the air flaps to warm up the engine rapidly
during cold start.

Specifications
Items Specifications
Operating temperature -22~185°F (-30~85°C)
Operating voltage DC 9~16V
Rated voltage DC 12V
Rated current (No load) 300mA or less

Engine Mechanical System

Components
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1. Active air housing 4. Active air actuator

2. Active air flap 5. Active air duct
3. Active air link 6. Active air actuator cover

Engine Mechanical System

Schematic Diagram
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Circuit Diagram
 Page 137 of 169

Engine Mechanical System

Removal and Installation

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the front bumper.
(Refer to Body - "Front Bumper Cover")
3. Disconnect the connector and remove the lower air guard (A).

4. Remove the active air flap (AAF) assembly (A) and disconnect the connector (B).
Tightening torque
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
 Page 138 of 169

5. To install, reverse the removal procedure.

6. After installation, perform the "Actuation test" using GSD to check on the system.

Disassembly
1. Loosen the fixing screw and then remove the active air flap rear cover (A).

2. Remove the active air flap actuator cover (A).

3. Remove the active air link (A).

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4. Remove the active air actuator (A).

5. To install, reverse the removal procedure.

Engine Mechanical System

Troubleshooting
Symptoms Possible Causes Remedy
• Inspect the flap and remove the foreign substance
Active Air Flap System Fail
Warning illuminated • Check the Active Air Flap assembly
(Flap stuck)
"Check active air flap system" • Repair or replace as required
Actuator Fault Replace the actuator
Linkage damage Replace the linkage
• Inspect the flap and remove the foreign substance
Active Air Flap System Fail
Malfunction Indicating Lamp On • Check the Active Air Flap assembly
(Flap stuck)
• Repair or replace as required
Actuator Fault Replace the actuator

※ After performing repairs, clear Diagnostic Trouble Codes (DTC) and check the warning and Malfunction Indicating Lamp.
Engine Mechanical System

Replacement

• Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful substance which may cause skin cancer.
• Use caution to minimize the length and frequency of contact of your skin to used oil. Wear protective clothing and gloves. Wash your skin thoroughly
with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
• In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites.
1. Park the car on the level ground.
Start the engine and let it warm up.
2. Wait for 5 minutes after loosening the oil filter cap to fully drain the oil from the oil filter.
3. Remove the engine under cover.
4. Drain engine oil.
(1) Remove the oil filler cap.
(2) After lifting the car, remove the oil drain plug (A) and drain oil into a container.
5. Replace the oil filter.
(1) Disconnect the oil filter cap (A) from the oil filter body.
Turn the cap slightly and wait a minute to allow the residual oil in the filter to run out.
Then, remove the cap completely.
 Page 140 of 169

(2) Remove the oil filter element.

(3) Check the part number of a new oil filter is the same as the old one.
(4) Install a new oil filter element (A) and new O-ring (B).

Check whether the o-ring is installed in the proper place.

(5) Apply clean engine oil to the new O-rings.
Lightly screw the oil filter cap into place, and tighten it until the O-ring contacts the seat.
(6) Finally tighten it again with specified tightening torque.
Tightening torque :
31.4 ~ 38.2 N.m (3.2 ~ 3.9 kgf.m,23.1 ~ 28.2 Ib-ft)
6. Fill new engine oil.
(1) Install the oil drain plug (A) with a new gasket.
Tightening torque :
34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)

(2) Fill new engine oil, while checking the oil level on the dipstick.
Capacity
Total : 7.3 L (7.71 U.S qt., 6.42 lmp.qt., 1.92 U.S.gal.)
Oil pan : 6.8 L (7.18 U.S qt., 5.98 lmp.qt., 1.79 U.S.gal.)
Drain and refill including oil filter :
6.9 L (7.29 U.S.qt., 6.06 lmp.qt., 1.82 U.S.gal.)
(3) Install the oil filler cap.
7. Start the engine and check that no oil leaks from the drain plug or oil filter.
8. Recheck the engine oil level.

Inspection
1. Check the engine oil quality.
Check the oil deterioration, addition of water or coolant, discoloring or thinning.
If the quality is visibly poor, replace the oil.
 Page 141 of 169
2. Check the engine oil level.
Warm up and stop the engine, and then wait 5 minutes before checking whether the oil level is between the “F” and “L” marks in the dipstick.
If the level is lower than “L,” check for leakage and add oil up to the “F” mark.

Do not fill with engine oil above the “F” mark.

Selection Of Engine Oil

Recommendation :
- ACEA A5 or above / 5W-30
Allowed Oil Grade :
- ACEA A3, A5 or above
Allowed SAE Viscosity

For best performance and maximum protection of all types of operation, select only those lubricants which:
1. Satisfy the requirement of the ACEA classification.
2. Have proper SAE grade number for expected ambient temperature range.
3. Lubricants that do not have both an SAE grade number and ACEA service classification on the container should not be used.
Engine Mechanical System

Engine oil flow diagram

 Page 142 of 169

Engine Mechanical System

Components
 Page 143 of 169

1. Oil filter cap 4. Oil filter body

2. O-ring 5. Oil seal
3. Oil filter element

Engine Mechanical System

Removal and Installation

Oil filter body
1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
3. Remove the engine oil filter body (A).
Tightening torque :
20.6 ~ 22.6 N.m (2.1 ~ 2.3 kgf.m, 15.2 ~ 16.1 lb-ft)
 Page 144 of 169

• Check the existence of oil seal.

• Do not reuse the oil seal.
• When installing, check the damage and rip of a gasket.
4. To install, reverse the removal procedure.
5. Start engine and check for oil leaks.
6. Recheck the engine oil level.

Oil filter
1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
3. Drain engine oil.
(Refer to Lubrication System - "Engine Oil")
4. Replace the oil filter.
(1) Disconnect the oil filter cap (A) from the oil filter body.
Turn the cap slightly and wait a minute to allow the residual oil in the filter to run out.
Then, remove the cap completely.

(2) Remove the oil filter element.

(3) Check the part number of a new oil filter is the same as the old one.
(4) Install a new oil filter element (A) and new O-ring (B).

Check whether the o-ring is installed in the proper place inside a cap.
(5) Apply clean engine oil to the new O-rings.
Lightly screw the oil filter cap into place, and tighten it until the O-ring contacts the seat.
(6) Finally tighten it again by applying specified tightening torque.
Tightening torque :
31.4 ~ 38.2 N.m (3.2 ~ 3.9 kgf.m,23.1 ~ 28.2 Ib-ft)
 Page 145 of 169
5. To install, reverse the removal procedure.
6. Start engine and check for oil leaks.
7. Recheck the engine oil level.
Engine Mechanical System

Components

1. 2WD Lower oil pan 3. 2WD Upper oil pan

2. AWD Lower oil pan 4. AWD Upper oil pan
5. Cylinder block

Engine Mechanical System

Removal
[Lower oil pan]
1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
3. Drain the engine oil.
(Refer to Lubrication System - "Engine Oil")
4. Remove the lower oil pan (A).
[2WD]
 Page 146 of 169

[AWD]

• Insert the blade of SST (09215-3C000) between the upper oil pan and lower oil pan.
Cut off applied sealer and remove the lower oil pan.
• Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
• After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
• Do not use the SST as a prybar.
Hold the tool in position (on the gasket line) and tap in with a light hammer.
• Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.

[2WD Upper oil pan]

1. Remove the sub frame from the vehicle.
2. Remove the timing chain cover.
(Refer to Timing System - "Timing Chain Cover")
3. Remove the lower oil pan.
(Refer to Lubrication System - "Oil Pan")
4. Remove the air conditioning compressor.
(Refer to Heating, Ventilation, Air Conditioning - "Compressor")
5. Remove the upper oil pan (A).

Insert the blade of SST (09215-3C000) between the upper oil pan and lower oil pan.
Cut off applied sealer and remove the lower oil pan.

[AWD Upper oil pan]

1. Remove the sub frame from the vehicle.
2. Remove the Driveshaft and axle.
(Refer to Driveshaft and Axle - "Front Driveshaft")
 Page 147 of 169
3. Remove the front differential carrier.
(Refer to Driveshaft and Axle - "Front Differential Carrier")
4. Remove the Timing chain cover.
( Refer to Timing System - "Timing Chain Cover")
5. Remove the lower oil pan.
(Refer to Lubrication System - "Oil Pan")
6. Remove the air conditioning compressor.
(Refer to Heating, Ventilation, Air Conditioning - "Compressor")
7. Remove the adjustable oil pump connector, and after retaining clips (A), push the connector (B) inward.

8. Remove the upper oil pan (A).

Insert the blade of SST (09215-3C000) between the upper oil pan and lower oil pan.
Cut off applied sealer and remove the lower oil pan.
9. Remove the oil pump.
(Refer to Lubrication System - "Oil Pump")
10. Remove the oil pump (A), together with the upper oil pan (B).

Installation
[Lower oil pan]
1. Install the lower oil pan (A).
A. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
B. Before assembling the oil pan, the liquid sealant THREE BOND 1217H should be applied on oil pan. The assembly must be done within 5 minutes after
the sealant is applied.
Bead width :2.5 mm (0.1 in.)
[2WD]
 Page 148 of 169

[AWD]

• Clean the sealing face before assembling two parts.

• Remove harmful foreign matters on the sealing face before applying sealant.
• When applying sealant gasket, sealant must not protrude into the inside of oil pan.
• To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
• After assembly, wait at least 30 minutes before filling the engine with oil.
C. Install the oil pan (A).
Tighten the bolts in two or three steps.
[2WD]

[AWD]

2. After assembly, wait at least 30 minutes before filling the engine with oil.
(Refer to Lubrication System - "Engine Oil")
3. Install all other parts in the reverse order of removal.

[2WD Upper oil pan]

 Page 149 of 169
1. Install the lower oil pan (A).
A. Using a gasket scraper, remove all the old packing materials from the gasket surfaces.
B. Before assembling the oil pan, the liquid sealant THREE BOND 1217H should be applied on oil pan. The assembly must be done within 5 minutes after
the sealant is applied.
Bead width :2.5 mm (0.1 in.)

• Clean the sealing face before assembling two parts.

• Remove harmful foreign matters on the sealing face before applying sealant.
• When applying sealant gasket, sealant must not protrude into the inside of oil pan.
• To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
• After assembly, wait at least 30 minutes before filling the engine with oil.
C. Install the upper oil pan.
Tighten the bolts in two or three steps.
Tightening torque
Short bolt :
20.6 ~ 22.6 N.m (2.1 ~ 2.3 kgf.m, 15.2 ~ 16.6 lb-ft)
Long bolt :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

2. Install all other parts in the reverse order of removal.

[AWD Upper oil pan]

1. Install the oil pump (A) and upper oil pan (B).

A. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
B. Before assembling the oil pan, the liquid sealant THREE BOND 1217H should be applied on oil pan. The assembly must be done within 5 minutes after
the sealant is applied.
Bead width :2.5 mm (0.1 in.)
 Page 150 of 169

• Clean the sealing face before assembling two parts.

• Remove harmful foreign matters on the sealing face before applying sealant.
• When applying sealant gasket, sealant must not protrude into the inside of oil pan.
• To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
• After assembly, wait at least 30 minutes before filling the engine with oil.
C. Tighten the bolts in two or three steps.
Tightening torque
Short bolt :
20.6 ~ 22.6 N.m (2.1 ~ 2.3 kgf.m, 15.2 ~ 16.6 lb-ft)
Long bolt :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

2. Install all other parts in the reverse order of removal.

Engine Mechanical System

Description
2-Stage variable Vane Pump improves the fuel economy by controlling the oil pressure into two stages and by optimizing the hydraulics of low/medium rpm.
The oil pressure/temperature sensor delivers the pressure information to ECM by measuring the oil pressure and temperature from oil pump, and ECM
maintains the pressure discharged from the RPM constantly by controlling the proportional control valve.
 Page 151 of 169

Operation
 Page 152 of 169

Control the frequent operation of solenoid by setting the mode change timing differently when increasing or decreasing the engine rpm.

Engine Mechanical System

Components
 Page 153 of 169

1. Oil pump (2WD) 3. Oil pump sprocket

2. Oil pump (AWD)

Engine Mechanical System

Removal and Installation

1. Remove the lower oil pan.
(Refer to Lubrication System - "Oil pan")
2. Remove the upper oil pan.
3. Remove the bolt (A) and then separate the chain with sprocket from the oil pump.
Tightening torque :
19.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.5 ~ 18.1 lb-ft)
 Page 154 of 169
4. Remove the oil of proportional control solenoid connector (A).

5. Remove the oil pump bracket bolt (A).

6. After loosening the oil pump mounting bolt, remove the oil pump (A) and upper oil pan together.
Tightening torque :
20.6 ~ 22.6 N.m (2.1 ~ 2.3 kgf.m, 15.2 ~ 16.6 lb-ft)

7. To install, reverse the removal procedure.

Engine Mechanical System

Components
 Page 155 of 169

1. Engine oil level gauge 2. Engine oil level gauge rod

Engine Mechanical System

Removal and Installation

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine room under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
3. Remove the engine room cover and the radiator grill upper cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
4. Remove the oil level gauge.
5. Remove the water outlet pipe & hose (B) and then oil level gauge rod (A).
Tightening torque
19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 Ib-ft)
 Page 156 of 169

• When installing, apply engine oil to the O-ring and take care not to damage the O-ring.
• Do not reuse the oil level gauge O-ring.
• Do not reuse the water pipe o-ring.
6. To install, reverse the removal procedure.
Engine Mechanical System

Components

1. Air cleaner cover 4. Air intake hose

2. Air cleaner element 5. Resonator
3. Air cleaner body 6. Intake air temperature sensor (IATS)

Engine Mechanical System

Removal and Installation

[Air Cleaner Assembly]
1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
3. Remove the engine room cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
4. Remove the front strutbar (A).
 Page 157 of 169

5. Remove the air intake hose and air cleaner assembly.

(1) Disconnect the IATS connector (A).
(2) Disconnect the breather hose (B).
(3) Disconnect the vacuum hose (C).
(4) Remove the air intake hose (D) and air cleaner assembly (E).

6. To install, reverse the removal procedure.

[Air Cleaner Element]

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine cover.
3. Remove the engine room cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
4. Remove the front strutbar (A).

5. Remove the retaining clips air cleaner cover, and then the air cleaner element (A).

6. To install, reverse the removal procedure.

Engine Mechanical System
 Page 158 of 169
Removal and Installation
1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
3. Remove the VIS actuator (A).
Tightening torque :
3.9~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 Ib-ft)

4. To install, reverse the removal procedure.

Engine Mechanical System

Components
 Page 159 of 169
1. Surge tank 2. VIS actuator

Engine Mechanical System

Removal and Installation

1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the engine cover.
3. Remove the engine room cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
4. Remove the Cowl Top Cover.
(Refer to Body - "Cowl Top Cover")
5. Remove the Engine room bulkhead (A).

6. Remove the air cleaner assembly.

(Refer to Intake Exhaust System - "Air Cleaner")
7. Disconnect the fuel hose (A,B) and Brake vacuum hose (C).

8. Disconnect the PCSV connector (A).

9. Disconnect the VIS connector (A), Condenser connector (B), MAP sensor connector (C).
 Page 160 of 169

10. Disconnect the throttle body connector (A).

11. After loosening the fixing bolt, remove the wiring protector (A).

12. Remove the throttle body Cooling hose (A), PCSV hose (B).

13. Remove the surge tank fixing bracket (A).

Tightening torque :
18.6~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 Ib-ft)
 Page 161 of 169

14. Remove the surge tank (A).

Tighten the surge tank bolts in two or three steps.

a ~ h : 1st step order / 1 ~ 8 : 2st step order
Tightening torque
Step 1 : 3.9~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 Ib-ft)
Step 2 : 9.8~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 Ib-ft)

15. To install, reverse the removal procedure.

Engine Mechanical System

Components
 Page 162 of 169

1. Intake manifold

Engine Mechanical System

Removal and Installation

1. Remove the surge tank.
(Refer to Intake and Exhaust System - "Surge Tank")
2. Remove the breather pipe & hose (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

3. Remove the water hose (C) and pipe (A) and then remove the intake manifold (B).
 Page 163 of 169

• Be sure to drain the engine coolant before removing the intake manifold.
• If coolant which drained from the cylinder head vent hole enters the intake port, it could potentially cause combustion chamber trouble.
4. To install, reverse the removal procedure.

Tighten the intake manifold bolts in two or three steps.

a ~ h : 1st step order
1 ~ 8 : 2nd step order
Tightening torque
1st step : 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
Step 2:
26.5 ~ 31.4 N.m (2.7 ~ 3.2 kgf.m, 19.5 ~ 23.1 lb-ft)
Step 3: Repeat 2nd step twice or more.

• Fill the engine coolant after installing intake manifold and check coolant level.
Engine Mechanical System

Components
 Page 164 of 169

1. LH Gasket 4. RH Gasket
2. LH Exhaust manifold 5. RH Exhaust manifold
3. RH Exhaust manifold stay 6. RH Exhaust manifold stay

Engine Mechanical System

Removal and Installation

LH Exhaust Manifold
1. Disconnect the battery "-" terminal from the trunk room.
2. Loosen the drain plug and drain the engine coolant.
(Refer to Cooling System - "Coolant")
3. Remove the water outlet pipe.
(Refer to Cooling System - "Water Temperature Control Assembly")
4. Remove the LH front muffler.
(Refer to Intake And Exhaust System - "Muffler")
5. Remove the engine oil level gauge and the pipe.
6. Disconnect the LH front oxygen sensor connector (A).
 Page 165 of 169

7. Remove the LH exhaust manifold stay (A).

Tightening torque :
34.3 ~ 41.2 N.m (3.5 ~ 4.2 kgf.m, 25.3 ~ 30.4 Ib-ft)

8. Remove the LH exhaust manifold assembly (A).

Tightening torque :
49.0 ~ 53.9 N.m (5.0 ~ 5.5 kgf.m, 36.1 ~ 39.8 Ib-ft)

9. To install, reverse the removal procedure.

When installing the exhaust manifold, tighten the nuts in the sequence shown below.

RH Exhaust Manifold
1. Disconnect the battery "-" terminal from the trunk room.
2. Loosen the drain plug and drain the engine coolant.
(Refer to Cooling System - "Coolant")
3. Remove the air cleaner assembly.
 Page 166 of 169
(Refer to Intake And Exhaust System - "Air Cleaner")
4. Remove the water inlet pipe.
(Refer to Cooling System - "Water Temperature Control Assembly")
5. Remove the RH front muffler.
(Refer to Intake And Exhaust System - "Muffler")
6. Disconnect the RH front oxygen sensor connector (A).

7. Remove the RH exhaust manifold stay (A).

Tightening torque :
34.3 ~ 41.2 N.m (3.5 ~ 4.2 kgf.m, 25.3 ~ 30.4 Ib-ft)

8. Remove the RH exhaust manifold assembly (A).

Tightening torque :
49.0 ~ 53.9 N.m (5.0 ~ 5.5 kgf.m, 36.1 ~ 39.8 Ib-ft)

9. To install, reverse the removal procedure.

When installing the exhaust manifold, tighten the nuts in the sequence shown below.
 Page 167 of 169
Engine Mechanical System

Components

1. Front muffler 4. Hanger

2. Center muffler 5. Gasket
3. Rear muffler

Engine Mechanical System

Removal and Installation

LH Front Muffler
1. Disconnect the battery "-" terminal from the trunk room.
2. Disconnect the LH rear oxygen sensor connector (A).

3. Remove the transmission stay bracket (A) and LH front muffler (B).
 Page 168 of 169
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

4. To install, reverse the removal procedure.

RH Front Muffler
1. Disconnect the battery "-" terminal from the trunk room.
2. Disconnect the RH rear oxygen sensor connector (A).

3. Remove the transmission stay bracket (A) and RH front muffler (B).
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

4. To install, reverse the removal procedure.

Center Muffler
1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the center muffler (A).
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
 Page 169 of 169

3. To install, reverse the removal procedure.

LH Rear Muffler
1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the LH rear muffler (A).
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

3. To install, reverse the removal procedure.

RH Rear Muffler
1. Disconnect the battery "-" terminal from the trunk room.
2. Remove the RH rear muffler (A).
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

3. To install, reverse the removal procedure.