Page 254 of 346
EM-92 _. ENGINE MECHANICAL +’ Cylinder Block
-..
: .
;,,
“.’
‘i4. (7M-GE w/ Oil Cooler)
INSTALL Oil.. REGULATOR
Install a new gasket and oil regulator with. the two bolts.
(7M-GE w/o Oil Cooler and.7M-GTE)
INSTALL OIL HOLE COVER PLATE
Install a new gasket and oil hole cover plate with the two .
bolts.
15. (7M-GE)
INSTALL NEW OIL FILTER
(See page LU-6)
16. INSTALL ENGlNE MOUNTING BRACKETS
17. INSTALL FUEL RETURN PIPE SUPPORT
Install a new insulator and fuel pipe support with the two
nuts. :
Torque: 130 kg-cm (69 ft-lb, ‘1.3 N&l
18. (7M-GE)
INSTALL VACUUM CONTROL VALVE SET
19. INSTALL GROUND STRAP TO CYLI’NDER BLOCK
20. lN,STALL WATER BY- PASS PIPE
(a) “Install a new gasket and water by-pass pipe to the
timing belt case with the two nuts.
Torque: 140 kg-cm (IO ft-!b, 14 N-m)
(b) Install the water by-pass pipe tqthe cylinder block
with the three bolts.
Torque: 130 kg-cm (9 ft-lb, 13 N-m)
21. INSTALL CYLINDER HEAD
(See steps 1 and 4 to 18 on pages EM-59 to 64)
22. INSTALL TIMING BELT
(See step 1 to 8 and 10 to 15 on pages EM33 to 36)
23. REMOVE ENGiNE STAND
24. INSTALL REAR END PLATE
Torque: 130. kg-cm (9 ft-lb, 13 N.m)
25. INSTALL FLYWHEEL OR DRIVE PLATE ON
CRANKSHAFT
(a) Install the flywheel or drive plate on crankshaft.
(b) Install and uniformly tighten the bolts in several
passes, in the sequence shown.
Torque: 750 kg-cm (54 ft-lb, 74 N*m)
Page 261 of 346
IGNITION SYSTEM - On-Vehicle Inspection (‘/M-GE)
IG-lf.
~. .
__
1
8 SST I ffio59
IGOt! i2
INSPECTION OF SPARK PLUGS
(Conventional Tipped Type Spark Plug)
1. REMOVE SPARK PLUGS
(a) Remove the high-tension cords.
(See page. IG-6)
2.
3.
I
lGOl48
4.
5. (b) Using SST, remove the spark plug.
SST 0915~5-16100
CLEAN SPARK PLUGS
Using a spark plug cleaner or wire brush, clean the spark
plug.
VISUALLY INSPECT SPARK PLUGS
Check the spark plug for electrode wear, threads damage
and insulator damage.
If abnormal, replace the plugs.
Recommended spark plugs:
ND Q20R- U
NGK BCPRGEY
ADJUST ELECTRODE GAP
Carefully bend the outer electrode to obtain the correct
electrode gap.
Correct electrode gap: 0.8 mm (0.031 in.)
INSTALL SPARK PLUGS
(a) Using SST, install and torque the spark plug.
SST 09155-l 6100
Torque : 180 kg-cm (13 ft-lb, 18 Nmrn)
I..
Page 263 of 346
IGNITION SYSTEM
- On-Vehicle Inspection (7M-GE)
,“lG-9
16031
0.8 mm (7M-GTE)
1 .I
mm (7M-GE)
VISUALLY INSPECT SPARK PLUGS
Check the spark plug for thread or insulator damage.
If abnormal, replace the plug.
Recommended spark plugs:
7M-GE’ ND
PQ16R ’
NGK BCPR5EPll
7M-GTE ND
PQ20R-P6
NGK BCPRGEP-N8
INSPECT ELECTRODE GAP
Maximum electrode gap:
7M-GE
1.3 mm (0.051 in.)
7M-GTE 1.0 mm (0.039 in.)
If the gap is greater than maximum, replace the plug.
Correct electrode gap of new plug:
7M-GE
1.1 mm (0.043 in.)
7M-GTE 0.8 mm (0.031 in.)
If adjusting the gap of a new plug, bend only the base of
5. CLEAN SPARK PLUGS
6. the ground electrode, do not touch the tip.
If the electrode has traces of wet carbon, allow it to dry
and then clean with a spark plug cleaner.
Air pressure: Below 6 kg/cm2 (85 psi, 588 kPa)
Duration : 20 seconds or less
NOTE: If there are traces of oil, remove it with gasoline
before using the spark plug cleaner.
INSTALL SPARK PLUGS
(a) Using SST, install and torque the spark plug.
SST 09155-l 6100
Torque : 180 kg-cm (13 ft-lb, 18 N*m)
(b) Install the high-tension cords.
Page 269 of 346
IGNITION-SYSTEM - On-V?hicle Inspection (7M-GTE)
IO-1 5
5. INSTALL IGNITION COIL WITH BRACKET .
(a) Connect the ignition coil connector.
(b) install the high-tension cords as shown in the illustra- ’
tion; No.5 and No.6, No.3 and No.4, and No.1 and
No.2.
(c) Install and torque the nut.
Torque : 55 kg-cm (48 in.-lb, 5.4 Nmrn)
CAUTION: Do not over tighten the nut.
IGOB,
12
- 6. INSTALL IGNITION COIL COVER
(a) Remove the oil filler cap.
(b) Install the ignition coil cover with the five nuts.
(c) install the oil filler cap.
7. INSTALL INTAKE AIR CONNECTOR
(a) Install the intake air connector.
(b) Install and tighten the two bolts.
(c) Tighten the clamp.
Id) Connect the air valve hose.
Page 287 of 346
-.
LUBRICATION SYSTEM
- Replacement.of Engine Oil and Oil Filter
L&.7*.
(d) Lightly screw in the oil filter to where you feel resis-
tance.
(el Then, using SST, tighten.the oil filter an extra 3/4
turn. .
SST 09228-07500
3. FILL WITH ENGINE OIL
(a) Clean and install the oil drain plug with a new gasket.
Torque: 350 kg-cm (25 ft-lb, 34 N.m)
(b) Fill the engine with new oil.
Oil capacity:
Dry fill
7M-GE MA (GCC Countries*)
5.0 liters (5.3 US qts, 4.4 Imp. qts)
‘/M-GE MA (Others)
4.9 liters (5.2 US qts, 4.3 Imp. qts)
7M-GE MS
5.3 liters (5.6 US qts, 4.7 Imp. qts)
7M-GTE (A/T)
5.0 liters (5.3 US qts, 4.4 Imp. qts)
7M-GTE (M/T)
5.1 liters (5.4 US qts, 4.5 Imp. qts)
Drain and refil
w/o oil filter change
MA
3.9 liters (4.1 US qts, 3.4 Imp. qts)
MS
4.1 liters (4.3 US qts, 3.6 Imp. qts)
w/ oil filter change
MA
4.2 liters (4.4 US qts, 3.7 Imp. qts)
MS
4.4 liters (4.7 US qts, 3.9 Imp. qts)
4.
START ENGINE AND CHECK FOR LEAKS
5. RECHECK ENGINE OIL LEVEL (See page LU-5)
’ GCC Countries: Soudi Arabia, Sultanate of Oman,
Bahrain, United Arab Emirates, Qatar, Kuwait.
Page 289 of 346
-.
LUBRICATION SYSTEM
- Replacement.of Engine Oil and Oil Filter
L&7_
4.
5. (d) Lightly screw in the oil filter to where you feel resis-
tance.
(e) Then, using SST, tighten. the oil filter an extra 3/4 .
turn.
SST 09228-07500
FILL WITH ENGINE OIL
(a) Clean and install the oil drain plug with a new gasket.
Torque: 350 kg-cm (25 ft-lb, 34 N-m)
(b) Fill the engine with new oil,
Oil capacity:
Dry fill
7M-GE MA (GCC Countries*)
5.0 liters (5.3 US qts, 4.4 Imp. qts)
7M-GE MA (Others)
4.9 liters (5.2 US qts, 4.3 Imp. qts)
7M-GE MS
5.3 liters (5.6 US qts, 4.7 Imp. qts)
7M-GTE (A/T)
5.0 liters (5.3 US qts, 4.4 Imp. qts)
7M-GTE (M/T)
5.1 liters (5.4 US qts, 4.5 Imp. qts)
Drain and refil
w/o oil filter change
MA
3.9 liters (4.1 US qts, 3.4 Imp. qts)
MS
4.1 liters (4.3 US qts, 3.6 Imp. qts)
w/ oil filter change
MA
4.2 liters (4.4 US qts, 3.7 Imp. qts)
MS
4.4 liters (4.7 US qts, 3.9 Imp. qtsl
START ENGINE AND CHECK FOR LEAKS
RECHECK ENGINE OIL LEVEL (See page LU-5)
l GCC Countries: Soudi Arabia, Sultanate of Oman,
Bahrain, United Arab Emirates, Qatar, Kuwait.
Page 294 of 346
LU-12
-.
LUBRICATION SYSTEM - Oij Pump
LUOJS
ASSEMBLY AND OPERATION CHECK OF OIL
”
PUMP
(See page LU-8)
5. INSTALL OIL PUMP DRIVE SHAFT
Install the oil pump drive shaft, key, shaft drive gear,
spacer, and using snap ring pliers, install the snap ring.
INSTALL OIL PUMP DRIVEN GEAR
INSTALL OIL PUMP COVER
Install the oil pump cover with the five bolts.
Torque the bolts.
Torque: 75 kg-cm (65 in.-lb, 7.4 N-m)
INSTALL RELIEF VALVE
Install the relief valve and spring with the relief valve plug.
Torque the plug.
Torque:
375 kg-cm (27 ft-lb, 37 N.m)
CHECK PUMP OPERATION
(a) Immerse the suction end of the pump into clean
engine oil and turn the shaft counterclockwise. Oil
should come out of the discharge hole.
(b) Close the discharge hole with your thumb, and turn
the shaft as before. The shaft should be difficult to
turn.
Page 295 of 346
-.
LUBRICATION SYSTEM.-- Oil Pump
LU-13
. .
6.
(MAI
INSTALL OIL PUMP STRAINER
(a1 Install a new O-ring to oil pump strainer.
(b) Install the oil pump strainer with the two bolts.
Torque: 130 kg-cm (9 ft-lb, 13 N-m)
’ /--J Ld LU0527
7. INSTALL. OIL PUMP OUTLET PIPE
Install the oil pump outlet pipe with a new lock
washer,gasket and the union bolt. Finger tighten the union
bolt.
INSTALLATION OF OIL PUMP
(See page LU-8)
1. INSTALL OIL PUMP
(a) install the oil pump with the bolt. Torque the bolt.
Torque: 220 kg-cm (16 ft-lb, 22 Nam)
(b) Install the mount bolt holding the oil pump strainer
stay to block.
Torque: 60 kg-cm (52 in.-lb, 5.9 Nsm)
(c) Connect the outlet pipe with the union bolt,
Torque the union bolt and nut.
Torque: 350 kg-cm (25 ft-lb, 34 N-m)
Id) Stake the lock washer.
