1-iv Table of Contents
Pistons, Piston Rings, Connecting Rods
and Cylinders Disassembly and Assembly .....1D-44
Cylinders, Pistons and Piston Rings
Inspection........................................................1D-45
Piston Pins and Connecting Rods
Inspection........................................................1D-47
Crank Pin and Connecting Rod Bearings
Inspection........................................................1D-48
Main Bearings, Crankshaft and Cylinder
Block Components..........................................1D-52
Main Bearings, Crankshaft and Cylinder
Block Removal and Installation .......................1D-53
Crankshaft Inspection .......................................1D-56
Main Bearings Inspection..................................1D-57
Sensor Plate Inspection ....................................1D-61
Rear Oil Seal Inspection ...................................1D-61
Flywheel Inspection...........................................1D-62
Cylinder Block Inspection..................................1D-62
Specifications.....................................................1D-63
Tightening Torque Specifications......................1D-63
Special Tools and Equipment ...........................1D-64
Recommended Service Material .......................1D-64
Special Tool ......................................................1D-64
For J20 Engine ......................................................1D-66
General Description ...........................................1D-66
Engine Construction Description.......................1D-66
Air Cleaner Element Introduction ......................1D-68
IMT (Intake Manifold Tuning) System ...............1D-68
Diagnostic Information and Procedures..........1D-70
Compression Check..........................................1D-70
Engine Vacuum Check......................................1D-71
Valve Lash (Clearance) Inspection ...................1D-72
Repair Instructions ............................................1D-75
Air Cleaner Assembly Removal and
Installation.......................................................1D-75
Air Cleaner Filter Removal and Installation.......1D-75
Air Cleaner Filter Inspection and Cleaning........1D-75
Throttle Body and Intake Manifold
Components....................................................1D-76
Throttle Body On-Vehicle Inspection.................1D-76
Electric Throttle Body Assembly Removal
and Installation ................................................1D-76
Throttle Body Cleaning......................................1D-77
Intake Manifold Removal and Installation .........1D-77
Cylinder Head Cover Removal and
Installation.......................................................1D-78
Engine Mountings Components ........................1D-80
Engine Assembly Removal and Installation ......1D-81
Timing Chain Cover Components .....................1D-84
Timing Chain Cover Removal and
Installation.......................................................1D-84
Timing Chain Cover Cleaning and
Inspection........................................................1D-87
2nd Timing Chain and Chain Tensioner
Components....................................................1D-87
2nd Timing Chain and Chain Tensioner
Removal and Installation.................................1D-88
2nd Timing Chain and Chain Tensioner
Inspection........................................................1D-90
1st Timing Chain and Chain Tensioner
Components....................................................1D-91
1st Timing Chain and Chain Tensioner
Removal and Installation.................................1D-92
1st Timing Chain and Chain Tensioner
Inspection........................................................1D-94
Camshafts, Tappet and Shim Components ......1D-95
Camshafts, Tappet and Shim Removal
and Installation ................................................1D-95
Camshaft, Tappet and Shim Inspection ............1D-97
Valves and Cylinder Head Components ...........1D-99
Valves and Cylinder Head Removal and
Installation .......................................................1D-99
Valves and Cylinder Head Disassembly
and Assembly................................................1D-101
Valves and Valve Guides Inspection...............1D-104
Cylinder Head Inspection ................................1D-106
Valve Spring Inspection ..................................1D-107
Pistons, Piston Rings, Connecting Rods
and Cylinders Components...........................1D-108
Pistons, Piston Rings, Connecting Rods
and Cylinders Removal and Installation........1D-108
Pistons, Piston Rings, Connecting Rods
and Cylinders Disassembly and Assembly ...1D-109
Pistons, Piston Rings, Connecting Rods
and Cylinders Inspection and Cleaning.........1D-112
Main Bearings, Crankshaft and Cylinder
Block Components ........................................1D-118
Main Bearings, Crankshaft and Cylinder
Block Removal and Installation .....................1D-119
Main Bearings, Crankshaft and Cylinder
Block Inspection ............................................1D-122
Specifications ...................................................1D-129
Tightening Torque Specifications....................1D-129
Special Tools and Equipment .........................1D-130
Recommended Service Material .....................1D-130
Special Tool ....................................................1D-130
Engine Lubrication System .................... 1E-1
For M16A Engine with VVT.....................................1E-1
General Description .............................................1E-1
Engine Lubrication Description ...........................1E-1
Diagnostic Information and Procedures ............1E-3
Oil Pressure Check .............................................1E-3
Repair Instructions ..............................................1E-4
Oil Pan and Oil Pump Strainer Components.......1E-4
Oil Pan and Oil Pump Strainer Removal
and Installation ..................................................1E-5
Oil Pan and Oil Pump Strainer Cleaning.............1E-6
Oil Pump Components ........................................1E-7
Oil Pump Removal and Installation .....................1E-7
Oil Pump Disassembly and Reassembly ............1E-7
Oil Pump Inspection ............................................1E-8
Specifications .....................................................1E-10
Tightening Torque Specifications......................1E-10
Special Tools and Equipment ...........................1E-10
Recommended Service Material .......................1E-10
Special Tool ......................................................1E-10
For J20 Engine.......................................................1E-11
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