Page 1545 of 2267

Parts Requiring Angular Tightening
ISome important engine parts are tightened using an angular-
tightening method rather than a torque setting method.
IIf 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.
IAlthough 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.
ITo assure the satisfactory maintenance of the engine, bolts
and nuts must be tightened using an angular-tightening
method.
IBefore tightening the bolts and nuts, ensure that the thread
and seating surfaces are clean and then coated with engine oil.
IThe 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
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.)
IBe 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).
IBe 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.
SEM164FInner
side
GrooveBolt hole
AEM080 Inner side
Groove
PRECAUTIONS
Parts Requiring Angular Tightening
EM-5
Page 1546 of 2267
Special Service Tools
Tool number
Tool nameDescriptionEngine
application
SR CD QG
ST0501S000
Engine stand
assembly
p1ST05011000
Engine stand
p2ST05012000
Base
NT042
When overhauling engine
XXX
KV10106500
Engine stand shaft
NT028
When overhauling engine
XÐX
KV10115300
Engine sub-attach-
ment
NT008
When overhauling engine
XÐÐ
Engine attachment
assembly
p1KV10106500
Engine attach-
ment
p2KV10113300
Sub-attach-
ment
NT029
When overhauling engine
ÐÐ X
p1KV10108101
Engine attach-
ment
p2KV10102500
Engine stand
shaft
NT366
When overhauling engine
ÐXÐ
ST10120000
Cylinder head bolt
wrench
NT583
Loosening and tightening cylinder
head bolt
XÐX
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
PREPARATION
Special Service Tools
EM-6
Page 1547 of 2267

Tool number
Tool nameDescriptionEngine
application
SR CD QG
KV10116200
Valve spring
compressor
p1KV10115900
Attachment
NT022
Disassembling and assembling
valve mechanism
XÐX
KV101092S0
Valve spring
compressor
p1KV10109210
Compressor
p2KV10109220
Adapter
NT021
Disassembling and assembling
valve mechanism
ÐXÐ
KV10115600
Valve oil seal drift
NT603Side A
Side B
Installing valve oil seal
X
(Side
B)ÐX
(Side
A)
Side A Side B
a: 20 (0.79) 20 (0.79)
b: 13 (0.51) 14.2 (0.559)
c: 10.3 (0.406) 11 (0.43)
d: 8 (0.31) 8 (0.31)
e: 10.7 (0.421) 10.7 (0.421)
f: 5 (0.20) 5 (0.20)
Unit: mm (in)
KV10107902
Valve oil seal
puller
p1KV10116100
Valve oil seal
puller adapter
NT605
Removing valve oil seal
XXX
KV10115700
Dial gauge stand
NT012
Adjusting shims
ÐÐ X
KV101151S0
Lifter stopper set
p1KV10115110
Camshaft
pliers
p2KV10115120
Lifter stopper
NT041
Changing shims
ÐX X
EM03470000
Piston ring com-
pressor
NT044
Installing piston assembly into cyl-
inder bore
XXX
PREPARATION
Special Service Tools (Cont'd)
EM-7
Page 1548 of 2267
Tool number
Tool nameDescriptionEngine
application
SR CD QG
KV10107400
Piston pin press
stand
p1KV10107310
Center shaft
p2ST13040020
Stand
p3ST13040030
Spring
p4KV10107320
Cap
p5ST13040050
DriftNT013
Disassembling and
assembling piston pin
XÐX
KV10109300*
Pulley holder
NT628
Removing and installing camshaft
sprocket
ÐXÐ
a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.
ED19600000*
Compression
gauge set
NT626
Measuring compression pressure
ÐXÐ
KV11100300
Nozzle holder
socket
No. 2-4 injection
nozzle holder
socket
NT563
Loosening and tightening injector
nozzle
ÐXÐ
KV119E0030
No. 1 injection
nozzle holder
socket
NT648
Loosening and tightening injector
nozzle
ÐXÐ
KV101111 0 0
Seal cutter
NT046
Removing oil pan
XXX
*: Special tool or commercial equivalent
PREPARATION
Special Service Tools (Cont'd)
EM-8
Page 1549 of 2267
Tool number
Tool nameDescriptionEngine
application
SR CD QG
WS39930000
Tube presser
NT052
Pressing the tube of liquid gasket
XXX
KV10112100
Angle wrench
NT014
Tightening bolts for bearing cap,
cylinder head, etc.
XXX
ST16610001*
Pilot bushing puller
NT045
Removing pilot bushing
XXÐ
KV11102900*
Pulley puller
NT647
Removing injection pump pulley
ÐXÐ
KV101056S0*
Ring gear stopper
p1KV10105630
Adapter
p2KV10105620
Adapter
p3KV10105610
Plate assem-
bly
NT617
Preventing crankshaft from rotating
ÐX X
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)
*: Special tool or commercial equivalent
PREPARATION
Special Service Tools (Cont'd)
EM-9
Page 1550 of 2267

Commercial Service Tools
Tool name DescriptionEngine
application
SR CD QG
Spark plug wrench
NT047
16 mm
(0.63 in)Removing and installing spark
plug
XÐX
Valve seat cutter set
NT048
Finishing valve seat dimensions
XXX
Piston ring expander
NT030
Removing and installing piston
ring
XXX
Valve guide drift
NT015
Removing and installing valve
guide
XÐX
SR Intake & Exhaust
a = 9.5 mm (0.374 in) dia.
b = 5.0 mm (0.197 in) dia.
QG Intake & Exhaust
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia.
Valve guide reamer
NT016
Reaming valve guidep1
or hole for oversize valve guide
p2
XÐXSR Intake & Exhaust
d1= 6.0 mm (0.236 in) dia.
d2= 10.175 mm (0.4006 in) dia.
QG Intake & Exhaust
d
1= 5.5 mm (0.217 in) dia.
d2= 9.685 mm (0.3813 in) dia.
Front oil seal drift
NT049
Installing front oil seal
XÐX
a = 75 mm (2.95 in) dia.
b = 45 mm (1.77 in) dia.
Rear oil seal drift
NT049
Installing rear oil seal
XÐX
a = 110 mm (4.33 in) dia.
b = 80 mm (3.15 in) dia.
PREPARATION
Commercial Service Tools
EM-10
Page 1551 of 2267

NVH Troubleshooting Ð Engine NoiseNCEM0005S01Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Location of
noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemReference
page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
Engine
Rocker
Cover Cyl-
inder HeadTicking or
clickC A Ð A B Ð Tappet
noiseValve clearance EM-40
Rattle C A Ð A B C Camshaft
bearing
noiseCamshaft journal clear-
ance
Camshaft runoutEM-35
Crankshaft
Pulley
Cylinder
block (Side
of Engine)
Oil panSlap or
knockÐ A Ð B B Ð Piston pin
noisePiston and piston pin
clearance
Connecting rod bushing
clearanceEM-54, 59
Slap or
rapA Ð Ð B B A Piston slap
noisePiston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend and
torsionEM-54, 55,
56
Knock A B CB B B Connecting
rod-bearing
noiseConnecting rod bearing
clearance (Big end)
Connecting rod bushing
clearance (Small end)EM-58, 59
Knock A B Ð A B C Main bear-
ing noiseMain bearing oil clear-
ance
Crankshaft runoutEM-57
Front of
Engine Tim-
ing Chain
CoverTapping or
tickingAAÐBBBTiming
chain and
chain ten-
sioner noiseTiming chain cracks and
wear
Timing chain tensioner
operationEM-24
Front of
EngineSqueak or
fizzingA B Ð B Ð C Other drive
belts (stick-
ing or slip-
ping)Drive belts deflection MA Section
(ªChecking
Drive Beltsº,
ªEngine
Mainte-
nanceº) CreakingABABABOther drive
belts (slip-
ping)Idler pulley bearing
operation
Squall or
creakABÐBABWater pump
noiseWater pump operation LC Section
(ªWater
Pump
Inspectionº,
ªEngine
Cooling
Systemº)
A: Closely related B: Related C: Sometimes related Ð: Not related
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTINGQG
NVH Troubleshooting Ð Engine Noise
EM-11
Page 1552 of 2267
SEM937F Camshaft bearing noise
Tappet noise
Timing chain
and chain
tensioner noise
VALVE MECHANISM
Valve
Piston pin noiseTIMING CHAIN
Water pump noise
ROTATION
MECHANISM
DRIVE BELT
Connecting rod
bearing noise
Piston slap noise
Main bearing noise
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTINGQG
NVH Troubleshooting Ð Engine Noise (Cont'd)
EM-12