Application	Description
General Data:	.
Engine Type	4 Cylinder (In-Line)
Displacement	1,206 cm³
Bore Stroke	69.7 x 79 mm (2.7441 x 3.1102 in.)
Compression Ratio	10.5 ± 0.2 : 1
Firing Order	1-3-4-2
Cylinder Bore:	.
Diameter	69.7 mm (2.7441 in.)
Out of Round (Maximum)	0.005 mm (0.0002 in.)
Taper (Maximum)	0.07 x 30°
Piston :	.
Diameter	69.7 mm (2.7441 in.)
Clearance to Bore	0.035 ± 0.010 mm (0.0013 ± 0.0177 in.)
Piston Rings:	.
Ring, End Gap:	.
Top Compression	0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.)
2nd Compression	0.3 ~ 0.45 mm (0.0118 ~ 0.0177 in.)
Groove Clearance:	.
Top Impression	0.02 ~ 0.06 mm (0.00078 ~ 0.00236 in)
2nd Impression	0.06 ~ 0.1 mm (0.00236 ~ 0.00393 in.)
Piston Pin :	.
Diameter	16.995 ~ 17.000 mm (0.6691 ~ 0.6693 in.)
Clearance to Bore	0.006 ~ 0.019 mm (0.00078 ~ 0.00236 in.)
Camshaft:	.
End Play	0.08 ~ 0.26 mm (0.0032 ~ 0.0102 in.)
Journal OD:	.
No. 1	23.939 ~ 23.96 mm (0.9425 ~ 0.9433 in.)
No. 2	23.939 ~ 23.96 mm (0.9425 ~ 0.9433 in.)
No. 3	23.939 ~ 23.96 mm (0.9425 ~ 0.9433 in.)
No. 4	23.939 ~ 23.96 mm (0.9425 ~ 0.9433 in.)
No. 5	23.939 ~ 23.96 mm (0.9425 ~ 0.9433 in.)
Journal ID:	.
No. 1	23 ~ 23.021 mm (0.9055 ~ 0.9063 in.)
No. 2	23 ~ 23.021 mm (0.9055 ~ 0.9063 in.)
No. 3	23 ~ 23.021 mm (0.9055 ~ 0.9063 in.)
No. 4	23 ~ 23.021 mm (0.9055 ~ 0.9063 in.)
No. 5	23 ~ 23.021 mm (0.9055 ~ 0.9063 in.)
Lift - Intake	40.00 mm (1.5748 in.)
Lift - Exhaust	39.45 mm (1.5531 in.)
Crankshaft :	.
Main Journal	.
Diameter (All)	48.982 ~ 49.000 mm (1.9284 ~ 1.9291 in.)
Main Bearing Clearance (All)	0.020 ~ 0.040 mm (0.00079 ~ 0.00158 in.)
Crankshaft End Play	0.08 ~ 0.26 mm (0.0032 ~0.0102 in.)
Connecting Rod Journal:	.
Diameter (All)	41.000 ~ 41.018 mm (1.6142 ~ 1.6149 in.)
Rod Bearing Clearance (All)	0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.)
Bending	0.03 mm (0.0012 in.)
Valve System:	.
Seat Inner Diameter:	.
Intake	23.862 mm (0.9394 in.)
Exhaust	21.079 mm (0.8299 in. )
Valve Guide Inside Diameter (All)	5.0 ~ 5.012 mm (0.1968 ~ 0.1973 in.)
Valve Stem Diameter	.
Intake	4.972 ± 0.007 mm (0.1957 ± 0.0002 in.)
Exhaust	4.963 ± 0.007 mm (0.1954 ± 0.0002 in.)
Valve Length:	.
Intake	99.17 ± 0.225 mm (3.904 ± 0.009 in.)
Exhaust	100.01 ± 0.225 mm (3.937 ± 0.009 in.)
Valve Spring:	.
Free Legnth	43.57 mm (1.715 in.)
Valve Closed	260 ± 13 N (191 ± 9.6 lbs) @ 32 mm (1.25 in.)

Application	N•m	Lb-Ft
Exhaust Manifold Retaining Nuts	20	14.7
Exhaust Manifold Retaining Bolts	25	18.4
Intake Manifold Support Bracket Upper Bolts	2	1.5
Transmission Assembly Blots (M/T & A/T)	60	44.2
Cylinder Head Cover Bracket Bolts	10	7.4
Cylinder Head Bolts	22 + 82°	16.2 + 82°
Cylinder Head Cover Bolts	10	7.4
Accessory Tensioner-Generator Assembly Bracket Mounting Bolt	25	18.4
Generator Adjusting Bolt	20	14.7
Air Cleaner Assembly Bolts	6	4.4
Air Filter Upper Housing Bolts	2	1.5
Engine Mount Retaining Bolts	55	40.5
Engine Mount Bracket Retaining Bolt/Nuts	65	47.9
Oil Level Gage Tube Retaining Bolt	10.5	7.7
Oil Pan Retaining Bolts	10.5	7.7
Oil Pump Cover Bolts	10	7.4
Water Pump Retaining Bolts	33	24.3
Spark Plugs Cable Cover Bolts	10	7.4
Catalytic Converter Retaining Nuts	40	29.5
Camshaft Cap Bolts	10	7.4
Camshaft Sprocket Retaining Bolts	60	44.2
Connecting Rod Bearing Cap Nuts	33	24.3
Crankshaft Rear Oil Seal Cover Bolts (M6 x 1.0)	10.5	7.7
Crankshaft Bearing Cap Bolts	57.5	42.4
Crankshaft Pulley Bolt	85	62.7
Timing Chain Guide Retaining Bolts	10	7.4
Timing Chain Lever Retaining Bolts	10	7.4
Timing Chain Cover Retaining Bolts (M6 x 1.0)	10.5	7.7
Timing Chain Cover Retaining Bolts (M8 x 1.25)	20	14.7
Timing Chain Tensioner Retaining Bolts	12	8.8
A/C Compressor Mounting Bracket Bolts	30	22.1
Power Steering Pump Bracket Mounting Bolts	25	18.4
Power Steering Pump Mounting Bolts	20	14.7
Front Exhaust Pipe-to-Main Catalytic Converter Nuts	40	29.5
Front Exhaust Pipe-to-Front Muffler Nuts	40	29.5
Flywheel/Flexible Plate Bolts	45	33.2
Intake Manifold Retaining Bolts	10	7.4
Exhaust Manifold Heat Shield Bolts	15	11
Oil Pressure Switch Fitting	30	22.1
Accessory Tensioner Hex-Socket Bolt (M8)	45	33.2

	DW010-010 "Engine & Transaxle Assembly Support Remover/Installer"
	EN–48356 Fixture-Engine
	KM-135 Adapter
	EN-49072 Installer-Crankshaft Front Seal
	EN-49074 Compressor-Universal Valve Spring
	EN-49076 Adapter-Cylinder Pressure
	EN-49078 Installer-Piston
	DW100-030 Stand-Engine Overhaul
	KM-498-A Gauge-Oil Pressure
	EN-49071 Installer-Crankshaft Rear Seal
	EN-49073 Pin-Timing Chain Tensioner
	EN-49075 Adapter-Valve Spring Compressing
	EN-49077 Gauge-Compression Pressure
	KM-470-B Angular Torque Gauge

1. Review the system operations to familiarise yourself with the system functions, refer to Section 1A, General Engine Information and Section 1F1, Engine Control – General Information.
2. Perform an engine management Diagnostic System Check, refer to Section 1F1 Engine Control – Diagnostics.

1. Inspect the vehicle for aftermarket accessories which may adversely affect engine operation.
2. Inspect the easily accessible or visible system components for obvious signs of damage or conditions that may cause the symptom.
3. Check the engine lubrication system for the following :
• correct oil level,
• correct lubricant viscosity,
• correct oil filter application, and
• contaminated or burnt oil.
4. Confirm the exact operating conditions under which the fault occurs. Note factors such as :
• engine speed (r.p.m.),
• ambient temperature,
• engine temperature,
• engine warm-up time, and
• vehicle road speed.
5. Compare the engine sounds, if applicable, to a known good engine, and ensure you are not trying to diagnose a normal operating condition.

1. Crank the engine to be at normal operating temperature(coolant temperature : 80~90°C).
2. Stop the engine and remove all the high-tension cables and ignition plugs.

3. Install the adapter-cylinder pressure(EN-49076)(b) and gauge-cylinder pressure(EN-49077)(a).
4. 2 persons should be needed while compression pressure testing. One person accelerate the pedal to make the throttle valve be fully opened and crank the engine.
5. The other person reads the maximum of the measured gauge value.
• Measured value should meet the specification or limit.
• Specification : 9 Bar(9.17 Kg/cm2)
• Limit : under 10%
• Ignition plug torque : 27 N•m (19.9 lb-ft)

1. Remove the cylinder head cover. Refer to "Cylinder Head" in this section.

2. Rotate the crankshaft pulley and adjust the pulley groove to the “0” point as following picture. This is to adjust TDC of the No.1 cylinder.

3. Check the both camshaft sprocket and timing chain.
4. Measure the valve clearance at each point as following picture.

5. Rotate the crankshaft pulley to 360° and adjust the pulley groove to the “0” point.
6. Measure the valve clearance at each point as following picture.

• Intake Specification : 0.075~0.125 mm (coolant temperature : 20°C)
• Exhaust Specification : 0.245~0.305 mm (coolant temperature : 20°C)
7. If the measured value is out of specification, replace the valve tappet. Refer to "Unit Repair - Valve Train Components" in this section.

1. Calculate the value of the valve tappet.
• Intake : Separated tappet Thickness + Measured valve clearance – 0.1 mm = New tappet thickness
• Exhaust : Separated tappet Thickness + Measured valve clearance – 0.27 mm = New tappet thickness
2. Use the following table and assemble with an adequate valve tappet.
3. Replace the New valve tappet. Refer to "Unit Repair - Valve Train Components" in this section.

NO.	PART NO.	THICKNESS "T"	MARKING NO.
1	96 449 601	3.12 ± 0.01	312
2	96 449 602	3.14 ± 0.01	314
3	96 449 603	3.16 ± 0.01	316
4	96 449 604	3.18 ± 0.01	318
5	96 449 605	3.20 ± 0.01	320
6	96 449 606	3.22 ± 0.01	322
7	96 449 607	3.24 ± 0.01	324
8	96 449 608	3.26 ± 0.01	326
9	96 449 609	3.28 ± 0.01	328
10	96 449 610	3.30 ± 0.01	330
11	96 449 611	3.32 ± 0.01	332
12	96 449 612	3.34 ± 0.01	334
13	96 449 613	3.36 ± 0.01	336
14	96 449 614	3.38 ± 0.01	338
15	96 449 615	3.40 ± 0.01	340
16	96 449 616	3.42 ± 0.01	342
17	96 449 617	3.44 ± 0.01	344
18	96 449 618	3.46 ± 0.01	346
19	96 449 619	3.48 ± 0.01	348
20	96 449 620	3.50 ± 0.01	350
21	96 449 621	3.52 ± 0.01	352
22	96 449 622	3.54 ± 0.01	354
23	96 449 623	3.56 ± 0.01	356
24	96 449 624	3.58 ± 0.01	358
25	96 449 625	3.60 ± 0.01	360
26	96 449 626	3.62 ± 0.01	362
27	96 449 627	3.64 ± 0.01	364
28	96 449 628	3.66 ± 0.01	366
29	96 449 629	3.68 ± 0.01	368
30	96 449 630	3.70 ± 0.01	370
31	96 449 631	3.72 ± 0.01	372
32	96 449 632	3.74 ± 0.01	374
33	96 449 633	3.76 ± 0.01	376
34	96 449 634	3.78 ± 0.01	378
35	96 449 635	3.80 ± 0.01	380
36	96 449 636	3.82 ± 0.01	382
37	96 449 637	3.84 ± 0.01	384
38	96 449 638	3.86 ± 0.01	386
39	96 449 639	3.88 ± 0.01	388
40	96 449 640	3.90 ± 0.01	390

Step	Action	Value(s)	Yes	No
1	Is the oil pressure warning lamp on?	-	Go to Step 2	System OK
2	Check the oil level in the crankcase. Is the oil level low?	-	Go to Step 3	Go to Step 4
3	Add oil so that the oil level is up to the full mark on the indicator. Is the repair complete?	-	Go to Step 1	-
4	Check the idle speed. Is the idle speed below the specified value ?	840 ± 20 rpm	Go to Step 5	Go to Step 6
5	Increase the idle speed. Is the speed increased?	-	Go to Step 1	-
6	Inspect the oil pressure switch. Is the oil pressure switch incorrect or malfunctioning?	-	Go to Step 7	Go to Step 8
7	Install a new oil pressure switch. Is the repair complete?	-	Go to Step 1	-
8	Inspect the oil pressure gauge. Is the oil pressure gauge incorrect or malfunctioning?	-	Go to Step 9	Go to Step 10
9	Install a new oil pressure gauge. Is the repair complete?	-	Go to Step 1	-
10	Inspect the engine oil. Is the engine oil in the crankcase diluted or of the improper viscosity?	-	Go to Step 11	Go to Step 12
11	Install new engine oil of the proper viscosity for the expected temperatures. Is the repair complete?	-	Go to Step 1	-
12	Inspect the oil pump. Is the pump worn or dirty?	-	Go to Step 13	Go to Step 14
13	Replace the oil pump. Is the repair complete?	-	Go to Step 1	-
14	Inspect the oil filter. Is the oil filter plugged?	-	Go to Step 15	Go to Step 16
15	Install a new oil filter. Is the repair complete?	-	Go to Step 1	-
16	Inspect the oil pickup screen. Is the oil pickup screen loose or plugged?	-	Go to Step 17	Go to Step 18
17	Tighten or replace the oil pickup screen, as necessary. Is the repair complete?	-	Go to Step 1	-
18	Inspect the oil pickup tube. Are there any holes in the oil pickup tube?	-	Go to Step 19	Go to Step 20
19	Replace the oil pickup tube. Is the repair complete?	-	Go to Step 1	-
20	Inspect the bearing clearances. Are the bearing clearances more than the specified values?	Crankshaft Journal Bearing Oil Clearance 0.020 ~ 0.040 mm (0.00079 ~ 0.00158 in.)	Go to Step 21	Go to Step 22
21	Replace the bearing, if necessary. Is the repair complete?	-	Go to Step 1	-
22	Inspect the oil galleries. Are the oil galleries cracked, porous, or plugged?	-	Go to Step 23	Go to Step 24
23	Repair or replace the engine block. Is the repair complete?	-	Go to Step 1	-
24	Inspect the gallery plugs. Are any of the gallery plugs missing or installed improperly?	-	Go to Step 25	Go to Step 26
25	Install the plugs or repair, as necessary. Is the repair complete?	-	Go to Step 1	-
26	Inspect the camshaft. Is the camshaft worn or is there evidence of poor machining?	-	Go to Step 27	System OK
27	Replace the camshaft. Is the repair complete?	-	Go to Step 1	-

1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering fluid, etc.
2. Identify where the fluid is leaking from.
1. After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper.
2. Wait a few minutes.
3. Find the approximate location of the leak by the drippings on the paper.
3. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach.
4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam, or spray solvent.
1. Thoroughly clean the area.
2. Dry the area.
3. Operate the vehicle for several miles at normal operating temperature and varying speeds.
4. After operating the vehicle, visually check the suspected component.
5. If you still cannot locate the leak, try using the powder or black light and dye method.

1. Clean the suspected area.
2. Apply an aerosol-type powder, (such as foot powder), to the suspected area.
3. Operate the vehicle under normal operating conditions.
4. Visually inspect the suspected component. Trace the leak path over the white powder surface to the source.

1. Pour the specified amount of dye into the engine oil fill tube.
2. Operate the vehicle under normal operating conditions as directed in the kit.
3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.

• The fluid level/pressure is too high.
• The crankcase ventilation system is malfunctioning.
• The fasteners are improperly tightened or the threads are dirty or damaged.
• The flanges or the sealing surface is warped.
• There are scratches, burrs or other damage to the sealing surface.
• The gasket is damaged or worn.
• There is cracking or porosity of the component.
• An improper seal was used, (where applicable).

• The fluid level/pressure is too high.
• The crankcase ventilation system is malfunctioning.
• The seal bore is damaged, scratched, burred or nicked.
• The seal is damaged or worn.
• Improper installation is evident.
• There are cracks in the component.
• The shaft surface is scratched, nicked or damaged.
• A loose or worn bearing is causing excess seal wear.

Condition	Action
Abnormalities (severe cracking, bumps or missing areas) in the accessory drive belt. Also worn, damaged, or misaligned accessory drive components or excessive pulley runout.	Abnormalities in the accessory drive belt and/or components may cause engine RPM variations, noises similar to a faulty lower engine and also lead to a misfire condition. A misfire code may be present without an actual misfire condition. Inspect the accessory drive components. Repair or replace all damaged components.
Loose and/or damaged crankshaft pulley	A misfire code may be present without an actual misfire condition. Inspect crankshaft pulley and pulley bolt. Repair or replace all damaged components.
Loose torque converter bolts	A misfire code may be present without an actual misfire condition. Inspect torque converter bolts and flywheel. Repair or replace all damaged components.
Loose and/or damaged flywheel	A misfire code may be present without an actual misfire condition. Inspect flywheel and flywheel attaching bolts. Repair or replace all damaged components.
Restricted exhaust system	A severe restriction in the exhaust flow can cause significant loss of engine performance and may set a misfire code. Possible causes of restrictions include collapsed or dented pipes, plugged mufflers and/or catalytic converters. Repair or replace all damaged components.
Air in fuel system	Inspect fuel filter, fuel system for leaks and/or restrictions. Repair or replace all damaged components.
Bent and/or worn valve bridge and finger-follower.	Inspect valve bridge and valve finger-follower. Repair or replace all damaged components.
Sticking valve	Carbon on the valve stem or valve seat may cause the valve to stick. Inspect valves and valve guides. Repair or replace all damaged components.
Damaged or misaligned timing gears	Inspect timing gears. Replace all damaged components.
Worn or faulty camshaft lobes	Inspect camshaft lobes. Repair or replace all damaged components.
Excessive piston-to-cylinder bore clearance	Perform compression tests. Inspect the piston, piston rings and cylinder bore. Repair or replace all damaged components.
Faulty cylinder head gaskets and/or cracking or other damage to the cylinder heads and engine block cooling system passages. (Coolant consumption may or may not cause the engine to overheat.)	Perform compression tests. Inspect the piston, piston rings and cylinder bore. Repair or replace all damaged components.

Condition	Action
Abnormalities (severe cracking, bumps or missing areas) in the accessory drive belt.	Abnormalities in the accessory drive belt and/or components may cause engine RPM variations, noises similar to a faulty lower engine and also lead to a misfire condition. A misfire code may be present without an actual misfire condition. Inspect the accessory drive components. Repair or replace all damaged components.
Worn, damaged, or misaligned accessory drive components or excessive pulley runout	A misfire code may be present without an actual misfire condition. Inspect the accessory drive components. Repair or replace all damaged components.
Loose and/or damaged crankshaft pulley	A misfire code may be present without an actual misfire condition. Inspect crankshaft pulley and pulley bolt. Repair or replace all damaged components.
Loose torque converter bolts	A misfire code may be present without an actual misfire condition. Inspect torque converter bolts and flywheel. Repair or replace all damaged components.
Loose and/or damaged flywheel	A misfire code may be present without an actual misfire condition. Inspect flywheel and flywheel attaching bolts. Repair or replace all damaged components.
Excessive piston-to-cylinder bore clearance	Perform cylinder leak down and compression tests Inspect the piston, piston rings and cylinder bore. Repair or replace all damaged components.
Excessive crankshaft thrust bearing clearance	Severely worn thrust surfaces on the crankshaft and/or thrust bearing may permit for and aft movement of the crankshaft and create a misfire code without an actual misfire condition. Inspect the crankshaft end play and crankshaft thrust bearings. Repair or replace all damaged components.

Condition	Action
Loose, worn or damaged valve bridge and finger-follower	Inspect valve bridge and finger-follower. Repair or replace all damaged components.
Broken valve springs	Inspect valve springs. Repair or replace all damaged components.
Sticking valve	Carbon on the valve stem or valve seat may cause the valve to stick. Inspect valves and valve guides. Repair or replace all damaged components.
Worn or faulty camshaft lobes	Inspect camshaft lobes. Repair or replace all damaged components.

Inspection	Action
Definition : Base engine misfire with coolant consumption
Preliminary Inspection	Verify that there are no external coolant leaks. Refer to Section 1D, Engine Cooling.
Isolate Affected Cylinders	Cylinder balance test with scan tool Cooling system pressurization Inspection of glow plugs Compression test
EGR System Inspection	Inspect EGR valve and intake system for evidence of coolant leakage. Replace the EGR cooler if any problem is found.
Cylinder Head Gasket Leakage	Remove cylinder heads of the affected cylinder bank and inspect for damage. Replace components as necessary.
Cylinder Head or Engine Block Damage	Inspect the cylinder heads for cracks. Inspect the cylinder block for damage. Inspect the cylinder block to head mating surface for staightness. Replace components as necessary.

Condition	Action
Worn valve guides	Inspect the valves and valve guides. Repair or replace all damaged components.
Worn valve stem oil seals	Inspect the valve stem oil seals. Repair or replace all damaged components.
Excessive piston-to-cylinder bore clearance	Perform compression tests to determine the cause. Inspect the piston rings for low ring tension, broken or worn rings. Inspect cylinder bore. Repair or replace all damaged components.

Condition	Action
Incorrect oil viscosity	Drain the oil. Install the correct viscosity oil.
Excessive piston-to-cylinder bore clearance	Inspect the piston and piston skirt, connecting rod, and cylinder bore. Repair or replace all damaged components.

Condition	Action
Low oil pressure	Insufficient or poor oil supply to valve train. Perform oil pressure test. Repair or replace all damaged components.
Improper lubrication to the valve finger-follower	Inspect valve finger-follower, valve bridge, valve finger follower lifter, oil pump and engine block oil galleries. Repair or replace all damaged components.
Worn or damaged valve finger-follower	Inspect valve bridge and finger-follower. Repair or replace all damaged components.
Sticking valve	Carbon on the valve stem or valve seat may cause the valve to stick. Inspect valves and valve guides. Repair or replace all damaged components.
Worn or faulty camshaft lobes	Inspect camshaft lobes. If damaged replace camshaft and all valve finger-followers.
Damaged or misaligned timing gears	Inspect timing gears. Replace all damaged components.

Condition	Action
Worn accessory drive components (abnormalities such as severe cracking, bumps or missing areas in the accessory drive belt and/or misalignment of the system components.)	Inspect the accessory drive components. Repair or replace all damaged components.
Low oil pressure	Insufficient or poor oil supply to crankshaft and connecting rod bearings. Perform oil pressure test. Repair or replace all damaged components.
Leaking and/or sticking fuel injection nozzle (A stuck fuel injection nozzle can cause a noise similar to a damaged piston, rod or rod bearing.)	Inspect the cylinder balance with scan tool to help locate the cylinder that is the source of the noise. If you cannot locate the cylinder that is the source of the noise, diagnose the engine for mechanical damage. If it has been determined that the fuel injection nozzle is causing the noise, replace the fuel injection nozzle.
Loose and/or damaged crankshaft pulley	Inspect crankshaft pulley and pulley bolt. Repair or replace all damaged components.
Loose torque converter bolts	Inspect torque converter bolts and flywheel. Repair or replace all damaged components.
Loose and/or damaged flywheel	Inspect flywheel and flyweel attaching bolts. Repair or replace all damaged components.
Excessive piston pin-to-bore clearance	Inspect the piston, piston pin, and the connecting rod. Repair or replace all damaged components.
Misaligned or bent connecting rod	Inspect connecting rod and connecting rod bearings. Repair or replace all damaged components.
Excessive connecting rod bearing clearance	Inspect the connecting rod bearings, connecting rods, crankshaft and crankshaft journals. Repair or replace all damaged components.
Excessive crankshaft bearing clearance	Inspect the crankshaft bearings and crankshaft journals. Repair or replace all damaged components.

Cause	Correction
Low oil pressure	Insufficient or poor oil supply to components. Perform oil pressure test. Repair or replace all damaged components.
Loose torque converter bolts	Inspect the torque converter bolts and flywheel. Repair or replace all damaged components.
Loose and/or damaged flywheel	Inspect the flywheel and flywheel attaching bolts. Repair or replace all damaged components.
Excessive piston-to-cylinder bore clearance	Inspect the piston rings for low ring tension, broken or worn rings, inspect cylinder bore. Repair or replace all damaged components.
Excessive crankshaft thrust bearing clearance	Inspect the crankshaft end play and crankshaft thrust bearings. Repair or replace all damaged components.
Excessive crankshaft bearing clearance	Inspect the crankshaft bearings and crankshaft journals. Repair or replace all damaged components.

Cause	Correction
Seized accessory drive system component	Inspect the accessory drive system components. Repair or replace all damaged components.
Hydraulically locked cylinder Coolant/antifreeze in cylinder Oil in cylinder Fuel in cylinder	Inspect for broken head gasket(s). Inspect for cracked engine block or cylinder head. Inspect for a sticking fuel injector.
Seized automatic transmission torque converter	Remove the engine assembly. The torque converter bolts are not accessible with the engine installed to the transmission. Rotate crankshaft at the pulley.
Seized manual transmission	Disengage the clutch. Rotate crankshaft at the pulley. Refer to Unit Repair Manual - Manual Transmission.
Material in cylinder : Broken valve Piston material Foreign material	Inspect cylinder for damaged components and/or foreign materials. Repair or replace as required.
Seized crankshaft or connecting rod bearings	Inspect crankshaft and connecting rod bearings. . Repair as required.
Bent or broken connecting rod	Inspect connecting rods. Repair as required.
Broken crankshaft	Inspect crankshaft. Repair as required.

Inspection	Action
Definition : Excessive white smoke and/or coolant type odor coming from the exhaust pipe may indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an "overtemperature" condition which may cause engine component damage.
Preliminary Inspection	Verify that there are no external coolant leaks. Refer to Section 1D, Engine Cooling.
Isolate Affected Cylinders	Cylinder balance test with scan tool Cooling system pressurization Compression test
EGR System Inspection	Inspect EGR valve and intake system for evidence of coolant leakage. Replace the EGR cooler if any problem is found.
Cylinder Head Gasket Leakage	Remove cylinder heads of the affected cylinder bank and inspect for damage. Replace components as necessary.
Cylinder Head or Engine Block Damage	Inspect the cylinder heads for cracks. Inspect the cylinder block for damage. Inspect the cylinder block to head mating surface for straightness. Replace components as necessary.

Cause	Correction
Definition : Foamy or discolored oil or an engine oil "overfill" condition may indicate coolant entering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an "overtemperature" condition which may cause engine component damage. Contaminated engine oil and oil filter should be changed. Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant may not properly lubricate the crankshaft bearings and may lead to component damage. Refer to "Lower Engine Noise, Regardless of Engine Speed" in this section. Inspect by performing a Cylinder Leak-Down Test. During this test, excessive air bubbles within the cooling system may indicate a faulty gasket or damaged component. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine block with low compression may indicate a failed cylinder head gasket. Refer to "Engine Compression Test" in this section.
Faulty cylinder head gasket	Replace the head gasket and components as required. Refer to Section 1C1, Engine Mechanical.
Warped cylinder head	Replace the cylinder head gasket. Refer to Section 1C1, Engine Mechanical.
Cracked cylinder head	Replace the cylinder head and gasket.
Cracked engine block	Replace the components as required.
Cylinder head, block, or manifold porosity	Replace the components as required.
Leaking engine oil cooler	Replace components as required.

1. Remove the oil level indicator and allow oil to drop onto a clean white paper towel.
2. If the oil is diluted with fuel, it will become apparent as the towel wicks the fuel away from the drop of oil on the towel. The fuel will expand out in a ring around the oil droplet.
3. If fuel dilution is apparent, inspect the vehicle for aftermarket performance accessories that may cause damage to the injection pump. After repairs are completed, perform the test again to verify the condition is corrected.
4. If no fuel dilution is present, verify the oil level and correct as needed.

2. The noise may not be engine related. This step is to confirm the engine is making the noise. If the engine is not making the noise, do not proceed further with this diagnostic procedure.
3. The noise may be an internal engine noise. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt.
4. Inspect all drive pump pulleys for pilling.

6. Misalignment of the accessory drive system pulleys may be caused by incorrect mounting of an accessory drive component (A/C compressor, generator etc.) or pulley. Misalignment may also be caused by incorrect installation of a pulley during a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to the relevant component service information for the correct installation and removal procedures.
10. Inspecting the fasteners can eliminate the possibility that an incorrect fastener has been installed.
12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface when the back end of the belt is used as the driving surface.
14. Replacing the drive belt when it is not damaged and there is no excessive pilling will only be a temporary repair.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Confirm the customer complaint. Is there a chirping noise?	-	Go to Step 3	Refer to Diagnostic Aids in this Section
3	Remove the drive belt, refer to Section 1C1, Engine Mechanical. Operate the engine for no more than 40 seconds. Does the chirping noise still exist?	-	Accessory drive system OK. Go to Symptoms, and restart the diagnosis of the noise	Go to Step 4
4	Inspect for severe pilling, i.e. in excess of 33% of the belt groove depth. Do the belt grooves have pilling?	-	Go to Step 5	Go to Step 6
5	Clean the drive belt pulleys with a wire brush. Are the belt pulleys clean?	-	Go to Step 15	Go to Step 6
6	Inspect for misalignment of the pulleys. Are the pulleys misaligned?	-	Go to Step 7	Go to Step 8
7	Replace or repair misaligned pulleys. Did you complete the repair?	-	Go to Step 15	-
8	Inspect for any bent or damaged accessory drive component mounting brackets. Did you find any bent or damaged brackets?	-	Go to Step 9	Go to Step 10
9	Replace or repair any bent or damaged Brackets. Did you complete the repairs?	-	Go to Step 15	-
10	Inspect for missing, loose or incorrect fasteners. Did you find any missing, loose or incorrect fasteners?	-	Go to Step 11	Go to Step 12
11	Tighten any loose fasteners to the torque specification. Replace any incorrect or missing fasteners. Did you complete the repairs?	-	Go to Step 15	-
12	Inspect for a bent pulley. Did you find any bent pulleys?	-	Go to Step 13	Go to Step 14
13	Replace bent pulleys as required. Did you complete the repair?	-	Go to Step 15	-
14	Replace the accessory drive belt, refer to Section 1C1, Engine Mechanical. Did you complete the repair?	-	Go to Step 15	-
15	Reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the chirp noise?	-	Accessory drive system OK	Go to Symptoms, and restart the diagnosis

2. The noise may not be engine related. This step is to confirm the engine is making the noise. If the engine is not making the noise, do not proceed further with this diagnostic procedure.
3. The noise may be an internal engine noise. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt.
4. Confirms an accessory drive component does not have a seized bearing. With the belt removed, test the bearings in the accessory drive components spin free and smooth.
5. Confirms the drive belt tensioner is operating correctly. If the drive belt tensioner is not operating correctly, drive belt tension will not be maintained, resulting in a belt squealing noise.
6. Confirms the belt is not too long, which would prevent the tensioner from working as intended. Also, if an excessively long belt has been fitted, it may also be routed incorrectly and may be turning an accessory drive component in the wrong direction.
7. Misalignment of the pulleys may be caused by one of the following :
• Incorrect mounting of an accessory drive component,
• Incorrect installation of an accessory drive pulley or,
• Bent or damaged pulley.
Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to the relevant component service information for the correct installation and removal procedures.
8. This test is to confirm the pulleys are the correct diameter and/or width. Using a known good vehicle, compare the pulley sizes.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Confirm the customer complaint. Is there a squealing noise?	-	Go to Step 3	Refer to Diagnostic Aids in this Section
3	Remove the drive belt, refer to Section 1C1, Engine Mechanical. Operate the engine for no more than 40 seconds. Does the squealing noise still exist?	-	Accessory drive system OK. Go to Symptoms, and restart the diagnosis of the noise	Go to Step 4
4	Inspect the accessory drive components for a seized bearing and general malfunctions. Did you find and correct any seized bearings or general malfunctions in the accessory drive system?	-	Go to Step 9	Go to Step 5
5	Test the accessory drive belt tensioner for correct operation, refer to Drive Belt Tensioner Diagnosis. Did you find and repair any problems with the tensioner?	-	Go to Step 9	Go to Step 6
6	Inspect the accessory drive belt is the correct length. Did you find and repair any problems with the drive belt length?	-	Go to Step 9	Go to Step 7
7	Inspect the accessory drive pulleys for misalignment. Did you find and correct any misaligned accessory drive pulleys?	-	Go to Step 9	Go to Step 8
8	Check the accessory drive pulleys are the correct size. Did you find and replace any incorrect pulleys?	-	Go to Step 9	Refer to Diagnostic Aids in this Section
9	Reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the squeal noise?	-	Accessory drive system OK	Go to Symptoms, and restart the diagnosis

3. The noise may be an internal engine noise. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt.
4. The inspection of bearings should include the following accessory drive components :
• drive belt tensioners,
• drive belt idlers,
• generator,
• power steering pump,
• A/C compressor.
The drive belt may need to be installed and the accessory drive components operated separately, at varying loads to confirm the location of the faulty bearing, refer to the relevant Sections for component inspection and repair procedures.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Confirm the customer complaint. Is there a whining noise?	-	Go to Step 3	Refer to Diagnostic Aids in this Section
3	Remove the drive belt, refer to Section 1C1, Engine Mechanical. Operate the engine for no more than 40 seconds. Does the whining noise still exist?	-	Accessory drive system OK. Go to Symptoms, and restart the diagnosis	Go to Step 4
4	Inspect the accessory drive components for a faulty or seized bearings and general malfunctions. Did you find and correct any faulty/seized bearings or general malfunctions in the accessory drive system?	-	Go to Step 5	Refer to Diagnostic Aids in this Section
5	Reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the whine?	-	Accessory drive system OK	Go to Symptoms, and restart the diagnosis

2. Confirms the symptom exists at the time of diagnosis. Other vehicle components may be causing the noise.
3. Confirms the accessory drive belt is the cause of the noise. Drive belt rumbling is often confused with an internal engine noise due to the similarity in the description. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt.
4. Inspecting the drive belt is to ensure that it is not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise and are not justification alone to replace the belt. Belt separation can be identified by the ply of the belt separating and may be seen at the edge of the belt or felt as lumps under the belt.
5. Small amounts of pilling is a normal condition and is deemed acceptable. When the pilling is severe (33% of the belt groove depth), the belt does not have a smooth surface to run on and should be replaced.

• pilling or strings in the drive belt grooves,
• separation of the drive belt, or
• a damaged or faulty drive belt.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Confirm the customer complaint. Is there a rumbling noise?	-	Go to Step 3	Refer to Diagnostic Aids in this Section
3	Remove the drive belt, refer to Section 1C1, Engine Mechanical. Operate the engine for no more than 40 seconds. Does the rumbling noise still exist?	-	Accessory drive system OK. Go to Symptoms, and restart the diagnosis	Go to Step 4
4	Inspect the accessory drive belt for damage, separation or sections of missing ribs. Did you find any damaged, separated or missing ribs?	-	Go to Step 7	Go to Step 5
5	Inspect the accessory drive belt for severe pilling (exceeding 33% of the belt groove depth). Did you find sever pilling?	-	Go to Step 6	Go to Step 5
6	Clean the drive belt using a suitable wire brush and reinstall to the engine, refer to Section 1C1, Engine Mechanical. Did you complete the repairs?	-	Go to Step 8	-
7	Install a new accessory drive belt, refer to Section 1C1, Engine Mechanical. Did you replace the accessory drive belt?	-	Go to Step 8	-
8	If required, reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the rumbling noise?	-	Accessory drive system OK	Go to Symptoms, and restart the diagnosis

2. Confirms the symptom exists at the time of diagnosis. Other vehicle components may be causing the noise.
3. Confirms the accessory drive belt is the cause of the noise. Drive belt rumbling is often confused with an internal engine noise due to the similarity in the description. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt.
4. The drive belt may cause a vibration. Inspecting the drive belt is considerably easier while the drive belt is removed.
6. Inspecting the fasteners can eliminate the possibility that an incorrect fastener has been installed.
8. This step should only be performed if the coolant pump is driven by the drive belt. Inspect the coolant pump for a bent shaft. Also inspect the coolant pump bearings for smooth operation and excessive play. Compare the coolant pump with a known good pump.
9. Accessory drive component brackets that are bent, cracked or loose may put extra strain on the accessory component causing it to vibrate.

• the vibration is engine speed related, or
• the vibration is sensitive to accessory drive system load.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Confirm the customer complaint. Is there a rumbling noise?	-	Go to Step 3	Refer to Diagnostic Aids in this Section
3	Remove the drive belt, refer to Section 1C1, Engine Mechanical. Operate the engine for no more than 40 seconds. Does the vibration noise still exist?	-	Accessory drive system OK. Go to Symptoms, and restart the diagnosis	Go to Step 4
4	Inspect the accessory drive belt for damage, wear, debris build-up or sections of missing ribs. Did you find any damage, wear, debris build-up or missing ribs?	-	Go to Step 5	Go to Step 6
5	Install a new accessory drive belt, refer to Section 1C1, Engine Mechanical. Did you replace the accessory drive belt?	-	Go to Step 9	-
6	Inspect for incorrect, loose, missing or damaged fasteners. Did you find any incorrect, loose, missing or damaged fasteners?	-	Go to Step 7	Go to Step 8
7	Tighten any loose fasteners to the correct torque specification. Replace any incorrect or missing fasteners. Did you complete the repairs?	-	Go to Step 9	-
8	Inspect for bent, cracked or damaged accessory drive component mounting brackets. Did you find and repair any bent brackets?	-	Go to Step 9	Refer to Diagnostic Aids in this Section
9	If required, reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the vibration?	-	Accessory drive system OK	Refer to Diagnostic Aids in this Section

• an incorrect drive belt length,
• a faulty drive belt tensioner, or
• a stretched or faulty drive belt.

2. Confirms the condition of the drive belt. Damage may have occurred to the drive belt when it first fell off or it may have been damaged which caused the belt to fall off.
4. Misalignment of the pulleys may be caused by :
• the incorrect installation or mounting of an accessory drive component,
• the incorrect installation of an accessory drive component pulley, or
• a damaged or bent accessory drive pulley.
Test for a misaligned pulley using a suitable straight edge in the pulley grooves across two or more pulleys. If a misaligned pulley is found, refer to the service information for the particular component, for the correct pulley replacement procedures.
5. Inspecting the pulleys should include an inspection for dents or other damage that would prevent the drive belt from seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used.
6. Accessory drive component mounting brackets that are bent will cause the drive belt to fall off.
7. Inspection of the fasteners can eliminate the possibility that an incorrect fastener was installed. Missing, loose or incorrect fasteners may cause pulley misalignment from the fasteners moving under load. Over-tightening of the fasteners may cause deflection of mounting brackets and result in misaligned accessory drive pulleys.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Inspect for a damaged accessory drive belt. Did you find any damage on the drive belt?	-	Go to Step 3	Go to Step 4
3	Install a new accessory drive belt, refer to Section 1C1, Engine Mechanical. Does the drive belt continue to fall off?	-	Go to Step 4	Go to Step 12
4	Inspect the accessory drive system pulleys for misalignment. Did you find and repair any misaligned drive system pulleys?	-	Go to Step 12	Go to Step 5
5	Inspect for a dented or cracked accessory drive system pulley. Did you find and repair any dented or cracked drive system?	-	Go to Step 12	Go to Step 6
6	Inspect for bent accessory drive component mounting brackets. Did you find and repair any bent mounting brackets?	-	Go to Step 12	Go to Step 7
7	Inspect for incorrect, loose, missing or damaged fasteners. Did you find any incorrect, loose, missing or damaged fasteners?	-	Go to Step 8	Go to Step 9
8	Tighten any loose fasteners to the correct torque specification. Replace any incorrect or missing fasteners. Does the drive belt continue to fall off?	-	Go to Step 9	Go to Step 12
9	Test the accessory drive belt tensioner for correct operation, refer to Section 1C1, Engine Mechanical. Did you accessory drive belt tensioner operate correctly?	-	Go to Step 11	Go to Step 10
10	Replace the drive belt tensioner, refer to Section 1C1, Engine Mechanical. Does the drive belt continue to fall off?	-	Go to Step 11	Go to Step 12
11	Inspect for a failed drive belt idler and drive belt tensioner bearings. Did you find and repair any failed bearings?	-	Go to Step 12	Refer to Diagnostic Aids in this Section
12	If required, reinstall the accessory drive belt and operate the system to confirm the repair. Does the drive belt continue to fall off?	-	Go to Step 2	Accessory drive system OK

2. Confirms the drive belt is correctly installed onto all of the accessory drive system pulleys. Wear on the drive belt may be caused by incorrectly positioning the drive belt by one or more grooves to a particular pulley.
3. The installation of the drive belt that is the incorrect width will cause wear on the drive belt. The drive belt ribs should match all the grooves on all the pulleys in the accessory drive system.
4. Confirms the drive belt is not contacting any parts of the engine or body while the engine is running. There should be sufficient clearance when the accessory drive component loads varies. The drive belt should not come into contact with any engine or body parts.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Inspect the accessory drive belt for correct installation. Is the drive belt installed correctly?	-	Go to Step 5	Go to Step 3
3	Ensure that the drive belt is the correct one for the application. Is the correct drive belt installed?	-	Go to Step 5	Go to Step 4
4	Is the drive belt contacting any engine or body components with the engine running?	-	Go to Step 6	Refer to Diagnostic Aids in this Section
5	Install a new accessory drive belt, refer to Section 1C1, Engine Mechanical. Did you replace the accessory drive belt?	-	Go to Step 6	-
6	If required, reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the excessive wear?	-	Accessory drive system OK	Go to Step 2

1. Spark Plug Cable Cover
2. Engine Oil Cap
3. Cylinder Head Cover
4. Cylinder Head Cover Gasket
5. Spark Plug Cable
6. Spark Plug
7. Ignition Coil (DIS) Bracket
8. Ignition Coil (DIS)
9. Camshaft Cap
10. Camshaft (Intake)
11. Camshaft (Exhaust)
12. Valve Tappet
13. Valve Key
14. Valve Spring Retainer
15. Valve Spring
16. Valve Stem Seal
17. Cylinder Head
18. Valve (Intake)
19. Valve (Exhaust)
20. Cylinder Head Gasket
21. Cylinder Head Bolt
22. Camshaft Position Sensor
23. Coolant Outlet Case Gasket
24. Coolant Outlet Case
25. Coolant Temperature Sensor
26. EGR Valve Gasket
27. EGR Valve

1. Piston Ring
2. Piston
3. Piston Pin Retainer
4. Piston Pin
5. Connecting Rod Cap Stud
6. Connecting Rod
7. Connecting Rod Bearing
8. Connecting Rod Cap
9. Dowel Pin
10. Cylinder Block
11. Timing Chain Cover
12. Crankshaft Front Oilseal
13. Oil Pump Inner Rotor
14. Oil Pump Outer Rotor
15. Oil Pump Cover
16. Oil Relif Valve
17. Oil Relif Valve Spring
18. Oil Relif Valve Cap
19. Oil Relif Valve Retainer
20. Oil Filter Stud
21. Oil Filter
22. Key
23. Crankshaft
24. Crankshaft Bearing Cap
25. Oil Strainer
26. Oil Pan
27. Crankshaft Rear Oil Seal
28. Cylinder Block Plate Plug
29. Cylinder Block Plate Plug Gasket

1. Resonator
2. Duct
3. Air Filter Snorkel Hose
4. Air Filter Lower Housing
5. Air Filter Element
6. Air Filter Upper Cover
7. Air Outlet Hose
8. Resonator
9. Resonator
10. Throttle Body
11. IACV (Idle Air Control Valve)
12. Throttle Position Sensor
13. Intake Manifold
14. EGR Pipe
15. EGR Pipe Gasket
16. EGR Valve
17. Thermostat Housing
18. Coolant Outlet Case
19. Fuel Rail
20. Injector
21. Exhaust Manifold
22. Exhaust Manifold Heat Shield

1. Timing Chain
2. Camshaft Sprocket (Intake)
3. Camshaft Sprocket (Exhaust)
4. Bushing
5. Camshaft Sprocket Retaining Bolts
6. Timing Chain Lever
7. Timing Chain Tensioner
8. Timing Chain Guide
9. Crankshaft Sprocket
10. Engine Mount Assembly
11. Rear Mount Bracket
12. Transmission Rear Mount
13. Transmission Mount Assembly
14. Transmission Mount Bracket