Page 1657 of 2267

REPLACEMENT OF CONNECTING ROD BUSHING
(Small end)
1. Drive in small end bushing until it is flush with end surface of
rod.
Be sure to align the oil holes.
2. After driving in small end bushing, ream the bushing. This is
to ensure the clearance between connecting rod bushing and
piston pin is the specified value.
Clearance between connecting rod bushing and pis-
ton pin:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT
CONVERTER (CVT)
1. Remove pilot bushing or pilot converter using Tool or suitable
tool.
2. Install pilot bushing or pilot converter as shown.
FLYWHEEL/DRIVE PLATE RUNOUT
Runout (Total indicator reading):
Flywheel (M/T model)
Less than 0.15 mm (0.0059 in)
Drive plate (CVT model)
Less than 0.20 mm (0.0079 in)
CAUTION:
Do not allow any magnetic materials to contact the ring gear
teeth.
Assembly
PISTON
1. Install new snap ring on one side of piston pin hole.
SEM062A Align.
SEM916AB
SEM163B M/TCrankshaft side
CVT
.SEM901E
SEM166B
CYLINDER BLOCKSR20DE
Inspection (Cont'd)
EM-117
Page 1658 of 2267
2. Heat piston to 60 to 70ÉC (140 to 158ÉF) and assemble piston,
piston pin, connecting rod and new snap ring.
IAlign the direction of piston and connecting rod.
INumbers stamped on connecting rod and cap correspond
to each cylinder.
IAfter assembly, make sure connecting rod swings
smoothly.
3. Set piston rings as shown.
CAUTION:
IWhen piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
IWhen replacing piston rings, those without punchmarks
can be mounted with either side up.
CRANKSHAFT
1. Set main bearings in their proper positions on cylinder block
and main bearing cap.
IConfirm that correct main bearings are used. Refer to
ªInspectionº of this section.
IApply new engine oil to bearing surfaces.
SEM946C
SEM965E Punchmark side up
(if mark is present.)
NEM336 Oil ring
expander
Engine
front
2nd ring
lTop ringlOil ring
upper rail
Oil ring
lower rail
SEM685D
CYLINDER BLOCKSR20DE
Assembly (Cont'd)
EM-118
Page 1659 of 2267

2. Install crankshaft and main bearing caps and tighten bolts to
the specified torque and in numerical order as shown in the
figure.
IApply new engine oil to thread of bearing cap bolts.
IPrior to tightening bearing cap bolts, shift crankshaft back
and forth to properly seat the bearing cap.
ITightening procedure
a.Tighten all bolts to 32 to 38 N´m (3.3 to 3.9 kg-m, 24 to
28 ft-lb).
b. Turn all bolts 30 to 35 degrees clockwise with Tool or
suitable angle wrench.
IIf an angle wrench is not available, mark all bearing cap
bolts on the side facing engine rear. Then, turn each bolt
specified degrees clockwise. Confirm angle of degrees
with a graduator, not by eye-measurement.
IAfter securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
3. Measure crankshaft end play.
Crankshaft end play:
Standard
0.10 - 0.26 mm (0.0039 - 0.0102 in)
Limit
0.30 mm (0.0118 in)
If beyond the limit, replace thrust bearings with new ones.
4. Install connecting rod bearings in connecting rods and con-
necting rod caps.
IConfirm that correct bearings are used. Refer to ªInspec-
tionº.
IInstall bearings so that oil hole in connecting rod aligns
with oil hole of bearing.
IApply new engine oil to bolt threads and bearing surfaces.
5. Install pistons with connecting rods.
a. Install them into corresponding cylinders with Tool.
IBe careful not to scratch cylinder wall by connecting rod.
IArrange so that front mark on piston head faces toward
front of engine.
IApply new engine oil to piston rings and sliding surface
of piston.
NEM151 Front
p7p3p1p5p9
p8p4p2p6p10
NEM152 KV10112100
NEM153 Feeler gauge
SEM159B Align oil hole.
SEM554EA EM03470000
or suitable tool
CYLINDER BLOCKSR20DE
Assembly (Cont'd)
EM-119
Page 1660 of 2267

b. Install connecting rod caps.
Tighten connecting rod cap nuts to the specified torque.
Tightening procedure:
1) Tighten nuts to 14 to 16 N´m (1.4 to 1.6 kg-m, 10
to 12 ft-lb).
2) Turn nuts 60 to 65 degrees clockwise with
angle wrench. If angle wrench is not available,
tighten nuts to 38 to 44 N´m (3.9 to 4.5 kg-m, 28
to 33 ft-lb).
6. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.20 - 0.35 mm (0.0079 - 0.0138 in)
Limit
0.50 mm (0.0197 in)
If beyond the limit, replace connecting rod and/or crankshaft.
7. Install rear oil seal retainer.
a. Before installing rear oil seal retainer, remove all traces of liq-
uid gasket from mating surface using a scraper.
lAlso remove traces of liquid gasket from mating surface of
cylinder block.
b. Apply a continuous bead of liquid gasket to mating surface of
rear oil seal retainer.
lUse Genuine Liquid Gasket or equivalent.
NEM154 Engine
front
Connecting rod cap nut
NEM153 Feeler gauge
SEM218D
SEM219D Liquid
gasket
2.0 - 3.0 mm
(0.079 -
0.118 in)
CYLINDER BLOCKSR20DE
Assembly (Cont'd)
EM-120
Page 1661 of 2267
NEM333 Camshaft
bearing noiseTappet noise
Belt tensioner
noise
Valve mechanism
Piston pin noiseTiming belt
Water pump
Rotation
mechanism
Drive belt
Connecting rod
bearing noise Piston
slap noise
Main bearing noiseDrive belt noise
(stick/slipping)
Belt tensioner
noise
Drive belt noise
(Slipping)
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGCD20T
EM-121
Page 1662 of 2267

NVH Troubleshooting Chart Ð Engine Noise
Use the chart below to help you find the cause of the problem.
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
startingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingCAÐABÐTappet
noiseValve clearance Ð
Rattle C A Ð A B CCamshaft
bearing
noiseCamshaft journal clearance
Camshaft runoutEM-147
Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil panSlap or
knockÐAÐB BÐPiston pin
noisePiston and piston pin clear-
ance
Connecting rod bushing
clearanceEM-168,
171
Slap or rap A Ð Ð B B APiston slap
noisePiston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend and
torsionEM-168,
169, 172,
174
Knock A B C B B BConnecting
rod bearing
noiseConnecting rod bushing
clearance (Small end)
Connecting rod bearing
clearance (Big end)EM-170,
171
Knock A B Ð A B CMain bear-
ing noiseMain bearing oil clearance
Crankshaft runoutEM-169,
172
Camshaft
and injection
pump
Timing belt
coverWhine or
hissingCAÐAAÐTiming belt
noise (too
tight)
Loose timing belt
Belt contacting caseEM-135
Clatter A B Ð C A ÐTiming belt
noise (too
loose)
Front of
engineSqueaking
or fizzingABÐBÐCOther drive
belts
(Sticking or
slipping)Drive belts deflection
*1
CreakingABABABOther drive
belts (Slip-
ping)Idler pulley bearing operation
Squall
CreakABÐBABWater pump
noiseWater pump operation *2
A: Closely related B: Related C: Sometimes related Ð: Not related
*1: MA section (ªChecking Drive Beltsº, ªENGINE MAINTENANCEº)
*2: LC section (ªWater Pump Inspectionº, ªENGINE COOLING SYSTEMº)
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGCD20T
NVH Troubleshooting Chart Ð Engine Noise
EM-122
Page 1663 of 2267
Right side
p1Starter motor
p2Injection pump
p3Injection tube
p4Thermostat housing
p5Injection nozzle
p6Spill hose
p7Water outlet
p8Belt cover
p9Timing belt
p10Injection pump sprocket
p11Rear camshaft sprocket
p12Tensioner
p13Vacuum pump
p14Rear back cover
p15Oil cooler
p16Gasket
p17Bracket
p18Power steering oil pump
adjusting bar
p19Gasket
NEM240
17 - 21 (1.7 - 2.1, 12 - 15)2 - 4 (0.2 - 0.4, 18 - 35)
3 - 5 (0.3 0.5, 26 - 43)
49-59
(5.0 - 6.0, 36 - 43)
49 - 59 (5.0 - 6.0,
36 - 43)
31-42
(3.2 - 4.3, 23 - 31)16-21
(1.6 - 2.1,
12 - 15)
16 - 21 (1.6 - 2.1, 12 - 15)
54 - 64 (5.5 - 6.5, 40 - 47)
22 - 25 (2.2 - 2.5, 16 - 18)
16 - 21 (1.6 - 2.1, 12 - 15)
SEC. 130×135×185×186×210×213×233
îî: Apply liquid gasket
: N´m (kg-m, in-lb)
îî
: N´m (kg-m, ft-lb)
: Do not re-use
16 - 21 (1.6 - 2.1, 12 - 15)
OUTER COMPONENT PARTSCD20T
EM-123
Page 1664 of 2267

Left side
p1Belt cover upper
p2Water pump pulley
p3Belt cover lower
p4Crankshaft pulley
p5Alternator
p6Alternator bracket
p7Exhaust manifold with turbo-
charger assembly
p8Gasket
p9Intake manifold
p10EGR passage (To install, face
EGR gas discharge port upward)
p11EGR valve
p12Air inlet
p13Air inlet hose
p14EGR tube
p15Exhaust manifold cover
p16Blow-by gas control valve
p17Turbocharger oil return hose
3 - 5 (0.3 - 0.5,
27 - 44)
37-50
(3.8 - 5.1,
27 - 37)p1
6.4 - 8.4
(0.65 - 0.86,
56.6 - 74.3)
p2
p9
p3
3-5
(0.3 - 0.5,
26 - 44)
p4
142 - 152
(14.5 - 15.5, 105 - 112)p6
16 - 21 (1.6 - 2.1, 12 - 15)
16 - 21 (1.6 - 2.1,
12 - 15)îî
: Apply liquid gasket
: N´m (kg-m, in-lb)
îî
: N´m (kg-m, ft-lb)
: Do not re-use
18 - 22 (1.8 - 2.2, 13 - 16)6.3 - 8.3
(0.64 - 0.85,
55.8- 73.5)
p11
p8
p10
.21-26
(2.1 - 2.7,
15 - 20)
p8
p12
p1318-22
(1.8 - 2.2,
13 - 16)
p8
21-26
(2.1 - 2.7,
15 - 20)
p14
39-49
(4.0 - 5.0, 29 - 36)
p8
p7
18-22
(1.8 - 2.2,
13 - 16)
.18-22
(1.8 - 2.2, 13 - 16)
p17p15
4-5
(0.4 - 0.5,
35 - 44)
70 - 89 (7.1 - 9.1, 51 - 66)
p5
41 - 52 (4.2 - 5.3, 30 - 38)
NEM197
SEC. 120×135×140×144×210×230
3.8 - 4.5
(0.39 - 0.46,
33.6 - 39.8)
p16
20-31
(2.0 - 3.2,
14 - 23)
OUTER COMPONENT PARTSCD20T
EM-124