GROUP 11D ENGINE OVERHAUL

11D-1

GROUP 11D

ENGINE OVERHAUL

CONTENTS

GENERAL SPECIFICATIONS . . . . . . SERVICE SPECIFICATIONS. . . . . . .

11D-2 11D-2

OIL PAN AND TIMING CHAIN CASE. . . . . . . . . . . . . . . . . . . . . . . . . . 11D-25

REMOVAL AND INSTALLATION . . . . . . . . 11D-25

REWORK DIMENSIONS . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . .

11D-3 11D-4

TIMING CHAIN . . . . . . . . . . . . . . . . . . 11D-32

REMOVAL AND INSTALLATION . . . . . . . . 11D-32 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-37

SEALANTS . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS. . . . . . . . . . . . . . . .

11D-7 11D-8

CAMSHAFT . . . . . . . . . . . . . . . . . . . . 11D-41

REMOVAL AND INSTALLATION . . . . . . . . 11D-41 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-44

GENERATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11D-10

REMOVAL AND INSTALLATION . . . . . . . . 11D-10

THROTTLE BODY AND EGR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11D-14

REMOVAL AND INSTALLATION . . . . . . . . 11D-14

INTAKE MANIFOLD AND FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11D-16

REMOVAL AND INSTALLATION . . . . . . . . 11D-16

EXHAUST MANIFOLD. . . . . . . . . . . . 11D-20

REMOVAL AND INSTALLATION . . . . . . . . 11D-20

WATER HOSE AND PIPE . . . . . . . . . 11D-23

REMOVAL AND INSTALLATION . . . . . . . . 11D-23

CYLINDER HEAD AND VALVES. . . . 11D-47

REMOVAL AND INSTALLATION . . . . . . . . 11D-47 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-51

BALANCER CHAIN . . . . . . . . . . . . . . 11D-55

REMOVAL AND INSTALLATION . . . . . . . . 11D-55

PISTON AND CONNECTING ROD . . 11D-63

REMOVAL AND INSTALLATION . . . . . . . . 11D-63 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-70

CRANKSHAFT AND CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 11D-72

REMOVAL AND INSTALLATION . . . . . . . . 11D-72 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-77

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ENGINE OVERHAUL

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Engine model

Type

Number of cylinders

Combustion chamber

Total displacement cm3 (cu in)

Cylinder bore mm (in)

Piston stroke mm (in)

Compression ratio

Valve timing

Intake valve

Exhaust valve

Auto lash adjuster

Open Close Open Close

Specifications 4B12 In-line OHV, DOHC 4 Pentroof type 2,360 (144.0)

88 (3.5) 97 (3.8) 10.5 0? BTDC -40? BTDC 64? ABDC -24? ABDC 44? BBDC -24? BBDC 0? ATDC -20? ATDC Non-equipped

M1113000202593

SERVICE SPECIFICATIONS

Item

Timing chain Valve clearance mm (in)

Intake Exhaust

Camshaft Cam height of camshaft mm (in) Intake

Exhaust Camshaft oil clearance mm (in)

Cylinder head and valves Distortion of cylinder head bottom mm (in) Grinding limit of cylinder head bottom mm (in) Overall height of cylinder head mm (in)

Overall length of valve mm (in) Intake

Exhaust

Valve margin mm (in)

Intake

Exhaust

Free height of valve spring mm (in)

Squareness of valve spring

Standard value

0.20 ? 0.03 (0.008 ? 0.001) 0.30 ? 0.03 (0.012 ? 0.001)

44.1 (1.74) 45.0 (1.77) 0 -0.032 (0.013)

Within 0.05 (0.002) - 128.5 (5.06) 113.18 (4.456) 105.89 (4.169) 1.022 (0.0402) 1.094 (0.0431) 47.2 (1.858) 2? or less

Limit

M1113000302824

- -

43.6 (1.72) 44.5 (1.75) -

0.2 (0.008) 0.2 (0.008)

- 112.68 (4.436) 105.39 (4.149) 0.522 (0.0206) 0.594 (0.0234) - 4?

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ENGINE OVERHAUL

REWORK DIMENSIONS

Item

Clearance between valve guide and valve stem mm (in)

Intake Exhaust

Valve seat contact width mm (in) Intake Exhaust

Valve guide press-in height mm (in)

Standard value 0.020 -0.047 (0.0008 - 0.0019) 0.030 -0.054 (0.0012 - 0.0021) 1.16 -1.46 (0.046 -0.058)

1.35 -1.65 (0.053 -0.065)

14.6 -15.2 (0.57 -0.60)

Piston and connecting rod Piston pin press-fit load N (lbf)

Clearance between piston ring Number 1

and ring groove mm (in)

Number 2

Piston ring end gap mm (in)

Number 1

Number 2

Oil

Clearance of connecting rod big end thrust mm (in)

Difference of outside diameter of connecting rod bolt mm (in)

Connecting rod bearing oil clearance mm (in)

7,500 -17,500 (1.686 - 3.934) 0.03 -0.07 (0.001 -0.003) 0.03 -0.07 (0.001 -0.003) 0.15 -0.25 (0.006 -0.011) 0.25 -0.40 (0.010 -0.016) 0.10 -0.35 (0.004 -0.014) 0.10 -0.25 (0.004 -0.010) -

0.018 -0.045 (0.0007 - 0.0018)

Crankshaft and cylinder block

Underhead length of crankshaft bearing cap bolt mm 75.5 -76.5 (2.972 -3.012) (in)

Crankshaft end play mm (in)

0.05 -0.25 (0.002 -0.010)

Crankshaft journal oil clearance mm (in)

0.012 -0.030 (0.0005 - 0.0012)

Distortion of cylinder block top surface mm (in)

-

Grinding limit of cylinder block top surface mm (in) -

Cylinder block cylinder bore mm (in)

88 (3.46)

Cylindricity of cylinder block mm (in)

0.0076 (0.0003)

11D-3

Limit 0.10 (0.0039)

0.11 (0.0043)

- - -

-

0.1 (0.004) 0.1 (0.004) 0.8 (0.03) 0.8 (0.03) 1.0 (0.04) 0.4 (0.016) 0.1 (0.04)

0.1 (0.04)

-

0.4 (0.016) 0.08 (0.0031)

0.05 (0.0020) 0.2 (0.008) - -

REWORK DIMENSIONS

Item Cylinder head and valve Cylinder head oversize valve seat bore diameter mm (in)

Intake

Exhaust

Cylinder head oversize valve guide bore diameter mm (in)

0.30 Over size

0.30 Over size

0.25 Over size

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M1113024300930

Standard value

36.22 -36.24 (1.426 -1.427) 30.22 -30.24 (1.190 -1.191) 11.23 -11.25 (0.442 -0.443)

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ENGINE OVERHAUL

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

M1113023403892

Item

Specification

Generator and ignition system Idler pulley bolt Auto tensioner bolt Crankshaft pulley center bolt Generator nut Generator bolt Ignition coil bolt Spark plug Power steering pump bracket bolt (M8) Power steering pump bracket bolt (M10)

48 ? 7 N m (36 ? 4 ft-lb) 22 ? 4 N m (17 ? 2 ft-lb) 210 N m (155 ft-lb) 44 ? 10 N m (32 ? 7 ft-lb) 44 ? 10 N m (32 ? 7 ft-lb) 10 ? 2 N m (89 ? 17 in-lb) 25 ? 5 N m (18 ? 4 ft-lb) 23 ? 2 N m (17 ? 1 ft-lb) 44 ? 8 N m (33 ? 5 ft-lb)

Throttle body and EGR system Vacuum pipe and hose bolt Throttle body bolt Throttle body stay bolt EGR valve support bolt EGR pipe bolt EGR support stay A bolt EGR support stay B bolt EGR valve bolt Manifold absolute pressure (MAP) sensor screw Purge solenoid valve screw

11 ? 1 N m (98 ? 8 in-lb) 9.5 ? 2.5 N m (84 ? 22 in-lb) 20 ? 2 N m (15 ? 1 ft-lb) 20 ? 2 N m (15 ? 1 ft-lb) 20 ? 2 N m (15 ? 1 ft-lb) 20 ? 2 N m (15 ? 1 ft-lb) 20 ? 2 N m (15 ? 1 ft-lb) 24 ? 3 N m (18 ? 1 ft-lb) 4.0 ? 1.0 N m (36 ? 8 in-lb) 4.0 ? 1.0 N m (36 ? 8 in-lb)

Intake manifold and fuel system Oil dipstick guide bolt Injector protector rear bolt

Fuel rail bolt

Intake manifold bolt and nut

Intake manifold stay bolt Injector protector front bolt

Generator bracket bolt Knock sensor bolt Engine oil pressure switch

10 ? 2 N m (89 ? 17 in-lb)

3.5 ? 1.5 N m (31 ? 13 in-lb) 20 ? 2 N m (15 ? 1 ft-lb)

3.5 ? 1.5 N m (31 ? 13 in-lb) 20 ? 2 N m (15 ? 1 ft-lb)

3.5 ? 1.5 N m (31 ? 13 in-lb) 20 ? 2 N m (15 ? 1 ft-lb)

20 ? 2 N m (15 ? 1 ft-lb)

3.5 ? 1.5 N m (31 ? 13 in-lb) 20 ? 2 N m (15 ? 1 ft-lb)

44 ? 8 N m (33 ? 5 ft-lb)

20 ? 2 N m (15 ? 1 ft-lb)

10 ? 2 N m (89 ? 17 in-lb)

Exhaust manifold Exhaust manifold upper cover bolt Exhaust manifold upper cover bolt

14 ? 1 N m (124 ? 8 in-lb) 8 ? 2 N m (71 ? 17 in-lb)

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ENGINE OVERHAUL

TORQUE SPECIFICATIONS

11D-5

Item Exhaust manifold lower cover bolt Exhaust manifold lower cover bolt Exhaust manifold nut Exhaust manifold bracket bolt (M8) Exhaust manifold bracket bolt (M10) Exhaust manifold bracket bolt Crankshaft position sensor bolt Crankshaft position sensor cover bolt (M6) Water hose and pipe Water inlet fitting bolt Water outlet fitting bolt Thermostat housing bolt Engine hanger bolt Engine coolant temperature sensor Water pump bolt Water pipe nut Camshaft position sensor bolt Oil pan and timing chain case Cylinder head cover bolt

Timing chain case bolt (M6) Timing chain case bolt (M8 ? 10) Timing chain case bolt (M8 ? 28) Oil pan bolt (M6) Oil pan bolt (M8) Air compressor bracket bolt Oil drain plug Oil filter Positive Crankcase Ventilation Valve Engine support bracket bolt (M10) Engine support bracket bolt (M8) Timing chain Chain upper guide bolt Oil jet bolt V.V.T. intake sprocket bolt V.V.T. exhaust sprocket bolt Timing chain tensioner bolt Tensioner lever bolt

Specification 14 ? 1 N m (124 ? 8 in-lb)

8 ? 2 N m (71 ? 17 in-lb) 49 ? 5 N m (36 ? 3 ft-lb) 20 ? 5 N m (15 ? 3 ft-lb)

41 ? 10 N m (30 ? 7 ft-lb)

41 ? 10 N m (30 ? 7 ft-lb) 11 ? 1 N m (98 ? 8 in-lb) 11 ? 1 N m (98 ? 8 in-lb)

24 ? 3 N m (18 ? 1 ft-lb) 24 ? 3 N m (18 ? 1 ft-lb) 24 ? 3 N m (18 ? 1 ft-lb) 28 ? 8 N m (21 ? 5 ft-lb) 30 ? 9 N m (22 ? 6 ft-lb) 24 ? 3 N m (18 ? 1 ft-lb) 24 ? 3 N m (18 ? 1 ft-lb) 11 ? 1 N m (98 ? 8 in-lb)

3.0 ? 1.0 N m (27 ? 8 in-lb) 5.5 ? 0.5 N m (49 ? 4 in-lb) 10 ? 2 N m (89 ? 17 in-lb) 13 ? 1 N m (115 ? 8 in-lb) 24 ? 4 N m (18 ? 2 ft-lb) 10 ? 2 N m (89 ? 17 in-lb) 29 ? 2 N m (21 ? 1 ft-lb) 23 ? 6 N m (17 ? 4 ft-lb) 39 ? 5 N m (29 ? 3 ft-lb) 14 ? 2 N m (124 ? 17 in-lb) 2.5 ? 0.4 N m (22 ? 3 in-lb) 45 ? 5 N m (33 ? 3 ft-lb) 23 ? 2 N m (17 ? 1 ft-lb)

10 ? 2 N m (89 ? 17 in-lb) 10 ? 2 N m (89 ? 17 in-lb) 59 ? 5 N m (44 ? 3 ft-lb) 59 ? 5 N m (44 ? 3 ft-lb) 10 ? 2 N m (89 ? 17 in-lb) 10 ? 2 N m (89 ? 17 in-lb)

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