" set SECTION 5 — SPECIFICATIONS AND GENERAL INFORMATION 6G72 SPECIFICATIONS ENGINE GENERAL Type. V6 OHC/OHV Number of eylinders Six Bore 91.1 mm Stroke 76.0 ron Displacement 2972 ce Max. power -95 RON fuel 123 kW (DIN) @ 5500 rpm “91 RON fuel Compression ratio Compression pressure @ 250 rpm Pressure difference between cylinders Spark plug type Firing order Direction of rotation CYLINDER HEAD Material ‘Type Maximum allowable distortion Grinding limit 112 KW (DIN) @ 5000 rpm 10:1 1300 kPa 100 kPa NOYC4 Pre 123-456 Clockwise abserved from front of engine ipped Aluminium alloy ‘Compact hemi-spherical 02 mm 02 mm NOTE: If the cylinder block gasket surface has already been ground, then the thickness of the removed stock should be included in the grinding limit. Inlet valve seat insert hole diameter —0.3 mm Oversize 06 mm Oversize Exhaust valve seat insert hole diameter 0.3 mm Oversize -0.6 mm Oversize Inlet and exhaust valve seat insert height 0.3 min Oversize 0.6 mm Oversize Valve guide hole diameter ~0.05 mm Oversize 0.25 mm Oversize —0.30 mm Oversize Camshaft/camshaft bearing clearance VALVES Head diameter — Inlet — Exhaust Valve length — Inlet . — Exhaust Stem diameter — Inlet — Exhaust ‘Stem diameter wear limit — Inlet — Exhaust Valve face angle : Valve head thickness — Inlet — Exhaust Valve seat contact width Valve stem to guide clearance — Inlet ~ Exhaust Installed height between spring seat and retainer Hydraulic lash adjuster dry clearance 44.300 to 44.325 mm 44,600 to 44.625 mm 38.300 to 38,325 mm. 38.600 10 38.625 mm 7.90 to 8.10 mm 8.20 to 8.40 mm 13.050 to 13.068 mm 13.250 to 13.268 mm 13,500 to 13.518 mm 0.05 to 0.09 mm 43. mm 35 mm 103.0 mm 102.7 mm 7.960 to 7.975 mm £71930 to 7.950 mm. 0.0 mm 0.45 mm 45° 10 45.5° 12 mm 3.5 mm 0,90 to 1,30 mm 0.03 to 0.06 mm (0.05 to 0.09 mm 40.4 to 41.4 mm 05 t0 1.3 mmCylinder head hole size for oversize puides (405 mm oversize 01.25 mm oversize — 050mm everize Lone! @inscalled height Insalle! height ut of Square VALVE TIMING. Inlet opens, Inlet closes Duration Esshaust opens Eshaust closes. Duration Overlap CAMSHAL Material Camshat bear Beatin Four Height of eam lobe Inlet Exhaust Nominal ear fit Rocker arm iw rocker shalt clearance CYLINDER BLOCK. Material Flainess oF gasket s jing Lot ‘Should be included the grinding. Cylinder bore diameter Maximum bore oversize Maximum diameter diference betwer Maximum bore wear ¢hefore reconditioning) Maximum ovatity and taper (before reconditioning) eylinders W-s-2 ——— SPECIFICATIONS CONT. inder head gasket surface has already been ground, it of 0.2 mm 13.0610 13.07 mm 8,000 10 8.02 mm 440 mm 48.0 mm 14.60 £0.30 m 13.050 10 13.068 1 13.250 t0 13.268 nm 13.500 G0 13.518 mm R 4981 323N@ 40.4 mm 404 mm max. le’ BTDC 66" ABDC. 50” ABDC 26° ATDC Cast iron ‘Aluminium alloy 0.01 W008 ¥4.0mm 41.25 many 41.25 mm 6.25 mm 1,01 O04 mm Alloy east iron Less than 0.05 mm 02mm the thickness of the removed stock mm 100 mm, 0.02 man 00: 0.02 men ‘tation tors Australia Lid. March 1995 awn4205-8PISTONS Material Type... a Piston pin hole diameter . Piston diameter Piston to bore clearance Piston oversizes — PISTON PIN ‘Type Material Diameter Offset in piston PISTON RINGS Number 5 Ring gap — New — Compression Scraper — Oil ring Service limit — Compression |. — Scraper — Oil ring Side clearance — Compression — Scraper = Service limit CONNECTING RODS Material ceseeee Length between centres Small end bore diameter Big end bore diameter . Conrod bearing clearance Conrod bearing undersizes — Conrod — bend — owist Conrod side clearance on journal . = service limit Bearing material . CRANKSHAFT Material Number of main bearings... Main bearing journals diameter... End float controlled by . W-s-3 ‘SPECIFICATIONS CONT. Aluminium alloy ‘Auto thermic type 22.0 mm 91.05 to 91.07 mm. 0.03 to 0.05 mm 0.25 mm 0.50 mm. £0.75 mm. 1.00 mm Press fit in connecting rod Alloy steel 22.001 10 22.007 mm. 0.3 mm 0.03—0.09 mm 0.02—0.06 mm 0.1 mm Forged carbon steel 140.9 to 141.0 mm (22: mm 53: mm £0,016 to 0.086 mm 0.25 mm. 0.50 mm 0.75 mm 0.05 mm. O41 mm 0.10 to 0.25 mm 0.4 mm Aluminium alloy Cast iron 4 60.0 mm No, 3 bearingCRANKSHAFT (Continued) End play. = Limi¢ S Big end journal diameter ....... — maximum allowable ovality — maximum allowable taper Main bearing clearance Big end bearing clearance... E192 0102 MB990767 E9M30EA MD998I15 E9M40 E1150... MD998713, E9M20A .. MD998722 MD998718. MD998747 MD998719 EIIMI2 APPLICATION Alternator bracket bolt ‘Alternator mounting bolt Alternator pivot nut... Alternator stay bolt “Alternator stay nut... ‘Camshaft bearing cap bolt Camshaft sprocket bolt Connecting rod cap : Coolant temperature gauge unit. . Coolant temperature sensor Crankshaft bolt Cylinder head bolt — Cold Dipstick mounting bolt ues -4 SPECIFICATIONS CONT. — Service limit (main/big end) --- 0.05 to 0.25 mm. 0.3 mm 50.0 mm 0.03 mm 0.005 mm 0.02 to 0.048 mm £0,016 to 0.048 mm 0.1 mm SPECIAL TOOLS - Compressor—Piston ring ‘Compressor—Valve Spring "cRemover/Installer — Camshaft sprocket Installer valve stem seat Remover/Installer — valve guide “Hydraulic tappet adjuster kit U Hydraulic tappet leakdown tester “Installer — camshaft oil seal Remover/Installer — cylinder head bolts Remover/Installer — piston pin Installer — Crankshaft oil seal rear ‘Crankshaft pulley holder Pins — To be used with MB990767 Piston pin removing tool TORQUE SPECIFICATIONS Nm 20.30 1245 20.25 20-30 15-22 19.21 80-100 50-53 10-12, 20-40 150-160 100-110 1215We5-5 TORQUE SPECIFICATIONS CONT. APPLICATION Distributor adaptor bole .. Drive belt tension bolt Drive belt tension nut Drive plate bolt Engine mount front = Through bolt nut large... — small Engine mount front to mounting bracket Engine mounting bracket front to block 10 x 45 mm bolts 10 x 35 mm bolts 10 x 97 mm bolt 10 x 68 mm bolt 12x71 mm Exhaust manifold nut Flywheel mounting bolt Heat protector boll Heater pipe bolt Intake manifold nut Knock sensor Main bering cap bolt Oil filter — bracket bolt Oil pan — bolt Oil pan drain plug Oil pressure switch Oil pump cover bolt Oil relier valve plug Oil screen bolt Rocker cover bolt Roll stopper front ‘Support bracket to block 10 x 25 mm bolts 32.49 12x 30 mm bolt 64.83 ‘Through bolt nut ; 50-65 Mounting bolt 60-70 Roll stopper rear Support bracket to block 10 x 25 mm bolts 12 x 30 mm bolts Through bolt nut Mounting bolt Sump drain plug Timing belt cover bolt Timing belt rear upper cover, left ‘Tensioner bolt ‘Tensioner bracket bolt — 10 mm — 8mm ‘Tensioner bracket stay bolt Thermo switch .... Water inlet fitting bolt Water outlet fitting bolt Water pipe bolt ‘Water pump bolt1-5-6 Fig. I-6G72 engine longitudinal section GENERAL INFORMATION ‘The 6G72 engine is a 60° V6, overhead valve, overhead cam crotsflow design, with a compact hemi spherical combusion chamber, petrol engine, The cylinder head is made of an aluminium alloy casting, into which the valve guides and valve seat rings Of heat resisting stecl, have been press-fitted. The eylinder block is an alloyed casting. The block is a short skirt type. The walls are made as thin as possible to minimise the overall weight of the cylinder block. The exterior walls are shaped and ribbed to provide sufficient strength, The water jacket is of the full-jacket type, which ensures that each cylinder is cooled properly. The right and left banks are angled 60° which makes the engine easy to install in the vehicle and enhances serviceability of the auxiliaries. The inlet and exhaust ports ate in a cross-flow arrangement which contributes to better intake/exhaust efficiency.W-6-1 SECTION 6 — SERVICE DIAGNOSIS Condition Possible Cause Corrective Action LOW COMPRESSION | Valves sticking or seating poorly. | Overhaul valve system. Ca Blown cylinder head gasket (if Install new head gasket. pressure low in adjacent eslinders br coolant is contaminated with engine oi LOW COMPRESSION | Worn or sticking rings. Replace or fee-up rings. OvET TEST) NOISY VALVES, Worn rocker arms. Replace arms and check oil supply holes ‘Worn valve guides. Replace guides and if necessary install new valves. ‘Worn or damaged camshatt lobes. | Replace camshaft Excessive valve seat or valve face | Re-cut valves and seas. runout Malfunctioning hydraulic tappet | Replace defective tappet adjusters. adjusters. CONNECTING ROD | Insufficient oil supply Check engine oil evel NOISE Low oil pressure Check oll pump output Thin or diluted oil Change ofl 10 correct viscosity Excessive bearing clearance Measure bearings for correct clearances. Replace if necessary Connecting rod journal Remove crankshaft and resrind outoFround. journals Misaligned connecting rods Replace the bent connecting rods MAIN BEARING NOISE | Insufficient ofl supply: Check engine oil level. Low oll pressure Check oil pump output. Thin oF diluted oil, Change oil 10 correct viscosity Excessive bearing clearance. ‘Measure bearings for correct clearances, Replace if necessary Excessive end play ‘Check respective end thrust bearing for wear on flanges Crankshaft journals outoF-round | Remove the crankshaft and regrind or worn, journals Loose flywheel Tighten o correct torque O1L PUMPING AT Worn, scuffed or broken rings Hone cylinder bores and install new RINGS rings. Carbon in oil ring slots. Tnstall new rings Rings fitted too tight in grooves, | Remove the rings. Check the grooves. If groove is not correct ‘width, replace the pistons1-6-2 Condition Possible Cause Corrective Action (OIL PUMPING AT RINGS (CONT), Compression rings installed upside down, Remove and refit rings correctly. INDICATED LOW OIL PRESSURE Low oil level Check and top up oil level if required, Faulty oil pressure sending unit Install a new sending unit Thin oF diluted oil, Change the oil to corre viscosity Oil pump relief valve stuck. il pump suction tube loose, bent or eracked. Remove the valve and inspect. Remove the oil pan and install a new tube iF required. Clogged oil filter. Install 4 new oil filter. Excessive bearing clearance. ‘Check the bearing clearance. Excessive oil pump gear clearance. Remove oil pump and check gears for wear and clearance. ENGINE DIAGNOSIS WITH VACUUM GAUGE ‘A vacuum gauge can be beneficial as an aid in Giagnosing engine problems. librated vacuum guage and “tee” Obiain a reliable, it into the inlet manifold at the brake booster vacuum Use the readings as outlined opposite, to carry out your diagnosis,1-6 WORN RiNGS OR INFERIOR LUBRICANT 1a 6 ‘CARBURETTOR LEAKING INTAKE, "ADJUSTMENT SYSTEM, Readings — ins Hg (xPa) 2 ‘Witn ma ngineIing, Yh haa aoa hetuooe 17 and 21 (57 0 70, With a rapid opening and closing of the thot, the hand wil fat 9 2 (85) and swing back to 28 or 25 (81 {0 84), selling on normal idle reading. Rings and valves indicated OK ‘With fast running engine, the hand reads between 10 and 22 (9410 78). Increase speed increases hand fluctuations ‘With engine ling, nand vibrates rapidly between 14 and 18 (47 to 64). When valve should close, hand drops two or tree points 6. Arde, the hand drops consistantly a few points Aide, the hand sometimes drops around four points 8. Al fast ile, the hand reads steady tom @ f0 15 (27 050) ‘VALVE SPRINGS. WEAK VALVE GUIDES ‘WORN 8 ‘VALVE TIMING LATE " 2 IGNITION DEFECTIVE IGNITION RETARDED 15 6 LEAKING HEAD BLOCKED EXHAUST ‘GASKET ‘SYSTEM (between cylinders) © Ata the hand read stot hel nuer than nema interior lubrcant may also be indicated 10. With rapid opening and closing of the throttle, the hand falls (90 and 1ses to 23 (78) oF less 11, With 2 stowiy fluctuating hand between 14 and 16 (47 10 54), check igaton system for faults. 12. Al fast idle, a steady reacing betweon 14 and 17 (47 {o 56) is wegstered 13. Check isle mixture hand moves slowly between 13. ‘and 17 (84 (0 57) 14, tide oF fast ile, hand reac between 3 and & (10 ‘ana 17). Check gaskets, 15. Hand moves consistamly between 5 ang 19 (17 and 64) 16. High ading at start reducing 101 (9) oF © ana Increases to 15 lo 15 (51 0 58)rel SECTION 7 — IN-VEHICLE SERVICE PROCEDURE COMPRESSION TEST An engine without reasonably high and uniform compression cannot be effectively tuned. The com- pression of each cylinder should be tested before any other tuning operations are performed. The engine must be at operating temperature when performing the compression test. ‘Compression pressure with engine warm, spark plugs removed, wide open throttle at minimum cranking speed of 250 rp.m. should be within the specified limits. (1) Remove any foreign matter from around spark plugs by blowing out plug area with compressed air, then loosen all plugs one turn, (2) Start the engine and accelerate to 1000 p.m. to bblow out loosened carbon. Stop engine and remove plugs, note cylinder trom which each plug was removed for future reference. NOTE: Clearing out carbon in this manner is important in. preventing false compression readings due to particles of carbon becoming lodged under the valves, Va \ WHY wr oe IK t “0110479, Fig, | — Checking compression 3) Disconnect coil primary lead. (Disconnect the EC1-Multi control relay to prevent fuel injection. (5) Connect remote control starter switch to the starter solenoid. (6) Insert the compression gauge in spark plug, opening, and crank engine through at least four ‘compression strokes to obtain highest possible reading, (7) Test and record compression of each cylinder. Compression should read within the limits indicated in the specifications. (8) If one or more cylinders read low or uneven, inject about a tablespoon of engine oil on top of pistons in low reading cylinders. Crank engine several times and re-check compression. { compression comes, up but does not reach normal, rings are worn. If compression does not improve, valves are sticking or seating poorly. If two adjacent eylinders show low compression, and injecting oil docs not improve condition, the cause may bea head gasket leak between the cylinders. TIMING BELT ADJUSTMENT (1) Ensure engine is at No, 1 TDC and remove the access cover, refer Fig. 2. (2) Using Special Tool No, MD998160 loosen timing bolt 1-2 turns. (3) Rotate direction. (4) Tighten tension bolt to specified torque. (5) Replace the access cover \kshaft TWO TURNS in a clockwise oR Access cover ortoras ontor4s Fig. 2 — Timing belt adjustmentWe7-2 TIMING BELT Removal (1) Remove alternator, power steering and air conditioning belts (2) Remove power steering pump and air conditioner compressor. 3) Remove crankshaft pulley, bolt and washer using Special Tool Nos, MB990767 and MD9987I5, refer Fig. 3. Fig, 3 — Crankshaft pulley removal (4) Remove right and left upper timing belt covers. (5) Remove front crankshaft flange, (6) Remove lower timing belt cover (7) Manually rotate engine to No. 1 Top Dead Centre using Special Too! No. MD998716, as shown in Fig. 3. Ensure that all timing marks ‘are aligned, refer Fig. 10, NOTE: When the timing bel is (o be reused, the direction of rotation should be marked on the belt, so that on assembly it is installed in the Fig. 4 — Marking direction of timing belt (8) Remove lockbolt, tensioner and spring and remove the timing bel Anspection XK, Crack Separation SG Crack venzo7 Fig. 5 — Timing belt cracked Inspect timing belt for cracking, brittleness, damage or worn and broken teeth. Refer Figs. 5 and 6. Rubber exposed Tooth missing end canvas liber exposed 7EN209 Fig. 6 — Timing belt teeth damage Inspect timing belt tensioner by rotating the pulley: IF it does not rotate smoothly or irregular noise or backlash is observed, replace timing belt tensioner. Refer Fig. 7. Fig. 7 — Timing belt tensioneru-7-3 Installation (1) Install timing belt tensioner and tighten bolt finger tight (Q) Install tensioner spring to the pin above the water pump case and the tensioner. NOTE: Ensure the direction of the tensioner spring hook is as shown in Fig. 8, Timing belt 7 Fig. 8 — Tensioner spring fitment (3) Force the tensioner in direction of arrow, refer Fig. 9 and tighten the lock bolt Fig. 9 — Delt tensioner positioning (4) Align timing marks on camshaft sprockets and crankshaft sprocket, refer Fig. 10. (5) Install timing belt as follows:— Route the timing belt onto the crankshaft sprocket and then onto the camshaft sprocket of the left hand bank, maintaining tension in the tension side, refer Fig. 10. Timing mark (on belt cover) Timing mark (on sprocket) —, Camshatt sprocket Timing belt tensioner Crankshaft sprocket Water pump pulley Timing mark (on belt cover) | Timing mark (on sprocket) Camshaft sprocket Tension side Timing mark (on front case) ‘Timing mark (on sprocket) Fig. 10 — Timing mark identification