SECTION 1C1 ENGINE MECHANICAL - 1.2L DOHC Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical erminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. SPECIFICATIONS Engine Specifications Application Description General Data: Engine Type 4 Cylinder (In-Line) Displacement 1,206 cm* Bore Stroke 69.7 x79 mm (2.7441 x3.1102 in.) ‘Compression Ratio 105+02:1 Firing Order 1-3-4-2 Cy der Bore: Diameter 69.7 mm (2.7441 in.) [Out of Round (Maximum) (0,005 mm (0.0002 in.) Taper (Maximum) 0.07 x30" Piston: Diameter 69.7 mm (2.7441 in) (Clearance to Bore 0.035 £ 0,010 mm (0.0013 + 0.0177 in) Piston Rings: Ring, End Gap: Top Compression 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.) ‘2nd Compression (0.3 ~ 0.45 mm (0.0118 ~ 0.0177 in.) (Groove Clearance: Top Impression 0.02 ~ 0.06 mm (0.00078 ~ 0.00236 in) 2nd Impression 0.06 ~ 0.1 mm (0.00236 ~ 0.00393 in.) Piston Pin : Diameter 16.995 ~ 17.000 mm (0.6691 ~ 0.6693 in.) Clearance to Bore 0.006 ~ 0.019 mm (0.00078 ~ 0.00236 in.) Camshaft: End Play 0.08 ~ 0.26 mm (0.0032 ~ 0.0102 in) Journal OD:No.1 23.939 ~ 23.96 mm (0.9425 ~ 0.9433 in.) No.2 23.939 ~ 23.96 mm (0.9425 ~ 0.9433 in.) No.3 23.939 ~ 23.96 mm (0.9425 ~ 0.9433 in.) No.4 23.939 ~ 23.96 mm (0.9425 ~ 0.9433 in.) No.5 23.939 ~ 23.96 mm (0.9425 ~ 0.9433 in.) Journal 1D: No.1 23 ~ 23.021 mm (0.9055 ~ 0.9063 in.) No.2 23 ~ 23.021 mm (0.9055 ~ 0.9063 in.) No. 3 23 ~ 23.021 mm (0.9055 ~ 0.9063 in.) No.4 23 ~ 23.021 mm (0.9055 ~ 0.9063 in.) No.5 23 ~ 23.021 mm (0.9055 ~ 0.9063 in) Lift Intake 40.00 mm (1.5748 in.) Lift- Exhaust 39.45 mm (1.5531 in.) Crankshaft : Main Journal Diameter (All) 48.982 ~ 49.000 mm (1.9284 ~ 1.9291 in) any Bearing Clearance 0.020 ~ 0.040 mm (0.00079 ~ 0.00158 in.) Crankshaft End Play 0.08 ~ 0.26 mm (0.0032 ~0.0102 in.) Connecting Rod Journal: Diameter (Alll) Rod Bearing Clearance (All) 41.000 ~ 41.018 mm (1.6142 ~ 1.6149 in) 0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.) Bending 0.03 mm (0.0012 in.) \Valve System: [Seat Inner Diameter: take 23.862 mm (0.9394 in.) Exhaust 21.079 mm (0.8299 in. ) Valve Guide Inside Diameter (All) 5.0 ~ 5.012 mm (0.1968 ~ 0.1973 in.) Valve Stem Diameter Intake 4.972 & 0.007 mm (0.1957 + 0.0002 in.) Exhaust 4.963 + 0.007 mm (0.1954 + 0.0002 in.) \Valve Length: Intake 99.17 + 0.225 mm (3.904 + 0.009 in) Exhaust 100.01 + 0.225 mm (3.937 # 0.009 in.) Valve Spring Free Legnth 43.57 mm (1.715 in.) Valve Closed 260 + 13 N (191 + 9.6 lbs) @ 32 mm (1.25 in.) Fastener Tightening SpecifcationsApplication Nem Lb-Ft Exhaust Manifold Retaining Nuts 20 147 Exhaust Manifold Retaining Bolts 25 18.4 Intake Manifold Support Bracket Upper Bolts 2 15 Transmission Assembly Blots (MT & A/T) 60 442 Cylinder Head Cover Bracket Bolts 10 74 Cylinder Head Bolts 22482" | 16.2+82° Cylinder Head Cover Bolts 10 74 [Accessory Tensioner-Generator Assembly Bracket Mounting Bolt 25 184 [Generator Adjusting Bolt 20 147 [Air Cleaner Assembly Bolts 6 44 [Air Filter Upper Housing Bolts 2 15 Engine Mount Retaining Bolts 55 40.5 Engine Mount Bracket Retaining Bol/Nuts 65 479 Oil Level Gage Tube Retaining Bolt 10.5 77 Oil Pan Retaining Bolts 10.5 77 Oil Pump Cover Bolts 10 74 \Water Pump Retaining Bolts 33 243 [Spark Plugs Cable Cover Bolts 10 74 (Catalytic Converter Retaining Nuts 40 295 Camshaft Cap Bolts, 10 74 Camshaft Sprocket Retaining Bolts 60 442 Connecting Rod Bearing Cap Nuts 33 243 (Crankshaft Rear Oil Seal Cover Bolts (M6 x 1.0) 10.5 77 Crankshaft Bearing Cap Bolts 575 424 (Crankshaft Pulley Bolt 85 627 Timing Chain Guide Retaining Bolts 10 74 Timing Chain Lever Retaining Bolts 10 74 Timing Chain Cover Retaining Bolts (M6 x 1.0) 10.5 77 Timing Chain Cover Retaining Bolts (M8 x 1.25) 20 14.7 Timing Chain Tensioner Retaining Bolts 12 88 [A/C Compressor Mounting Bracket Bolts 30 22.1 Power Steering Pump Bracket Mounting Bolts 25 184 Power Steering Pump Mounting Bolts 20 147 Front Exhaust Pipe-to-Main Catalytic Converter Nuts 40 295 Front Exhaust Pipe-to-Front Muffler Nuts 40 295 Flywheel/Flexible Plate Bolts 45 33.2 Intake Manifold Retaining Bolts 10 7A Exhaust Manifold Heat Shield Bolts 15 4 Oil Pressure Switch Fitting 30 22.1[Accessory Tensioner Hex-Socket Bolt (M8) 45 33.2 SPECIAL TOOLS Special Tools Table DWw010-010 “Engine & Transaxle Assembly Support Remover/lnstaller” EN-48356 Fixture-Engine KM-135 Adapter EN-49072 Installer-Crankshaft Front Seal EN-49074 Compressor-Universal Valve Spring EN-49076 Adapter-Cylinder Pressure EN-49078 Installer-Piston DW100-030 Stand-Engine Overhaul KM-498-A Gauge-Oil Pressure EN-49071 Installer-Crankshaft Rear Seal EN-49073 Pin-Timing Chain Tensioner EN-49075Adapter-Valve Spring Compressing EN-49077 Gauge-Compression Pressure KM-470-B Angular Torque Gauge DIAGNOSIS Engine Diagnosis Reviewing the description and operation information provided will assist in determining whether the condition described by the customer is a fault or normal engine operation. Symptoms Strategy Based Diagnosis 1. Review the system operations to familiarise yourself with the system functions, refer to Section 1A, General Engine Information and Section 1F1, Engine Control — General Information. 2. Perform an engine management Diagnostic System Check, refer toSection 11 Engine Control — Diagnostics. Alldiagnosis on a vehicle should follow a logical process. Strategy based diagnosis is a uniform approach for repairing all vehicle systems. The strategy based diagnostic flow chart may always be used to resolve a system problem. The diagnostic flow chart is the place to start when repairs are required. For a detailed explanation of strategy based diagnosis and the flow chart, refer to Section 1F1 Engine Control = Diagnostics. Visual / Physical Inspection 1. Inspect the vehicle for aftermarket accessories which may adversely affect engine operation 2. Inspect the easily accessible or visible system components for obvious signs of damage or conditions that may cause the symptom. 3. Check the engine lubrication system for the following © correct oil level, © correct lubricant viscosity, © correct oil filter application, and © contaminated or bumt oil 4, Confirm the exact operating conditions under which the fault occurs. Note factors such as © engine speed (r.p.m.), © ambient temperature, © engine temperature, © engine warm-up time, and© vehicle road speed. 5. Compare the engine sounds, if applicable, to a known good engine, and ensure you are not trying to diagnose a normal operating condition. Intermittent For intermittent faults, test the vehicle under the same conditions the customer reported in order to confirm whether the system is operating correctly. Compression Test Inspect the engine compression pressure as following procedure: 1. Crank the engine to be at normal operating temperature(coolant temperature : 80~90°C). 2. Stop the engine and remove all the high-tension cables and ignition plugs. Caution : Not to use tools when installing the adapter-cylinder pressure. If use tools, it may be forced excessively and make a damage to the engine performance. 3. Install the adapter-cylinder pressure(EN-49076)(b) and gauge-cylinder pressure(EN-49077) a). 4,2 persons should be needed while compression pressure testing. One person accelerate the pedal to make the throttle valve be fully opened and crank the engine. 5, The other person reads the maximum of the measured gauge value. Measured value should meet the specification or limit. Specification : 9 Bar(9.17 Kgicm2) Limit: under 10% Ignition plug torque : 27 Nem (19.9 lb-ft) Valve Clearance Test Measuring & Inspection Caution : Valve clearance test should be tested when coolant temperature is normal(15~25°C). In addition, should be tested only when cylinder head and block is assembled. 1. Remove the cylinder head cover. Refer to “Cylinder Head" in this section. 2. Rotate the crankshaft pulley and adjust the pulley groove to the “0” point as following picture: This is to adjust TDC of the No.1 cylinder.3. Check the both camshaft sprocket and timing chain. 4, Measure the valve clearance at each point as following picture. 5. Rotate the crankshaft pulley to 360° and adjust the pulley groove to the “O" point. 6. Measure the valve clearance at each point as following picture © Intake Specification : 0.075~0.125 mm (coolant temperature : 20°C) © Exhaust Specification : 0.245~0.305 mm (coolant temperature : 20°C) 7. f the measured value is out of specification, replace the vaive tappet. Refer to "Unit Repair - Valve Train Components" in this section. Replacing Valve Tappet Caution : Must use the following table and assemble an adequate valve tappet before replacing valve tappet. 1, Calculate the value of the valve tappet. © Intake : Separated tappet Thickness + Measured valve clearance — 0.1 mm = New tappet thickness © Exhaust : Separated tappet Thickness + Measured valve clearance — 0.27 mm = New tappet thickness 2. Use the following table and assemble with an adequate valve tappet. 3. Replace the New valve tappet. Refer to "Unit Repair - Valve Train Components"in this section. NO. PART NO. THICKNESS MARKING NO. 1 96 449 601 3.12 + 0.01 312 2 96 449 602 3.1440.01 314 3 96 449 603 3.16 + 0.01 316 4 96 449 604 3.18 + 0.01 3185 96 449 605 3.20 + 0.01 320 6 96 449 606 3.22 + 0.01 322 7 96 449 607 3.24 40.01 324 8 96 449 608 3.26 + 0.01 326 9 96 449 609 3.28 + 0.01 328 10 96 449 610 3.30 + 0.01 330 1 96 449 611 3.32 + 0.01 332 12 96 449 612 3.34 + 0.01 334 13 96 449 613 3.36 + 0.01 336 14 96 449 614 3.38 + 0.01 338 15 96 449 615 3.40+0.01 340 16 96 449 616 3.424001 342 17 96 449 617 3.444001 344 18 96 449 618 3.46 40.01 346 19 96 449 619 3.48 + 0.01 348 20 96 449 620 3.50 + 0.01 350 24 96 449 621 3.52 £0.01 352 22 96 449 622 3.54 + 0.01 354 23 96 449 623 3.56 + 0.01 356 24 96 449 624 3.58 + 0.01 358 25 96 449 625 3.60 + 0.01 360 26 96 449 626 3.62 + 0.01 362 27 96 449 627 3.64 + 0.01 364 28 96 449 628 3.66 + 0.01 366 29 96 449 629 3.68 + 0.01 368 30 96 449 630 3.70 + 0.01 370 31 96 449 631 3.724001 372 32 96 449 632 3.74 0.01 374 33 96 449 633 3.76 +0.01 376 34 96 449 634 3.78+0.01 378 35 96 449 635 3.80 + 0.01 380 36 96 449 636 3.824001 382 37 96 449 637 3.84 + 0.01 384 38 96 449 638 3.86 + 0.01 386 39 96 449 639 1 388 40 96 449 640 3.90 + 0.01 390 Oil Pressure Test Step ‘Action Value(s) Yes NoIs the oil pressure warming lamp on? Go toStep 2 System OK \Check the oil level in the crankcase Is the oil level low? Go toStep 3 Go toStep 4 [Add oil so that the oil level is up to the full mark lon the indicator. ls the repair complete? Go toStep 1 ICheck the idle speed. Is the idle speed below the specified value 7 840 ¢ 20 rpm Go toStep 5 Go toStep 6 Increase the idle speed Is the speed increased? Go toStep 1 Inspect the oil pressure switch. Is the oil pressure switch incorrect or Imatfunctioning? Go toStep 7 Go toStep 8 install a new oil pressure switch. Is the repair complete? Go toStep 1 inspect the oil pressure gauge. Is the oil pressure gauge incorrect or imatfunctioning? Go toStep 9 Go toStep 10 Install a new oil pressure gauge. Is the repair complete? Go toStep 1 Inspect the engine oil. Is the engine oil in the crankcase diluted or of the improper viscosity? Go toStep 11 Go toStep 12 Install new engine oil of the proper viscosity for ithe expected temperatures. is the repair complete? Go toStep 1 Inspect the oil pump. Is the pump worn or dirty? Go toStep 13 Go toStep 14 Replace the oil pump. is the repair complete? Go toStep 1 Inspect the oil fiter. is the oil filter plugged? Go toStep 15 Go toStep 16 Install a new oil filter. is the repair complete? Inspect the oil pickup screen. is the oil pickup screen loose or plugged? Tighten or replace the oil pickup screen, as necessary. Is the repair complete? Go toStep 1 Go toStep 17| Go toStep 1 Go toStep 18 Inspect the oil pickup tube. JAre there any holes in the oil pickup tube? Go toStep 19 Go toStep 20 Replace the oil pickup tube. is the repair complete? Go toStep 1Inspect the bearing clearances. Crankshaft [Are the bearing clearances more than the Journal specified values? Bearing Oil Clearance (0.020 ~ 0.040) mm (0.00079 ~ 0.00158 in.) 20 Go toStep 21|Go toStep 22 24 [Replace the bearing, ifnecessary, is the repair complete? Go toStep 1 : Inspect the oil galleries. 22 |Are the oil galleries cracked, porous, or : plugged? Go toStep 23| Go toStep 24 123 [Repair or replace the engine block Is the repair complete? Go toStep 1 : Inspect the gallery plugs 24 |Are any of the gallery plugs missing or installed : improperly? Go toStep 25|Go toStep 26 25, [stall the plugs or repair, as necessary. is the repair complete? Go toStep 1 - Inspect the camshaft. 26 |Is the camshaft wom or is there evidence of - lpoor machining? Go toStep 27| System OK 27 [Replace the camshaft. is the repair complete? Go toStep 1 - Oil Leak Diagnosis Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions, a fluid leak may be difficult to locate or repair. The following procedures may help you in locating and repairing most leaks Finding the Leak: 1. Kdentify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering fluid, etc. 2. Kentify where the fluid is leaking from. 1. After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper. 2. Wait a few minutes. 3. Find the approximate location of the leak by the drippings on the paper. 3. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach. 4. Ifthe leak still cannot be found, it may be necessary to clean the suspected area witha degreaser, steam, or spray solvent. 1. Thoroughly clean the area. 2. Dry the area.3. Operate the vehicle for several miles at normal operating temperature and varying speeds. 4. After operating the vehicle, visually check the suspected component. 5. Ifyou stil cannot locate the leak, try using the powder or black light and dye method, Powder Method: 1, Clean the suspected area. 2. Apply an aerosol-type powder, (such as foot powder), to the suspected area. 3. Operate the vehicle under normal operating conditions. 4. Visually inspect the suspected component. Trace the leak path over the white powder surface to the source. Black Light and Dye Method: A dye and light kit is available for finding leaks. Refer to the manufacturer's directions when using the kit 41. Pour the specified amount of dye into the engine oil fill tube. 2. Operate the vehicle under normal operating conditions as directed in the kit. 3, Direct the light toward the suspected area, The dyed fluid will appear as a yellow path leading to the source. Repairing the Leak Onee the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be determined in order for it to be repaired properly, fa gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must be repaired also. Before attempting to repair a leak, check for the following conditions and correct them as they may cause a leak. Gaskets: The fluid level/pressure is too high. The crankcase ventilation system is malfunctioning The fasteners are improperly tightened or the threads are dirty or damaged. The flanges or the sealing surface is warped There are scratches, burrs or other damage to the sealing surface The gasket is damaged or won, There is cracking or porosity of the component. + Animproper seal was used, (where applicable). Seals: The fluid level/pressure is too high. The crankcase ventilation system is malfunctioning. The seal bore is damaged, scratched, burred or nicked. The seal is damaged or worn, Improper installation is evident.+ There are cracks in the component. + The shaft surface is scratched, nicked or damaged. + Aloose or worn bearing is causing excess seal wear. Base Engine Misfire without Internal Engine Noises Condi Action |Abnormalities (severe cracking, bumps or missing areas) in the accessory drive belt. |Also wom, damaged, or misaligned accessory drive components or excessive pulley runout. [Abnormalities in the accessory drive belt and/or components may cause engine RPM variations, noises similar to a faulty lower engine and also lead to a misfire condition. A misfire code may be present without an actual] misfire condition. 1. Inspect the accessory drive components. 2. Repair or replace all damaged components Loose and/or damaged crankshaft pulley JA misfire code may be present without an actual misfire condition, 1. Inspect crankshaft pulley and pulley bolt. 2. Repair or replace all damaged components Loose torque converter bolts JA misfire code may be present without an actual misfire condition. 1. Inspect torque converter bolts and flywheel 2. Repair or replace all damaged components Loose and/or damaged flywheel [A misfire code may be present without an actual misfire condition 1. Inspect flywheel and flywheel attaching botts 2. Repair or replace all damaged components. Restricted exhaust system |A severe restriction in the exhaust flow can cause significant loss of engine performance and may set a Imisfire code. Possible causes of restrictions include collapsed or dented pipes, plugged mufflers and/or catalytic converters. Repair or replace all damaged components. \Air in fuel system 1. Inspect fuel filter, fuel system for leaks and/or restrictions. 2. Repair or replace all damaged components Bent and/or worn valve bridge and Hinger-follower. 1. Inspect valve bridge and valve finger-follower. 2. Repair or replace all damaged componentsSticking valve Carbon on the valve stem or valve seat may cause the lvalve to stick. Inspect valves and valve guides. Repair or replace all damaged components. po Damaged or misaligned timing gears Inspect timing gears. Replace all damaged components. po Wom or faulty camshaft lobes inspect camshaft lobes. Repair or replace all damaged components. no Excessive piston-to-cylinder bore clearance Perform compression tests. Inspect the piston, piston rings and cylinder bore Repair or replace all damaged components. Faulty cylinder head gaskets and/or cracking or other damage to the cylinder heads and engine block cooling system passages. (Coolant consumption may or may not cause ithe engine to overheat.) Perform compression tests. Inspect the piston, piston rings and cylinder bore Repair o replace all damaged components. Base Engine Misfire with Abnormal Internal Lower Engine Noises Condition Action lAbnormalities (severe cracking, bumps or missing areas) in the accessory drive belt. [Abnormalities in the accessory drive belt and/or components may cause engine RPM variations, noises similar to a faulty lower engine and also lead to a misfire condition. A misfire code may be present without an actual] misfire condition. 1. Inspect the accessory drive components. 2. Repair or replace all damaged components lWorn, damaged, or misaligned laccessory drive components or lexcessive pulley runout [A misfire code may be present without an actual misfire condition. 1. Inspect the accessory drive components. 2. Repair or replace all damaged components Loose and/or damaged crankshaft pulley JA misfire code may be present without an actual misfire condition. 1. Inspect crankshaft pulley and pulley bolt. 2. Repair or replace all damaged components [A misfire code may be present without an actual misfireLoose torque converter bolts condition. 1. Inspect torque converter bolts and flywheel 2. Repair or replace all damaged components Loose and/or damaged flywheel JA misfire code may be present without an actual misfire condition. 1. inspect flywheel and flywheel attaching botts 2. Repair or replace all damaged components. Excessive piston-to-cylinder bore clearance 1. Perform cylinder leak down and compression tests 2. Inspect the piston, piston rings and cylinder bore 3. Repair or replace all damaged components. Excessive crankshaft thrust bearing clearance [Severely wom thrust surfaces on the crankshaft and/or Ithrust bearing may permit for and aft movement of the crankshaft and create a misfire code without an actual Imisfire condition. 1. Inspect the crankshaft end play and crankshaft thrust bearings. 2. Repair or replace all damaged components Base Engine Misfir ‘e with Abnormal Valve Train Noise Condition Action Loose, worn or damaged valve bridge land finger-follower 1. Inspect valve bridge and finger-follower. 2. Repair or replace all damaged components Broken valve springs 1. Inspect valve springs. 2. Repair or replace all damaged components. Sticking valve (Carbon on the valve stem or valve seat may cause the \valve to stick. 1. Inspect valves and vaive guides. 2. Repair or replace all damaged components ‘Wom or faulty camshaft lobes 1. Inspect camshaft lobes. 2. Repair or replace all damaged components Base Engine Mi isfire with Coolant Consumption Inspection Action Definition : Base engine misfire with coolant consumptionPreliminary Inspection |\Verify that there are no external coolant leaks. Refer |toSection 1D, Engine Cooling. Isolate Affected Cylinders Cylinder balance test with scan tool Cooling system pressurization Inspection of glow plugs * Compression test EGR System Inspection inspect EGR valve and intake system for evidence of coolant leakage. Replace the EGR cooler if any problem is found ‘Cylinder Head Gasket Leakage Remove cylinder heads of the affected cylinder bank’ and inspect for damage. Replace components as necessary. Cylinder Head or Engine Block Damage Inspect the cylinder heads for cracks. Inspect the cylinder block for damage. Inspect the cylinder block to head mating surface for staightness. Replace components as necessary. Base Engine Misfir ‘e with Excessive Oil Consumption Condition Action Wom valve guides 1. Inspect the valves and valve guides. 2. Repair or replace all damaged components. \Wom valve stem oil seals 1. Inspect the valve stem oil seals. 2. Repair or replace all damaged components. Excessive piston-to-cylinder bore clearance Perform compression tests to determine the cause Inspect the piston rings for low ring tension, broken or wom rings. Inspect cylinder bore. Repair or replace all damaged components. no Engine Noise on Start. -Up, but Only Lasting a Few Seconds Condition Action Incorrect oil viscosity Drain the oil. Install the correct viscosity oil. po Excessive piston-to-cylinder bore clearance Inspect the piston and piston skirt, connecting rod, and cylinder bore. Repair or replace all damaged components.Upper Engine Nol ise, Regardless of Engine Speed Condition Action Low oil pressure Insufficient or poor oil supply to valve train. 1, Perform oil pressure test. 2. Repair or replace all damaged components. Improper lubrication to the valve finger- \follower 1. Inspect valve finger-follower, valve bridge, valve finger follower lifter, oil pump and engine block oil galleries. 2. Repair or replace all damaged components. Wom or damaged valve finger follower 1. Inspect valve bridge and finger-follower. 2. Repair or replace all damaged components Sticking valve Carbon on the valve stem or valve seat may cause the lvalve to stick, 1. Inspect valves and valve guides. 2. Repair or replace all damaged components Wom or faulty camshaft lobes 1, Inspect camshaft lobes. 2. ff damaged replace camshaft and all valve finger- followers. Damaged or misaligned timing gears Lower Engine Noi 1. Inspect timing gears 2. Replace alll damaged components. ise, Regardless of Engine Speed Condition Action Wom accessory drive components (abnormalities such as severe icracking, bumps or missing areas in the accessory drive belt and/or misalignment of the system components.) 1. Inspect the accessory drive components. 2. Repair or replace all damaged components Low oil pressure Insufficient or poor oil supply to crankshaft and connecting rod bearings. 1, Perform oil pressure test. 2. Repair or replace all damaged components 1 Insnect the evinder halance with sean taal ta helnLeaking and/or sticking fuel injection nozzle (A stuck fuel injection nozzle ican cause a noise similar to a damaged piston, rod or rod bearing.) locate the cylinder that is the source of the noise. 2. If you cannot locate the cylinder that is the source of the noise, diagnose the engine for mechanical damage. 3. fit has been determined that the fuel injection nozzle} is causing the noise, replace the fuel injection nozzle. Loose and/or damaged crankshaft pulley inspect crankshaft pulley and pulley bolt. Repair or replace all damaged components. no Loose torque converter bolts Inspect torque converter bolts and flywheel Repair or replace all damaged components no Loose and/or damaged flywheel Inspect flywheel and fyweel attaching bolts Repair or replace all damaged components. Ro Excessive piston pin-to-bore clearance 1. Inspect the piston, piston pin, and the connecting rod. 2. Repair or replace all damaged components Misaligned or bent connecting rod Inspect connecting rod and connecting rod bearings. Repair or replace all damaged components. po Excessive connecting rod bearing clearance 1. Inspect the connecting rod bearings, connecting rods, crankshaft and crankshaft journals. 2. Repair or replace all damaged components. Excessive crankshaft bearing clearance 1. Inspect the crankshaft bearings and crankshaft journals, 2. Repair or replace all damaged components Engine Noise Under Load Cause Correction Low oil pressure Insufficient or poor oil supply to components. 1, Perform oil pressure test. 2. Repair or replace all damaged components Loose torque converter bolts 1. Inspect the torque converter bolts and flywheel. 2. Repair or replace all damaged components Loose and/or damaged flywheel 1. Inspect the flywheel and flywheel attaching botts. 2. Repair or replace all damaged components.Excessive pistor-to-cylinder bore clearance 1. Inspect the piston rings for low ring tension, broken or wom rings, inspect cylinder bore. 2. Repair or replace all damaged components Excessive crankshaft thrust bearing clearance 1. inspect the crankshaft end play and crankshaft thrust bearings. 2. Repair or replace all damaged components Excessive crankshaft bearing clearance 1. Inspect the crankshaft bearings and crankshaft journals, 2. Repair or replace all damaged components Engine Will Not Crank - Crankshaft Will Not Rotate Cause Correction Seized accessory drive system component 1. Inspect the accessory drive system components. 2. Repair or replace all damaged components Hydraulically locked cylinder © Coolanvantifreeze in cylinder © Oilin cylinder © Fuel in cylinder Inspect for broken head gasket(s). Inspect for cracked engine block or cylinder head Inspect for a sticking fuel injector. ena ‘Seized automatic transmission torque converter ‘Seized manual transmission 1, Remove the engine assembly. The torque converter bolts are not accessible with the engine installed to the transmission. Rotate crankshaft at the pulley. N Disengage the clutch. Rotate crankshaft at the pulley. nN Refer to Unit Repair Manual - Manual Transmission. Material in cylinder : © Broken valve © Piston material © Foreign material * Inspect cylinder for damaged components and/or foreign materials. + Repair or replace as required. ‘Seized crankshaft or connecting rod bearings * Inspect crankshaft and connecting rod bearings. * Repair as required. Bent or broken connecting rod * inspect connecting rods. + Repair as required.+ nspect cannsnan, Broken crankshaft * Repair as required. Coolant in Combustion Chamber Inspection Action Definition : Excessive white smoke and/or coolant type odor coming from the exhaust pipe may indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or a lraulty thermostat may lead to an “overtemperature" condition which may cause engine component: damage. |\Verify that there are no external coolant leaks. Refer Preliminary inspection Losec Section 1D, Engine Cooling. * Cylinder balance test with scan tool + Cooling system pressurization Isolate Affected Cylinders + Compression test * Inspect EGR valve and intake system for evidence of coolant leakage. EGR System Inspection + Replace the EGR cooler if any problem is found * Remove cylinder heads of the affected cylinder bank and inspect for damage. Cylinder Head Gasket Leaka vinder Head Gasket Leakage + Replace components as necessary. * Inspect the cylinder heads for cracks. * Inspect the cylinder block for damage Cylinder Head or Engine Block * Inspect the cylinder block to head mating surface for Damage straightness. + Replace components as necessary. Coolant in Engine Oil Cause Correction Definition : Foamy or discolored oil or an engine oil "overfil” condition may indicate coolant lentering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an “overtemperature" condition which may cause engine component damage. Contaminated engine oil and oil fiter should be changed. 1, Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant may not properly lubricate the crankshaft bearings and may lead to component damage. Refer to "Lower Engine Noise, Regardless of Engine Speed’ in this section. 2. Inspect by performing a Cylinder Leak-Down Test. During this test, excessive air bubbles within the cooling system may indicate a faulty gasket or damaged component. 3. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine block with low compression may indicate a failed cylinder head gasket. Referto"Engine Compression Test" in this section. Replace the head gasket and components as required Refer toSection 1C1, Engine Mechanical. Replace the cylinder head gasket. Refer toSection 1C/. Engine Mechanical. Faulty cylinder head gasket Warped cylinder head Cracked cylinder head Replace the cylinder head and gasket. Cracked engine block Replace the components as required. Cylinder head, block, or manifold Replace the components as required, porosity Leaking engine oil cooler Replace components as required. Fuel in Engine Oil Definition : Iffuel is suspected of leaking into the crankcase, the following procedure should be performed to verify the condition. 1, Remove the oil level indicator and allow oil to drop onto a clean white paper towel. 2. I the oil is diluted with fuel, it will become apparent as the towel wicks the fuel away from the drop of oil on the towel. The fuel will expand out in a ring around the oil droplet. 3. fuel dilution is apparent, inspect the vehicle for aftermarket performance accessories that may cause damage to the injection pump. After repairs are completed, perform the test again to verify the condition is corrected 4. Ifno fuel dilution is present, verify the oil level and correct as needed. Drive Belt Chirp Notice : Chirping during start-up in cold damp conditions that abates once the engine reaches operating temperature is considered normal. Diagnostic Aids The symptom may be intermittent due to moisture on the drive belts or pulleys. it may be necessary to spray a small amount of water on the drive belt to duplicate and confirm a customers concem. If spraying water onto the drive belt system duplicates the symptom, cleaning the belt pulleys may be the solution. A loose of incorrectly installed body component, suspension component or other item may be the cause of the noise. Test Description The numbers below refer to steps in the diagnostic table. 2. The noise may not be engine related. This step is to confirm the engine is making the noise. I the engine is not making the noise, do not proceed further with this diagnostic procedure. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt4. inspect all drive pump pulleys for pilling Notice : Pilling is the small balls (pills) or strings of rubber in the belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive system pulleys may be caused by incorrect mounting of an accessory drive component (A/C compressor, generator etc.) or pulley. Misalignment may also be caused by incorrect installation of a pulley during a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. ifa misaligned pulley is found, refer to the relevant component service information for the correct installation and removal procedures 10. nspecting the fasteners can eliminate the possibility that an incorrect fastener has been installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface when the back end of the beltis used as the driving surface. 14, Replacing the drive belt when it is not damaged and there is no excessive pilling will only be a temporary repair. Diagnostic Table Notice : Chirping during start-up in cold damp conditions that abates once the engine reaches operating temperature is considered normal. Definition : Accessory drive belt chirping can be defined as a high-pitched noise that is heard once er revolution of the drive belt or a pulley. Step| Action Value(s) Yes No Did you review the information provided in 1 |Symptoms, and perform the required - inspections. Go to Step 2|Go toSymptoms. Confirm the customer complaint. Is there a Refer to 2 chirping noise? - Diagnostic Aids Go to Step 3| in this Section 1, Remove the drive belt, refer toSection ‘Accessory 1C1, Engine Mechanical. drive system 2. Operate the engine for no more than 40 OK. 3 seconds. . Go to ‘Symptoms, Does the chirping noise still exist? and restart the diagnosis| ofthe noise | Go to Step 4 Inspect for severe piling, i.e. in excess of 4 |33% of the belt groove depth. : Do the belt have pilling? omhe Belt grooves have ping Goto Step 5| Goto Step 6 Clean the drive belt pulleys with a wire brush. Go to Step |Are the belt pulleys clean? 15 Go to Step 6Inspect for misalignment of the pulleys. lAre the pulleys misaligned? Goto Step 7) Goto Step 8 7_ [Replace or repair misaligned pulleys Go to Step Did you complete the repair? 15 . inspect for any bent or damaged accessory 8 {drive component mounting brackets. Did you find any bent or damaged brackets? Goto Step 9| Goto Step 10 Replace or repair any bent or damaged 9 Brackets. Go to Step Did you complete the repairs? 15 - Inspect for missing, loose or incorrect 40 |fasteners. Did you find any missing, loose or incorrect Go to Step lrasteners? fo Go to Step 12 Tighten any loose fasteners to the torque 41 |Specification. Replace any incorrect or missing fasteners. Go to Step Did you complete the repairs? 15 - 42 |hspect for a bent pulley. Go to Step Did you find any bent pulleys? 13 Go to Step 14 13 [Replace bent pulleys as required Go to Step Did you complete the repair? 15 - Replace the accessory drive belt, refer 14 |toSection 11, Engine Mechanical. Go to Step Did you complete the repair? 15 - Reinstall the accessory drive belt and Go ‘operate the system to confirm the repair. Accessory |toSymptoms.and| 15 |Did you correct the chirp noise? drive system | _ restart the OK diagnosis Drive Belt Squeal Diagnostic Aids ifthe noise is intermittent, confirm the accessory drive components by varying their loads, making sure they are operated to their maximum capacity. An overcharged A/C system, restrictions in the power steering pressure circuit or a faully generator is likely causes of accessory drive belt squeal. A loose or incorrectly installed body component, suspension component or other item may be the cause of the noise. Test Description The numbers below refer to steps in the diagnostic table. 2. The noise may not be engine related. This step is to confirm the engine is making the noiseIfthe engine is not making the noise, do not proceed further with this diagnostic procedure The noise may be an internal engine noise. Removing the drive belt and operating the engine briefty will confirm whether or not the noise is related to the drive belt. Confirms an accessory drive component does not have a seized bearing. With the belt removed, test the bearings in the accessory drive components spin free and smooth. Confirms the drive belt tensioner is operating correctly. I the drive belt tensioner is not operating correctly, drive belt tension will not be maintained, resulting in a belt squealing noise. Confirms the belt is not too long, which would prevent the tensioner from working as intended. Also, if an excessively long belt has been fitted, it may also be routed incorrectly and may be turning an accessory drive component in the wrong direction. Misalignment of the pulleys may be caused by one of the following : © Incorrect mounting of an accessory drive component, © Incorrect installation of an accessory drive pulley or, © Bent or damaged pulley. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. Ifa misaligned pulley is found, refer to the relevant component service information for the correct installation and removal procedures. This test is to confirm the pulleys are the correct diameter and/or width. Using a known good vehicle, compare the pulley sizes. Diagnostic Table Definition : Accessory drive belt squealing can be defined as a loud screeching noise caused bya slipping drive belt. Belt squeal is unusual in mult-rib belts. Drive belt squeal generally occurs when a hea vy load is applied to the drive belt, such as an air-conditioning compressor engagement, snapping the throttle, seized pulley or a faulty accessory drive component. Step Action Value(s) Yes No Did you review the information provided in 1 |Symptoms, and perform the required - inspections. Go to Step 2|Go toSymptoms (Confirm the customer complaint, & there a Refer fo 2 |squealing noise? - Diagnostic Aids Go to Step 3| inthis Section 1, Remove the drive belt, refer toSection ‘Accessory 1€1, Engine Mechanical. drive system 2, Operate the engine for no more than 40 OK. 3 seconds. . Go to Symptoms, Does the squealing noise still exist? and restart the diagnosis ofthe noise | Go to Step 4 Inspect the accessory drive components for al seized bearing and general matfunctions. 4 |Did you find and correct any seized bearings - lor general malfunctions in the accessory drive system? Goto Step 9| Goto Step 5Test the accessory drive belt tensioner for correct operation, refer to Drive Belt 5. [Tensioner Diagnosis Did you find and repair any problems with the tensioner? Goto Step 9 Goto Step 6 Inspect the accessory drive beltis the correct! length. Did you find and repair any problems with the drive belt length? Goto Step 9 Goto Step 7 Inspect the accessory drive pulleys for 7 |misalignment. Did you find and correct any misaligned accessory drive pulleys? Goto Step 9 Goto Step & Check the accessory drive pulleys are the 8 correct size. Did you find and replace any incorrect Refer to Diagnostic Aids pulleys? Go to Step 9| inthis Section Reinstall the accessory drive belt and Go g_ [operate the system to confirm the repair Accessory |toSymptoms,and Did you correct the squeal noise? drive system] restart the OK diagnosis Drive Belt Whine Diagnostic Aids Test Description The numbers below refer to steps in the diagnostic table. The drive belts themselves wil not cause a whine. I the noise is intermittent, confirm the accessory drive components by varying their loads, making sure they are operated to their maximum capacity. An overcharged A/C system, restrictions in the power steering pressure circuit or a faulty generator is likely causes of accessory drive belt whine. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt. 4. The inspection of bearings should include the following accessory drive components drive belt tensioners, drive bet idlers, generator, power steering pump, AIC compressor. The drive belt may need to be installed and the accessory drive components operated separately, at varying loads to confirm the location of the faulty bearing, refer to the relevant Sections for component inspection and repair procedures.Diagnostic Table Definition : Accessory drive belt whine can be defined as a high-pitched continuous noise that is most likely to be caused by a failed bearing in one of the accessory drive components Step] Action Value(s) Yes No Did you review the information provided in 1 |Symptoms, and perform the required - inspections. Go to Step 2|Go toSymptoms, Confirm the customer complaint. s there a Refer to 2 [whining noise? - Diagnostic Aids Go to Step 3| in this Section 1, Remove the drive belt, refer toSection ‘Accessory 1C1, Engine Mechanical. drive system 2. Operate the engine for no more than 40 OK. 3 seconds. - Go to ‘Symptoms, Does the whining noise still exist? and restart the diagnosis| Go to Step 4 Inspect the accessory drive components for a Htaulty or seized bearings and general 4, {Matfunctions. . Did you find and correct any faulty/seized Refer to bearings or general malfunctions in the Diagnostic Aids accessory drive system? Go to Step 5| inthis Section Reinstall the accessory drive belt and Go 5, [operate the system to confirm the repair, - Accessory |toSymptoms,and Did you correct the whine? drive system | restart the OK diagnosis Drive Belt Rumble Diagnostic Aids Vibration from the engine may cause a body component or other parts to emit a rumbling noise The drive belt may have a condition that cannot be seen or felt. Sometimes the replacement of the belt may be the only way to confirm the belt is faulty. ifthe drive belt has been replaced and the diagnostic table completed, but the rumble is still present only when the drive belt is installed, an accessory drive component such as the A/C compressor may be the cause. Varying the load to each accessory drive component in tum, should help isolate which component is causing the noise. Test Description The numbers below refer to steps in the diagnostic table. 2. Confirms the symptom exists at the time of diagnosis. Other vehicle components may be causing the noise.3. Confirms the accessory drive beltis the cause of the noise. Drive belt rumbiing is often confused with an internal engine noise due to the similarity in the description. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt. Inspecting the drive belt is to ensure that itis not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise and are not justification alone to replace the belt Belt separation can be identified by the ply of the belt separating and may be seen at the edge of the belt or felt as lumps under the belt. ‘Small amounts of pilling is a normal condition and is deemed acceptable. When the pilling is severe (33% of the belt groove depth), the belt does not have a smooth surface to run on and should be replaced. Diagnostic Table Definition : Definition: Accessory drive belt rumble can be defined as a low pitch tapping, knocking or thumping noise heard at or just above idle, once per rotation of the drive belt or a specific component. Drive belt rumble is generally caused by one of the following : pilling or strings in the drive belt grooves, separation of the drive belt, or a damaged or faulty drive belt. Notice : Pilling is the small balls (pills) or strings of rubber in the belt grooves caused by the accumulation of rubber dust. Step] Action Value(s) Yes No Did you review the information provided in 1 |Symptoms, and perform the required - inspections. Go to Step 2|Go toSymptoms (Confirm the customer complaint. Is there a Refer to 2. |rumbling noise? - Diagnostic Aids Go to Step 3| inthis Section 1. Remove the drive belt, refer toSection ‘Accessory 1C1. Engine Mechanical. drive system 2. Operate the engine for no more than 40 OK. 3 seconds. - Go to Symptoms, Does the rumbling noise still exist? and restart the diagnosis] Go to Step 4 Inspect the accessory drive belt for damage, 4, {Separation or sections of missing ribs . Did you find any damaged, separated or missing ribs? Go to Step 7| Go to Step 5 Inspect the accessory drive belt for severe pilling (exceeding 33% of the belt groove 5 |depth). - i 2 Did you find sever pilling Go to Step 6| Go to Step 5‘Clean the drive belt using a suitable wire brush and reinstall to the engine, refer ito Section 1C1, Engine Mechanical. Did you complete the repairs? Goto Step 8 - Install a new accessory drive belt, refer 7 |toSection 1C1, Engine Mechanical. - Did you replace the accessory drive belt? Goto Step & - Frequired, reinstall the accessory drive belt Go g_ [and operate the system to confirm the repair, . Accessory |toSymptoms,and Did you correct the rumbling noise? drive system] restart the oK diagnosis Drive Belt Vibration Diagnostic Aids The accessory drive components such as the A/C compressor or generator can have an affect on engine vibration. To aid in locating which component is causing the vibration, vary the load to each accessory drive component in tum and note the effect it has on the vibration if any. Test Description The numbers below refer to steps in the diagnostic table 2. Confirms the symptom exists at the time of diagnosis. Other vehicle components may be causing the noise. 3. Confirms the accessory drive belt is the cause of the noise. Drive belt rumbling is often confused with an internal engine noise due to the similarity in the description. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt. 4, The drive belt may cause a vibration, inspecting the drive belt is considerably easier while the drive belt is removed. 6. Inspecting the fasteners can eliminate the possibilty that an incorrect fastener has been installed. 8. This step should only be performed if the cootant pump is driven by the drive belt. Inspect the coolant pump for a bent shaft. Also inspect the coolant pump bearings for smooth operation and excessive play. Compare the coolant pump with a known good pump. 9. Accessory drive component brackets that are bent, cracked or loose may put extra strain on the accessory component causing it to vibrate Diagnostic Table Definition : Accessory drive belt vibration can be defined as a drive belt that jumps, shakes or rattles. Accessory drive belt vibration is usually indicated by one of the following : * the vibration is engine speed related, or + the vibration is sensitive to accessory drive system load.‘Step Action Value(s) Yes No Did you review the information provided in 1. |Symptoms, and perform the required - Go inspections. Go to Step 2| toSymptoms [Confirm the customer complaint. s there a Refer to 2 {rumbling noise? . Diagnostic Aids in this Goto Step 3| Section 1. Remove the drive belt, refer toSection ‘Accessory 1C1, Engine Mechanic: drive system 2. Operate the engine for no more than 40 OK. 3 seconds. - Goto Symptoms, Does the vibration noise still exist? and restart the diagnosis| Go to Step 4 Inspect the accessory drive belt for damage, |wear, debris build-up or sections of missing 4 |ribs. - Did you find any damage, wear, debris build-up lor missing ribs? Go to Step 5| Go to Step 6 install a new accessory drive belt, refer 5 |toSection 1C1, Engine Mechanical. - Did you replace the accessory drive belt? Go to Step 9 - Inspect for incorrect, loose, missing or g {damaged fasteners. . Did you find any incorrect, loose, missing or damaged fasteners? Go to Step 7| Goto Step 8 Tighten any loose fasteners to the correct 7 [torque specification. . Replace any incorrect or missing fasteners. Did you complete the repairs? Go to Step 9 : Inspect for bent, cracked or damaged Refer to g_ {accessory drive component mounting brackets. . Diagnostic Did you find and repair any bent brackets? Aids in this Go to Step 9}| Section if required, reinstall the accessory drive belt and Refer to g_ [operate the system to confirm the repair. . Accessory | Diagnostic Did you correct the vibration? drive system | Aids in this OK Section Drive Belt Falls Off Diagnostic Aids ifthe accessory drive belt repeatedly falls off the drive pulleys, this is most likely due to pulley misalignment.Anextra load that is quickly applied and released by an accessory drive component (e.g. A/C compressor) may cause the accessory drive belt to fall off. In this circumstance, confirm the fautt by operating the accessory drive components in turn, noting which one caused the belt to fall off. Lack of drive belt tension may also cause the belt to fall off the pulleys. Low drive belt tension could be caused by one of the following : + anincorrect drive belt length, + a faulty drive belt tensioner, or + asstretched or faulty drive belt. Test Description The numbers below refer to steps in the diagnostic table. 2. Confirms the condition of the drive belt. Damage may have occurred to the drive belt when it first fell off or it may have been damaged which caused the belt to fall off. 4. Misalignment of the pulleys may be caused by © the incorrect installation or mounting of an accessory drive component, © the incorrect installation of an accessory drive component pulley, or © adamaged or bent accessory drive pulley. Test for a misaligned pulley using a suitable straight edge in the pulley grooves across two or more pulleys. if'a misaligned pulley is found, refer to the service information for the particular component, for the correct pulley replacement procedures. 5. Inspecting the pulleys should include an inspection for dents or other damage that would prevent the drive belt from seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used. 6. Accessory drive component mounting brackets that are bent will cause the drive belt to fall off. 7. Inspection of the fasteners can eliminate the possibility that an incorrect fastener was installed. Missing, loose or incorrect fasteners may cause pulley misalignment from the fasteners moving under load. Over-tightening of the fasteners may cause deflection of mounting brackets and result in misaligned accessory drive pulleys. Diagnostic Table Definition : The drive belt falls off during normal operation or does not ride correctly on the accessory drive pulleys. Step’ Action Value(s) Yes No Did you review the information provided in 1 Symptoms, and perform the required : Go inspections. Go toStep 2 | toSymptoms 2. [Inspect for a damaged accessory drive belt. . Did you find any damage on the drive belt? Go toStep 3 | Go to Step 4 install a new accessory drive belt, refer 3 |toSection 11, Engine Mechanical. - Does the drive belt continue to fall off? Go toStep 4 |Go to Step 12) Inspect the accessory drive system pulleys formisalignment. Did you find and repair any misaligned drive Isystem pulleys? Go toStep 12 Goto Step 5 Inspect for a dented or cracked accessory drive| Isystem pulley. Did you find and repair any dented or cracked ldrive system? Go toStep 12 Goto Step 6 Inspect for bent accessory drive component Imounting brackets. Did you find and repair any bent mounting brackets? Go toStep 12 Goto Step 7 Inspect for incorrect, loose, missing or damaged fasteners. Did you find any incorrect, loose, missing or damaged fasteners? Go toStep 8 Goto Step 9 Tighten any loose fasteners to the correct torque specification Replace any incorrect or missing fasteners. Does the drive belt continue to fall off? Go toStep 9 Go to Step 12] Test the accessory drive belt tensioner for lcorrect operation, refer toSection 1C1, Engine Mechanical, Did you accessory drive belt tensioner operate correctly? Go toStep 11 Go to Step 10) 10 Replace the drive belt tensioner, refer ltoSection 1C1, Engine Mechanical. Does the drive belt continue to fall off? Go toStep 11 Go to Step 12! 1 Inspect for a failed drive belt idler and drive belt tensioner bearings. Did you find and repair any failed bearings? Go toStep 12 Refer to Diagnostic Aids in this Section 12 If required, reinstall the accessory drive belt and| loperate the system to confirm the repair. Does the drive belt continue to fall off? Go toStep 2 ‘Accessory drive system OK Drive Belt Excessive Wear Diagnostic Aids Excessive wear of a drive beltis usually caused by an incorrect installation or an incorrect drive belt fitted. Minor pulley misalignment will not cause excessive wear, but will cause the drive belt to fall off. Major pulley misalignment may cause excessive wear, but would also result in the drive belt falling off. Test DescriptionThe numbers below refer to steps in the diagnostic table. 2. Confirms the drive belt is correctly installed onto all of the accessory drive system pulleys. Wear on the drive belt may be caused by incorrectly positioning the drive belt by one or more grooves to a particular pulley. 3. The installation of the drive belt that is the incorrect width will cause wear on the drive belt The drive belt ribs should match all the grooves on all the pulleys in the accessory drive system. 4, Confirms the drive belt is not contacting any parts of the engine or body while the engine is running. There should be sufficient clearance when the accessory drive component loads varies. The drive belt should not come into contact with any engine or body parts Diagnostic Table Definition : Excessive wear can be defined as wear at the outside ribs of the drive belt (frayed edges), usually caused by an incorrectly installed drive belt. Step Action Value(s) Yes No Did you review the information provided in 1 Symptoms, and perform the required : Go inspections. Go toStep 2 | toSymptoms Inspect the accessory drive belt for correct 2 |installation. - Is the drive belt installed correctly? Go toStep 5 | Go to Step 3 Ensure that the drive beltis the correct one for 3. |the application. - is the correct drive belt installed? Go toStep 5 | Go to Step 4 Is the drive belt contacting any engine or body Refer to 4. [eomponents with the engine running? . Diagnostic Aids in this GotoStep 6| Section install a new accessory drive belt, refer 5 |toSection 1C1, Engine Mechanical. a Did you replace the accessory drive belt? Go toStep 6 : if required, reinstall the accessory drive belt and! ‘Accessory 6 operate the system to confirm the repair. : drive system Did you correct the excessive wear? OK Goto Step 2 COMPONENT LOCATOR Cylinder Head 1, Spark Plug Cable CoverEngine Oil Cap Cylinder Head Cover Cylinder Head Cover Gasket Spark Plug Cable Spark Plug Ignition Coil (DIS) Bracket Ignition Coil (DIS) Camshaft Cap 10. Camshaft (Intake) 14, Camshaft (Exhaust) 12. Valve Tappet 13, Valve Key 14. Valve Spring Retainer 45. Valve Spring 16. Valve Stem Seal 17. Cylinder Head 18. Valve (Intake) 19. Valve (Exhaust) 20. Cylinder Head Gasket 21. Cylinder Head Bolt 22. Camshaft Position Sensor 23, Coolant Outlet Case Gasket 24, Coolant Outlet Case 25. Coolant Temperature Sensor 26. EGR Valve Gasket 27. EGR Valve O©@NAARWN Cylinder Block Piston Ring Piston Piston Pin Retainer Piston Pin Connecting Rod Cap Stud Connecting Rod Connecting Rod Bearing Connecting Rod Cap Dowel Pin 10. Cylinder Block 11, Timing Chain Cover 12. Crankshaft Front Oilseal 13. Oil Pump Inner Rotor 14, Oil Pump Outer Rotor 15. Oil Pump Cover Ce2VOTRONS16 17 18 19 20. 21 22. 23, 24, 25. 26. 27. 28. 29. © @NAARWRA 10. 4 12 13 14, 15. 16. 17 18 19. 20. 21 22 Oil Relif Valve Oil Relif Valve Spring Oil Relif Valve Cap Oil Relif Vaive Retainer Oil Filter Stud Oil Filter Key Crankshaft Crankshaft Bearing Cap Oil Strainer Oil Pan Crankshaft Rear Oil Seal Cylinder Block Plate Plug Cylinder Block Plate Plug Gasket Manifold & Air Charging System Resonator Duet Air Filter Snorkel Hose Air Filter Lower Housing Air Filter Element Air Filter Upper Cover Air Outlet Hose Resonator Resonator Throttle Body ACV (dle Air Control Valve) Throttle Position Sensor Intake Manifold EGR Pipe EGR Pipe Gasket EGR Valve Thermostat Housing Coolant Outlet Case Fuel Rail hijector Exhaust Manifold Exhaust Manifold Heat Shield Timing System & MountTiming Chain Camshaft Sprocket (Intake) Camshaft Sprocket (Exhaust) Bushing Camshaft Sprocket Retaining Bolts Timing Chain Lever Timing Chain Tensioner Timing Chain Guide Crankshaft Sprocket 10. Engine Mount Assembly 11, Rear Mount Bracket 12. Transmission Rear Mount 13, Transmission Mount Assembly 14, Transmission Mount Bracket CHVOMRONS