EM-168
< SERVICE INFORMATION >[VK45DE]
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noise Type of
noise Operating condition of engine
Source of noise Check item
Refer-
ence page
Be-
fore
warm- up After
warm-
up When
start-
ing When
idling When
racing While
driving
Top of en-
gine
Rocker
cover
Cylinder
head Ticking or
clicking
C A — A B — Tappet noise Valve clearance
EM-218
Rattle C A — A B CCamshaft
bearing noiseCamshaft journal oil
clearance
Camshaft runout EM-211EM-211
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock
—A—B B— Piston pin
noisePiston to piston pin oil
clearance
Connecting rod bushing
oil clearance EM-256
EM-256
Slap or
rap
A——B B A Piston slap
noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsion EM-256EM-256
EM-256
EM-256
Knock A B C B B B
Connecting
rod bearing
noiseConnecting rod bushing
oil clearance
Connecting rod bearing
oil clearance
EM-256EM-256
Knock A B — A B C
Main bearing
noiseMain bearing oil clear-
ance
Crankshaft runout EM-256EM-256
Front of
engine
front coverTapping or
ticking
AA—BBB Timing chain
and chain
tensioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operation
EM-200
EM-199
Front of
engineSqueak-
ing or fizz-
ing
AB—B—C Drive belts
(Sticking or
slipping)Drive belts deflection
EM-170
Creaking A B A B A B Drive belts
(Slipping)Idler pulley bearing op-
eration
Squall
Creak AB—BAB Water pump
noise
Water pump operation
CO-50
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
EM-214
< SERVICE INFORMATION >[VK45DE]
CAMSHAFT
Install dial indicator in thrust direction on front end of camshaft.
Measure the end play of dial indicator when camshaft is moved for-
ward/backward (in direction to axis).
Measure the following parts if out of the limit.
- Dimension “A” for camshaft No. 1 journal
- Dimension “B” for cylinder head No. 1 journal bearing
Refer to the standards above, and then replace camshaft and/or cylinder head.
Camshaft Sprocket Runout
1. Put V-block on precise flat table, and support No. 2 and 5 journal of camshaft.
CAUTION:
Do not support journal No. 1 (on the side of cam shaft sprocket) because it has a different diameter
from the other four locations.
2. Measure the camshaft sprocket runout with dial indicator. (Total indicator reading)
If it exceeds the limit, replace camshaft sprocket.
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
If anything above is found, replace valve lifter. Refer to EM-218,
"Valve Clearance".
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
Standard:
0.115 - 0.188 mm (0.0045 - 0.0074 in)
PBIC2446E
Standard : 30.500 - 30.548 mm (1.2008 - 1.2027 in)
Standard : 30.360 - 30.385 mm (1.1953 - 1.1963 in)
KBIA2426J
Limit : 0.15 mm (0.0059 in)
PBIC0930E
KBIA2285E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
CYLINDER BLOCKEM-241
< SERVICE INFORMATION > [VK45DE]
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CYLINDER BLOCK
ComponentINFOID:0000000001325803
1. Knock sensor sub harness 2. Knock sensor 3. Cylinder block
4. Cover 5. Main bearing 6. Top ring
7. Second ring 8. Oil ring 9. Crankshaft key
10. Piston 11. Connecting rod 12. Snap ring
13. Piston pin 14. Connecting rod bearing 15. Connecting rod bearing cap
16. Block heater protector 17. Connector cap 18. Cylinder block heater
19. Gasket 20. Main bearing cap 21. Thrust bearing
PBIC4691E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
EM-242
< SERVICE INFORMATION >[VK45DE]
CYLINDER BLOCK
Refer to
GI-8, "Component" for symbols in the figure.
Disassembly and AssemblyINFOID:0000000001325804
DISASSEMBLY
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ-
ent type of engine stand, note with difference in steps and etc.
1. Remove engine assembly from vehicle, and separa te front suspension member, transmission and front
final drive from engine. Refer to EM-237, "
Component".
2. Remove the parts that may restrict installation of engine to widely use engine stand. NOTE:
The procedure is described assuming that you use wi dely use engine holding the surface, to which trans-
mission is installed.
a. Remove drive plate. Holding ring gear with ring gear stopper (SST).
Loosen mounting bolts diagonally order.
CAUTION:
Do not disassemble drive plate.
Do not place drive plate with signal plate facing down.
When handling signal plate, take care not to damage or scratch it.
Handle signal plate in a manner that prevents it from becoming magnetized.
b. Remove engine rear plate.
3. Lift engine with hoist to install it onto widely use engine stand. CAUTION:
Use engine stand that has a load capacity [approximately 240 kg ( 529 lb) or more] large enough for
supporting the engine weight.
If the load capacity of stand is not adequate, remo ve the following parts beforehand to reduce the poten-
tial risk of overturning stand.
- Intake manifolds (upper and lower): Refer to EM-175, "
Component".
- Exhaust manifold: Refer to EM-179, "
Component".
- Fuel tube and fuel injector assembly: Refer to EM-190, "
Component".
22. Main bearing 23. Rear plate 24. Crankshaft
25. Pilot converter 26. Drive plate 27. Thrust bearing
28. Side bolt 29. Reinforcement plate 30. Crankshaft position sensor (POS)
31. O-ring 32. Rear oil seal 33. Rear oil seal retainer
A.Refererence: Installed on transmis-
sion B. Refer to
EM-242
C. Right bank
D. Cylinder block heater (For Canada) E. Chamfered F. Crankshaft side : Engine front
PBIC1656E
PBIC2367E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
CYLINDER BLOCKEM-243
< SERVICE INFORMATION > [VK45DE]
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- A/C compressor: Refer to
ATC-121, "Component".
- Ignition coil: Refer to EM-187, "
Component".
- Rocker cover: Refer to EM-196, "
Component".
- Other removable brackets
NOTE:
The figure shows an example of widely use engine stand that
can hold mating surface of transmission with drive plate and rear
plate removed.
CAUTION:
Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.
4. Drain engine oil. Refer to LU-24, "
Changing Engine Oil".
5. Drain engine coolant from inside engine by removing water drain plugs “B” as shown in the figure.
6. Remove the following parts and related parts (The parts listed in step 3 are not included here). Oil pan and oil strainer: Refer to EM-183, "
Component".
Crankshaft pulley, front cover and timing chain: Refer to EM-199, "
Component".
Camshaft: Refer to EM-211, "
Component".
Cylinder head: Refer to EM-226, "
On-Vehicle Service".
7. Remove knock sensor. CAUTION:
Carefully handle sensor, avoiding shocks.
8. Remove piston and connecting rod assembly as follows: Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-256, "
Inspection After Disassembly".
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod bearing cap.
c. Using hammer handle or similar tool, push piston and connect- ing rod assembly out to the cylinder head side.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interf erence of the connecting rod big
end.
9. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
Identify installation po sitions, and store them without mixing them up.
PBIC0085E
PBIC1265E
PBIC0086E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
EM-244
< SERVICE INFORMATION >[VK45DE]
CYLINDER BLOCK
10. Remove piston rings from piston.
Before removing the piston rings, check the piston ring side clearance. Refer to EM-256, "
Inspection
After Disassembly".
Use piston ring expander (commercial service tool).
CAUTION:
When removing piston rings, be careful not to damage piston.
Be careful not to damage piston rings by expanding them
excessively.
11. Remove piston from connecting rod as follows:
a. Using snap ring pliers, remove the snap rings.
b. Heat piston to 60 to 70 °C (140 to 158 °F) with industrial use drier
or equivalent.
c. Push out piston pin with stick of outer diameter approximately 20 mm (0.8 in).
12. Remove rear oil seal retainer from cylinder block. Insert screwdriver or similar tool between rear end of crankshaft counter weight and rear oil sealretainer, and separate liquid gasket to remove.
CAUTION:
Be careful not to damage the mating surfaces.
13. Using screwdriver or similar tool, and lever off rear oil seal from rear oil seal retainer.
14. Remove main bearing cap as follows:
PBIC0087E
PBIC0088E
PBIC0089E
EMM0072D
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
CYLINDER BLOCKEM-245
< SERVICE INFORMATION > [VK45DE]
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Before loosening main bearing cap bolts, measure the crankshaft end play. Refer to
EM-256, "Inspec-
tion After Disassembly".
Loosen main bearing cap bolts in several different steps.
a. Remove cover attached to the rear left side of cylinder block (next to the starter motor housing).
NOTE:
Bolts (No. 27 shown in the figure) are installed on the inside of
cover.
b. Loosen side bolts (M10) starting from 30 to 21 to remove.
c. Loosen main bearing cap sub bolts (M9) starting from 20 to 11 to remove.
d. Loosen main bearing cap bolts (M12) starting from 10 to 1 to remove.
e. Using main bearing cap remover (SST), remove main bearing cap.
15. Remove crankshaft.
16. Remove main bearings and thrust bearings from cylinder block and main bearing caps. CAUTION:
Identify installation po sitions, and store them without mixing them up.
17. If pilot converter must be remov ed, remove it from the rear end
of the crankshaft using pilot bushing puller (SST).
It is possible to remove pilot converter without hoisting engine with engine stand.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
2. Install each plug to the cylinder block. (Only screwed-type plugs are shown in the figure.)
Apply sealant to the thread of each plug “A” and “D”.
Use Genuine High Strength Locking Sealant or equiva-
lent. Refer to GI-44, "
Recommended Chemical Product
and Sealant".
Apply sealant to the thread of each plug “B” and “C”. Use Anaerobic Liquid Gasket or equivalent. Refer to GI-
44, "Recommended Chemical Product and Sealant".
Replace copper washers with new ones.
PBIC0090E
PBIC0091E
PBIC0092E
PBIC1265E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
EM-246
< SERVICE INFORMATION >[VK45DE]
CYLINDER BLOCK
Tighten each plug as specified below.
3. Install main bearings and thrust bearings as follows:
a. Remove dust, dirt and oil on the bearing mating surfaces of cylinder block and main bearing caps.
b. Install thrust bearings to the both sides of the No. 3 journal hous- ing on cylinder block and main bearing cap.
Install thrust bearings with the oil groove facing the crankshaftarm (outside).
Install thrust bearing with a protrusion on one end on cylinder block, and thrust bearing with a protrusion at center on main
bearing cap. Align each protrusion with mating notch.
c. Install main bearings paying attention to the direction. Main bearing with oil hole and groove goes on cylinder block.
The one without them goes on main bearing cap.
Before installing main bearings, apply engine oil to the bearing
surface (inside). Do not apply engine oil to the back surface,
but thoroughly clean it.
When installing, align main bearing stopper protrusion to cut- out of cylinder block and main bearing caps.
Ensure the oil holes on cylinder block and those on the corre-
sponding bearing are aligned.
4. Install pilot converter to crankshaft, if removed. With drift [outer diameter: appr ox. 35 mm (1.38 in)], press-fit
as far as it will go.
Press-fit pilot converter with its chamfering side facing crank- shaft as shown in the figure.
It is possible to remove pilot converter without hoisting engine with engine stand.
Part Washer Tightening torque
A Yes 53.9 N·m (5.5 kg-m, 40 ft-lb)
B No 19.6 N·m (2.0 kg-m, 14 ft-lb)
C Yes 62.7 N·m (6.4 kg-m, 46 ft-lb)
D Yes 62.7 N·m (6.4 kg-m, 46 ft-lb)
PBIC2368E
PBIC2369E
EMP0569D
SEM537E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C