Repair Procedure
How to use this Service Information .
NOTICE:
When working with a vehicle equipped with the electronic air suspension, be sure to set it to the leveling off mode to prevent unexpected operation. Refer to the Electronic Air Suspension System Service Precautions - Refer to: Electronic Air Suspension System Connector Fitting Precautions or Electronic Air Suspension System Service Precautions for the procedure.
: Torque, N.m (lbf.ft)
: Replace
: Warning/Caution
: Inspection/Adjustment
*: Learning
: SPL Tool
: Required Removal
: Torque, N.m (lbf.ft)
: Replace
: Warning/Caution
: Inspection/Adjustment
*: Learning
: SPL Tool
: Required Removal
*1: In the illustration, other parts are omitted because the component parts and the removal/installation procedure are the same.
: Torque, N.m (lbf.ft)
: Replace
: Warning/Caution
: Inspection/Adjustment
*: Learning
: SPL Tool
: Required Removal
- A.-
Key Information
Do the following before starting your work.
Remove:
- Fuel Rail/Injector - Refer to: Intake Manifold Area (3.0L Engine) or Intake Manifold Area (3.5L Engine)
Sub-Procedure
Installation
NOTICE:
Make sure the direction of the sensor connector (a) as shown.
Installation Directions
Position Direction Front Bank b Crankshaft Pulley Side Rear Bank Transmission Side - B.-
Key Information
Do the following before starting your work.
Remove:
- Drive Plate - Refer to: Transmission Area (3.5L Engine) or Transmission Area (3.0L Engine)
Sub-Procedure
Removal
NOTE: Be careful not to damage the crankshaft and the oil seal case.
Figure 1
Figure 2
Installation
- Clean and dry the oil seal case.
Lubricant Specifications (Figure 1)
Position Type a Engine Oil Installation Depth (Figure 2)
Standard Value b No Clearance - Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.
- C.-
Key Information
Do the following before starting your work.
Remove:
- Drive Plate - Refer to: Transmission Area (3.5L Engine) or Transmission Area (3.0L Engine)
- Oil Pan - Refer to: A/C Compressor/Engine Oil Pan Area (3.5L Engine) or A/C Compressor/Engine Oil Pan Area (3.0L Engine)
Sub-Procedure
Installation
- Remove all of the old gasket from the mating surfaces of each part and clean it.
Lubricant Specifications
Position Type Detail a Liquid Gasket (P/N 08718-0003, 08718-0004, or 08718-0009) b 2.5 mm (0.098 in) Lubricant Specifications
Position Type The lip of the oil seal Engine Oil NOTICE:
- Install the component within 5 minutes of applying the liquid gasket.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
- Wait at least 30 minutes before filling the engine with oil.
- Do not run the engine for at least 3 hours after installing the parts.
- D.-
Key Information
Do the following before starting your work.
Remove:
- Timing Belt Drive Pulley - Refer to: Timing Belt Case/Timing Belt Area (3.0L Engine) or Timing Belt Case/Timing Belt Area (3.5L Engine)
Sub-Procedure
Removal
NOTE: Be careful not to damage the engine oil pump.
Figure 1
Figure 2
Installation
- Clean and dry the oil seal housing.
Lubricant Specifications (Figure 1)
Position Type a Engine Oil Installation Depth (Figure 2)
Standard Value b No Clearance - Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.
- E.-
Key Information
Do the following before starting your work.
Remove:
- Timing Belt Case/Timing Belt Area Parts - Refer to: Timing Belt Case/Timing Belt Area (3.0L Engine) or Timing Belt Case/Timing Belt Area (3.5L Engine)
-
- -
Timing Belt Drive Pulley
- -
Idler Pulley
- -
Removal
1. Temporary install the timing belt mount cover and the side engine mount bracket - Refer to: Timing Belt Case/Timing Belt Area (3.0L Engine) or Timing Belt Case/Timing Belt Area (3.5L Engine) .
2. Remove the oil pan - Refer to: A/C Compressor/Engine Oil Pan Area (3.5L Engine) or A/C Compressor/Engine Oil Pan Area (3.0L Engine) .
Sub-Procedure
Installation
- Remove all of the old gasket from the mating surfaces of each part and clean it.
Lubricant Specifications
Position Type Detail a Liquid Gasket (P/N 08718-0003, 08718-0004, or 08718-0009) b 2.5 mm (0.098 in) Lubricant Specifications
Position Type The lip of the oil seal Engine Oil Lubricant Specifications
Object Type Specified Amount Pump Rotor Chamber Engine Oil 2 mL (0.07 fl oz, 0.07 Imp oz) NOTICE:
- Install the component within 5 minutes of applying the liquid gasket.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
- Wait at least 30 minutes before filling the engine with oil.
- Do not run the engine for at least 3 hours after installing the parts.
- F.-
NOTICE:
Keep all removed parts in order, and install them of the original position when installing.
Sub-Procedure
Figure 1
Figure 2
Removal
- Refer to figure 1.
NOTICE:
- If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (a). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the piston as it is pushed out. (Figure 2)
- Take care not to damage the cylinder with the connecting rod.
- Mark the cylinder number on the connecting rod and the connecting rod bearing cap to avoid mixing them up during reassembly.
Tool Details (Figure 2)
Name a Ridge Reamer (Commercially Available) Figure 3
Installation
1. Check the connecting rod bearing is securely in place.
Lubricant Specifications
Position Type - Piston
- Inside of Ring Compressor
- Cylinder Bore
Engine Oil 2. Position the piston/rod assembly with the arrow (b) facing the timing belt side of the engine block. (Figure 3)
Figure 4
3. Push down on the ring compressor (c) to prevent the rings from expanding before entering the cylinder bore. (Figure 4)
Tool Details (Figure 4)
Name c Ring Compressor (Commercially Available) 4. Stop after the ring compressor pops free, and check the connecting rod-to-rod journal alignment before pushing the piston into place.
5. Adjust the connecting rod bearing - Refer to: Connecting Rod Bearing Adjustment (3.0L Engine) or Connecting Rod Bearing Adjustment (3.5L Engine)
(if necessary).
Figure 5
Figure 6
6. Set the crankshaft to bottom dead center (BDC) for the cylinder.
7. Install the connecting rod cap. Line up the mark (d) on the connecting rod and the connecting rod cap. (Figure 5)
Lubricant Specifications
Position Type - Threads
- Flange
Engine Oil Tightening Procedure (Figure 6)
Step Operation Standard Value 1 Hand Tighten The bolts until they sit on the connecting rod cap 2 Temporarily Tighten 23 N.m (17 lbf.ft) 3 Angle Tighten e 120 deg. NOTICE:
Remove the connecting rod bolt if you tightened it beyond the specified angle, and go back to step 1 of the tightening procedure. Do not loosen it back to the specified angle.
8. Inspect the connecting rod and crankshaft end play - Refer to: Connecting Rod and Crankshaft End Play Inspection (3.0L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.5L Engine) or Connecting Rod and Crankshaft End Play Inspection (3.5L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.0L Engine) . (if necessary)
- G.-
Key Information
Do the following before starting your work.
Remove:
- Engine Assembly - Refer to: Engine Removal and Installation (3.0L Engine) or Engine Removal and Installation (3.5L Engine)
- Drive Plate - Refer to: Transmission Area (3.5L Engine) or Transmission Area (3.0L Engine)
- Cylinder Head - Refer to: Engine Compression Inspection (3.5L Engine) or Engine Compression Inspection (3.0L Engine) or Cylinder Head Removal and Installation (3.0L Engine) or Cylinder Head Removal and Installation (3.5L Engine)
- Timing Belt Drive Pulley - Refer to: Timing Belt Case/Timing Belt Area (3.0L Engine) or Timing Belt Case/Timing Belt Area (3.5L Engine)
Sub-Procedure
NOTICE:
- Keep all removed parts in order, and install them of the original position when installing.
- Be careful not to damage the journals and the CKP pulse plate.
NOTE: The No. 1 journal is on the crankshaft pulley side.
Figure 1
Removal
- Loosen the bearing cap bolts and the bearing cap side bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. (Figure 1)
Figure 2
Installation
1. Adjust the main bearing - Refer to: Crankshaft Main Bearing Adjustment (3.0L Engine) or Crankshaft Main Bearing Adjustment (3.5L Engine)
(if necessary).
2. Install the crankshaft.
Lubricant Specifications
Position Type - Main Bearings
- Connecting Rod Bearings
Engine Oil 3. Install the thrust washer (a) as shown. (Figure 2)
Lubricant Specifications
Position Type Thrust Washer Surfaces Engine Oil Figure 3
4. Install the main bearings and the main bearing caps.
NOTICE:
Install the main bearing caps aligning the arrows (b) facing the timing belt side of the engine block. (Figure 3)
Installation Directions (Figure 3)
Position Direction c Crankshaft Pulley Side Figure 4
Figure 5
5. Tighten the bolts, in sequence. (Figure 4)
Lubricant Specifications
Position Type - Threads
- Flanges
Engine Oil Tightening Procedure (Figure 4 and 5)
Step Operation Object Specification 1 Temporarily Tighten All Bolts 2 Tighten -
22 N.m (16 lbf.ft) 3 Angle Tighten -
d 30deg. 4 Tighten -
43 N.m (32 lbf.ft) 5 Angle Tighten -
d 30deg. 6 Tighten -
26 N.m (19 lbf.ft) Step Operation Object Specification 7 Angle Tighten -
d 30deg. - H.-
Sub-Procedure
NOTICE:
Keep all removed parts in order, and install them of the original position when installing.
Figure 1
Removal
- Refer to figure 1.
Tool Details (Figure 1)
Name a Ring Expander (Commercially Available) Figure 2
Installation
1. Clean all ring grooves thoroughly with a squared-off broken ring or a ring groove cleaner with a blade to fit the piston grooves. File down a blade if necessary. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tools.
2. If necessary, inspect the piston ring end gap - Refer to: Block and Piston Inspection (3.0L Engine) or Block and Piston Inspection (3.5L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.5L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.0L Engine)
.NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet.
Specifications (Figure 2)
Standard Value (New) b 1.5 mm (0.059 in) c 1.2 mm (0.047 in) d 2.0 mm (0.079 in) Figure 3
Figure 4
3. The manufacturing marks (e)/(f) must be facing upward. (Figure 3)
Specifications (Figure 3)
Marking Position Mark e 1TU f 2TU Specifications (Figure 4)
Standard Value (New) Top Ring g 2.7 mm (0.106 in) h 1.5 mm (0.047 in) Second Ring g 2.7 mm (0.106 in) h 1.2 mm (0.047 in) Lubricant Specifications
Position Type Piston Rings Engine Oil 4. Rotate the rings in their grooves to make sure they do not bind.
Figure 5
5. Position the ring end gaps as shown. (Figure 5)
Specifications (Figure 5)
Position Object i Oil Ring Gap k Second Ring Gap m Oil Ring Gap n Top Ring Gap and Spacer Ring Gap o Piston Pin Specifications (Figure 5)
Specifications p About 90 deg. q About 45 deg. After Installation
- If necessary, inspect the ring-to-groove clearance - Refer to: Block and Piston Inspection (3.0L Engine) or Block and Piston Inspection (3.5L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.5L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.0L Engine) .
- I.-
Sub-Procedure
NOTICE:
Keep all removed parts in order, and install them of the original position when installing.
Figure 1
Figure 2
Removal
1. Remove the snap rings.
Lubricant Specifications (Figure 1)
Position Type a Engine Oil -1. Turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (b). (Figure 1)
NOTICE:
Take care not to damage the ring grooves.
-2. Remove the snap rings from both sides of each piston. Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear goggles or safety glasses to prevent eye injury. (Figure 2)
Figure 3
2. Remove the piston pin. (Figure 3)
- Heat the piston/rod assembly to about 158 deg. F (70 deg.C).
3. If necessary, do the following inspection.
- Piston Pin - Refer to: Block and Piston Inspection (3.0L Engine) or Block and Piston Inspection (3.5L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.5L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.0L Engine)
- Piston Pin-to-Piston Clearance - Refer to: Block and Piston Inspection (3.0L Engine) or Block and Piston Inspection (3.5L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.5L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.0L Engine)
- Piston Pin-to-Connecting Rod Clearance - Refer to: Block and Piston Inspection (3.0L Engine) or Block and Piston Inspection (3.5L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.5L Engine) or Piston, Ring, Pin, and Connecting Rod Inspection (3.0L Engine)
- Piston Skirt Diameter - Refer to: Block and Piston Inspection (3.0L Engine) or Cylinder Bore Honing or Block and Piston Inspection (3.5L Engine)
- Piston-to-Cylinder Bore Clearance - Refer to: Block and Piston Inspection (3.0L Engine) or Cylinder Bore Honing or Block and Piston Inspection (3.5L Engine)
Figure 4
Figure 5
Figure 6
Installation
1. Install the snap ring. (only on one side)
2. Install the piston pin.
Lubricant Specifications (Figure 4)
Position Type c Engine Oil d e - Heat the piston to about 158 deg.F (70 deg.C). (Figure 5)
- Align the arrow (f) with the groove (g) direction on the connecting rod as shown. (Figure 6)
NOTICE:
Pay attention to the direction for installing the connecting rod according to the marks.
3. Install the remaining snap ring.
- Turn the snap rings in the ring grooves until the end gaps are positioned at the bottom of the piston.
- J.-
Sub-Procedure
NOTICE:
Be careful not to damage the CKP pulse plate.
Installation
- Align the portion (a) on the CKP pulse plate and groove (b) on the crankshaft.
Lubricant Specifications
Position Type - Bolt Threads
- Bolt Flange
Engine Oil