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Engine (G6EA GSL 2.
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EMA -2 ENGINE (G6EA - GSL 2.7) GENERAL SPECIFICATIONS EAFA9CDF Description Specifications Limit General Type V-type, DOHC Number of cylinder 6 Bore 86.7mm(3.4134in.) Stroke 75mm(2.9528in.) Total displacement 2,656cc Compression ratio 10.4 Firing order 2-3-4-5-6-1 Valve timing Intake valve Exhaust valve Opens (ATDC) 4 ~ -56 Closes (ABDC) 60 ~ 0 Opens (BBDC) 46 Closes (ATDC) 10 Cylinder head Flatness of gasket surface 0.03mm(0.0012in.
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GENERAL EMA -3 Description Thickness of valvehead(margin) Valve stem to valve guide clearance Specifications Limit Intake 1.0mm(0.0394in.) Exhaust 1.3mm(0.0512in.) Intake 0.020 ~ 0.050mm(0.0008 ~ 0.0020in.) 0.10mm(0.0039in.) or less Exhaust 0.035 ~ 0.065mm(0.0014 ~ 0.0026in.) 0.13mm(0.0051in.) or less Intake 6.000 ~ 6.015mm(2.2362 ~ 2.2368in.) Exhaust 6.000 ~ 6.015mm(2.2362 ~ 2.2368in.) Intake 45.8 ~ 46.2mm(1.8031 ~ 1.8189in.) Exhaust 46.8 ~ 47.2mm(1.8425 ~ 1.8583in.
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EMA -4 ENGINE (G6EA - GSL 2.7) Description Ring groove width Specifications No. 1 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.) No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.) Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in.) Piston O.S. Limit 0.25mm(0.0098in.) Piston ring Side clearance End gap No. 1 ring 0.04 ~ 0.08mm(0.0016 ~ 0.0031in.) 0.1mm(0.0039in.) No. 2 ring 0.03 ~ 0.07mm(0.0012 ~ 0.0027in.) 0.1mm(0.0039in.) Oil ring 0.06 ~ 0.15mm(0.0024 ~ 0.0059in.) 0.2mm(0.0079in.
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GENERAL EMA -5 Description Coolant quantity Thermostat Radiator cap Specifications 8.2~8.3L(8.66~8.77U.S.qts,7.22~7.30lmp.qts) Type Wax pellet type Opening temperature 82±2 C (179.6±35.6 F) Fully opened temperature 95 C (203 F) Full lift 10mm (0.3937in.) or more Main valve opening pressure 93.16 ~ 122.58kpa(0.95 ~ 1.25 kg/cm², 13.51 ~ 17.78psi) Vacuum valve opening pressure 0.98 ~ 4.90 kpa(0.01 ~ 0.05 kg/cm², 0.14 ~ 0.
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EMA -6 ENGINE (G6EA - GSL 2.7) TIGHTENING TORQUE Quantity Nm kgf.m lb-ft Oil seal case bolt 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Main bearing cap bolt(M10) 8 29.4 + 90 3.0 + 90 21.7 + 90 Main bearing cap bolt(M8) 8 15.7 + 90 1.6 + 90 11.6 ~ + 90 Rear plate bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Oil pump case bolt(8×25) 1 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4 Oil pump case bolt(8×35) 1 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4 TimingOil pump case bolt(8×65) 1 18.6 ~ 23.5 1.9 ~ 2.4 13.
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GENERAL EMA -7 Quantity Nm kgf.m lb-ft Drive belt tensioner bolt 1 34.3 ~ 53.9 3.5 ~ 5.5 25.3 ~ 39.8 Water pipe bolt 1 16.7 ~ 19.6 1.7 ~ 2.0 12.3 ~ 14.5 Water temp. control assembly nut 4 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4 Oil level gauge bolt 1 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4 Oil screen bolt 2 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9 Water outlet pipe bolt 3 16.7 ~ 19.6 1.7 ~ 2.0 12.3 ~ 14.5 Water inlet pipe bolt 2 16.7 ~ 19.6 1.7 ~ 2.0 12.3 ~ 14.
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EMA -8 ENGINE (G6EA - GSL 2.7) COMPRESSION PRESSURE INSPECTION EBCD8F14 NOTE This measurement must be done in as short a time as possible. NOTE If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. Warm up the engine until the normal operating temperature becoming 80~95 C(176~203 F). 2. Remove the surge tank. 3. Remove the ignition coil connectors(A) and ignition coils(B). Compression pressure: 1,176.79kPa (12.0kgf/cm², 170.
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GENERAL EMA -9 VALVE CLEARANCE INSPECTION AND ADJUSTMENT NOTE Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20 C±5 C(59~77 F)) and cylinder head is installed on the cylinder block. 1. Remove the engine cover. 2. Remove air cleaner assembly. 3. Remove the surge tank. 4. Remove the cylinder head cover. 1) 2) KCBF119B NOTE Disconnect the ignition coil connector and remove the ignition coil. Remove the cylinder head cover.
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EMA -10 ENGINE (G6EA - GSL 2.7) 2) Turn the crankshaft pulley one revolution (360 ) clockwise and align the groove with the timing mark "T" of the timing chain cover. 3) With the piston of the No.4 cylinder positioning at TDC, the valves which can be measured its clearance are as shown below. RH EXHAUST EDKE889D INTAKE 7) LH EXHAUST LDLG031A 7. Adjust the intake and the exhaust valve clearances. 1) Set the piston of the No.1 cylinder to the TDC/position. 2) Remove the timing belt.
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GENERAL TROUBLESHOOTING EMA -11 EAB59BFE Symptom Engine misfire with abnormal internal lower engine noises. Engine misfire with abnormal valve train noise. Engine misfire with coolant consumption. Engine misfire with excessive oil consumption. Engine noise on start-up, but only lasting a few seconds. Suspect area Remedy Worn crankshaft bearings. Loose or impropes engine drive plate. Replace the crankshaft and bearings as required. Repair or replace the drive plate as required. Worn piston rings.
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EMA -12 ENGINE (G6EA - GSL 2.7) Symptom Upper engine noise,regardless of engine speed. Suspect area Low oil pressure. Repair or replace as required. Broken valve spring. Replace the valve spring. Worn or dirty valve lifters. Replace the valve lifters. Stretched or broken timing chain and/or damaged sprocket teeth. Replace the timing chain and sprockets. Worn timing chain tensioner, if applicable. Replace the timing chain tensioner as required. Worn camshaft lobes.
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GENERAL Symptom Engine noise under load. Engine will not crank-crankshaft will not rotate. EMA -13 Remedy Suspect area Low oil pressure Repair or replace as required. Excessive connecting rod bearing clearance . Inspect the following components and repair as required : • The connecting rod bearings. • The connecting rods. • The crankshaft. Excessive crankshaft bearing clearance. Inspect the following components, and repair as required. • The crankshaft bearings. • The crankshaft main journals.
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EMA -14 SPECIAL TOOLS ENGINE (G6EA - GSL 2.
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GENERAL EMA -15 Tool (Number and name) Valve spring compressor (09222-3K000) (09222-3C300) Illustration Use Removal and installation of the intake or exhaust valves.
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EMA -16 ENGINE (G6EA - GSL 2.7) ENGINE BLOCK COMPONENTS E98DF5AD 19.6(2.0, 14.5) + 90 18.6 ~ 23.5 (1.9 ~ 2.4, 13.7 ~ 17.4) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) TORQUE : N.m (kgf.m, lb-ft) 1. 2. 3. 4. Piston ring Piston Piston Connecting rod 5. 6. 7. 8.
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ENGINE BLOCK EMA -17 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 1 4 2 11 3 5 7 6 8 9 10 29.4(3.0, 21.7) + 90 (M10) 15.7(1.6, 11.6) + 90 (M8) TORQUE : N.m (kgf.m, lb-ft) 1. 2. 3. 4. 5. 6. Rear oil seal Rear oil seal case Rear plate Crankshaft upper bearing Crankshaft Lower thrust bearing 7. 8. 9. 10. 11.
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EMA -18 REMOVAL 1. ENGINE (G6EA - GSL 2.7) DISASSEMBLY E2BF11E6 Remove the drive plate(A). 1. EB2506EF Remove the power steering pump bracket(A) and the knock sensor(B). A B A KCBF120A 2. Remove the rear plate(A). KCBF122A 2. Remove the air conditioning compressor bracket(A). A A KCBF121A 3. Remove timing belt. 4. Remove intake manifold. 5. Remove exhaust manifold. 6. Remove generator from engine.(Refer to ’ST’ group). 7. Remove power steering pump from engine.
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ENGINE BLOCK 4. EMA -19 10. Remove the oil seal case(A). Remove the oil screen(A). A A B KCBF124A 5. Remove the upper oil pan(A). A EDQF174B 11. Check the crankshaft end play. 12. Remove the crankshaft bearing cap and check oil clearance. 09215-3C000 KCBF125B CAUTION When removing the oil pan, use the SST(092153C000) not to damage the contacting surface of the oil pan. 6. Check the connecting rod side clearance. 7. Check the connecting rod bearing oil clearance. 8.
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EMA -20 ENGINE (G6EA - GSL 2.7) 13. Lift the crankshaft(A) out of the block, being careful not to damage journals. 15. Remove the CKP sensor(A). A A KCBF128A 16. Check the free play between a piston and a piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and the piston pin as a set. EDQF074A 17. Remove the piston rings. 14. Remove and arrange the main bearings and thrust bearings in the correct order.
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ENGINE BLOCK INSPECTION EMA -21 E3F92BD3 NOTE Do not turn the crankshaft. CONNECTING ROD AND CRANKSHAFT 1. Check the connecting rod side clearance. Using a feeler gauge, measure the side clearance while moving the connecting rod back and forth. 7) Remove the connecting rod cap again. 8) Measure the plastigage at its widest point. Standard oil clearance 0.018 ~ 0.036mm(0.0007 ~ 0.0014in.) Specification Standard : 0.1~ 0.25mm(0.0039 ~ 0.0098in.) Limit : 0.4mm(0.0157in.
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EMA -22 ENGINE (G6EA - GSL 2.7) with a wire brush or scraper. Clean them only with solvent or detergent. CONNECTING ROD MARK LOCATION DISCRIMINATION OF CRANKSHAFT CLASS MARK OUTSIDE DIAMETER OF PIN I 1 or A 47.994 ~ 48.000mm (1.8895 ~ 1.8898in.) II 2 or B 47.988 ~ 47.994mm (1.8893 ~ 1.8895in.) III 3 or C 47.982 ~ 47.988mm (1.8891 ~ 1.8893in.) PLACE OF IDENTIFICATION MARK (CONNECTING ROD BEARING) EDQF196A DISCRIMINATION OF CONNECTING ROD CLASS MARK INSIDE DIAMETER 0 a 51.000 ~ 51.
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ENGINE BLOCK EMA -23 11) Select the proper connecting rod bearing from the table below. Tightening torque M8 : 15.7Nm(1.6 kgf.m, 11.6lb-ft) + 90 M10 : 29.4 Nm(3.0 kgf.m, 21.7lb-ft)+ 90 CONNECTING ROD IDENTIFICATION MARK CRANKSHAFT INDENTIFICATION MARK 3. 0(A) 1(B) 2(C) I(A) E (YELLOW) D (GREEN) C (-) II(B) D (GREEN) C (-) B (BLACK) III(C) C (-) B (BLACK) A (BLUE) NOTE Tighten the bolts in order. 5) Remove the cap and bearing again, and measure the widest part of the plastigage.
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EMA -24 ENGINE (G6EA - GSL 2.7) CRANKSHAFT JOURNAL MARK LOCATION CAUTION If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. DISCRIMINATION OF CRANKSHAFT Crankshaft bore mark location Letters have been stamped on the block as a mark for the each size of the 4 main journal bores. No.1 journal stamping mark starts from the front of the engine.
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ENGINE BLOCK EMA -25 DISCRIMINATION OF CRANKSHAFT BEARING If the end play is greater than the maximum, replace the center bearing. MARK THICKNESS OF BEARING A BLUE 2.007 ~ 2.010mm (0.0790 ~ 0.0791in.) BLACK 2.004 ~ 2.007mm (0.0789 ~ 0.0790in.) 6. B Inspect the main journals and the pin journals of the crankshaft. C - 2.001 ~ 2.004mm (0.0788 ~ 0.0789in.) 7. Using a micrometer, measure the outer diameter of each main journal and pin journal. D GREEN 1.998 ~ 2.001mm (0.0787 ~ 0.0788in.
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EMA -26 ENGINE (G6EA - GSL 2.7) CYLINDER BLOCK 1. Remove gasket materials. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. 2. Clean cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block. 3. A B Inspect the top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
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ENGINE BLOCK 7. EMA -27 Check the piston size code(A) on the piston top face. CYLINDER BORING 1. The over size piston is chosen on the maximum inner diameter of the cylinder. NOTE The piston size mark is on the top surface of the piston. A KCBF176D Class Size code Piston outer diameter A A 86.67 ~ 86.68mm (3.4122 ~ 3.4126in.) B - 86.68 ~ 86.69mm (3.4126 ~ 3.4130in.) C 86.69 ~ 86.70mm (3.4130 ~ 3.4134in.) C 8. Select the proper piston related to the cylinder bore class. Clearance : 0.
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EMA -28 ENGINE (G6EA - GSL 2.7) PISTON AND RINGS 1. 4. Clean pistons. 1) Using a gasket scraper, remove the carbon from the piston top. 2) Using a groove cleaning tool or a broken ring, clean the piston ring grooves. 3) Using solvent and a brush, thoroughly clean the piston. NOTE Inspect the piston ring side clearance. Using a feeler gauge, measure the clearance between a new piston ring and the ring groove. Piston ring side clearance Standard No.1 : 0.04 ~ 0.08mm (0.0016 ~ 0.0031in.) No.2 : 0.
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ENGINE BLOCK 5. EMA -29 Inspect piston ring end gap. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter. If the bore is over the service limit, the cylinder block must be replaced or bored PISTON PINS 1.
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EMA -30 REASSEMBLY ENGINE (G6EA - GSL 2.7) 3. EBDEDDF4 NOTE • Thoroughly clean all parts before reassembling. • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. • Replace all gaskets, O-rings and oil seals with new parts. 1. Install the connecting rod bearings. 1) Align the bearing(A) claw with the groove of the connecting rod or connecting rod cap(B). 2) Install the bearings(A) in the connecting rod and connecting rod cap(B).
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ENGINE BLOCK 5. EMA -31 Install main bearings. 6. NOTE Upper bearings have the oil grooves of the oil holes; Lower bearings do not. 1) Aligning the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings(A). Install thrust bearings. Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing outward. A A ECKD324A 7. Place crankshaft(A) on the cylinder block.
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EMA -32 9. ENGINE (G6EA - GSL 2.7) Install main bearing cap bolts. 10. Check crankshaft end play. 1) 11. Install the piston and connecting rod assemblies. Install and uniformly tighten the bearing cap bolts, in two steps, in the sequence shown. NOTE Tightening torque M8 : 15.7Nm(1.6 kgf.m, 11.6lb-ft) + 90 M10 : 29.4Nm(3.0 kgf.m, 21.7lb-ft)+ 90 • Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
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ENGINE BLOCK EMA -33 • Use SST(09221-4A000), install connecting rod bearing cap bolts. 2) 09221-4A000 Assembling rear oil seal case, the liquid sealant TB1217H should be applied to the rear oil seal case. The part must be assembled within 5 minutes after sealant was applied. KCBF127C 12. Install the rear oil seal case. KCBF129A Tightening torque 9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.67lb-ft) 13. Using SST(09231-33000), install rear oil seal after applying engine oil on the rip of the oil seal.
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EMA -34 ENGINE (G6EA - GSL 2.7) 17. Install the lower oil pan. NOTE • Clean the sealing face before assembling two parts. • Remove harmful foreign materials on the sealing face before applying sealant. • When applying sealant gasket, sealant must not protrude into the inside of oil pan. • To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. 1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
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ENGINE BLOCK EMA -35 18. Install the air conditioning compressor bracket(A). (Refer to ’HA’ group) A KCBF138A 19. Install the power steering pump bracket(A) and the knock sensor(B). INSTALLATION EF30F311 1. Install the water pump. 2. Install the air conditioning compressor.(Refer to ’HA’ group). 3. Install the cylinder head. 4. Install the power steering pump.(Refer to ’ST’ group). 5. Install the generator. 6. Install the intake manifold. 7. Install the exhaust manifold. 8.
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EMA -36 ENGINE (G6EA - GSL 2.7) COOLING SYSTEM COMPONENTS E3589507 7 8 2 4 6 1 2 5 3 1. 2. 3. 4. Radiator Radiator bracket Coolant reservoir tank Radiator upper hose 5. 6. 7. 8.
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COOLING SYSTEM EMA -37 16.7 ~ 19.6 (1.7 ~ 2.0, 12.3 ~ 14.5) 16.7 ~ 19.6 (1.7 ~ 2.0, 12.3 ~ 14.5) 29.4 ~ 41.2 (3.0 ~ 4.2, 21.7 ~ 30.4) 14.7 ~ 21.6 (1.5 ~ 2.2, 10.8 ~ 15.9) TORQUE : N.m (kgf.m, lb-ft) 1. 2. 3. 4. 5. Water pump Water pump gasket Water pipe O-ring Water inlet pipe Water outlet pitting 6. 7. 8. 9. Thermostat Water inlet pitting Water temp. control assembly Water temp.
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EMA -38 ENGINE COOLANT REFILLING AND BLEEDING EDA90EDC ENGINE (G6EA - GSL 2.7) 15. Stop the engine and wait until coolant gets cool. 16. Repeat 10 to 15 until the coolant level doesn’t fall any more, bleeding air out of the cooling system. WARNING Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.
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COOLING SYSTEM EMA -39 CAP TESTING 1. Remove the radiator cap, wet its seal with engine coolant, and install it to a pressure tester. ECKD501X 2. Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm², 14 ~ 19psi). 3. Check for a drop in pressure. 4. If the pressure drops, replace the cap.
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EMA -40 REMOVAL ENGINE (G6EA - GSL 2.7) WATER TEMPERATURE CONTROL ASSEMBLY EEAF37FE WATER PUMP 1. Drain the engine coolant. 1. 2. Remove the air cleaner assembly. 3. Disconnect the radiator upper and lower hose(A, B). Drain the engine coolant. WARNING System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool. 2. Remove drive belt(A). A A B LDLG008A 4.
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COOLING SYSTEM 8. EMA -41 Remove the water pipe(A). THERMOSTAT NOTE Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. A 1. Drain engine coolant so its level is below thermostat. 2. Remove the coolant inlet pitting(A) and the thermostat(B).
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EMA -42 ENGINE (G6EA - GSL 2.7) RADIATOR RH 1. Drain the engine coolant. Remove the radiator cap to speed coolant draining. 2. Remove the air duct. 3. Remove the upper radiator hose(A) and lower radiator hose. B SCMEM6037D 5. Remove the radiator grill upper cover.(A) A SCMEM6017D A 4. Disconnect the radiator fan connector.(A, B) LH A SCMEM6039D 6. SCMEM6036D Remove the head lamp washer nozzle cover and front bumper.
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COOLING SYSTEM 7. EMA -43 Remove the radiator cap hose.(A) RH A A SCMEM6040D 8. First, remove the cooling fan.(First, separate LH side) NOTE Remove the bracket bolt of radiator lower hose. 9. Remove the radiator bracket bolt of the radiator upper side(A). LH A SCMEM6041D SCMEM6042D 10. Remove the radiator assembly from the engine.
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EMA -44 INSPECTION ENGINE (G6EA - GSL 2.7) INSTALLATION ECD22755 WATER PUMP WATER PUMP 1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary. 1. 2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if necessary. 3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly. E8886E63 Install the water pump(A) and a new gasket(B) with the bolts.
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COOLING SYSTEM EMA -45 WATER TEMPERATURE CONTROL ASSEMBLY 1. 6. Connect the radiator upper and the lower hose(A). Install the water pipe(A). Tightening torque 16.7 ~ 19.6Nm (1.7 ~ 2.0kgf.m, 12.3 ~ 14.5lb-ft) A A B LDLG008A KCBF140A 2. Install the water temperature control assembly(A) with a new gasket(B). Tightening torque 29.4 ~ 41.2Nm(3.0 ~ 4.2kgf.m, 21.7 ~ 30.4lb-ft B A KCBF139A NOTE Use new O-rings and wet them with water or coolant when reassembling. 3. Install the wiring protector.
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EMA -46 ENGINE (G6EA - GSL 2.7) THERMOSTAT RADIATOR 1. 1. Install the engine from radiator assembly. 2. Install the radiator bracket bolt.(A) Place thermostat(B) in coolant inlet pitting(A). Install the thermostat with the jiggle valve upward. LH B A KCBF141A 2. Install the coolant inlet pitting(A). Tightening torque 16.66 ~ 19.60Nm (1.7 ~ 2.0kgf.m, 12.30 ~ 14.47lb-ft) 3. Fill with engine coolant. 4. Start engine and check for leaks. A SCMEM6041D RH A SCMEM6042D 3.
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COOLING SYSTEM 4. EMA -47 Install the radiator cap hose.(A) LH A A SCMEM6036D SCMEM6040D 5. Install the front bumper and head lamp washer nozzle cover.(Refer to BD group) 6. Install the radiator grill upper cover.(A) RH B A SCMEM6037D 8. Install the upper radiator hose.(A) SCMEM6039D 7. Connect the radiator fan connector.(A, B) A SCMEM6017D 9. Install the air duct. 10. Refill with engine coolant.
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EMA -48 ENGINE (G6EA - GSL 2.7) LUBRICATION SYSTEM COMPONENTS ED860823 1 2 4 3 7 8 9 5 6 15 10 7 11 12 16 13 1. 2. 3. 4. 5. 6. 7. 8. Oil pump cover Oil pump outer rotor Oil pump inner rotor Oil pump case rotor Oil seal Crankshaft sprocket O-ring Relief plunger 9. 10. 11. 12. 13. 15. 16.
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LUBRICATION SYSTEM INSPECTION 1. 2. EMA -49 If low, check for leakage and add oil up to the "F" mark. E56035AA Check engine oil quality. Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace oil. Check the engine oil level. After warning up the engine, make the engine stand still for five minutes or more. The oil level should be between the ’L’ and ’F’ marks on the dipstick, then.
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EMA -50 REMOVAL ENGINE (G6EA - GSL 2.7) E21D8F6A CAUTION OIL PUMP CASE 1. Drain engine oil. 2. Remove the front right wheel and tire. 3. Remove the front right side cover. 4. Remove the front muffler. 5. Remove the generator. 6. Remove the timing belt. 7. Remove the oil filter bracket(A). Be careful not to damage the contact surfaces of upper oil pan and lower oil pan. 9. Remove the oil screen(A). A A KCBF124A 10. Remove the upper oil pan, using the SST(092153C000)(A). A KCBF147A 8.
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LUBRICATION SYSTEM EMA -51 INSPECTION 11. Remove the oil pump case(A). EA202EEB RELIEF SPRING 1. Check the relief plunger. Apply engine oil on the plunger and check that it moves smoothly in the hole. If it does not, replace the plunger or the front case only in necessary cases. 2. Check the relief valve spring. Check deformation or damage of the relief valve spring. A KCBF163A 12. After removing the plug(A), remove the relief spring(B) and the velief plunger(C).
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EMA -52 ENGINE (G6EA - GSL 2.7) OIL PRESSURE SWITCH REPLACEMENT 1. OIL AND FILTER Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil pressure switch. CAUTION • Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
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LUBRICATION SYSTEM 2) Check the part number of a new oil filter is as the same as that of the old one. 3) Replace the oil filter. 4) Tighten it slightly until the o-ring of the filter cap contacting on its position. 5) Tighten it with the specified torque. EMA -53 INSTALLATION E811FEC1 OIL PUMP CASE 1. Assembly the relief spring(B) and the relief plunger(C) and tighten the plug(A). Tightening torque 39.2 ~ 49.0Nm (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lb-ft) Tightening torque 16.7 ~ 24.5Nm(1.7 ~ 2.5kgf.
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EMA -54 ENGINE (G6EA - GSL 2.7) 3. CAUTION Using the SST(09214~33000), install the oil pump case oil seal. • Make clean the sealing face before assembling two parts. • Remove harmful foreign materials on the sealing face before applying sealant. • When applying sealant gasket, sealant must not be protrude into the inside of oil pan. • To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. • After assembly, wait at least 30 minutes before filling the engine with oil.
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LUBRICATION SYSTEM EMA -55 NOTE CAUTION • Make clean the sealing face before assembling two parts. • Remove harmful foreign materials on the sealing face before applying sealant. • When applying sealant gasket, sealant must not be protrude into the inside of oil pan. • To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. • After assembly, wait at least 30 minutes before filling the engine with oil. 3) Always use a new gasket. 6. Install the lower oil pan.
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EMA -56 3) ENGINE (G6EA - GSL 2.7) Fix the oil pan and tighten the bolts in several steps uniformly. Tightening torque 9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 8. Install the timing belt, the generator and the front muffler. 9. Install the front right side cover and the wheel and tire. 10. Fill with engine coolant. 11. Start engine and check for leaks. 9 10 12. Recheck engine coolant level. 6 5 2 1 4 3 8 11 7 KCBF133A 7. Install the oil filter bracket(A). Tightening torque 18.6 ~ 23.
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INTAKE AND EXHAUST SYSTEM EMA -57 INTAKE AND EXHAUST SYSTEM COMPONENTS E37D8ABE 8.8 ~ 13.7 (0.9 ~ 1.4, 6.5 ~ 10.1) 18.4 ~ 23.5 (1.9 ~ 2.4, 13.7 ~ 17.4) 3 18.4 ~ 23.5 (1.9 ~ 2.4, 13.7 ~ 17.4) 1 5 4 2 TORQUE : N.m (kgf.m, lb-ft) 1. 2. 3. 4. 5.
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EMA -58 ENGINE (G6EA - GSL 2.7) 16.7 ~ 21.6 (1.7 ~ 2.2, 12.3 ~ 15.9) 1 4 2 5 3 6 29.4 ~ 34.3 (3.0 ~ 3.5, 21.7 ~ 25.3) TORQUE : N.m (kgf.m, lb-ft) 1. Bank 1 heat protector 2. Bank 1 exhaust manifold 3. Bank 1 exhaust gasket 4. Bank 2 protector 5. Bank 2 exhaust manifold gasket 6.
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INTAKE AND EXHAUST SYSTEM EMA -59 4 4 5 4 3 4 2 4 1 6 5 4 1. Catalytic convert 2. Center muffler 3. Main muffler 4. Lever hanger 5. Gasket 6.
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EMA -60 REMOVAL ENGINE (G6EA - GSL 2.7) 3. E375DF19 Disconnect the engine wiring harness connectors. 1) INTAKE MANIFOLD ASSEMBLY 1. Remove the engine cover. 2. Remove the intake air hose and air cleaner assembly. Disconnect the No.1/No.2 knock sensor connectors(A,B), the oil pressure switch connector(C), the ignition coil harness(D) and the No.1 VIS(Variable Induction System) connector(E). E 1) Disconnect the MAF connector(A). 2) Disconnect the breather hose(B) from air cleaner hose.
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INTAKE AND EXHAUST SYSTEM 3) EMA -61 Disconnect the injection connectors(A,B,C), the ground lines(D), the condensor connector(E) and the Ignition coil connectors(F). 5) C B Disconnect the MAPS(Manifold Absolute Pressure Sensor) connector(A), the ETC(Electronic Throttle Control) connector(B) and the PCSV(Purge Control Solenoid Valve) connector(C). E A B D A F LDLG060A 4) Disconnect the injection harness connector(A), the No.2 VIS(Variable Induction System) connector(B), the No.1/No.
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EMA -62 7) ENGINE (G6EA - GSL 2.7) Disconnect the bank 2 CMP sensor connector(A) and the ECT(Engine Coolant Temperature) sensor connector(B). 4. Remove the PCV(Pulge Control Valve) hose(A). A A B KCBF180A KCBF155A 8) 5. Remove the ETC(Electric Throttle Control) bracket(A) and the cooling hoses(B). Disconnect the bank 2 front/rear O2 sensor connectors(A,B) and the CKP sensor connector(C). A A C B B KCBF179A KCBF154A 9) 6. Disconnect the brake vaccume hose(A).
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INTAKE AND EXHAUST SYSTEM 7. EMA -63 Remove the surge tank mounting bracket(A). 10. Remove the intake manifold assembly(A). A A KCBF178A 8. Remove the surge tank(A). EDQF063A A KCBF181A 9. Remove the delivery pipe assembly(A).
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EMA -64 ENGINE (G6EA - GSL 2.7) EXHAUST MANIFOLD ASSEMBLY 4. Remove the oil level gauge. 1. Remove the under cover. 5. Remove the heat protector(A). 2. Remove the front muffler(A). A A KDRF184A SCMEM6005L 3. Disconnect the oxygen sensor connectors(A). A KCBF154B A KCBF160A 6. Remove the exhaust manifold assembly(A).
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INTAKE AND EXHAUST SYSTEM INSTALLATION EMA -65 EXHAUST MANIFOLD ASSEMBLY E8A999C8 1. INTAKE MANIFOLD ASSEMBLY 1. Install the intake manifold assembly with a new gasket to a cylinder head assembly. Tighten the bolts in two steps. Tightening torque Step 1(a~h): 3.9~5.9Nm(0.4~0.6kgf.m, 2.9~4.3lb-ft) Step 2(1~8): 18.6~23.5Nm(1.9~2.4kgf.m, 13.7~17.4lb-ft) Tightening torque 29.4~34.3Nm(3.0~3.5kgf.m, 21.7~25.3lb-ft) 2.
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EMA -66 ENGINE (G6EA - GSL 2.7) CYLINDER HEAD ASSEMBLY COMPONENTS EBE1AEDF 7.8 ~ 9.8 (0.8 ~ 1.0, 5.8 ~ 7.2) 20.6 ~ 25.5 (2.1 ~ 2.6, 15.2 ~ 18.8) 64.7 ~ 78.5 (6.6 ~ 8.0, 47.7 ~ 57.9) 10.8 ~ 12.7 (1.1 ~ 1.3, 8.0 ~ 9.4) 10.8 ~ 12.7 (1.1 ~ 1.3, 8.0 ~ 9.4) 20.6 ~ 25.5 (2.1 ~ 2.6, 15.2 ~ 18.8) 88.3 ~ 107.9 (9.0 ~ 11.0, 65.1 ~ 79.6) TORQUE : N.m (kgf.m, lb-ft) 1. 2. 3. 4. 5. 6.
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CYLINDER HEAD ASSEMBLY EMA -67 1 24.5 (2.5, 18.1) + 60 + 45 5 4 2 3 6 7 8 9 TORQUE : N.m (kgf.m, lb-ft) 1. 2. 3. 4. 5. MLA(Mechanical Lash Adjuster) Retainer lock Retainer OCV(Oil Control Valve) Valve spring 6. 7. 8. 9.
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EMA -68 REMOVAL ENGINE (G6EA - GSL 2.7) 4) E84FDA9C Disconnect the PCM connectors(D). D CAUTION • Use fender covers to avoid damaging painted surfaces. • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it. • When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket. • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
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CYLINDER HEAD ASSEMBLY 5. EMA -69 Remove the fuel inlet hose(A) from the delivery pipe. 3) Disconnect the injection connectors(A,B,C), the ground lines(D), the condensor connector(E) and the Ignition coil connectors(F). C B E D A A LDLG062A 6. F Disconnect the engine wiring harness connectors. 1) Disconnect the No.1/No.2 knock sensor connectors(A,B), the oil pressure switch connector(C), the ignition coil harness(D) and the No.1 VIS(Variable Induction System) connector(E).
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EMA -70 5) ENGINE (G6EA - GSL 2.7) Disconnect the MAPS(Manifold Absolute Pressure Sensor) connector(A), the ETC(Electronic Throttle Control) connector(B) and the PCSV(Purge Control Solenoid Valve) connector(C). 7) Disconnect the bank 2 CMP sensor connector(A) and the ECT(Engine Coolant Temperature) sensor connector(B). A A B B KCBF155A LDLG034A 8) Disconnect the bank 2 front/rear O2 sensor connectors(A,B) and the CKP sensor connector(C).
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CYLINDER HEAD ASSEMBLY 7. EMA -71 Remove the PCV(Pulge Control Valve) hose(A). 11. Remove the power steering pump.(Refer to ’ST’ group). 12. Remove the exhaust manifold assembly.(Refer to ’Intake and exhause system’). A 13. Remove the intake manifold assembly.(Refer to ’Intake and exhause system’). 14. Remove the timing belt.(Refer to ’Timing system’). 15. Remove the ignition coils. 16. Remove the water temp. control assembly. 17. Remove the cylinder head cover(A). KCBF180A 8.
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EMA -72 ENGINE (G6EA - GSL 2.7) 19. Remove the timing chain tensioner(A). 23. Remove the CKP sensor connector bracket(A). A A KCBF172A KCBF168A 24. Remove the cylinder head assembly. 20. Remove the camshaft. 1) 21. Remove the bank 1 timing belt rear cover(A). A Remove the bolts in 2~3 steps as following orders. 3 7 6 2 4 8 5 1 1 5 8 4 2 6 7 3 KCBF170A KCBF176A 22. Remove the bank 2 timing belt rear cover(A).
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CYLINDER HEAD ASSEMBLY DISASSEMBLY EMA -73 5) E63D4DE3 Using SST(09222-29000), remove the valve stem seal. NOTE Identify MLA(Mechanical Lash Adjuster), valves and valve springs as they are removed so that each item can be reinstalled in its original position. 1. 09222-29000 Remove MLA(Mechanical Lash Adjuster)s(A). A KDRF234A NOTE Do not reuse the removed valve stem seals. 3. Remove OCV(Oil Control Valve)(A). KCBF173D 2. Remove valves.
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EMA -74 ENGINE (G6EA - GSL 2.7) INSPECTION VALVE AND VALVE SPRING EEB401B1 1. CYLINDER HEAD 1. Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and the manifolds for warpage. Flatness Standard Flatness Standard of cylinder head gasket surface : 0.03mm(0.0012in.) or less of manifold gasket surface : 0.15mm(0.0059in.) or less Inspect valve stems and valve guides.
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CYLINDER HEAD ASSEMBLY 3) EMA -75 Calculate the clearance between the valve guides and the stems by difference between the valve stem measured diameter and the valve guide measured inside diameter. 3. Valve stem-to-guide clearance [Standard] Intake : 0.020 ~ 0.050mm (0.0008 ~ 0.0020in.) Exhaust : 0.035 ~ 0.065mm (0.0014 ~ 0.0026in.) [Limit] Intake : 0.10mm (0.0039in.) or less Exhaust : 0.13mm (0.0051in.) or less 2.
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EMA -76 ENGINE (G6EA - GSL 2.7) MLA(MECHANICAL LASH ADJUSTER) CAMSHAFT 1. 1. Inspect MLA. Using a micrometer, measure the MLA outside diameter. MLA O.D. Intake/Exhaust : 29.964 ~ 29.980mm(1.1797 ~ 1.1803in.) 2. Inspect cam lobes. Using a micrometer, measure the cam lobe height. Cam height [Standard value] Intake : 44.5mm (1.7520in.) Exhaust : 44.5mm (1.7520in.) Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head. Tappet bore I.D. Intake/Exhaust : 30.000 ~ 30.025mm(1.
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CYLINDER HEAD ASSEMBLY 4) EMA -77 Install the bearing caps with the tightening torque. CAUTION 4. Inspect camshaft end play. 1) Install the camshafts. 2) Using a dial indicator, measure the end play while moving the camshaft back and forth. Do not turn the camshaft. 5) Remove the bearing caps. 6) Measure the plastigage at its widest point. Camshaft end play [Standard value] : 0.05 ~ 0.15mm(0.0020 ~ 0.0059in.) Bearing oil clearance [Standard value] Intake : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.
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EMA -78 ENGINE (G6EA - GSL 2.7) CVVT ASSEMBLY 1. 7) Inspect CVVT assembly. 1) Fix the CVVT assembly with a vice. Ensure that the cam lobe and journal is not damaged. 2) Check that the CVVT assembly will not turn. It should not be turned. 3) Apply vinyl tape to the retard hole except the one(A) indicated by the arrow in the illustration. Turn the CVVT assembly with your hand in retard direction and lock it at the maximum delay angle position.
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CYLINDER HEAD ASSEMBLY REPLACEMENT EMA -79 E3AC3B4D VALVE GUIDE 1. Using the SST(09221-3F100A), remove the valve guide from the downside of the cylinder head assembly. 09221-3F100A 09221-3F100A 09221-3F100B EDKD900B 4. After installing the valve guides, insert new valves and check the clearance between the valve stems and the valve guides. 5. After replacing the valve guides, check if they are properly installed with the valve seats. Reprocess valve seats if necessary. EDKD900A 2. 3.
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EMA -80 REASSEMBLY ENGINE (G6EA - GSL 2.7) 3) ECABCEB6 NOTE • Thoroughly clean all parts to be assembled. • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. • Replace oil seals with new ones. 1. Using the SST(09222 - 3K000, 09222-3C300), compress the springs and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor. 09222-3K000 Install valves.
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CYLINDER HEAD ASSEMBLY 3. EMA -81 INSTALLATION Install OCV(Oil Control Valve)(A). Tightening torque 7.8 ~ 9.8Nm(0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft) E77C23D4 NOTE • Thoroughly clean all parts to be assembled. • Always use a new head and manifold gasket. • The cylinder head gasket is a metal gasket. Take care not to bend it. • Rotate the crankshaft to set the No.1 cylinder piston at TDC. 1. A After putting the cylinder head gasket on the cylinder block, install the cylinder head.
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EMA -82 ENGINE (G6EA - GSL 2.7) 6 2 3 4. 7 Install the camshaft in the cylinder head assembly. 1) 5 1 4 LH CAMSHAFT CHAIN TIMING MARK 8 8 4 1 5 7 3 2 6 Align the timing mark of the camshaft timinig chain. KCBF176B NOTE Using the SST(09221-4A000), tighten the bolts which need to be tightened with the angular tightening method. KCBF164A RH CAMSHAFT CHAIN TIMING MARK 09221-4A000 LDLG063A 3.
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CYLINDER HEAD ASSEMBLY 5. EMA -83 Install the timing chain tensioner. 1) 2) Insert the set pin by pressing the timing chain tensioner. C A Install the chain tensioner(A) in the cylinder head assembly. A B KDRF228A A(LH/RH HEAD): L(LH), R(RH) B(Intake/Exhaust): I(Intake), E(Exhaust) C(Cap no.): 1,2,3 CAUTION KCBF168A 6. When installing the bearing caps, turn the crankshaft to place a piston in the middle of the block because linterference between valves and pistons can occur.
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EMA -84 8. ENGINE (G6EA - GSL 2.7) 11. Install the timing belt.(Refer to ’Timing system’). Install the CKP sensor connector bracket(A). 12. Check and adjust the valve clearance. 13. Install the cylinder head cover. 1) Remove oil, dust or sealant on the upper surface of the cylinder before assembling cylinder head cover. 2) Assemble the cylinder head cover in five minites after applying liquid gasket(LOCTITE 5900) on the camshaft cap and packing part. A KCBF172A 9.
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CYLINDER HEAD ASSEMBLY EMA -85 21. Install the PCV(Pulge Control Valve) hose(A). NOTE • Do not start engine for thirty minites after assembling the cylinder head cover. • Do not reuse the cylinder head cover gasket. A 14. Install the water temp. control assembly. 15. Install the intake manifold assembly. 16. Install the exhaust mainfold assembly. 17. Install the power steering pump.(Refer to ’ST’ group). 18. Install the drive belt(A). KCBF180A 22. Connect the engine wiring harness connectors.
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EMA -86 3) ENGINE (G6EA - GSL 2.7) Connect the bank 2 CMP sensor connector(A) and the WTS(Water Temperature Sensor) connector(B). 5) Connect the MAPS(Manifold Absolute Pressure Sensor) connector(A), the ETC(Electronic Throttle Control) connector(B) and the PCSV(Purge Control Solenoid Valve) connector(C). A A B B KCBF155A 4) LDLG034A Connect the generator connector(A) and the air conditioning compressor connector(B).
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CYLINDER HEAD ASSEMBLY 7) EMA -87 Connect the injection connectors(A,B,C), the ground lines(D), the condensor connector(E) and the Ignition coil connectors(F). B 9) Connect the No.1/No.2 knock sensor connectors(A,B), the oil pressure switch connector(C), the ignition coil harness(D) and the No.1 VIS(Variable Induction System) connector(E). C E E D D A C A F B LDLG060A LDLG005A 8) Connect the bank 1 front/rear O2 sensor connectors(A). 23. Install the fuel inlet hose(A) from the delivery pipe.
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EMA -88 ENGINE (G6EA - GSL 2.7) 25. Install the intake air hose and air cleaner assembly. 1) Connect the PCM connectors(D). D C B A SCMEM6004L D LDLG061A 2) Install the intake air hose and air cleaner assembly(C). 3) Connect the breather hose(B) from air cleaner hose. 4) Connect the MAF connector(A). 26. Install the engine cover. 27. Refill engine coolant.
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TIMING SYSTEM EMA -89 TIMING SYSTEM COMPONENTS E19F8373 58.8 ~ 68.6 (6.0 ~ 7.0, 43.4 ~ 50.6) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 2 1 3 5 4 19.6 ~ 26.5 (2.0 ~ 2.7, 14.5 ~ 19.5) 6 7 34.3 ~ 53.9 (3.5 ~ 5.5, 25.3 ~ 39.8) 8 9 12 10 11 49.0 ~ 58.8 (5.0 ~ 6.0, 36.2 ~ 43.4) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 166.7 ~ 176.5 (17.0 ~ 18.0, 123.0 ~ 130.2) TORQUE : N.m (kgf.m, lb-ft) 1. 2. 3. 4. 5. 6.
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EMA -90 REMOVAL ENGINE (G6EA - GSL 2.7) 6. EDEF75A6 1. Remove the engine cover. 2. Remove the front right wheel and tire. 3. Remove the right side cover. 4. Remove the drive belt(A), the idler(B) and the tensioner(C). Align the groove of the pulley with the timing mark of the timing belt cover by turning the crankshaft pulley clockwise. Check if the timing mark of the camshaft sprocket is aligned with that of the cylinder head cover at the moment. (No.
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TIMING SYSTEM 8. EMA -91 Remove the crankshaft damper pulley(A). NOTE After the removal, engine coolant can be drained a little from that point(B) which is a matter of no importance. 11. Remove the timing belt auto tensioner(A). A A KCBF109A 9. Remove the timing belt lower cover(A). KCBF112A A 12. Remove the timing belt(A). A KCBF110A 10. Remove the engine support bracket(A). KCBF113A A NOTE Make a direction mark of revolution on the timing belt for reusal.
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EMA -92 ENGINE (G6EA - GSL 2.7) 13. Remove the tensioner arm assembly(A) and the idler(B). INSPECTION EFF268C6 SPROCKETS, TENSIONER, IDLER A B 1. Check the camshaft sprocket and crankshaft sprocket, tensioner pulley and idler pulley for abnormal wear, cracks, or damage. Replace as necessary. 2. Inspect the tensioner and the idler for easy and smooth rotation and check for play or noise. Replace as necessary. KCBF114A 14. Remove the crankshaft sprocket. KCBF115A 3.
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TIMING SYSTEM INSTALLATION EMA -93 2) E8CBF683 1. Install the crankshaft sprocket. 2. Install the tensioner arm assembly(A) and the idler(B). Install the auto tensioner(A) to the front case with the set-pin inserted. Tightening torque 19.6 ~ 26.5Nm(2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft) Tightening torque Tensioner arm bolt : 34.3 ~ 53.9Nm(3.5 ~ 5.5kgf.m, 25.3~ 39.8lb-ft) Idler pulley bolt : 49.0 ~ 58.8Nm(5.0 ~ 6.0kgf.m, 36.2~ 43.4lb-ft) A B A KCBF117A 4.
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EMA -94 5. ENGINE (G6EA - GSL 2.7) Install the timing belt. Crankshaft sprocket(A) Idler(B) Bank 2 exhaust camsprocket(C) Water pump pulley(D) Bank 1 exhaust camsprocket(E) Tensioner pulley(F). 8. Install the engine support bracket(A). Tightening torque 58.8 ~ 68.6Nm(6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb-ft) C E A D B F A LDLG067A 6. Remove the auto tensioner set-pin. 7. Check the tension of the timing belt. 1) LDLG068A 9. Turn the crankshaft 2 rev. clockwise which makes the No.
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TIMING SYSTEM EMA -95 10. Install the crankshaft damper pulley(A). 12. Install the timing belt upper cover(A). Tightening torque 166.7 ~ 176.5Nm(17.0 ~ 18.0kgf.m, 123.0 ~ 130.2lb-ft) Tightening torque 9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) A A KCBF109A 11. Install the engine mounting bracket(A). KCBF106A 13. Install the drive belt tensioner(C). Tightening torque 63.7 ~ 83.4Nm(6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft) Tightening torque 34.3 ~ 53.9Nm(3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb-ft) 14.
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EMA -96 ENGINE (G6EA - GSL 2.7) ENGINE AND TRANSAXLE ASSEMBLY REMOVAL 4) Disconnect the PCM connectors(D). D E73C468F CAUTION • Use fender covers to avoid damaging painted surfaces. • To avoid damage, unplug the wiring connectors carefully while holding the connector portion. C B NOTE A • Mark all wiring and hoses to avoid misconnection. 1. SCMEM6004L Remove the air duct and the battery(A) after disconnecting the terminals(B) from the battery. B D LDLG061A A 4.
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ENGINE AND TRANSAXLE ASSEMBLY 5. EMA -97 Remove the upper radiator hose(A) and lower radiator hose(B). E D A C A B LDLG005A 2) B LDLG008A 6. Remove the transaxle oil cooler hoses(A/T vehicles only). 7. Remove the fuel inlet hose(A) from the delivery pipe. Disconnect the bank 1 front/rear O2 sensor connectors(A). A KCBF160A 3) A Disconnect the injection connectors(A,B,C), the ground lines(D), the condensor connector(E) and the Ignition coil connectors(F). LDLG062A 8.
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EMA -98 4) ENGINE (G6EA - GSL 2.7) Disconnect the injection harness connector(A), the No.2 VIS(Variable Induction System) connector(B), the No.1/No.2 OCV(Oil Control Valve) connectors(C,D) and the OTS(Oil Temperature Sensor) connector(E). B A D C LDLG035A 6) C Disconnect the generator connector(A) and the air conditioning compressor connector(B).
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ENGINE AND TRANSAXLE ASSEMBLY 8) EMA -99 Disconnect the bank 2 front/rear O2 sensor connectors(A,B) and the CKP sensor connector(C). 10. Disconnect the battery wirings(A,B) from the engine room fuse relay box(C). A C B C A B KCBF154A 9) Disconnect the bank 1 CMP sensor connector(A). LDLG011A 11. Remove the heater hoses. 12. Disconnect the brake vaccume hose(A). A A KCBF152A LDLG036A 9. Disconnect ground lines(A) from the engine and the transaxle assembly. A SCMEM6008L 13.
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EMA -100 ENGINE (G6EA - GSL 2.7) 14. After draining or gathering power steering fluid, disconnect the power steering hose(A). 24. Remove the front muffler(A). A A SCMEM6005L SCMEM6009L 25. Disconnect the power steering return hose. 15. Remove the steering column shaft joint bolt.(Refer to ST group). 16. Disconnect the air conditioning hoses.(Refer to HA group). compressor 26. Remove the engine mounting bracket(A). [MT] 17. Remove the front wheels and tires.(Refer to DS group). A 18.
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ENGINE AND TRANSAXLE ASSEMBLY EMA -101 INSTALLATION 27. Remove the transaxle mounting bracket(A). A LDLG013A 28. Supporting the engine and transaxle assembly with a jack, remove the assembly from the vehicle by loosening the subframe mouting bolts and lifting up the vehicle slowly. NOTE When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components. E4AC8DA7 Installation is in the reverse order of removal.