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ENGINE MECHANICAL
SECTION EM
EM
CONTENTS
PRECAUTIONS ...............................................................5
Parts Requiring Angular Tightening .............................5
Liquid Gasket Application Procedure ..........................5
PREPARATION ................................................................6
Special Service Tools ..................................................6
Commercial Service Tools .........................................10
CAMSHAFT CAM HEIGHT .......................................35
CAMSHAFT JOURNAL CLEARANCE ........................35
CAMSHAFT END PLAY ............................................36
CAMSHAFT SPROCKET RUNOUT ...........................36
VALVE GUIDE CLEARANCE ....................................36
VALVE GUIDE REPLACEMENT ................................37
VALVE SEATS .........................................................38
VALVE DIMENSIONS ...............................................39
VALVE SPRING .......................................................39
VALVE LIFTER AND VALVE SHIM .............................40
Valve Clearance .........................................................40
CHECKING .............................................................40
ADJUSTING ............................................................41
Assembly ...................................................................43
Installation ..................................................................43
ENGINE REMOVAL .......................................................48
Removal and Installation ...........................................48
REMOVAL ...............................................................49
INSTALLATION ........................................................51
CYLINDER BLOCK .......................................................52
Components ...............................................................52
Removal and Installation ...........................................53
Disassembly ...............................................................53
PISTON AND CRANKSHAFT ....................................53
Inspection. ..................................................................54
PISTON AND PISTON PIN CLEARANCE ...................54
PISTON RING SIDE CLEARANCE ............................54
PISTON RING END GAP . .........................................54
PISTON-TO-BORE CLEARANCE ..............................56
CRANKSHAFT .........................................................57
BEARING CLEARANCE ...........................................57
(Small end) ..............................................................59
BUSHING (Small end) ..............................................60
FLYWHEEL/DRIVE PLATE RUNOUT .........................60
QG
TROUBLESHOOTING ................................................... 11
NVH Troubleshooting - Engine Noise ....................... 11
OUTER COMPONENT PARTS .....................................13
Removal and Installation ...........................................13
OIL PAN .........................................................................17
Components ...............................................................17
Removal .....................................................................17
Installation ..................................................................18
TIMING CHAIN ..............................................................19
Components ...............................................................19
Removal .....................................................................20
Inspection ...................................................................24
Installation ..................................................................24
OIL SEAL .......................................................................29
Replacement ..............................................................29
VALVE OIL SEAL .....................................................29
FRONT OIL SEAL ....................................................29
REAR OIL SEAL ......................................................30
CYLINDER HEAD ..........................................................31
Components ...............................................................31
Removal .....................................................................32
Disassembly ...............................................................34
Inspection ...................................................................34
CYLINDER HEAD DISTORTION ...............................34
CAMSHAFT VISUAL CHECK ....................................34
CAMSHAFT RUNOUT ..............................................35
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CONTENTS (Cont’d)
Assembly ...................................................................60
PISTON ..................................................................60
CRANKSHAFT . ........................................................61
Inspection. ................................................................ 110
PISTON AND PISTON PIN CLEARANCE ................. 110
PISTON RING SIDE CLEARANCE .......................... 111
PISTON RING END GAP . ....................................... 111
PISTON-TO-BORE CLEARANCE ............................ 112
CRANKSHAFT ....................................................... 113
BEARING CLEARANCE ......................................... 114
(Small end) ............................................................ 116
BUSHING (Small end) ............................................ 117
PILOT CONVERTER (CVT) .................................... 117
FLYWHEEL/DRIVE PLATE RUNOUT ....................... 117
Assembly ................................................................. 117
PISTON ................................................................ 117
CRANKSHAFT ....................................................... 118
SR20DE
TROUBLESHOOTING ........................................64
NVH Troubleshooting - Engine Noise .......................65
OUTER COMPONENT PARTS .....................................66
COMPRESSION PRESSURE . .......................................69
Measurement of Compression Pressure ...................69
OIL PAN .........................................................................70
Removal .....................................................................70
Installation ..................................................................73
TIMING CHAIN ..............................................................75
Components ...............................................................75
Removal .....................................................................76
Inspection ...................................................................79
Installation ..................................................................79
OIL SEAL REPLACEMENT ..........................................84
VALVE OIL SEAL .....................................................84
FRONT OIL SEAL ....................................................84
REAR OIL SEAL ......................................................85
CYLINDER HEAD ..........................................................86
Components ...............................................................86
Removal .....................................................................87
Disassembly ...............................................................89
Inspection ...................................................................91
CYLINDER HEAD DISTORTION ...............................91
CAMSHAFT VISUAL CHECK ....................................91
CAMSHAFT RUNOUT ..............................................92
CAMSHAFT CAM HEIGHT .......................................92
CAMSHAFT JOURNAL CLEARANCE ........................92
CAMSHAFT END PLAY ............................................93
CAMSHAFT SPROCKET RUNOUT ...........................93
VALVE GUIDE CLEARANCE ....................................93
VALVE GUIDE REPLACEMENT ................................94
VALVE SEATS .........................................................95
VALVE DIMENSIONS ...............................................95
VALVE SPRING .......................................................96
HYDRAULIC LASH ADJUSTER ................................96
Assembly ...................................................................97
Installation ..................................................................99
ENGINE REMOVAL .....................................................106
Components .............................................................106
Removal ...................................................................107
Installation ................................................................108
CYLINDER BLOCK .....................................................109
Components .............................................................109
Disassembly ............................................................. 110
PISTON AND CRANKSHAFT .................................. 110
CD20T
TROUBLESHOOTING .....................................121
OUTER COMPONENT PARTS ...................................123
COMPRESSION PRESSURE ......................................126
OIL PAN .......................................................................129
Removal ...................................................................129
Installation ................................................................129
TIMING BELT ...............................................................131
Camshaft Timing Belt ..............................................131
REMOVAL .............................................................131
Inspection. ................................................................133
Installation ................................................................134
Injection Pump Timing Belt ......................................135
REMOVAL .............................................................135
INSTALLATION ......................................................136
OIL SEAL REPLACEMENT ........................................138
VALVE OIL SEAL ...................................................138
CAMSHAFT OIL SEALS .........................................138
CRANKSHAFT FRONT OIL SEAL ...........................139
CRANKSHAFT REAR OIL SEAL .............................139
CYLINDER HEAD ........................................................140
Components .............................................................140
Removal ...................................................................141
Disassembly .............................................................141
Inspection. ................................................................142
CYLINDER HEAD DISTORTION .............................142
VALVE GUIDE CLEARANCE ..................................142
VALVE GUIDE REPLACEMENT ..............................142
VALVE SEATS .......................................................143
VALVE SEAT REPLACEMENT ................................143
EM-2
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CONTENTS (Cont’d)
VALVE DIMENSIONS .............................................144
VALVE SPRING SQUARENESS ..............................145
VALVE SPRING PRESSURE LOAD ........................145
VALVE LIFTER ......................................................145
CAMSHAFT VISUAL CHECK ..................................147
CAMSHAFT END PLAY ..........................................147
CAMSHAFT RUNOUT ............................................147
CAMSHAFT CAM HEIGHT .....................................147
CAMSHAFT JOURNAL CLEARANCE ......................147
Valve clearance .......................................................148
Checking ..................................................................148
Adjusting ..................................................................149
Assembly .................................................................151
Installation ................................................................151
TURBOCHARGER . ......................................................156
Removal ...................................................................156
Disassembly .............................................................157
Inspection .................................................................158
OIL AND WATER TUBES ........................................158
ROTOR SHAFT .....................................................158
TURBINE WHEEL ..................................................159
COMPRESSOR WHEEL .........................................159
WASTEGATE VALVE ..............................................160
WASTEGATE VALVE ACTUATOR ...........................160
Assembly .................................................................160
Installation ................................................................160
ENGINE REMOVAL .....................................................162
CYLINDER BLOCK .....................................................166
Components .............................................................166
Preparation ..............................................................167
Disassembly .............................................................167
PISTON AND CRANKSHAFT ..................................167
Inspection .................................................................168
PISTON AND PISTON PIN CLEARANCE . ................168
PISTON RING SIDE CLEARANCE ..........................168
PISTON RING END GAP ........................................169
MAIN BEARING CLEARANCE ................................169
end) ......................................................................170
CLEARANCE (Small end) .......................................171
CRANKSHAFT . ......................................................172
CYLINDER BLOCK DISTORTION ...........................173
CYLINDER BORE ..................................................173
PISTON-TO-BORE CLEARANCE ............................174
Assembly .................................................................175
PISTON ................................................................175
CRANKSHAFT . ......................................................175
PISTON WITH CONNECTING ROD ........................176
FLYWHEEL RUNOUT .............................................177
QG
General Specifications .............................................178
Compression Pressure ............................................178
Cylinder Head ..........................................................178
Valve ........................................................................179
VALVE . ..................................................................179
VALVE SPRING .....................................................179
VALVE LIFTER ......................................................179
VALVE CLEARANCE ..............................................179
VALVE GUIDE .......................................................180
AVAILABLE SHIMS ................................................180
VALVE SEAT .........................................................182
VALVE SEAT RESURFACE LIMIT ...........................183
Camshaft and Camshaft Bearing ............................183
Cylinder Block ..........................................................184
Piston, Piston Ring and Piston Pin .........................185
PISTON ................................................................185
PISTON RING .......................................................185
PISTON PIN ..........................................................185
Connecting Rod .......................................................186
Crankshaft ................................................................186
Main Bearing ............................................................186
STANDARD ...........................................................186
UNDERSIZE ..........................................................186
Connecting Rod Bearing .........................................187
STANDARD SIZE ...................................................187
UNDERSIZE ..........................................................187
Bearing Clearance ...................................................187
Miscellaneous Components. ....................................187
SR20DE
General Specifications .............................................188
Inspection and Adjustment ......................................188
COMPRESSION PRESSURE .................................188
CYLINDER HEAD ..................................................188
VALVE . ..................................................................189
CAMSHAFT AND CAMSHAFT BEARING .................192
CYLINDER BLOCK ................................................192
CONNECTING ROD ...............................................193
CRANKSHAFT .......................................................194
AVAILABLE MAIN BEARING ...................................194
MISCELLANEOUS COMPONENTS .........................195
CD20T
General Specifications .............................................196
Inspection and Adjustment ......................................196
COMPRESSION PRESSURE .................................196
CYLINDER HEAD ..................................................196
EM-3
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CONTENTS (Cont’d)
CAMSHAFT AND CAMSHAFT BEARING .................196
VALVE ...................................................................197
VALVE LIFTER ......................................................198
AVAILABLE SHIMS ................................................198
VALVE CLEARANCE . .............................................198
CYLINDER BLOCK ................................................199
CONNECTING ROD ...............................................200
CRANKSHAFT .......................................................200
AVAILABLE MAIN BEARINGS .................................200
TURBOCHARGER .................................................201
MISCELLANEOUS COMPONENTS .........................201
EM-4
PRECAUTIONS
Parts Requiring Angular Tightening
Parts Requiring Angular Tightening
I
Some important engine parts are tightened using an angular-
tightening method rather than a torque setting method.
I
If these parts are tightened using a torque setting method,
dispersal of the tightening force (axial bolt force) will be two or
three times that of the dispersal produced by using the correct
angular-tightening method.
I
Although the torque setting values (described in this manual)
are equivalent to those used when bolts and nuts are tightened
with an angular-tightening method, they should be used for
reference only.
I
To assure the satisfactory maintenance of the engine, bolts
and nuts must be tightened using an angular-tightening
method.
I
Before tightening the bolts and nuts, ensure that the thread
and seating surfaces are clean and then coated with engine oil.
I
The bolts and nuts which require the angular-tightening
method are as follows:
(1) Cylinder head bolts ..... SR, CD, QG
(2) Main bearing cap bolts ..... SR
(3) Connecting rod cap nuts ..... SR, QG
Inner
side
Liquid Gasket Application Procedure
a. Before applying liquid gasket, use a scraper to remove
all traces of old liquid gasket from mating surface and
groove, and then completely clean any oil stains from
these areas.
b. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
I
Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197
in) wide for SR engine and 3.5 to 4.5 mm (0.138 to
0.177 in) wide for QG and CD engine (for oil pan).
Groove
Bolt hole
Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to
0.118 in) wide (in areas except oil pan).
c. Apply liquid gasket to inner surface around hole perim-
eter area.
(Assembly should be done within 5 minutes after coat-
ing.)
d. Wait at least 30 minutes before refilling with engine oil
and engine coolant.
I
SEM164F
Groove
Inner side
AEM080
EM-5
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