ENGINE

SECTION
ENGINE MECHANICAL
EM EM

E
CONTENTS
VQ EXHAUST MANIFOLD AND THREE WAY F
CATALYST ........................................................ 23
SERVICE INFORMATION ............................ 5 Component ..............................................................23
Removal and Installation .........................................23 G
PRECAUTIONS ................................................... 5
Precaution for Procedure without Cowl Top Cover...... 5 OIL PAN AND OIL STRAINER ......................... 28
Precaution for Supplemental Restraint System Component ..............................................................28
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- H
Removal and Installation .........................................28
SIONER" ................................................................... 5
Precautions For Engine Service ................................ 5 IGNITION COIL ................................................. 33
Parts Requiring Angle Tightening ............................. 6 Component ..............................................................33 I
Precaution for Liquid Gasket ..................................... 6 Removal and Installation .........................................33

PREPARATION ................................................... 8 SPARK PLUG (PLATINUM-TIPPED TYPE) ..... 34

Special Service Tool ................................................. 8 Component ..............................................................34 J
Commercial Service Tool ........................................ 10 Removal and Installation .........................................34

NOISE, VIBRATION AND HARSHNESS FUEL INJECTOR AND FUEL TUBE ................ 36 K
(NVH) TROUBLESHOOTING ............................12 Component ..............................................................36
NVH Troubleshooting - Engine Noise ..................... 12 Removal and Installation .........................................36
Use the Chart Below to Help You Find the Cause L
of the Symptom ....................................................... 12
ROCKER COVER ............................................. 41
Component ..............................................................41
DRIVE BELTS ....................................................14 Removal and Installation .........................................41
Checking Drive Belts ............................................... 14 M
Tension Adjustment ................................................ 14
FRONT TIMING CHAIN CASE ......................... 44
Removal and Installation .........................................44
Removal and Installation ......................................... 14
Drive Belt Auto Tensioner and Idler Pulley ............. 15 TIMING CHAIN .................................................. 53 N
AIR CLEANER AND AIR DUCT ........................16 Component ..............................................................53
Removal and Installation .........................................54
Component .............................................................. 16
Removal and Installation ......................................... 16 O
CAMSHAFT ....................................................... 71
Changing Air Cleaner Filter ..................................... 16 Component ..............................................................71
INTAKE MANIFOLD COLLECTOR ...................18 Removal and Installation .........................................72
Valve Clearance ......................................................79 P
Component .............................................................. 18
Removal and Installation ......................................... 18 OIL SEAL .......................................................... 85
INTAKE MANIFOLD ...........................................21 Removal and Installation of Valve Oil Seal ..............85
Removal and Installation of Front Oil Seal ..............85
Component .............................................................. 21
Removal and Installation of Rear Oil Seal ...............86
Removal and Installation ......................................... 21
CYLINDER HEAD ............................................. 88

EM-1
 On-Vehicle Service ................................................. 88 INTAKE MANIFOLD ......................................... 163
Component ............................................................. 89 Component ........................................................... 163
Removal and Installation ........................................ 89 Removal and Installation ....................................... 164
Component ............................................................. 93
Disassembly and Assembly .................................... 93 CATALYST ....................................................... 166
Inspection After Disassembly ................................. 95 Component ........................................................... 166
Removal and Installation ....................................... 166
ENGINE ASSEMBLY ....................................... 100
Component ............................................................100 TURBO CHARGER .......................................... 167
Removal and Installation .......................................101 Component ........................................................... 167
Removal and Installation ....................................... 168
CYLINDER BLOCK ......................................... 104
Component ............................................................104 EXHAUST MANIFOLD ..................................... 171
Disassembly and Assembly ...................................105 Component ........................................................... 171
How to Select Piston and Bearing .........................114 Removal and Installation ....................................... 171
Inspection After Disassembly ................................119
OIL PAN AND OIL STRAINER ........................ 173
SERVICE DATA AND SPECIFICATIONS Component ........................................................... 173
(SDS) ................................................................ 131 Removal and Installation ....................................... 173
Standard and Limit ................................................131
GLOW PLUG .................................................... 178
YD Component ........................................................... 178
Removal and Installation ....................................... 178
SERVICE INFORMATION .......................... 142
VACUUM PUMP ............................................... 179
PRECAUTIONS ............................................... 142
Component ........................................................... 179
Precaution Necessary for Steering Wheel Rota-
Removal and Installation ....................................... 179
tion After Battery Disconnect .................................142
Precaution for Procedure without Cowl Top Cover..142 INJECTION TUBE AND FUEL INJECTOR ...... 181
Precautions For Engine Service ............................142 Exploded View ...................................................... 181
Precaution for Supplemental Restraint System Removal and Installation ....................................... 182
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Inspection .............................................................. 185
SIONER" ................................................................143
Parts Requiring Angle Tightening ..........................143 FUEL PUMP ..................................................... 186
Precaution for Liquid Gasket .................................144 Component ........................................................... 186
Removal and Installation ....................................... 186
PREPARATION ............................................... 146
Special Service Tool ..............................................146 FUEL PUMP SUCTION CONTROL VALVE .... 193
Commercial Service Tool ......................................148 Component ........................................................... 193
Removal and Installation ....................................... 193
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING .......................... 151 ROCKER COVER ............................................. 196
NVH Troubleshooting - Engine Noise ....................151 Component ........................................................... 196
Use the Chart Below to Help You Find the Cause Removal and Installation ....................................... 196
of the Symptom .....................................................151
CAMSHAFT ...................................................... 199
DRIVE BELTS .................................................. 153 Component ........................................................... 199
Checking Drive Belts .............................................153 Removal and Installation ....................................... 199
Deflection Adjustment ............................................154 Valve Clearance .................................................... 206
Removal and Installation .......................................156
OIL SEAL .......................................................... 210
AIR CLEANER AND AIR DUCT ...................... 157 Removal and Installation of Valve Oil Seal ........... 210
Component ............................................................157 Removal and Installation of Front Oil Seal ............ 210
Removal and Installation .......................................157 Removal and Installation of Rear Oil Seal ............ 211

EGR SYSTEM .................................................. 159 SECONDARY TIMING CHAIN ......................... 213

Exploded View .......................................................159 Component ........................................................... 213
Removal and Installation .......................................160 Removal and Installation ....................................... 213
Inspection .............................................................. 218
CHARGE AIR COOLER .................................. 161
Component ............................................................161 PRIMARY TIMING CHAIN ................................ 219
Removal and Installation .......................................161 Component ........................................................... 219

EM-2
 Removal and Installation ....................................... 220 DRIVE BELTS ................................................. 295
Inspection .............................................................. 230 Exploded View ....................................................... 295 A
Checking ................................................................ 295
CYLINDER HEAD ............................................ 232 Tension Adjustment ............................................... 295
On-Vehicle Service ............................................... 232 Removal and Installation ....................................... 295
Exploded View ...................................................... 233 EM
Removal and Installation ....................................... 234 AIR CLEANER FILTER ................................... 297
Disassembly and Assembly .................................. 237 Removal and Installation ....................................... 297
Inspection .............................................................. 239 C
REMOVAL AND INSTALLATION ............. 298
ENGINE ASSEMBLY ....................................... 244
Component ............................................................ 244 DRIVE BELT AUTO TENSIONER AND IDLER
D
Removal and Installation ....................................... 245 PULLEY ........................................................... 298
Exploded View ....................................................... 298
CYLINDER BLOCK .......................................... 248 Removal and Installation ....................................... 298
Component ............................................................ 248 E
Disassembly and Assembly .................................. 249 ENGINE COVER ............................................. 299
Inspection .............................................................. 256 Exploded View ....................................................... 299
How to Select Piston and Bearing ......................... 265 Removal and Installation ....................................... 299 F
SERVICE DATA AND SPECIFICATIONS AIR CLEANER AND AIR DUCT ..................... 300
(SDS) ................................................................ 271 Exploded View ....................................................... 300
Standard and Limit ................................................ 271 Removal and Installation ....................................... 300 G
V9X Inspection .............................................................. 301

PRECAUTION ............................................ 281 VACUUM PUMP .............................................. 302

H
Exploded View ....................................................... 302
PRECAUTIONS ................................................ 281 Removal and Installation ....................................... 302
Precaution for Battery Service (for V9X Models) .. 281
Precaution for Procedure without Cowl Top Cover.. 281 FUEL PUMP .................................................... 304 I
Precaution Necessary for Steering Wheel Rota- Exploded View ....................................................... 304
tion After Battery Disconnect ................................. 281 Removal and Installation ....................................... 304
Precautions For Engine Service ............................ 282 Inspection .............................................................. 305 J
Precaution for Supplemental Restraint System CHARGE AIR COOLER .................................. 307
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
Exploded View ....................................................... 307
SIONER" ............................................................... 282 K
Removal and Installation ....................................... 307
Parts Requiring Angular Tightening ...................... 283 Inspection .............................................................. 308
Precaution for Liquid Gasket ................................. 283
Precaution for Diesel Equipment ........................... 284 ELECTRIC THROTTLE CONTROL ACTUA- L
Definitions of Bank Names .................................... 287 TOR ................................................................. 309
Exploded View ....................................................... 309
PREPARATION ......................................... 288 Removal and Installation ....................................... 309
M
PREPARATION ................................................ 288 CATALYST ...................................................... 311
Special Service Tools ............................................ 288
Exploded View ....................................................... 311
Commercial Service Tools .................................... 290
Removal and Installation ....................................... 311 N
BASIC INSPECTION ................................. 292 Inspection .............................................................. 312

COMPRESSION PRESSURE .......................... 292 GLOW PLUG ................................................... 313

Exploded View ....................................................... 313 O
Inspection .............................................................. 292
Removal and Installation ....................................... 313
SYMPTOM DIAGNOSIS ............................ 293
INJECTION TUBE AND FUEL INJECTOR .... 315 P
NOISE, VIBRATION AND HARSHNESS Exploded View ....................................................... 315
(NVH) TROUBLESHOOTING .......................... 293 Removal and Installation ....................................... 316
NVH Troubleshooting - Engine Noise ................... 293 Inspection .............................................................. 319
Use the Chart Below to Help You Find the Cause OIL PAN .......................................................... 320
of the Symptom ..................................................... 294
Exploded View ....................................................... 320
PERIODIC MAINTENANCE ....................... 295 Removal and Installation ....................................... 320

EM-3
TIMING CHAIN ................................................ 322 EXHAUST MANIFOLD ..................................... 355
Exploded View .......................................................322 Exploded View ...................................................... 355
Removal and Installation .......................................323 Disassembly and Assembly .................................. 355
Inspection ..............................................................337 Inspection .............................................................. 357

OIL SEAL ......................................................... 339 EGR SYSTEM ................................................... 358

Exploded View ...................................................... 358
FRONT OIL SEAL ....................................................339 Disassembly and Assembly .................................. 358
FRONT OIL SEAL : Removal and Installation .......339 Inspection .............................................................. 360
REAR OIL SEAL ......................................................340 OIL SEPARATOR ............................................. 361
REAR OIL SEAL : Removal and Installation .........340
Exploded View ...................................................... 361
UNIT REMOVAL AND INSTALLATION .... 342 Disassembly and Assembly .................................. 361

ENGINE ASSEMBLY ....................................... 342 CAMSHAFT ...................................................... 363

Exploded View ...................................................... 363
Exploded View .......................................................342
Disassembly and Assembly .................................. 363
Removal and Installation .......................................342
Inspection .............................................................. 368
Inspection ..............................................................345
CYLINDER HEAD ............................................. 370
UNIT DISASSEMBLY AND ASSEMBLY .. 346
Exploded View ...................................................... 370
ENGINE STAND SETTING .............................. 346 Disassembly and Assembly .................................. 370
Setting ...................................................................346 Inspection .............................................................. 375

ENGINE UNIT .................................................. 347 CYLINDER BLOCK .......................................... 377

Disassembly ..........................................................347 Exploded View ...................................................... 377
Assembly ...............................................................347 Disassembly and Assembly .................................. 378
Inspection .............................................................. 386
TURBOCHARGER .......................................... 348
Exploded View .......................................................348 SERVICE DATA AND SPECIFICATIONS
Disassembly and Assembly ...................................348 (SDS) ......................................................... 393
Inspection ..............................................................349
SERVICE DATA AND SPECIFICATIONS
INTAKE MANIFOLD ........................................ 351 (SDS) ................................................................ 393
Exploded View .......................................................351 General Specification ............................................ 393
Disassembly and Assembly ...................................351 Drive Belts ............................................................. 393
Inspection ..............................................................354 Cylinder Head ....................................................... 393

EM-4
 PRECAUTIONS
< SERVICE INFORMATION > [VQ]

SERVICE INFORMATION A
PRECAUTIONS
Precaution for Procedure without Cowl Top Cover INFOID:0000000005447615
EM
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
C

PIIB3706J

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT F
PRE-TENSIONER" INFOID:0000000005447616

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along G
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SUPPLEMENTAL
RESTRAINT SYSTEM” and “SEAT BELTS” of this Service Manual.
H
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. I
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SUPPLEMENTAL RESTRAINT SYSTEM”. J
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
K
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the L
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the M
battery, and wait at least 3 minutes before performing any service.
Precautions For Engine Service INFOID:0000000008180049
N

DISCONNECTING FUEL PIPING

• Before starting work, check no fire or spark producing items are in the work area. O
• Release fuel pressure before disconnecting and disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.

P
DRAINING ENGINE COOLANT
Drain engine coolant and engine oil when the engine is cooled.

INSPECTION, REPAIR AND REPLACEMENT

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.

EM-5
 PRECAUTIONS
< SERVICE INFORMATION > [VQ]
REMOVAL AND DISASSEMBLY
• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin-
structed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position.
• Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.

ASSEMBLY AND INSTALLATION

• Use torque wrench to tighten bolts or nuts to specification.
• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.

Parts Requiring Angle Tightening INFOID:0000000005447622

• Use angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
- Cylinder head bolts
- Lower cylinder block bolts
- Connecting rod cap bolts
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000005447623

REMOVAL OF LIQUID GASKET SEALING

• After removing mounting nuts and bolts, separate the mating sur-
face using the seal cutter (SST) and remove the old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.
• Tap seal cutter to insert it, and then slide it by tapping on the side
as shown in the figure.
• In areas where seal cutter (SST) is difficult to use, use plastic ham-
mer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason tool such as screwdriver is
PBIC0275E
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE

EM-6
 PRECAUTIONS
< SERVICE INFORMATION > [VQ]
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface. A
• Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts, and bolt
holes.
EM
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
C

PBIC0003E

D
3. Attach liquid gasket tube to tube presser (commercial service
tool).
Use Genuine Liquid Gasket or equivalent.
E
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
• If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove. F

G
EMA0622D

• As for the bolt holes, normally apply the liquid gasket inside H
the holes. If specified, it should be applied outside the holes.
Check to read the text of this manual.
• Within five minutes of liquid gasket application, install the mat-
I
ing component.
• If the liquid gasket protrudes, wipe it off immediately.
• Do not retighten mounting bolts or nuts after the installation.
• After 30 minutes or more have passed from the installation, fill J
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe K
SEM159F
them.

EM-7
 PREPARATION
< SERVICE INFORMATION > [VQ]
PREPARATION
Special Service Tool INFOID:0000000005447624

Tool number
Description
Tool name
ST0501S000 Disassembling and assembling engine
Engine stand assembly
1. ST05011000
Engine stand
2. ST05012000
Base

NT042

KV10106500
Engine stand shaft

NT028

KV10117000 KV10117000 has been replaced with

Engine sub-attachment KV10117001 (KV10117000 is no longer in
production, but it is usable).

NT373

KV10117001 Installing on cylinder block

Engine sub-attachment

NT372

KV10116200 Disassembling valve mechanism

Valve spring compressor Part (1) is a component of KV10116200, but
1. KV10115900 Part (2) is not so.
Attachment
2.KV10109220
Adapter

PBIC1650E

KV10107902 Replacing valve oil seal

Valve oil seal puller

NT011

EM-8
 PREPARATION
< SERVICE INFORMATION > [VQ]
Tool number
Description
Tool name A
KV10115600 Installing valve oil seal
Valve oil seal drift
EM

C
ZZA0996D

EM03470000 Installing piston assembly into cylinder bore

Piston ring compressor D

NT044
F
ST16610001 Removing pilot bushing (M/T models) or pilot
Pilot bushing puller converter (A/T models)

H
NT045

KV10111100 Removing oil pan (lower and upper), front and

Seal cutter rear timing chain case, etc.
I

NT046

KV10112100 Tightening bolts for bearing cap, cylinder K

Angle wrench head, etc. in angle

NT014 M
KV991J0050 Loosening or tightening air fuel ratio sensor 1
Heated oxygen sensor wrench a: 22 mm (0.87 in)
N

O
LBIA0444E

KV10114400 Loosening or tightening heated oxygen sen-

Heated oxygen sensor wrench sor 2 P
a: 22 mm (0.87 in)

NT636

EM-9
 PREPARATION
< SERVICE INFORMATION > [VQ]
Tool number
Description
Tool name
KV10117700 Removing and installing crankshaft pulley
Ring gear stopper

NT822

— Removing fuel tube quick connectors in en-

Quick connector release gine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)

PBIC0198E

Commercial Service Tool INFOID:0000000005447625

Tool name Description

Tube presser Pressing the tube of liquid gasket

NT052

TORX socket Removing and installing flywheel

Size: T55

PBIC1113E

Manual lift table caddy Removing and installing engine

ZZA1210D

Cylinder head bolt wrench Loosening and tightening cylinder head bolt,
and used with angle wrench [SST:
KV10112100]
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
NT583

EM-10
 PREPARATION
< SERVICE INFORMATION > [VQ]
Tool name Description
A
Spark plug wrench Removing and installing spark plug

EM

C
NT047

Valve seat cutter set Finishing valve seat dimensions

NT048

Piston ring expander Removing and installing piston ring F

NT030
H
Valve guide drift Removing and installing valve guide
Intake and Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia. I

J
NT015

Valve guide reamer (1): Reaming valve guide inner hole

(2): Reaming hole for oversize valve guide K
Intake and Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia.
L

NT016

Oxygen sensor thread cleaner Reconditioning the exhaust system threads M

before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
a: 18 mm (0.71 in) dia. for zirconia heated
N
oxygen sensor
b: 12 mm (0.47 in) dia. for titania heated ox-
ygen sensor
AEM488
O
Anti-seize lubricant (Permatex 133AR Lubricating oxygen sensor thread cleaning
or equivalent meeting MIL specifica- tool when reconditioning exhaust system
tion MIL-A-907) threads P

AEM489

EM-11
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SERVICE INFORMATION > [VQ]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting - Engine Noise INFOID:0000000005447626

JPBIA1478GB

Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000005447627

1. Locate the area where noise occurs.

2. Confirm the type of noise.

EM-12
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SERVICE INFORMATION > [VQ]
3. Specify the operating condition of engine.
4. Check specified noise source. A
If necessary, repair or replace these parts.

Operating condition of engine EM

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing C
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-79
gine clicking noise
Rocker
cover Camshaft Camshaft runout D
EM-72
Cylinder Rattle C A — A B C bearing Camshaft journal oil
EM-72
head noise clearance

Piston to piston pin oil E

Slap or Piston pin clearance EM-119
— A — B B —
knock noise Connecting rod bushing EM-119
oil clearance
F
Piston to cylinder bore
Crank- clearance
EM-119
shaft pul- Piston ring side clear-
Slap or Piston EM-119
ley A — — B B A ance G
rap slap noise EM-119
Cylinder Piston ring end gap
EM-119
block Connecting rod bend
(Side of and torsion
H
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-119
Knock A B C B B B
bearing Connecting rod bearing EM-119
noise oil clearance (Big end I
Main bearing oil clear-
Main bear- EM-119
Knock A B — A B C ance
ing noise EM-119
Crankshaft runout J
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear EM-54
A A — B B B chain ten-
Timing ticking Timing chain tensioner EM-53 K
sioner
chain case operation
noise
Drive belts
Squeak-
(Sticking L
ing or fizz- A B — B — C Drive belts deflection
or slip-
ing EM-14
ping)
Front of
Drive belts Idler pulley bearing op- M
engine Creaking A B A B A B
(Slipping) eration
Water CO-23,
Squall
A B — B A B pump Water pump operation "Compo-
Creak N
noise nent"
A: Closely related B: Related C: Sometimes related —: Not related

EM-13
 DRIVE BELTS
< SERVICE INFORMATION > [VQ]
DRIVE BELTS
Checking Drive Belts INFOID:0000000005447628

LBIA0427E

1. Drive belt 2. Power steering oil pump pulley 3. Alternator pulley

4. Crankshaft pulley 5. A/C compressor pulley 6. Cooling fan pulley
7. Idler pulley 8. Drive belt auto tensioner

WARNING:
Be sure to perform when engine is stopped.
• Remove engine undercover front and air-duct-and-resonator-assembly when inspecting drive belt. Refer to
EI-12 and EM-16.
• Check that indicator (A) of auto tensioner is within the allowable
working range (between three line notches “B”).

: Engine front

NOTE:
• Check auto tensioner indication when engine is cold.
• When new drive belt is installed, the range should be (C).
• The indicator notch is located on the moving side of auto ten-
sioner for alternator, water pump and A/C compressor belt, while
it is found on the fixed side for power steering oil pump belt.
• Visually check drive belt for wear, damage or cracks. PBIC3875E

• If the indicator is out of allowable working range or belt is dam-

aged, replace drive belt.
Tension Adjustment INFOID:0000000005447629

Belt tensioning is not necessary, as it is automatically adjusted by auto tensioner.

Removal and Installation INFOID:0000000005447630

REMOVAL
1. Remove engine undercover front and air-duct-and-resonator-assembly when inspecting drive belt. Refer
to EI-12 and EM-16.

EM-14
 DRIVE BELTS
< SERVICE INFORMATION > [VQ]
2. While securely holding the square hole in pulley center of auto
tensioner (1) with a spinner handle (A), move spinner handle in A
the direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur
EM
if the holding tool accidentally comes off.
3. Under the above condition, insert a metal bar (B) of approxi-
mately 6 mm (0.24 in) in diameter (hexagonal bar wrench shown
as example in the figure) through the holding boss to lock auto C
tensioner pulley arm.
• Leave auto tensioner pulley arm locked until drive belt is PBIC3876E
installed again. D
4. Remove drive belt.
INSTALLATION
Note the following, and install in the reverse order of removal. E
CAUTION:
• Check drive belt is securely installed around all pulleys.
• Check drive belt is correctly engaged with the pulley groove. F
• Check for engine oil and engine coolant are not adhered drive belt and pulley groove.
• Check that drive belt tension is within the allowable working range, using indicator notch on auto
tensioner. Refer to EM-14, "Checking Drive Belts".
G
Drive Belt Auto Tensioner and Idler Pulley INFOID:0000000005447631

M
LBIA0429E

1. Idler pulley 2. Drive belt auto tensioner

N
REMOVAL
1. Remove engine undercover front and air-duct-and-resonator-assembly when inspecting drive belt. Refer
to EI-12 and EM-16. O
2. Remove drive belt. Refer to EM-14, "Removal and Installation".
• Keep auto tensioner pulley arm locked after belt is removed.
3. Remove auto tensioner and idler pulley. P
• Keep auto tensioner pulley arm locked to install or remove auto tensioner.
INSTALLATION
Installation is the reverse order of removal.

EM-15
 AIR CLEANER AND AIR DUCT
< SERVICE INFORMATION > [VQ]
AIR CLEANER AND AIR DUCT
Component INFOID:0000000005447632

JPBIA1552GB

1. Air cleaner case (lower) 2. Air cleaner filter 3. Air cleaner case (upper)
4. Mass air flow sensor 5. PCV hose 6. Air duct and resonator
A. To rocker cover
: Vehicle front

• Refer to GI-9, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000005447633

REMOVAL
1. Disconnect harness connector from mass air flow sensor.
2. Disconnect PCV hose.
3. Remove air cleaner case & mass air flow sensor assembly and air duct assembly disconnecting their
joints.
• Add marks as necessary for easier installation.
CAUTION:
Handle mass air flow sensor with care.
• Never shock mass air flow sensor.
• Never disassemble mass air flow sensor.
• Never touch mass air flow sensor.
INSPECTION AFTER REMOVAL
Inspect air duct for crack or tear.
• If anything found, replace air duct.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Align marks. Attach each joint. Screw clamps firmly.
Changing Air Cleaner Filter INFOID:0000000005447634

REMOVAL
1. Unhook clips, and lift air cleaner case (upper).
2. Remove air cleaner filter.
INSTALLATION
EM-16
 AIR CLEANER AND AIR DUCT
< SERVICE INFORMATION > [VQ]
Installation is the reverse order of removal.
A

EM

EM-17
 INTAKE MANIFOLD COLLECTOR
< SERVICE INFORMATION > [VQ]
INTAKE MANIFOLD COLLECTOR
Component INFOID:0000000005447635

PBIC2874E

1. Vacuum tank 2. VIAS control solenoid valve 3. Vacuum hose

4. Intake manifold collector support 5. Water hose 6. Electric throttle control actuator
7. Water hose 8. EVAP hose 9. Bracket
EVAP canister purge volume control
10. EVAP hose 11. 12. Gasket
solenoid valve
13. Gasket 14. Intake manifold collector 15. Clip
16. PCV hose 17. Connector 18. PCV hose

Removal and Installation INFOID:0000000005447636

REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Remove engine cover.
CAUTION:
Be careful not to damage or scratch engine cover.
a. Loosen mounting bolts.
b. Lift up on engine cover firmly to dislodge snap fit mounts.

WBIA0622E

2. Remove air cleaner case (upper) with mass air flow sensor and air duct assembly. Refer to EM-16.
3. Remove electric throttle control actuator as follows:

EM-18
 INTAKE MANIFOLD COLLECTOR
< SERVICE INFORMATION > [VQ]
a. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-10, "Changing Engine Coolant". A
CAUTION:
• Perform when engine is cold.
• Never spill engine coolant on drive belt.
EM
b. Disconnect water hoses from electric throttle control actuator.
• When engine coolant is not drained from radiator, attach plug to water hoses to prevent engine coolant
leakage.
C
c. Disconnect harness connector.
d. Loosen mounting bolts in reverse order as shown in the figure.
CAUTION:
• Handle carefully to avoid any shock to electric throttle D
control actuator.
• Never disassemble.
E

PBIC2875E

4. Remove the following parts: G

• Vacuum hose (to brake booster)
• PCV hose
5. Loosen mounting bolts in reverse order as shown in the figure to H
remove intake manifold collector support.

PBIC2876E
K

6. Disconnect EVAP hoses and harness connector from EVAP canister purge volume control solenoid valve.
7. Remove EVAP canister purge volume control solenoid valve. L
8. Remove VIAS control solenoid valve and vacuum tank.
• Add mating marks as necessary for easier installation.
9. Loosen mounting nuts and bolts in reverse order as shown in M
the figure, and remove intake manifold collector.
CAUTION:
Cover engine openings to avoid entry of foreign materials. N

PBIC2877E P
INSTALLATION
Note the following, and install in the reverse order of removal.
Intake Manifold Collector
• If stud bolts were removed from intake manifold, install them and tighten to the specified torque below.

EM-19
 INTAKE MANIFOLD COLLECTOR
< SERVICE INFORMATION > [VQ]

: 6.9 N·m (0.70 kg-m, 61 in-lb)

• Tighten mounting nuts and bolts in numerical order as shown in the
figure.

PBIC2877E

Electric Throttle Control Actuator

• Tighten mounting bolts in numerical order as shown in the figure.
• Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is disconnected.
Refer to EC-82, "Throttle Valve Closed Position Learning" (for Aus-
tralia models) or EC-566, "Throttle Valve Closed Position Learning"
(except for Australia models).
• Perform the “Idle Air Volume Learning” and “Throttle Valve Closed
Position Learning” when electric throttle control actuator is
replaced. Refer to EC-82, "Idle Air Volume Learning" (for Australia
models) or EC-566, "Idle Air Volume Learning" (except for Austra-
lia models).
PBIC2875E

EM-20
 INTAKE MANIFOLD
< SERVICE INFORMATION > [VQ]
INTAKE MANIFOLD
A
Component INFOID:0000000005447637

EM

G
PBIC2878E

1. Intake manifold 2. Gasket

H
Removal and Installation INFOID:0000000005447638

REMOVAL I
1. Release fuel pressure. Refer to EC-84, "Fuel Pressure Check" (for Australia models) or EC-568, "Fuel
Pressure Check" (except for Australia models).
2. Remove intake manifold collector. Refer to EM-18. J
3. Remove fuel tube and fuel injector assembly. Refer to EM-36.
4. Loosen mounting nuts and bolts with power tool in reverse order
as shown in the figure to remove intake manifold. K

PBIC2879E
N
5. Remove gaskets.
CAUTION:
Cover engine openings to avoid entry of foreign materials. O
INSPECTION AFTER REMOVAL
Surface Distortion
P

EM-21
 INTAKE MANIFOLD
< SERVICE INFORMATION > [VQ]
• Check the surface distortion of the intake manifold mating surface
with straightedge and feeler gauge.

Limit : 0.1 mm (0.004 in)

• If it exceeds the limit, replace intake manifold.

PBIC0870E

INSTALLATION
Note the following, and install in the reverse order of removal.
Intake Manifold
• If stud bolts were removed from cylinder head, install them and tighten to the specified torque below.

: 10.8 N·m (1.1 kg-m, 8 ft-lb)

• Tighten all mounting nuts and bolts to the specified torque in two or
more steps in numerical order shown in the figure.

1st step
: 7.4 N·m (0.75 kg-m, 5 ft-lb)
2nd step and after
: 29.0 N·m (3.0 kg-m, 21 ft-lb)

PBIC2879E

EM-22
 EXHAUST MANIFOLD AND THREE WAY CATALYST
< SERVICE INFORMATION > [VQ]
EXHAUST MANIFOLD AND THREE WAY CATALYST
A
Component INFOID:0000000005447639

EM

J
PBIC4063E

1. Air fuel ratio sensor 1 (bank 1) 2. Ring gasket 3. Exhaust manifold cover (right bank) K
4. Exhaust manifold (right bank) 5. Gasket 6. Exhaust manifold (left bank)
Three way catalyst (manifold) (left
7. Exhaust manifold cover (left bank) 8. Air fuel ratio sensor 1 (bank 2) 9.
bank) L
Three way catalyst (manifold) (right
10.
bank)

• Refer to GI-9, "Component" for symbol marks in the figure. M

Removal and Installation INFOID:0000000005447640

N
REMOVAL (LEFT BANK)
1. Remove air cleaner case and air duct. Refer to EM-16.
2. Remove engine undercover front and engine undercover middle. Refer to EI-12. O

EM-23
 EXHAUST MANIFOLD AND THREE WAY CATALYST
< SERVICE INFORMATION > [VQ]
3. Disconnect harness connector and remove heated oxygen sen-
sor 2 on both banks using heated oxygen sensor wrench (C)
[SST: KV10114400].

A : Right bank
B : Left bank
: Vehicle front

CAUTION:
• Be careful not to damage heated oxygen sensor 2.
• Discard any heated oxygen sensor 2 which has been PBIC3882E
dropped onto a hard surface such as a concrete floor.
Replace with a new sensor.

4. Fasten main muffler temporarily to the vehicle, and remove exhaust front tube (left bank). Refer to EX-3.
5. Remove exhaust manifold cover (left bank).
6. Disconnect harness connector and remove air fuel ratio sensor
1 on both banks using heated oxygen sensor wrench (C) [SST:
KV991J0050].

A : Left bank
B : Right bank
: Vehicle front

CAUTION:
• Be careful not to damage air fuel ratio sensor 1.
• Discard any air fuel ratio sensor 1 which has been PBIC3883E
dropped onto a hard surface such as a concrete floor.
Replace with a new sensor.

7. Remove three way catalyst (manifold) (left bank).

8. Loosen mounting nuts in reverse order as shown in the figure to
remove exhaust manifold.
NOTE:
Disregard the numerical order No. 7 and 8 in removal.

PBIC2881E

9. Remove gaskets.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSPECTION AFTER REMOVAL (LEFT BANK)

EM-24
 EXHAUST MANIFOLD AND THREE WAY CATALYST
< SERVICE INFORMATION > [VQ]
Surface Distortion
• Check the surface distortion of the exhaust manifold mating sur- A
face with straightedge and feeler gauge.

Limit : 0.3 mm (0.012 in) EM

• If it exceeds the limit, replace exhaust manifold.

PBIC1096E D
INSTALLATION (LEFT BANK)
Note the following, and install in the reverse order of removal.
E
Exhaust Manifold Gasket
Install in direction shown in the figure.
F

PBIC2882E

Exhaust Manifold I
• If stud bolts (between engine and exhaust manifold) were removed, install them and tighten to the specified
torque below.
J
: 14.7 N·m (1.5 kg-m, 11 ft-lb)
• Install exhaust manifold and tighten mounting nuts in numerical
order as shown in the figure. K
NOTE:
Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7
and 8 shows second step. L

PBIC2881E

Three Way Catalyst

• If stud bolts were removed, install them and tighten to the specified torque below.

EM-25
 EXHAUST MANIFOLD AND THREE WAY CATALYST
< SERVICE INFORMATION > [VQ]

: 25.4 N·m (2.6 kg-m, 19 ft-lb)

Heated Oxygen Sensor
CAUTION:
• Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system
threads using oxygen sensor thread cleaner (commercial service tool) and apply anti-seize lubricant
(commercial service tool).
• Never over torque air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage
to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the “MIL” coming on.
REMOVAL (RIGHT BANK)
1. Remove engine assembly. Refer to EM-100.
2. Loosen nuts in reverse order as shown.
NOTE:
Disregard the numerical order No. 7 and 8 in removal.

PBIC2881E

3. Remove gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSPECTION AFTER REMOVAL (RIGHT BANK)
Surface Distortion
• Check the surface distortion of the exhaust manifold mating sur-
face with straightedge and feeler gauge.

Limit : 0.3 mm (0.012 in)

• If it exceeds the limit, replace exhaust manifold.

PBIC1096E

INSTALLATION (RIGHT BANK)

Note the following, and install in the reverse order of removal.
Exhaust Manifold Gasket

EM-26
 EXHAUST MANIFOLD AND THREE WAY CATALYST
< SERVICE INFORMATION > [VQ]
Install in direction shown in the figure.
A

EM

PBIC2882E

D
Exhaust Manifold
• If stud bolts were removed, install them and tighten to the specified torque below.

E
: 14.7 N·m (1.5 kg-m, 11 ft-lb)
• Install exhaust manifold and tighten mounting nuts in numerical
order as shown in the figure.
F
NOTE:
Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7
and 8 shows second step.
G

PBIC2881E
L

Three Way Catalyst

• If stud bolts were removed, install them and tighten to the specified torque below.
M
: 25.4 N·m (2.6 kg-m, 19 ft-lb)
Heated Oxygen Sensor N
CAUTION:
• Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system
threads using oxygen sensor thread cleaner (commercial service tool) and apply anti-seize lubricant O
(commercial service tool).
• Never over torque air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage
to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the “MIL” coming on.
P

EM-27
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [VQ]
OIL PAN AND OIL STRAINER
Component INFOID:0000000005447641

PBIC4067E

1. Oil pan (upper) 2. Oil pressure switch 3. O-ring

4. Relief valve 5. O-ring 6. Oil cooler
7. Connector bolt 8. Oil filter 9. Drain plug
10. Drain plug washer 11. Oil pan (lower) 12. Rear cover plate
13. Oil strainer 14 O-ring 15. Oil level gauge guide
16. Oil level gauge 17. Crankshaft position sensor (POS)
A. Oil pan side B. Refer to LU-10. C. Refer to LU-9.

• Refer to GI-9, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000005447642

REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine oil when engine is hot.
NOTE:
To remove oil pan (lower) only, take step 3 and step 4, then step 14. Step 1 to 2, 5 to 13 and 15 to 19 are
unnecessary.
1. Remove engine cover. Refer to EM-18.
2. Remove air duct. Refer to EM-16.
3. Remove engine undercover front and engine undercover middle. Refer to EI-12.
4. Drain engine oil. Refer to LU-7, "Changing Engine Oil".
CAUTION:

EM-28
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [VQ]
• Perform this step when engine is cold.
• Never spill engine oil on drive belts. A
5. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant".
CAUTION:
• Perform this step when engine is cold. EM
• Never spill engine coolant on drive belts.
6. Remove front final drive assembly (4WD models). Refer to FFD-16.
7. Disconnect steering gear lower joint shaft bolt and steering gear nuts and bolts, position out of the way. C
Refer to PS-14.
8. Remove starter motor. Refer to SC-41, "Removal and Installation".
9. Disconnect A/T fluid cooler tube brackets and position out of the way (A/T models). Refer to AT-256. D
10. Install engine slinger to sling engine assembly for positioning. Refer to EM-100.
11. Disconnect oil cooler water hoses, and remove oil cooler water pipe mounting bolt. Refer to LU-10.
12. Remove oil filter. Refer to LU-9. E
13. Remove oil cooler. Refer to LU-10.
14. Remove oil pan (lower) as follows:
F
a. Loosen mounting bolts in reverse order as shown in the figure to
remove.

I
PBIC2890E

b. Insert seal cutter (SST) between oil pan (upper) and oil pan
(lower). J
CAUTION:
• Be careful not to damage the mating surfaces.
• Never insert screwdriver, this will damage the mating sur- K
faces.

SEM365ED
M
c. Slide seal cutter by tapping on the side of the tool with hammer. Remove oil pan (lower).
15. Remove oil strainer.
16. Remove transmission joint bolts which pierce oil pan (upper). Refer to MT-19 (M/T models) or AT-259 (A/ N
T models).
17. Remove rear cover plate.
18. Loosen mounting bolts in reverse order as shown in the figure to O
remove.
• Insert seal cutter [SST: KV10111100] between oil pan (upper)
and lower cylinder block. Slide seal cutter by tapping on the P
side of tool with hammer. Remove oil pan (upper).
CAUTION:
Be careful not to damage mating surfaces.

PBIC2887E

EM-29
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [VQ]
19. Remove O-rings from bottom of lower cylinder block and oil
pump.

PBIC2885E

INSPECTION AFTER REMOVAL

Clean oil strainer if any object attached.
INSTALLATION
1. Install oil pan (upper) as follows:
a. Use scraper to remove old liquid gasket from mating surfaces.
• Also remove the old liquid gasket from mating surface of lower
cylinder block.
• Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket.

PBIC2884E

b. Install new O-rings on the bottom of lower cylinder block and oil
pump.

PBIC2885E

c. Apply a continuous bead of liquid gasket with tube presser

(commercial service tool) to the lower cylinder block mating sur-
faces of oil pan (upper) to a limited portion as shown in the fig-
ure.
Use Genuine Liquid Gasket or equivalent.
CAUTION:
• For bolt holes with mark, apply liquid gasket outside
the hole.
• Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 in) in diame-
ter to area “A”.
• Attaching should be done within 5 minutes after coating. PBIC2886E

d. Install oil pan (upper).

CAUTION:
Install avoiding misalignment of both oil pan gaskets and O-rings.

EM-30
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [VQ]
• Tighten mounting bolts in numerical order as shown in the fig-
ure. A
• There are two types of mounting bolts. Refer to the following
for locating bolts.
EM
M8 × 100 mm (3.94 in) : 7, 11, 12, 13
M8 × 25 mm (0.98 in) : Except the above
C

PBIC2887E

D
e. Tighten transmission joint bolts. Refer to MT-19 (M/T models) or AT-259 (A/T models).
2. Install oil strainer to oil pan (upper).
3. Install oil pan (lower) as follows: E
a. Use scraper to remove old liquid gasket from mating surfaces.
• Also remove old liquid gasket from mating surface of oil pan
(upper).
F
• Remove old liquid gasket from the bolt holes and thread.
CAUTION:
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket. G

H
PBIC2888E

b. Apply a continuous bead of liquid gasket with tube presser I

(commercial service tool) to the oil pan (lower) as shown in the
figure.
Use Genuine Liquid Gasket or equivalent.
CAUTION: J
Attaching should be done within 5 minutes after coating.

PBIC2889E
L
c. Install oil pan (lower).
• Tighten mounting bolts in numerical order as shown in the fig-
ure. M

PBIC2890E
P
4. Install oil pan drain plug.
• Refer to the figure of components of former page for installation direction of drain plug washer. Refer to
EM-28, "Component".
5. Installation is the reverse order of removal after this step.
NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.

EM-31
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [VQ]
INSPECTION AFTER INSTALLATION
1. Check engine oil level and adjust engine oil. Refer to LU-6.
2. Start engine, and check there is no leak of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-6.

EM-32
 IGNITION COIL
< SERVICE INFORMATION > [VQ]
IGNITION COIL
A
Component INFOID:0000000005447643

EM

G
PBIC2901E

1. Ignition coil 2. Spark plug

H
Removal and Installation INFOID:0000000005447644

REMOVAL (LEFT BANK) I

1. Remove engine cover. Refer to EM-18.
2. Remove air cleaner case and air duct. (At the left bank side, remove ignition coil) Refer to EM-16.
3. Move aside harness, harness bracket, and hoses located above ignition coil. J
4. Disconnect harness connector from ignition coil.
5. Remove ignition coil.
K
CAUTION:
Never shock ignition coil.
INSTALLATION (LEFT BANK) L
Installation is the reverse order of removal.
REMOVAL (RIGHT BANK)
1. Remove intake manifold collector. Refer to EM-18. M
2. Move aside harness, harness bracket, and hoses located above ignition coil.
3. Disconnect harness connector from ignition coil.
N
4. Remove ignition coil.
CAUTION:
Never shock ignition coil.
O
INSTALLATION (RIGHT BANK)
Installation is the reverse order of removal.
P

EM-33
 SPARK PLUG (PLATINUM-TIPPED TYPE)
< SERVICE INFORMATION > [VQ]
SPARK PLUG (PLATINUM-TIPPED TYPE)
Component INFOID:0000000005447645

PBIC2901E

1. Ignition coil 2. Spark plug

Removal and Installation INFOID:0000000005447646

REMOVAL
1. Remove ignition coil. Refer to EM-33.
2. Remove spark plug using spark plug wrench (commercial ser-
vice tool).
CAUTION:
Never drop or shock spark plug.

SEM294A

INSPECTION AFTER REMOVAL

Use standard type spark plug for normal condition.
Hot type spark plug is suitable when fouling occurs with standard type spark plug under conditions such as:
• Frequent engine starts
• Low ambient temperatures
Cold type spark plug is suitable when spark plug knock occurs with standard type spark plug under conditions such as:
• Extended highway driving
• Frequent high engine revolution

Make NGK
Standard type PLFR5A-11
Hot type PLFR4A-11
Cold type PLFR6A-11

EM-34
 SPARK PLUG (PLATINUM-TIPPED TYPE)
< SERVICE INFORMATION > [VQ]

Gap (Nominal) : 1.1 mm (0.043 in) A

CAUTION:
• Never drop or shock spark plug.
• Never use wire brush for cleaning. EM
• If plug tip is covered with carbon, spark plug cleaner may be
used.
C
Cleaner air pressure:
Less than 588 kPa (5.9 bar, 6 kg/cm2, 85 psi)
Cleaning time: D
Less than 20 seconds

SMA773C E

• Checking and adjusting plug gap is not required between

change intervals. F

SMA806CA

INSTALLATION I
Installation is the reverse order of removal.

EM-35
 FUEL INJECTOR AND FUEL TUBE
< SERVICE INFORMATION > [VQ]
FUEL INJECTOR AND FUEL TUBE
Component INFOID:0000000005447647

PBIC4062E

1. Fuel tube 2. Fuel feed hose 3. Quick connector cap

4. Clip 5. O-ring (blue) 6. Fuel injector
7. O-ring (brown) 8. O-ring 9. Spacer
10. Fuel damper 11. Fuel damper cap
A. Refer to EM-36. B. Do not loosen these bolts.

• Refer to GI-9, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000005447648

REMOVAL
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
• To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Remove intake manifold collector. Refer to EM-18.
2. Release fuel pressure. Refer to EC-84, "Fuel Pressure Check" (for Australia models) or EC-568, "Fuel
Pressure Check" (except for Australia models).
3. Disconnect quick connector on the engine side as follows:

EM-36
 FUEL INJECTOR AND FUEL TUBE
< SERVICE INFORMATION > [VQ]
a. Remove quick connector cap.
A

EM

LBIA0090E

D
b. Disconnect quick connector as follows:
CAUTION:
Disconnect quick connector by using quick connector release (SST), not by picking out retainer
E
tabs.
i. With the sleeve side (B) of quick connector release (A) facing to
quick connector (1), install quick connector release onto fuel
tube (2). F
ii. Insert quick connector release into quick connector until sleeve
contacts and goes no further (D). Hold quick connector release
on that position. G
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it H
contacts and goes no further.
iii. Draw and pull out (E) quick connector straight from fuel tube. PBIC3886E

CAUTION:
I
• Pull quick connector holding (C) position as shown in the figure.
• Never pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth beforehand as fuel will leak out.
• Avoid fire and sparks. J
• Keep parts away from heat source. Especially, be careful when welding is performed around
them.
• Never expose parts to battery electrolyte or other acids. K
• Never bend or twist connection between quick connector and fuel tube during installation/
removal.
• To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with L
plastic bags or something similar.

PBIC1899E
O
4. Remove PCV hose between rocker covers (right and left banks).
5. Disconnect harness connector from fuel injector.
P

EM-37
 FUEL INJECTOR AND FUEL TUBE
< SERVICE INFORMATION > [VQ]
6. Loosen mounting bolts in reverse order as shown in the figure,
and remove fuel tube and fuel injector assembly.
CAUTION:
• Never tilt it, or remaining fuel in pipes may flow out from
pipes.
• Never disassemble fuel tube.

PBIC2902E

7. Remove fuel injector from fuel tube as follows:

a. Open and remove clip.
b. Remove fuel injector from fuel tube by pulling straight.
CAUTION:
• Be careful with remaining fuel that may go out from fuel
tube.
• Be careful not to damage injector nozzles during removal.
• Never bump or drop fuel injector.
• Never disassemble fuel injector and fuel tube.

SBIA0364E

8. Loosen mounting bolts, to remove fuel damper cap and fuel damper, if necessary.
INSTALLATION

EM-38
 FUEL INJECTOR AND FUEL TUBE
< SERVICE INFORMATION > [VQ]
1. Install fuel damper as follows:
a. Install new O-ring to fuel tube as shown in the figure. A
• When handling new O-rings, be careful of the following cau-
tion:
CAUTION: EM
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign C
material.
• When installing O-ring, be careful not to scratch it with
tool or fingernails. Also be careful not to twist or stretch D
O-ring. If O-ring was stretched while it was being
attached, never insert it quickly into fuel tube.
• Insert new O-ring straight into fuel tube. Never decenter
or twist it. E
b. Install spacer to fuel damper.
c. Insert fuel damper straight into fuel tube.
• Insert fuel damper until “B” is hit “A” of fuel tube. F
d. Tighten mounting bolts evenly in turn.
• After tightening mounting bolts, check that there is no gap
between fuel damper cap and fuel tube. G
PBIC2903E
2. Install new O-rings to fuel injector, paying attention to the follow-
ing.
CAUTION: H
• Upper and lower O-ring are different. Be careful not to confuse them.

Fuel tube side : Blue I

Nozzle side : Brown
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil. J
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to K
twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly
into fuel tube.
• Insert O-ring straight into fuel injector. Never decenter or twist it.
L

EM-39
 FUEL INJECTOR AND FUEL TUBE
< SERVICE INFORMATION > [VQ]
3. Install fuel injector to fuel tube as follows:
a. Insert clip into clip mounting groove on fuel injector.
• Insert clip so that protrusion “A” of fuel injector matches cutout
“A” of clip.
CAUTION:
• Never reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion “B” of fuel tube matches
cutout “B” of clip.
• Check that fuel tube flange is securely fixed in flange fixing
groove on clip.
c. Check that installation is complete by checking that fuel injector
does not rotate or come off.
• Check that protrusions of fuel injectors are aligned with cut-
outs of clips after installation.

PBIC2545E

4. Install fuel tube and fuel injector assembly to intake manifold.

CAUTION:
Be careful not to let tip of injector nozzle come in contact with other parts.
• Tighten mounting bolts in two steps in numerical order as
shown in the figure.

1st step
: 10.1 N·m (1.0 kg-m, 7 ft-lb)
2nd step
: 22.0 N·m (2.2 kg-m, 16 ft-lb)

PBIC2902E

5. Connect fuel injector harness connector.

6. Install intake manifold collector. Refer to EM-18.
7. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Check on Fuel Leakage
1. Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.
2. Start engine. With engine speed increased, check again for fuel leakage at connection points.
CAUTION:
Never touch engine immediately after stopped, as engine becomes extremely hot.

EM-40
 ROCKER COVER
< SERVICE INFORMATION > [VQ]
ROCKER COVER
A
Component INFOID:0000000005447649

EM

I
PBIC4061E

1. Oil filler cap 2. PCV hose 3. PCV valve J

4. O-ring 5. Rocker cover (right bank) 6. PCV hose
7. Rocker cover gasket (right bank) 8. Rocker cover gasket (left bank) 9. Rocker cover (left bank)
10. PCV hose K
A. To intake manifold collector B. To air duct C. Refer to EM-41
D. Camshaft bracket side
L
• Refer to GI-9, "Component" for symbol marks in the figure.
Removal and Installation INFOID:0000000005447650

M
REMOVAL
1. Remove engine cover. Refer to EM-18.
2. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak- N
age. Refer to CO-10, "Changing Engine Coolant" and EM-18.
CAUTION:
Perform this step when engine is cold. O
3. Remove intake manifold collector. Refer to EM-18.
4. Separate engine harness removing their brackets from rocker covers.
5. Remove harness bracket from cylinder head (right bank). Refer to EM-88. P
6. Remove ignition coil. Refer to EM-33.
7. Remove PCV hoses from rocker covers.
8. Remove PCV valve and O-ring from rocker cover (right bank), if necessary.
9. Remove oil filler cap from rocker cover (left bank), if necessary.

EM-41
 ROCKER COVER
< SERVICE INFORMATION > [VQ]
10. Loosen mounting bolts with power tool in reverse order as
shown in the figure.

PBIC2906E

11. Remove rocker cover gaskets from rocker covers.

12. Use scraper to remove all trances of liquid gasket from cylinder head and camshaft bracket (No. 1).
CAUTION:
Never scratch or damage the mating surface when cleaning off old liquid gasket.
INSTALLATION
1. Apply liquid gasket with tube presser (commercial service tool)
to joint part among rocker cover, cylinder head and camshaft
bracket (No. 1) as follows:
Use Genuine Liquid Gasket or equivalent.
NOTE:
The figure shows an example of left bank side [zoomed in shows
camshaft bracket (No. 1)].
a. Refer to the figure “a” to apply liquid gasket to joint part of cam-
shaft bracket (No. 1) and cylinder head.
b. Refer to the figure “b” to apply liquid gasket to the figure “a”
squarely.

PBIC2474E

2. Install new rocker cover gasket to rocker cover.

3. Install rocker cover.
• Check if rocker cover gasket is not dropped from installation groove of rocker cover.

EM-42
 ROCKER COVER
< SERVICE INFORMATION > [VQ]
4. Tighten bolts in two steps separately in numerical order as
shown in the figure. A

1st step
: 1.96 N·m (0.20 kg-m, 17 in-lb) EM
2nd step
: 8.33 N·m (0.85 kg-m, 74 in-lb)
C

G
PBIC2906E

5. Install oil filer cap to rocker cover (left bank), if removed.

6. Install new O-ring and PCV valve to rocker cover (right bank), if removed. H
7. Install PCV hose.
• Insert PCV hose by 25 to 30 mm (0.98 to 1.18 in) from connector end.
• When installing, be careful not to twist or come in contact with other parts. I
8. Install in the reverse order of removal after this step.

EM-43
 FRONT TIMING CHAIN CASE
< SERVICE INFORMATION > [VQ]
FRONT TIMING CHAIN CASE
Removal and Installation INFOID:0000000005447651

NOTE:
• This section describes removal/installation procedure of front timing chain case and timing chain related
parts without removing oil pan (upper) on vehicle.
• When oil pan (upper) needs to be removed or installed, or when rear timing chain case is removed or
installed, remove oil pans (upper and lower) first. Then remove front timing chain case, timing chain related
parts, and rear timing chain case in this order, and install in the reverse order of removal. Refer to EM-53.
• Refer to EM-53 for component parts location.
REMOVAL
1. Remove engine cover. Refer to EM-18.
2. Remove engine undercover front and engine undercover middle. Refer to EI-12.
3. Release the fuel pressure. Refer to EC-84, "Fuel Pressure Check" (for Australia models) or EC-568, "Fuel
Pressure Check" (except for Australia models).
4. Drain engine oil. Refer to LU-7, "Changing Engine Oil".
CAUTION:
• Perform this step when engine is cold.
• Never spill engine oil on drive belts.
5. Drain engine coolant from radiator. Refer to CO-10, "Changing Engine Coolant".
CAUTION:
• Perform this step when engine is cold.
• Never spill engine coolant on drive belts.
6. Remove radiator cooling fan assembly. Refer to CO-21.
7. Separate engine harnesses removing their brackets from front timing chain case.
8. Remove drive belt. Refer to EM-14.
9. Remove power steering oil pump from bracket with piping connected, and temporarily secure it to aside.
Refer to PS-29, "VQ40DE : Removal and Installation".
10. Remove power steering oil pump bracket. Refer to PS-29, "VQ40DE : Removal and Installation".
11. Remove alternator. Refer to SC-25, "Removal and Installation".
12. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
13. Remove right and left intake valve timing control covers.
• Loosen mounting bolts in reverse order as shown in the figure.
• Use seal cutter [SST: KV10111100] to cut liquid gasket for
removal.
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) cen-
ter hole. When removing, keep it horizontal until it is com-
pletely disconnected.

SEM728G

14. Remove collared O-rings from front timing chain case (left and
right side).

PBIC2631E

EM-44
 FRONT TIMING CHAIN CASE
< SERVICE INFORMATION > [VQ]
15. Remove rocker covers (right and left banks). Refer to EM-41.
NOTE: A
When only timing chain (primary) is removed, rocker cover does not need to be removed.
16. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
NOTE: EM
When timing chain is not removed/installed, this step is not required.
a. Rotate crankshaft pulley clockwise to align timing mark (grooved
line without color) with timing indicator. C

KBIA1717J

F
b. Check that intake and exhaust cam noses on No. 1 cylinder
(engine front side of right bank) are located as shown in the fig-
ure.
• If not, turn crankshaft one revolution (360 degrees) and align G
as shown in the figure.
NOTE:
When only timing chain (primary) is removed, rocker cover does H
not need to be removed. To check that No. 1 cylinder is at its
compression TDC, remove front timing chain case first. Then
check mating marks on camshaft sprockets. Refer to EM-54,
I
"Removal and Installation".
SEM418G

17. Remove crankshaft pulley as follows:

J
a. Remove starter motor and set ring gear stopper (A) [SST:
KV10117700] as shown in the figure. Refer to SC-41, "Removal
and Installation".
K
1 : Transmission
2 : Oil pan (upper)
L

M
PBIC3889E

b. Loosen crankshaft pulley bolt and locate bolt seating surface as

10 mm (0.39 in) from its original position. N
CAUTION:
Never remove crankshaft pulley bolt. Keep loosened crank-
shaft pulley bolt in place to protect removed crankshaft pul-
O
ley from dropping.

PBIC2918E

c. Pull crankshaft pulley with both hands to remove it.

EM-45
 FRONT TIMING CHAIN CASE
< SERVICE INFORMATION > [VQ]
18. Loosen two mounting bolts in front of oil pan (upper) in reverse
order as shown in the figure.

PBIC2907E

19. Remove front timing chain case as follows:

a. Loosen mounting bolts in reverse order as shown in the figure.

PBIC2908E

b. Insert suitable tool into the notch at the top of the front timing
chain case as shown (1).
c. Pry off case by moving tool as shown (2).
• Use seal cutter [SST: KV10111100] to cut liquid gasket for
removal.
CAUTION:
• Never use screwdriver or something similar.
• After removal, handle front timing chain case carefully so
it does not tilt, cant, or warp under a load.

SEM156F

20. Remove O-rings from rear timing chain case.

PBIC2548E

21. Remove water pump cover and chain tensioner cover from front timing chain case, if necessary.
• Use seal cutter [SST: KV10111100] to cut liquid gasket for removal.

EM-46
 FRONT TIMING CHAIN CASE
< SERVICE INFORMATION > [VQ]
22. Remove front oil seal from front timing chain case using suitable
tool. A
• Use screwdriver for removal.
CAUTION:
Be careful not to damage front timing chain case.
EM

PBIC2909E

D
23. Remove timing chain and related parts. Refer to EM-53.
24. Use a scraper to remove all traces of old liquid gasket from front
and rear timing chain cases and oil pan (upper), and liquid gas- E
ket mating surfaces.
CAUTION:
Be careful not to allow gasket fragments to enter oil pan.
F

PBIC2910E

H
• Remove old liquid gasket from bolt hole and thread.

K
PBIC2084E

25. Use a scraper to remove all traces of old liquid gasket from L
water pump cover, chain tensioner cover and intake valve timing
control covers.
M

SEM926E O
INSTALLATION
1. Install timing chain and related parts. Refer to EM-53.
P

EM-47
 FRONT TIMING CHAIN CASE
< SERVICE INFORMATION > [VQ]
2. Hammer dowel pins (right and left) into front timing chain case
up to a point close to taper in order to shorten protrusion length.

PBIC2615E

3. Install new front oil seal on the front timing chain case.
• Apply new engine oil to both oil seal lip and dust seal lip.
• Install it so that each seal lip is oriented as shown in the figure.

SEM715A

• Using suitable drift [outer diameter: 60 mm (2.36 in)], press-fit

oil seal until it becomes flush with front timing chain case end
face.
• Check the garter spring is in position and seal lip is not
inverted.

PBIC2911E

4. Install water pump cover and chain tensioner cover to front timing chain case, if removed.
• Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to front timing chain case as shown
in the figure.
Use Genuine Liquid Gasket or equivalent.

PBIC2912E

5. Install front timing chain case as follows:

EM-48
 FRONT TIMING CHAIN CASE
< SERVICE INFORMATION > [VQ]
a. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to front timing chain case back side as A
shown in the figure.

B : Protrusion
EM
C : Both permissible
D : Bolt hole
Use Genuine Liquid Gasket or equivalent. C

G
PBIC3887E

b. Apply liquid gasket with tube presser (commercial service tool)

to top surface of oil pan (upper) as shown in the figure. H
Use Genuine Liquid Gasket or equivalent.

PBIC2914E
K
c. Install new O-rings on rear timing chain case.

N
PBIC2548E

d. Assemble front timing chain case as follows: O

EM-49
 FRONT TIMING CHAIN CASE
< SERVICE INFORMATION > [VQ]
i. Fit lower end of front timing chain case tightly onto top face of oil
pan (upper). From the fitting point, make entire front timing chain
case contact rear timing chain case completely.
CAUTION:
Be careful that oil pan gasket is in place.

PBIC1100E

ii. Since front timing chain case is offset for difference of bolt holes,
tighten bolts temporarily with holding front timing chain case
from front and top as shown in the figure.
iii. Same as the step ii, insert dowel pin with holding front timing
chain case from front and top completely.

PBIC2915E

e. Tighten mounting bolts to the specified torque in numerical order

as shown in the figure.
• There are four types of mounting bolts. Refer to the following
for locating bolts.

M10 × 70mm (2.76 in) :5

: 55.0 N·m (5.6 kg-m, 41 ft-lb)
M10 × 90mm (3.54 in) : 1, 2, 3, 4
: 55.0 N·m (5.6 kg-m, 41 ft-lb)
PBIC2908E
M6 × 40mm (1.57 in) : 24, 25
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
M6 × 25mm (0.98 in) : Except above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
f. After all bolts tightened, retighten them to the specified torque in numerical order as shown in the figure.
6. Install two mounting bolts in front of oil pan (upper) in numerical
order as shown in the figure.

: 22.0 N·m (2.2 kg-m, 16 ft-lb)

PBIC2907E

7. Install right and left intake valve timing control covers as follows:
a. Install new seal rings in shaft grooves.

EM-50
 FRONT TIMING CHAIN CASE
< SERVICE INFORMATION > [VQ]
b. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to intake valve timing control covers as A
shown in the figure.
Use Genuine Liquid Gasket or equivalent.
EM

SBIA0492E

D
c. Install new collared O-rings in front timing chain case oil hole
(left and right sides).
E

G
PBIC2631E

d. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain
H
case with the holes to install intake valve timing control covers.
e. Tighten mounting bolts in numerical order as shown in the fig-
ure.
I

PBIC0918E

8. Install crankshaft pulley as follows: L

a. Fix crankshaft using ring gear stopper [SST: KV10117700].
b. Install crankshaft pulley, taking care not to damage front oil seal.
• When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference). M
c. Tighten crankshaft pulley bolt.
N
: 44.1 N·m (4.5 kg-m, 33 ft-lb)
d. Place a paint mark (A) on crankshaft pulley (1) aligning with the
angle mark (B) on crankshaft pulley bolt (2). Tighten the bolt 90 O
degrees (angle tightening).

PBIC4627J

EM-51
 FRONT TIMING CHAIN CASE
< SERVICE INFORMATION > [VQ]
9. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns
smoothly.
10. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Inspection for Leaks

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-25.
• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
* Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc.

EM-52
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
TIMING CHAIN
A
Component INFOID:0000000005447652

EM

PBIC3888E

Timing chain tensioner (secondary) Timing chain tensioner (secondary)

1. 2. Internal chain guide 3.
(left bank) (right bank)
4. Camshaft sprocket (EXH) 5. Timing chain (secondary) 6. Timing chain (primary)

EM-53
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
7. Camshaft sprocket (INT) 8. Camshaft sprocket (INT) 9. Slack guide
10. Timing chain tensioner (primary) 11. Crankshaft sprocket 12. Collared O-ring
13. O-ring 14. Intake valve timing control cover 15. Idler pulley
16. Drive belt auto tensioner 17. Cooling fan bracket 18. Crankshaft pulley
19. Front oil seal 20. Water pump cover 21. Chain tensioner cover
22. Front timing chain case 23. Rear timing chain case 24. Water drain plug (front)
25. Tension guide 26. O-ring
A. Refer to EM-54

• Refer to GI-9, "Component" for symbol marks in the figure.

NOTE:
• This section describes procedures for removing/installing front timing chain case and timing chain related
parts, and rear timing chain case, when oil pan (upper) needs to be removed/installed for engine overhaul,
etc.
• To remove/install front timing chain case, timing chain, and its related parts without removing oil pan (upper),
refer to EM-44.
Removal and Installation INFOID:0000000005447653

REMOVAL
1. Remove engine cover. Refer to EM-18.
2. Remove air duct and resonator. Refer to EM-16.
3. Remove engine undercover front and engine undercover middle. Refer to EI-12.
4. Release the fuel pressure. Refer to EC-84, "Fuel Pressure Check" (for Australia models) or EC-568, "Fuel
Pressure Check" (except for Australia models).
5. Drain engine coolant from radiator. Refer to CO-10, "Changing Engine Coolant".
CAUTION:
• Perform this step when engine is cold.
• Never spill engine coolant on drive belts.
6. Drain engine oil. Refer to LU-7, "Changing Engine Oil".
CAUTION:
• Perform this step when engine is cold.
• Never spill engine oil on drive belts.
7. Remove radiator cooling fan assembly. Refer to CO-21.
8. Separate engine harnesses removing their brackets from front timing chain case.
9. Remove drive belt. Refer to EM-14.
10. Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to
avoid putting load on its piping. Refer to ATC-242, "Removal and Installation for Compressor".
11. Remove power steering oil pump from bracket with piping connected from engine. Temporarily secure it
on body with a rope to avoid putting load on its piping. Refer to PS-29, "VQ40DE : Removal and Installa-
tion".
12. Remove power steering oil pump bracket. Refer to PS-29, "VQ40DE : Removal and Installation".
13. Remove alternator. Refer to SC-25, "Removal and Installation".
14. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
15. Remove right and left intake valve timing control covers.
• Loosen mounting bolts in reverse order as shown in the figure.
• Use seal cutter [SST: KV10111100] to cut liquid gasket for
removal.
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) cen-
ter hole. When removing, keep it horizontal until it is com-
pletely disconnected.

SEM728G

EM-54
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
16. Remove collared O-rings from front timing chain case (left and
right side). A

EM

PBIC2631E
D
17. Remove rocker covers (right and left banks). Refer to EM-41.
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed. E
18. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
NOTE:
When timing chain is not removed/installed, this step is not required.
F
a. Rotate crankshaft pulley clockwise to align timing mark (grooved
line without color) with timing indicator.
G

I
KBIA1717J

b. Check that intake and exhaust cam noses on No. 1 cylinder

(engine front side of right bank) are located as shown in the fig- J
ure.
• If not, turn crankshaft one revolution (360 degrees) and align
as shown in the figure. K

SEM418G
M
19. Remove crankshaft pulley as follows:
a. Remove starter motor and set ring gear stopper (A) [SST:
KV10117700] as shown in the figure. Refer to SC-41, "Removal N
and Installation".

1 : Transmission O
2 : Oil pan (upper)

PBIC3889E

EM-55
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
b. Loosen crankshaft pulley bolt and locate bolt seating surface as
10 mm (0.39 in) from its original position.
CAUTION:
Never remove crankshaft pulley bolt. Keep loosened crank-
shaft pulley bolt in place to protect removed crankshaft pul-
ley from dropping.

PBIC2918E

c. Pull crankshaft pulley with both hands to remove it.

20. Remove oil pans (upper and lower). Refer to EM-28.
21. Remove front timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.

PBIC2908E

b. Insert suitable tool into the notch at the top of the front timing
chain case as shown (1).
c. Pry off case by moving the tool as shown (2).
• Use seal cutter [SST: KV10111100] to cut liquid gasket for
removal.
CAUTION:
• Never use screwdriver or something similar.
• After removal, handle front timing chain case carefully so
it does not tilt, cant, or warp under a load.

SEM156F

22. Remove O-rings from rear timing chain case.

PBIC2548E

23. Remove water pump cover and chain tensioner cover from front timing chain case.
• Use seal cutter [SST: KV10111100] to cut liquid gasket for removal.

EM-56
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
24. Remove front oil seal from front timing chain case using suitable
tool. A
• Use screwdriver for removal.
CAUTION:
Be careful not to damage front timing chain case.
EM

PBIC2909E

D
25. Remove timing chain tensioner (primary) as follows:
a. Loosen clip of timing chain tensioner (primary), and release
plunger stopper. (1) E
b. Insert plunger into tensioner body by pressing slack guide. (2)
c. Keep slack guide pressed and hold plunger in by pushing stop-
per pin through the tensioner body hole and plunger groove. (3) F

PBIC2919E

H
d. Remove mounting bolts and remove timing chain tensioner (primary).
26. Remove internal chain guide, tension guide and slack guide.
NOTE: I
Tension guide can be removed after removing timing chain (pri-
mary).

PBIC2266E
O

27. Remove timing chain (primary) and crankshaft sprocket.

CAUTION: P
After removing timing chain (primary), never turn crankshaft and camshaft separately, or valves
will strike the piston heads.
28. Remove timing chain (secondary) and camshaft sprockets as follows:

EM-57
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
a. Attach suitable stopper pin to the right and left timing chain ten-
sioners (secondary).
NOTE:
• Use approximately 0.5 mm (0.020 in) dia. hard metal pin as a
stopper pin.
• For removal of timing chain tensioner (secondary), refer to
EM-71. [Removing camshaft bracket (No. 1) is required.]

PBIC2047E

b. Remove camshaft sprocket (INT and EXH) bolts.

• Secure the hexagonal portion of camshaft using wrench to
loosen mounting bolts.
CAUTION:
Never loosen mounting bolts with securing anything
other than the camshaft hexagonal portion or with ten-
sioning the timing chain.

KBIA1698J

c. Remove timing chain (secondary) together with camshaft sprockets.

• Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.
• Insert thick metal [0.5 mm (0.020 in)] or resin plate between
timing chain and timing chain tensioner plunger (guide).
Remove timing chain (secondary) together with camshaft
sprockets with timing chain loose from guide groove.
CAUTION:
Be careful of plunger coming-off when removing timing
chain (secondary). This is because plunger of timing
chain tensioner (secondary) moves during operation,
leading to coming-off of fixed stopper pin.
NOTE:
Camshaft sprocket (INT) is two-for-one structure of sprockets
PBIC1978E
for timing chain (primary) and for timing chain (secondary).
• When handling camshaft sprocket (INT), be careful of the fol-
lowing caution:
CAUTION:
• Handle carefully to avoid any shock to camshaft
sprocket.
• Never disassemble. (Never loosen bolts “A” as shown in
the figure.)

PBIC2920E

29. Remove water pump. Refer to CO-23.

30. Remove rear timing chain case as follows:

EM-58
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
a. Loosen and remove mounting bolts in reverse order as shown in
the figure. A
b. Cut liquid gasket using seal cutter [SST: KV10111100] and
remove rear timing chain case.
EM

PBIC2921E

D
CAUTION:
• Never remove plate metal cover of oil passage.
• After removal, handle rear timing chain case carefully so E
it does not tilt, cant, or warp under a load.

PBIC2922E

H
31. Remove O-rings from cylinder head and camshaft bracket (No.
1).
I

K
SBIA0496E

32. Remove O-rings from cylinder block. L

PBIC0788E
O
33. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a. Remove camshaft brackets (No. 1). Refer to EM-72, "Removal and Installation".
P
b. Remove timing chain tensioners (secondary) with stopper pin attached.

EM-59
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
34. Use scraper to remove all traces of old liquid gasket from front
and rear timing chain cases, and opposite mating surfaces.

PBIC2910E

• Remove old liquid gasket from bolt hole and thread.

PBIC2084E

35. Use scraper to remove all traces of liquid gasket from water
pump cover, chain tensioner cover and intake valve timing con-
trol covers.

SEM926E

INSPECTION AFTER REMOVAL

Timing Chain
Check for cracks and any excessive wear at link plates and roller
links of timing chain. Replace timing chain as necessary.

PBIC0282E

INSTALLATION
NOTE:
The below figure shows the relationship between the mating mark on each timing chain and that on the corre-
sponding sprocket, with the components installed.

EM-60
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]

EM

H
PBIC4214E

1. Camshaft sprocket (INT) 2. Timing chain (secondary) 3. Camshaft sprocket (EXH)

4. Timing chain tensioner (primary) 5. Slack guide 6. Timing chain (primary) I
7. Crankshaft sprocket 8. Water pump 9. Tension guide
10. Timing chain tensioner (secondary) 11. Internal chain guide 12. Timing chain tensioner (secondary)
13. Crankshaft key J
A. Mating mark (copper color link) B. Mating mark (punched) C. Mating mark (notched)
D. Mating mark (yellow paint) E. Mating mark (back side)
K
1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Refer to EM-53, "Com-
ponent".
a. Install timing chain tensioners (secondary) with stopper pin attached and new O-ring. L
b. Install camshaft brackets (No. 1). Refer to EM-72, "Removal and Installation".
2. Install rear timing chain case as follows:
a. Install new O-rings onto cylinder block. M

PBIC0788E P

EM-61
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
b. Install new O-rings to cylinder head and camshaft bracket
(No. 1).

SBIA0496E

c. Apply liquid gasket with tube presser (commercial service tool) to rear timing chain case back side as
shown in the figure.
Use Genuine Liquid Gasket or equivalent.
CAUTION:
• For “A” in the figure, completely wipe out liquid gasket extended on a portion touching at engine
coolant.
• Apply liquid gasket on installation position of water pump and cylinder head very completely.

PBIC3890E

d. Align rear timing chain case with dowel pins (right and left) on cylinder block and install rear timing chain
case.
• Check O-rings stay in place during installation to cylinder block, cylinder head and camshaft bracket
(No. 1).

EM-62
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
e. Tighten mounting bolts in numerical order as shown in the fig-
ure. A
• There are two types of mounting bolts. Refer to the following
for locating bolts.
EM
Bolt length: Bolt position
20 mm (0.79 in) : 1, 2, 3, 6, 7, 8, 9, 10
16 mm (0.63 in) : Except the above C

: 12.7 N·m (1.3 kg-m, 9 ft-lb) PBIC2921E

D
f. After all bolts are tightened, retighten them to the specified torque in numerical order as shown in the fig-
ure.
• If liquid gasket protrudes, wipe it off immediately.
E
g. After installing rear timing chain case, check the surface height
difference between following parts on oil pan (upper) mounting
surface. F

Standard
Rear timing chain case to lower cylinder block: G
–0.24 to 0.14 mm (–0.0094 to 0.0055 in)
• If not within the standard, repeat the installation procedure.
H
PBIC2925E

3. Install water pump with new O-rings. Refer to CO-23. I

4. Check that dowel pin hole, dowel pin of camshaft and crankshaft
key are located as shown in the figure. (No. 1 cylinder at com-
pression TDC) J
• NOTE:
Though camshaft does not stop at the position as shown in the
figure, for the placement of cam nose, it is generally accepted
camshaft is placed for the same direction of the figure. K

Camshaft dowel pin hole (intake side)

: At cylinder head upper face side in each bank. L
Camshaft dowel pin (exhaust side) KBIA1073E

: At cylinder head upper face side in each bank.

M
Crankshaft key
: At cylinder head side of right bank.
CAUTION: N
Hole on small dia. side must be used for intake side dowel pin hole. Never misidentify (ignore big
dia. side).
5. Install timing chains (secondary) and camshaft sprockets as follows: O
CAUTION:
Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions
repeatedly during the installation process. P

EM-63
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with stopper pin.

SEM430G

b. Install timing chains (secondary) and camshaft sprockets (INT

and EXH).
• Align the mating marks on timing chain (secondary) (copper
color link) with the ones on camshaft sprockets (INT and EXH)
(punched), and install them.
NOTE:
• Mating marks for camshaft sprocket (INT) are on the back
side of camshaft sprocket (secondary).
• There are two types of mating marks, circle and oval types.
They should be used for the right and left banks, respec-
tively.

Right bank : Use circle type.

Left bank : Use oval type.
• Align dowel pin and pin hole on camshafts with the groove and
dowel pin on sprockets, and install them.
• On the intake side, align pin hole on the small diameter side of
the camshaft front end with dowel pin on the back side of cam-
shaft sprocket, and install them.
• On the exhaust side, align dowel pin on camshaft front end
with pin groove on camshaft sprocket, and install them.
• In case that positions of each mating mark and each dowel pin
PBIC2926E
are not fit on mating parts, make fine adjustment to the posi-
tion holding the hexagonal portion on camshaft with wrench or equivalent.
• Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is
enough to prevent the dislocation of dowel pins.
• It may be difficult to visually check the dislocation of mating
marks during and after installation. To make the matching eas-
ier, make a mating mark on the top of sprocket teeth and its
extended line in advance with paint.

PBIC2927E

EM-64
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
c. After confirming the mating marks are aligned, tighten camshaft
sprocket mounting bolts. A
• Secure camshaft using wrench at the hexagonal portion to
tighten mounting bolts.
EM

KBIA1698J

D
d. Pull stopper pins out from timing chain tensioners (secondary).

G
PBIC2110E

6. Install tension guide.

H
7. Install timing chain (primary) as follows:
a. Install crankshaft sprocket.
• Check the mating marks on crankshaft sprocket face the front I
of engine.

SEM929E

L
b. Install timing chain (primary).

EM-65
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
• Install timing chain (primary) so the mating mark (punched) (B)
on camshaft sprocket (1) is aligned with the copper color link
(A) on timing chain, while the mating mark (notched) (D) on
crankshaft sprocket (2) is aligned with the yellow paint (C) on
timing chain, as shown in the figure.

3 : Water pump
• When it is difficult to align mating marks of timing chain (pri-
mary) with each sprocket, gradually turn camshaft using
wrench on the hexagonal portion to align it with the mating
marks.
• During alignment, be careful to prevent dislocation of mating
mark alignments of timing chains (secondary).

PBIC4215E

8. Install internal chain guide, slack guide and timing chain ten-
sioner (primary).

PBIC2109E

CAUTION:

EM-66
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
Never overtighten slack guide mounting bolts. It is normal
for a gap to exist under the bolt seats when mounting bolt A
are tightened to specification.

EM

PBIC2633E

D
• When installing timing chain tensioner (primary), push in plunger and keep it pressed in with stopper pin.
• Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing
chain tensioner (primary). E
• After installation, pull out stopper pin by pressing slack guide.

9. Check again that the mating marks on camshaft sprockets and timing chain have not slipped out of align-
ment. F
10. Install new front oil seal on front timing chain case.
• Apply new engine oil to both oil seal lip and dust seal lip.
• Install it so that each seal lip is oriented as shown in the figure. G

SEM715A
J

• Using suitable drift [outer diameter: 60 mm (2.36 in)], press-fit

oil seal until it becomes flush with front timing chain case end K
face.
• Check the garter spring is in position and seal lip is not
inverted. L

PBIC2911E
N
11. Install water pump cover and chain tensioner cover to front timing chain case.
• Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to front timing chain case as shown O
in the figure.
Use Genuine Liquid Gasket or equivalent.
P

PBIC2912E

12. Install front timing chain case as follows:

EM-67
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
a. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to front timing chain case back side as
shown in the figure.

B : Protrusion
C : Both permissible
D : Bolt hole
Use Genuine Liquid Gasket or equivalent.

PBIC3887E

b. Install new O-rings on rear timing chain case.

PBIC2548E

c. Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
d. Tighten mounting bolts to the specified torque in numerical order
as shown in the figure.
• There are four types of mounting bolts. Refer to the following
for locating bolts.

M10 × 70 mm (2.76 in) :5

: 55.0 N·m (5.6 kg-m, 41 ft-lb)
M10 × 90 mm (3.54 in) : 1, 2, 3, 4
: 55.0 N·m (5.6 kg-m, 41 ft-lb)
PBIC2908E
M6 × 40 mm (1.57 in) : 24, 25
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
M6 × 25 mm (0.98 in) : Except above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
e. After all bolts are tightened, retighten them to the specified torque in numerical order as shown in the fig-
ure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).

EM-68
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
f. After installing front timing chain case, check surface height dif-
ference between the following parts on the oil pan (upper) A
mounting surface.

Standard EM
Front timing chain case to rear timing chain case:
–0.14 to 0.14 mm (–0.0055 to 0.0055 in)
• If not within the standard, repeat the installation procedure. C

PBIC2929E

D
13. Install right and left intake valve timing control covers as follows:
a. Install new seal rings in shaft grooves.
b. Apply a continuous bead of liquid gasket with tube presser E
(commercial service tool) to intake valve timing control covers as
shown in the figure.
Use Genuine Liquid Gasket or equivalent.
F

SBIA0492E H

c. Install new collared O-rings in front timing chain case oil hole
(left and right sides). I

PBIC2631E

L
d. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain
case with holes to install intake valve timing control covers.
e. Tighten mounting bolts in numerical order as shown in the fig-
ure. M

PBIC0918E
P
14. Install oil pans (upper and lower). Refer to EM-28.
15. Install rocker covers (right and left banks). Refer to EM-41.
16. Install crankshaft pulley as follows:
a. Fix crankshaft using ring gear stopper [SST: KV10117700].
b. Install crankshaft pulley, taking care not to damage front oil seal.
• When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference).

EM-69
 TIMING CHAIN
< SERVICE INFORMATION > [VQ]
c. Tighten crankshaft pulley bolt.

: 44.1 N·m (4.5 kg-m, 33 ft-lb)

d. Place a paint mark (A) on crankshaft pulley (1) aligning with the
angle mark (B) on crankshaft pulley bolt (2). Tighten the bolt 90
degrees (angle tightening).

PBIC4627J

17. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns
smoothly.
18. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Inspection for Leaks

The following are procedures for checking fluids leak, lubricant leak and exhaust gases leak.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-25.
• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
* Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc.

EM-70
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
CAMSHAFT
A
Component INFOID:0000000005447654

EM

PBIC3891E

N
Intake valve timing control solenoid
1. 2. Gasket 3. Camshaft bracket (No. 2 to 4)
valve (right bank)
4. Camshaft (EXH) 5. Camshaft (INT) 6. Camshaft bracket (No. 1)
O
7. Dowel pin 8. Valve lifter 9. O-ring
Timing chain tensioner (secondary)
10. 11. Spring 12. Plunger
(right bank)
Timing chain tensioner (secondary)
P
13. 14. Cylinder head (right bank) 15. Cylinder head (left bank)
(left bank)
Camshaft position sensor (PHASE) Camshaft position sensor (PHASE)
16. O-ring 17. 18.
(right bank) (left bank)
19. Intake valve timing control solenoid
valve (left bank)
A. Refer to EM-72.

EM-71
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
• Refer to GI-9, "Component" for symbol marks in the figure.
Removal and Installation INFOID:0000000005447655

REMOVAL
1. Remove front timing chain case, camshaft sprocket, timing chain and rear timing chain case. Refer to EM-
53.
2. Remove camshaft position sensor (PHASE) (right and left
banks) from cylinder head back side.
CAUTION:
• Handle carefully to avoid dropping and shocks.
• Never disassemble.
• Never allow metal powder to adhere to magnetic part at
sensor tip.
• Never place sensors in a location where they are exposed
to magnetism.

KBIA1046E

3. Remove intake valve timing control solenoid valves.

• Discard intake valve timing control solenoid valve gaskets and
use new gaskets for installation.

SEM443GA

4. Remove camshaft brackets.

• Mark camshafts, camshaft brackets and bolts so they are placed in the same position and direction for
installation.
• Equally loosen camshaft bracket bolts in several steps in
reverse order as shown in the figure.

PBIC2050E

5. Remove camshafts.

EM-72
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
6. Remove valve lifters.
• Identify installation positions, and store them without mixing them up. A
7. Remove timing chain tensioner (secondary) from cylinder head.
• Remove timing chain tensioner (secondary) with its stopper
pin attached. EM
NOTE:
Stopper pin was attached when timing chain (secondary) was
removed.
C

D
PBIC2111E

INSPECTION AFTER REMOVAL E

Camshaft Runout
1. Put V-block on precise flat table, and support No. 2 and 4 journal
F
of camshaft.
CAUTION:
Never support journal No. 1 (on the side of camshaft
sprocket) because it has a different diameter from the other G
three locations.
2. Set dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the H
camshaft runout on dial indicator. (Total indicator reading)

PBIC0929E
Standard : Less than 0.02 mm (0.0008 in) I
Limit : 0.05 mm (0.0020 in)
4. If it exceeds the limit, replace camshaft. J
Camshaft Cam Height
1. Measure the camshaft cam height with micrometer.
K
Standard:
Intake : 45.465 - 45.655 mm (1.7900 - 1.7974 in)
L
Exhaust : 45.075 - 45.265 mm (1.7746 - 1.7821 in)
Limit:
Intake : 45.265 mm (1.7821 in) M
Exhaust : 44.875 mm (1.7667 in)
2. If wear exceeds the limit, replace camshaft. EMQ0072D

N
Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL DIAMETER

• Measure the outer diameter of camshaft journal with micrometer. O

Standard:
No. 1 : 25.935 - 25.955 mm (1.0211 - 1.0218 in) P
No. 2, 3, 4 : 23.445 - 23.465 mm (0.9230 - 0.9238 in)

PBIC0040E

EM-73
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
CAMSHAFT BRACKET INNER DIAMETER
• Tighten camshaft bracket bolt with the specified torque. Refer to "INSTALLATION" for the tightening proce-
dure.
• Measure the inner diameter “A” of camshaft bracket with bore
gauge.

Standard:
No. 1 : 26.000 - 26.021 mm (1.0236 - 1.0244 in)
No. 2, 3, 4 : 23.500 - 23.521 mm (0.9252 - 0.9260 in)

PBIC1645E

CAMSHAFT JOURNAL OIL CLEARANCE

• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter).

Standard:
No. 1 : 0.045 - 0.086 mm (0.0018 - 0.0034 in)
No. 2, 3, 4 : 0.035 - 0.076 mm (0.0014 - 0.0030 in)
Limit : 0.15 mm (0.0059 in)
• If the calculated value exceeds the limit, replace either or both camshaft and cylinder head.
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
Camshaft End Play
• Install dial indicator in thrust direction on front end of camshaft.
Measure the end play of dial indicator when camshaft is moved for-
ward/backward (in direction to axis).

Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in)

Limit : 0.24 mm (0.0094 in)

SEM864E

• Measure the following parts if out of the limit.

- Dimension “A” for camshaft No. 1 journal

Standard : 27.500 - 27.548 mm (1.0827 - 1.0846 in)

- Dimension “B” for cylinder head No. 1 journal bearing

Standard : 27.360 - 27.385 mm (1.0772 - 1.0781 in)

• Refer to the standards above, and then replace camshaft and/or
cylinder head.
KBIA2404J

Camshaft Sprocket Runout

1. Put V-block on precise flat table, and support No. 2 and 4 journal of camshaft.
CAUTION:
Never support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter
from the other three locations.

EM-74
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
2. Measure the camshaft sprocket runout with dial indicator. (Total
indicator reading) A

Limit : 0.15 mm (0.0059 in)

• If it exceeds the limit, replace camshaft sprocket. EM

PBIC0930E

D
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-131,
"Standard and Limit". E

G
KBIA0182E

Valve Lifter Clearance H

VALVE LIFTER OUTER DIAMETER
• Measure the outer diameter at 1/2 height of valve lifter with
micrometer since valve lifter is in barrel shape. I

Standard (Intake and exhaust)

: 33.977 - 33.987 mm (1.3377 - 1.3381 in) J

JEM798G

L
VALVE LIFTER HOLE DIAMETER
• Measure the inner diameter of valve lifter hole of cylinder head with
inside micrometer. M

Standard (Intake and exhaust)

: 34.000 - 34.016 mm (1.3386 - 1.3392 in) N

SEM867E

P
VALVE LIFTER CLEARANCE
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)

Standard (Intake and exhaust)

: 0.013 - 0.039 mm (0.0005 - 0.0015 in)
• If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and
valve lifter hole diameter, replace either or both valve lifter and cylinder head.
EM-75
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
INSTALLATION
1. Install timing chain tensioners (secondary) on both sides of cyl-
inder head.
• Install timing chain tensioner with its stopper pin attached.
• Install timing chain tensioner with sliding part facing downward
on right-side cylinder head, and with sliding part facing upward
on left-side cylinder head.
• Install new O-rings as shown in the figure.

PBIC2111E

2. Install valve lifters.

• Install it in the original position.
3. Install camshafts.
• Install camshaft with dowel pin attached to its front end face on
the exhaust side.

KBIA1071E

• Follow your identification marks made during removal, or fol-

low the identification marks that are present on new camshafts
for proper placement and direction.

Paint marks Identification

Bank INT/EXH Dowel pin
M1 M2 mark

EXH Yes No White RE

RH
INT No Green No RE
INT No Green No LH
LH KBIA1009E
EXH Yes No White LH

• Install camshaft so that dowel pin hole and dowel pin on front
end face are positioned as shown in the figure. (No. 1 cylinder
TDC on its compression stroke)
NOTE:
• Large and small pin holes are located on front end face of
camshaft (INT), at intervals of 180 degrees. Face small dia.
side pin hole upward (in cylinder head upper face direction).
• Though camshaft does not stop at the portion as shown in
the figure, for the placement of cam nose, it is generally
accepted camshaft is placed for the same direction of the fig-
ure.
PBIC2478E

EM-76
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
4. Install camshaft brackets.
• Remove foreign material completely from camshaft bracket A
backside and from cylinder head installation face.
• Install camshaft bracket in original position and direction as
shown in the figure.
EM

G
PBIC2051E

• Install camshaft brackets (No. 2 to 4) aligning the stamp marks H

as shown in the figure.
NOTE:
There are no identification marks indicating left and right for
camshaft bracket (No. 1). I

PBIC2052E
K

• Apply liquid gasket to mating surface of camshaft bracket (No.

1) as shown on right and left banks. L
Use Genuine Liquid Gasket or equivalent.

PBIC2617E

EM-77
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
5. Tighten camshaft bracket bolts in the following steps, in numeri-
cal order as shown in the figure.
a. Tighten No. 7 to 10 in order as shown.

: 1.96 N·m (0.2 kg-m, 1 ft-lb)

b. Tighten No. 1 to 6 in order as shown.

: 1.96 N·m (0.2 kg-m, 1 ft-lb)

c. Tighten No. 1 to 10 in numerical order as shown.

: 5.88 N·m (0.6 kg-m, 4 ft-lb)

d. Tighten No. 1 to 10 in numerical order as shown.

: 10.4 N·m (1.1 kg-m, 8 ft-lb)

CAUTION:
After tightening mounting bolts of camshaft brackets (No.
1), be sure to wipe off excessive liquid gasket from the
parts list below.
• Mating surface of rocker cover PBIC2050E
• Mating surface of rear timing chain case

6. Measure the difference in levels between front end faces of

camshaft bracket (No. 1) and cylinder head.

Standard : –0.14 to 0.14 mm (–0.0055 to 0.0055 in)

• Measure two positions (both intake and exhaust side) for a
single bank.
• If the measured value is out of the standard, re-install cam-
shaft bracket (No. 1).

EMQ0044D

7. Check and adjust the valve clearance. Refer to EM-79, "Valve Clearance".
8. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011 or P0021 are detected in self-diagnostic results of
CONSULT and it is directed according to inspection procedure of EC section. Refer to EC-117, "CON-
SULT Function (ENGINE)" (for Australia models) or EC-600, "CONSULT Function (ENGINE)" (except
for Australia models).
• Check when engine is cold so as to prevent burns from any splashing engine oil.
1. Check the engine oil level. Refer to LU-6, "Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release fuel pressure. Refer to EC-84, "Fuel Pressure Check" (for Australia models) or EC-568, "Fuel
Pressure Check" (except for Australia models).
b. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to EM-71.

EM-78
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
4. Crank the engine, and then check that engine oil comes out
from camshaft bracket (No. 1) oil hole. End crank after checking. A
WARNING:
Be careful not to touch rotating parts (drive belts, idler pul-
ley, and crankshaft pulley, etc.). EM
CAUTION:
Engine oil may squirt from intake valve timing control sole-
noid valve installation hole during cranking. Use a shop
cloth to prevent the engine components and the vehicle. C
Never allow engine oil to get on rubber components such
as drive belt or engine mount insulators. Immediately wipe PBIC2869E
off any splashed engine oil. D
• Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not
come out from camshaft bracket (No. 1) oil hole. Refer to LU-5.
5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), E
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-5.
6. After inspection, install removed parts. F
Inspection for Leaks

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required G
quantity, fill to the specified level. Refer to MA-25.
• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak- H
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
I
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises. J
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system. K
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
L
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level M
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
N
* Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc.

Valve Clearance INFOID:0000000005447656

O
INSPECTION

EM-79
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
In cases of removing/installing or replacing camshaft and valve-
related parts, or of unusual engine conditions due to changes in
valve clearance (found malfunctions during stating, idling or causing
noise), perform inspection as follows:

SEM713A

1. Remove rocker covers (right and left banks). Refer to EM-41.

2. Measure the valve clearance as follows:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley clockwise to align timing mark
(grooved line without color) with timing indicator.

KBIA1717J

• Check that intake and exhaust cam noses on No. 1 cylinder

(engine front side of right bank) are located as shown in the
figure.
• If not, rotate crankshaft one revolution (360 degrees) and align
as shown in the figure.

SEM418G

b. Use feeler gauge, measure the clearance between valve lifter

and camshaft.

SEM139D

Valve clearance:
Unit: mm (in)

Cold Hot * (reference data)

Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)

EM-80
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
• By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below (locations A
indicated in the figure) with feeler gauge.
• No. 1 cylinder at compression TDC
EM
Measuring position (right bank) No. 1 CYL. No. 3 CYL. No. 5 CYL.

No. 1 cylinder at EXH ×

compression TDC INT × C
Measuring position (left bank) No. 2 CYL. No. 4 CYL. No. 6 CYL.

No. 1 cylinder at INT ×

compression TDC EXH ×
D

G
PBIC2054E

c. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 3 cylinder at
TDC of its compression stroke. H
NOTE:
• To align cylinder No. 3 with the compression top dead center,
place matching marks (A) on the crankshaft pulley (1) side and
I
on the cylinder block side at a point 240°counterclockwise
from the compression top dead center using the hex head of
the crankshaft pulley bolt as a guide.
J

PBIC4628J

EM-81
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
• By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below (locations
indicated in the figure) with feeler gauge.
• No. 3 cylinder at compression TDC

Measuring position (right bank) No. 1 CYL. No. 3 CYL. No. 5 CYL.

No. 3 cylinder at EXH ×

compression TDC INT ×
Measuring position (left bank) No. 2 CYL. No. 4 CYL. No. 6 CYL.

No. 3 cylinder at INT ×

compression TDC EXH ×

PBIC2055E

d. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 5 cylinder at
TDC of compression stroke.
NOTE:
• To align cylinder No. 5 with the compression top dead center,
place matching marks (A) on the crankshaft pulley (1) side and
on the cylinder block side at a point 240°counterclockwise
from the compression top dead center using the hex head of
the crankshaft pulley bolt as a guide.

PBIC4628J

EM-82
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
• By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below (locations A
indicated in the figure) with feeler gauge.
• No. 5 cylinder at compression TDC
EM
Measuring position (right bank) No. 1 CYL. No. 3 CYL. No. 5 CYL.

No. 5 cylinder at EXH ×

compression TDC INT × C
Measuring position (left bank) No. 2 CYL. No. 4 CYL. No. 6 CYL.

No. 5 cylinder at INT ×

compression TDC EXH ×
D

G
PBIC2056E

3. Perform adjustment if the measured value is out of the standard. Refer to"ADJUSTMENT".
H
ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
1. Measure the valve clearance. Refer to "INSPECTION".
I
2. Remove camshaft. Refer to EM-72, "Removal and Installation".
3. Remove valve lifters at the locations that are out of the standard.
4. Measure the center thickness of removed valve lifters with J
micrometer.

KBIA0057E M

5. Use the equation below to calculate valve lifter thickness for replacement.
N
Valve lifter thickness calculation: t = t1+ (C1 – C2)
t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness O
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.30 mm (0.0118 in)* P
Exhaust : 0.33 mm (0.0130 in)*
*: Approximately 20°C (68°F)

EM-83
 CAMSHAFT
< SERVICE INFORMATION > [VQ]
• Thickness of new valve lifter can be identified by stamp marks
on the reverse side (inside the cylinder).

KBIA0119E

Intake
Stamp mark Thickness
788U 7.88 mm (0.3102 in)
790U 7.90 mm (0.3110 in)
· ·
· ·
840U 8.40 mm (0.3307 in)
Available thickness of valve lifter: 27 sizes with range 7.88 to 8.40 mm (0.3102 to 0.3307 in) in steps of
0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-131, "Standard and Limit".
Exhaust
Stamp mark Thickness
N788 7.88 mm (0.3102 in)
N790 7.90 mm (0.3110 in)
· ·
· ·
N836 8.36 mm (0.3291 in)
Available thickness of valve lifter: 25 sizes with range 7.88 to 8.36 mm (0.3102 to 0.3291 in) in steps of
0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-131, "Standard and Limit".
CAUTION:
Install identification letter at the end and top, “U” and “N”, at each of proper positions. (Be care-
ful of mis-installation between intake and exhaust)
6. Install selected valve lifter.
7. Install camshaft. Refer to EM-72, "Removal and Installation".
8. Manually turn crankshaft pulley a few turns.
9. Check that the valve clearances for cold engine are within the specifications by referring to the specified
values.
10. Installation of all removed parts is in the reverse order of removal. Refer to EM-72, "Removal and Installa-
tion".
11. Start the engine, and check for unusual noise and vibration.

EM-84
 OIL SEAL
< SERVICE INFORMATION > [VQ]
OIL SEAL
A
Removal and Installation of Valve Oil Seal INFOID:0000000005447657

REMOVAL EM
1. Turn crankshaft until the cylinder requiring new valve oil seals is at TDC. This will prevent valve from drop-
ping into cylinder.
2. Remove camshaft relating to valve oil seal to be removed. Refer to EM-71. C
3. Remove valve lifters. Refer to EM-71.
4. Remove valve collet.
• Compress valve spring with valve spring compressor, attach- D
ment, adapter (SST). Remove valve collet with magnet hand.
CAUTION:
When working, take care not to damage valve lifter holes. E

PBIC1791E
G

5. Remove valve spring retainer and valve spring.

6. Remove valve oil seal using valve oil seal puller (SST). H

PBIC1610E
K

INSTALLATION
1. Apply new engine oil on new valve oil seal joint and seal lip. L
2. Using valve oil seal drift (SST), press fit valve seal to height “H”
shown in the figure.
NOTE:
M
Dimension “H”: Height measured before valve spring seat instal-
lation

Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in) N

O
PBIC1611E

3. Install in the reverse order of removal after this step.

P
Removal and Installation of Front Oil Seal INFOID:0000000005447658

REMOVAL
1. Remove the following parts:
• Engine undercover front, engine undercover middle: Refer to EI-12.
• Drive belts: Refer to EM-14.
• Radiator cooling fan assembly: Refer to CO-21.
EM-85
 OIL SEAL
< SERVICE INFORMATION > [VQ]
• Crankshaft pulley: Refer to EM-53.
2. Remove front oil seal using suitable tool.
CAUTION:
Be careful not to damage front timing chain case and crank-
shaft.

PBIC2931E

INSTALLATION
1. Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal.
2. Install front oil seal.
• Install front oil seal so that each seal lip is oriented as shown in
the figure.

SEM715A

• Using suitable drift, press-fit until the height of front oil seal is
level with the mounting surface.
- Suitable drift: outer diameter 60 mm (2.36 in), inner diameter
50 mm (1.97 in).
CAUTION:
• Be careful not to damage front timing chain case and
crankshaft.
• Press-fit straight and avoid causing burrs or tilting oil
seal.

PBIC2931E

3. Install in the reverse order of removal after this step.

Removal and Installation of Rear Oil Seal INFOID:0000000005447659

REMOVAL
1. Remove transmission assembly. Refer to MT-19 (M/T models) or AT-259 (A/T models).
2. Remove clutch cover and clutch disk (M/T models). Refer to CL-20.
3. Remove flywheel (M/T models) or drive plate (A/T models). Refer to EM-104.

EM-86
 OIL SEAL
< SERVICE INFORMATION > [VQ]
4. Remove rear oil seal with a suitable tool.
CAUTION: A
Be careful not to damage crankshaft and cylinder block.

EM

PBIC2932E

D
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown in E
the figure.

SEM715A H

• Press in rear oil seal to the position as shown in the figure.

I

SBIA0281E

L
• Press-fit rear oil seal with a suitable drift [outside diameter 104
mm (4.09 in), inside diameter 88 mm (3.46 in)].
CAUTION: M
• Be careful not to damage crankshaft and cylinder block.
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
• Never touch grease applied onto oil seal lip. N

O
PBIC2933E

3. Installation of the remaining parts is the reverse order of removal. P

EM-87
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]
CYLINDER HEAD
On-Vehicle Service INFOID:0000000005447660

CHECKING COMPRESSION PRESSURE

1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure. Refer to EC-84, "Fuel Pressure Check" (for Australia models) or EC-568, "Fuel
Pressure Check" (except for Australia models).
3. Disconnect fuel pump fuse to avoid fuel injection during mea-
surement.

BBIA0534E

4. Remove intake manifold collector. Refer to EM-18.

5. Remove ignition coil and spark plug from each cylinder. Refer to EM-33 and EM-34.
6. Connect engine tachometer (not required in use of CONSULT).
7. Install compression tester with adapter onto spark plug hole.

PBIC0900E

• Use compression gauge whose picking up end inserted to

spark plug hole is smaller than 20 mm (0.79 in) in diameter.
Otherwise, it may be caught by cylinder head during removal.

SBIA0533E

8. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and engine rpm. Perform these steps to check each cyl-
inder.
Compression pressure:
Unit: kPa (kg/cm2, psi) /rpm

Standard Minimum Differential limit between cylinders

1,275 (13.0, 185)/300 981 (10.0, 142)/300 98 (1.0, 14)/300
CAUTION:
Always use a fully changed battery to obtain specified engine speed.

EM-88
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]
• If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine speed
again with normal battery gravity. A
• If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again.
EM
• If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug
hole of the cylinder to re-check it for compression.
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check the
piston rings and replace if necessary. C
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
• If two adjacent cylinders have respectively low compression pressure and their compression remains D
low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
9. After inspection is completed, install removed parts.
E
10. Start engine, and check that engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-86 (for Australia models) or EC-570
(except for Australia models).
F
Component INFOID:0000000005447661

N
PBIC2934E

1. Rubber plug 2. Cylinder head (left bank) 3. Cylinder head bolt O

4. Cylinder head (right bank) 5. Harness bracket 6. Cylinder head gasket (right bank)
7. Cylinder head gasket (left bank)
P
Removal and Installation INFOID:0000000005447662

REMOVAL
1. Remove camshaft. Refer to EM-71.
2. Release the hoist from hanging, then remove the engine slingers.
3. Remove the following parts:
• Intake manifold: Refer to EM-21.
EM-89
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]
• Exhaust manifold: Refer to EM-23.
• Water inlet and thermostat assembly: Refer to CO-28.
• Water outlet, water pipe and heater pipe: Refer to CO-30.
4. Remove cylinder head bolts in reverse order as shown in the fig-
ure with cylinder head bolt wrench (commercial service tool) and
power tool to remove cylinder heads (right and left banks).

PBIC2057E

5. Remove cylinder head gaskets.

INSPECTION AFTER REMOVAL
Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace them with new one.

Limit (“d1” – “d2”) : 0.11 mm (0.0043 in)

• If reduction of outer diameter appears in a position other than “d2”,
use it as “d2” point.

PBIC2480E

Cylinder Head Distortion

NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-119, "Inspec-
tion After Disassembly".
1. Using scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.
CAUTION:
Never allow gasket fragments to enter engine oil or engine coolant passages.

EM-90
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions. A

Limit : 0.1 mm (0.004 in)

• If it exceeds the limit, replace cylinder head. EM

SEM861E

D
INSTALLATION
1. Install new cylinder head gasket.
2. Turn crankshaft until No. 1 piston is set at TDC. E
• Crankshaft key should line up with the right bank cylinder cen-
ter line as shown in the figure.
F

SEM532G H

3. Install cylinder head follow the steps below to tighten cylinder

head bolts in numerical order as shown in the figure.
CAUTION: I
If cylinder head bolts re-used, check their outer diameters
before installation. Refer to "Cylinder Head Bolts Outer
Diameter". J
a. Apply new engine oil to threads and seat surface of cylinder
head bolts.
b. Tighten all cylinder head bolts. K

: 98.1 N·m (10 kg-m, 72 ft-lb)

L
c. Completely loosen all cylinder head bolts.

: 0 N·m (0 kg-m, 0 ft-lb)

M
CAUTION:
In step “c”, loosen cylinder head bolts in reverse order of
that indicated in the figure.
N
d. Tighten all cylinder head bolts.

: 39.2 N·m (4.0 kg-m, 29 ft-lb) O

PBIC2057E

EM-91
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]
e. Turn all cylinder head bolts 90 degrees clockwise (angle tighten-
ing).
CAUTION:
Check the tightening angle by using angle wrench (SST).
Avoid judgment by visual inspection without tool.
• Check tightening angle indicated on angle wrench (SST) indi-
cator plate.
f. Turn all cylinder head bolts 90 degrees clockwise again.

PBIC1613E

4. After installing cylinder head, measure distance between front

end faces of cylinder block and cylinder head (left and right
banks).

Standard : 14.1 - 14.9 mm (0.555 - 0.587 in)

• If the measured value is out of the standard, re-install cylinder
head.

EMQ0662D

5. Install in the reverse order of removal after this step.

INSPECTION AFTER INSTALLATION
Inspection for Leaks

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-25.
• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
* Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc.

EM-92
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]
Component INFOID:0000000005447663

EM

PBIC2481E
I
1. Valve lifter 2. Valve collet 3. Valve spring retainer
4. Valve spring 5. Valve oil seal 6. Valve spring seat
7. Valve guide 8. Spark plug 9. Spark plug tube J
10. Cylinder head (right bank) 11. Valve seat 12. Valve (EXH)
13. Valve (INT) 14. Cylinder head (left bank)
K
Disassembly and Assembly INFOID:0000000005447664

DISASSEMBLY L
1. Remove spark plug with spark plug wrench (commercial service tool).
2. Remove valve lifter.
• Identify installation positions, and store them without mixing them up. M
3. Remove valve collet.
• Compress valve spring with valve spring compressor, attach-
ment and adapter (SST). Remove valve collet with magnet N
hand.
CAUTION:
When working, take care not to damage valve lifter holes.
O

P
PBIC1791E

4. Remove valve spring retainer, valve spring and valve spring seat.
5. Push valve stem to combustion chamber side, and remove valve.
• Identify installation positions, and store them without mixing them up.

EM-93
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]
6. Remove valve oil seals using valve oil seal puller (SST).

PBIC1610E

7. If valve seat must be replaced, refer to EM-95, "Inspection After Disassembly".

8. If valve guide must be replaced, refer to EM-95, "Inspection After Disassembly".
9. Remove spark plug tube, as necessary.
• Using pair of pliers, pull spark plug tube out of cylinder head.
CAUTION:
• Take care not to damage cylinder head.
• Once removed, spark plug tube will be deformed and cannot be reused. Never remove it unless
absolutely necessary.
ASSEMBLY
1. When valve guide is removed, install it. Refer to EM-95, "Inspection After Disassembly".
2. When valve seat is removed, install it. Refer to EM-95, "Inspection After Disassembly".
3. Install valve oil seals.
• Install with valve oil seal drift (SST) to match dimension in the
figure.

Height “H” (Without valve spring seat installed)

Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)

PBIC0802E

4. Install valve spring seat.

5. Install valves.
• Install it in the original position.
NOTE:
Larger diameter valves are for intake side.
6. Install valve spring (uneven pitch type).
• Install narrow pitch end (paint mark) to cylinder head side
(valve spring seat side).
• Intake side and exhaust side valve springs are different. Install
them referring to the following paint mark collar.

SEM085D

7. Install valve spring retainer.

EM-94
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]
8. Install valve collet.
• Compress valve spring with valve spring compressor, attach- A
ment and adapter (SST). Install valve collet with magnet hand.
CAUTION:
When working, take care not to damage valve lifter holes.
EM
• Tap valve stem edge lightly with plastic hammer after installa-
tion to check its installed condition.

PBIC1791E

D
9. Install valve lifter.
• Install it in the original position.
10. Install spark plug tube. E
• Press-fit spark plug tube as follows:
a. Remove old liquid gasket adhering to cylinder head mounting hole.
b. Apply sealant to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side. F
Use Genuine High Strength Locking Sealant or equivalent.
c. Using drift, press-fit spark plug tube so that its height “H” is as
specified in the figure. G
Standard press-fit height “H”:
: 37.7 - 38.7 mm (1.484 - 1.524 in) H
CAUTION:
• When press-fitting, take care not to deform spark plug
tube. I
• After press-fitting, wipe off liquid gasket protruding onto
cylinder-head upper face.
PBIC2634E
11. Install spark plug with spark plug wrench (commercial service J
tool).
Inspection After Disassembly INFOID:0000000005447665

K
VALVE DIMENSIONS
• Check dimensions of each valve. For dimensions, refer to "VALVE DIMENSIONS".
• If dimensions are out of the standard, replace valve and check the valve seat contact. Refer to "VALVE L
SEAT CONTACT".
VALVE GUIDE CLEARANCE
M
Valve Stem Diameter
Measure the diameter of valve stem with micrometer.

Standard N
Intake : 5.965 - 5.980 mm (0.2348 - 0.2354 in)
Exhaust : 5.955 - 5.970 mm (0.2344 - 0.2350 in)
O

P
SEM938C

Valve Guide Inner Diameter

Measure the inner diameter of valve guide with inside micrometer.

EM-95
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]

Standard
Intake and Exhaust : 6.000 - 6.018 mm (0.2362 - 0.2369 in)
Valve Guide Clearance
(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).

Valve guide clearance:

Standard
Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in)
Limit
Intake : 0.08 mm (0.0031 in)
Exhaust : 0.09 mm (0.0035 in)
• If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be
replaced, refer to "VALVE GUIDE REPLACEMENT".
VALVE GUIDE REPLACEMENT
When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.
1. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil.

SEM008A

2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US

ton, 2.0 lmp ton) pressure] or hammer and valve guide drift
(commercial service tool).
CAUTION:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.

SEM931C

3. Using valve guide reamer (commercial service tool), ream cylin-

der head valve guide hole.

Valve guide hole diameter (for service parts):

Intake and exhaust
: 10.175 - 10.196 mm (0.4006 - 0.4014 in)

SEM932C

EM-96
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil. A

EM

SEM008A

D
5. Using valve guide drift (commercial service tool), press valve
guide from camshaft side to the dimensions as in the figure.
E
Projection “L”
Intake and exhaust
: 12.6 - 12.8 mm (0.496 - 0.504 in) F
CAUTION:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned. G
SEM950E

6. Using valve guide reamer (commercial service tool), apply

H
reamer finish to valve guide.

Standard:
I
Intake and exhaust
: 6.000 - 6.018 mm (0.2362 - 0.2369 in)
J

SEM932C
K
VALVE SEAT CONTACT
• After confirming that the dimensions of valve guides and valves are
within the specifications, perform this procedure. L
• Apply prussian blue (or white lead) onto contacting surface of valve
seat to check the condition of the valve contact on the surface.
• Check if the contact area band is continuous all around the circum-
M
ference.
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions even after the re-check, replace
valve seat. Refer to "VALVE SEAT REPLACEMENT". N

SBIA0322E

O
VALVE SEAT REPLACEMENT
When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
P
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-131, "Standard and Limit".
CAUTION:
Prevent to scratch cylinder head by excessive boring.

EM-97
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]
2. Ream cylinder head recess diameter for service valve seat.

Oversize [0.5 mm (0.020 in)]

Intake : 38.500 - 38.516 mm (1.5157 - 1.5164 in)
Exhaust : 32.700 - 32.716 mm (1.2874 - 1.2880 in)
• Be sure to ream in circles concentric to valve guide center.
This will enable valve to fit correctly.

SEM795A

3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil.

SEM008A

4. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head.
CAUTION:
• Avoid directly touching cold valve seats.
• Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
5. Using valve seat cutter set (commercial service tool) or valve
seat grinder, finish seat to the specified dimensions. Refer to
EM-131, "Standard and Limit".
CAUTION:
When using valve seat cutter, firmly grip cutter handle with
both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with cutter or cutting many different times may
result in stage valve seat.

SEM934C

6. Using compound, grind to adjust valve fitting.

7. Check again for normal contact. Refer to "VALVE SEAT CONTACT".
VALVE SPRING SQUARENESS
• Set try square along the side of valve spring and rotate spring.
Measure the maximum clearance between the top face of spring
and try square.

Limit : 2.1 mm (0.083 in)

• If it exceeds the limit, replace valve spring.

PBIC0080E

VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

EM-98
 CYLINDER HEAD
< SERVICE INFORMATION > [VQ]
• Check valve spring pressure at the specified spring height.
A
Standard:
Intake and exhaust
Free height EM
: 47.07 mm (1.8531 in)
Installation height
C
: 37.00 mm (1.4567 in)
Installation load SEM113

: 166 - 188 N (16.93 - 19.18 kg, 37.3 - 42.3 lb) D

Height during valve open
: 27.20 mm (1.0709 in)
E
Load with valve open
: 373 - 421 N (38.04 - 42.94 kg, 83.9 - 94.6 lb)
• If the installation load or load with valve open is out of the standard, replace valve spring. F

EM-99
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [VQ]
ENGINE ASSEMBLY
Component INFOID:0000000005447666

PBIC4216E

1. RH engine mounting bracket (upper) 2. RH heat shield plate 3. RH engine mounting insulator
4. RH engine mounting bracket (lower) 5. LH engine mounting bracket (lower) 6. LH engine mounting insulator
Engine mounting insulator (rear)
7. LH heat shield plate 8. LH engine mounting bracket (upper) 9.
(4WD models)

EM-100
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [VQ]
Engine mounting insulator (2WD M/T
10. Transmission cross member 11. 12. Dynamic damper (2WD M/T models)
models) A
Engine mounting insulator (2WD A/T
13. 14. Dynamic damper (2WD A/T models)
models)

WARNING: EM
• Situate vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS C
CATALOG.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations.
• Never start working until exhaust system and engine coolant are cooled sufficiently. D
• If items or work required are not covered by the engine section, refer to the applicable sections.
• Always use the support point specified for lifting.
• Use either 2-point lift type or separate type lift. If board-on type is used for unavoidable reasons, E
support at the rear axle jacking point with transmission jack or similar tool before starting work, in
preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-42, "Pantograph Jack,
Garage Jack and Safety Stand". F

Removal and Installation INFOID:0000000005447667

G
REMOVAL

NOTE: H
When removing components such as hoses, tubes/lines, etc., cap or plug opening to prevent fluid from spill-
ing.
I
Preparation
1. Release fuel pressure. Refer to EC-84, "Fuel Pressure Check" (for Australia models) or EC-568, "Fuel
Pressure Check" (except for Australia models). J
2. Disconnect both battery cables. Refer to SC-4.
3. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant".
4. Remove the following parts. K
• Engine undercover front: Refer to EI-12.
• Engine undercover middle, engine undercover rear
• Hood assembly: Refer to BL-14, "Removal and Installation of Hood Assembly". L
• Battery: Refer to SC-4.
• Engine cover: Refer to EM-18.
• Air duct and air cleaner case assembly: Refer to EM-16.
• Radiator, radiator shroud (upper and lower) and cooling fan assembly: Refer to CO-13 and CO-21. M
• Drive belt: Refer to EM-14.
5. Disconnect vacuum hose between vehicle and engine and set it aside.
6. Disconnect the engine room harness from the engine side and set it aside for easier work. N
7. Disconnect the engine harness grounds.
8. Remove power steering fluid reservoir tank from engine and move it aside for easier work. Refer to PS-40.
O
9. Remove power steering oil pump from engine. Move it from its location and secure with a rope for easier
work. Refer to PS-29, "VQ40DE : Removal and Installation".
10. Remove the A/C compressor bolts and set aside. Refer to ATC-242, "Removal and Installation for Com-
pressor". P
11. Disconnect brake booster vacuum line.
12. Disconnect EVAP line.
13. Disconnect the fuel hose at the engine side connection. Refer to EM-36.
14. Disconnect the heater hoses at cowl, and install plugs to avoid leakage of engine coolant.
15. Remove the A/T oil level indicator and indicator tube. Refer to AT-259.

EM-101
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [VQ]
16. Remove front final drive assembly (4WD models). Refer to FFD-16.
17. Remove three way catalyst. Refer to EM-23.
18. Install engine slingers into left bank and right bank.

Engine slinger bolts:

: 28.0 N·m (2.9 kg-m, 21 ft-lb)

WBIA0624E

19. Remove transmission. Refer to MT-19 (M/T models) or AT-259 (A/T models).
20. Lift with hoist and secure the engine in position.
21. Loosen LH and RH engine mounting insulator mounting bolts.
22. Remove engine.
CAUTION:
• During the operation, check that no part interferes with
the body side.
• Before and during this lifting, always check if any har-
nesses are left connected.

SEM896G

23. Remove alternator. Refer to SC-25, "Removal and Installation".

24. Remove engine mounting insulator bracket (upper).
INSTALLATION
Installation is the reverse order of removal.
• Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
• Check that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
• Insert vacuum hose to vacuum gallery until vacuum hose comes in contact with the stopper when a stopper
is provided at vacuum gallery.
INSPECTION AFTER INSTALLATION
• Before starting engine, check the levels of engine coolant, lubrications and working oils. If less than required
quantity, fill to the specified level.
• Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working oil, fuel
and exhaust gas.
• Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
• After cooling down engine, again check amounts of engine coolant, lubricants, oil, and fluid. Refill to speci-
fied level, if necessary.
• Summary of the inspection items:

Item Before starting engine Engine running After engine stopped

Engine coolant Level Leakage Level
Engine oil Level Leakage Level

EM-102
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [VQ]
Item Before starting engine Engine running After engine stopped
A
Transmission / transaxle AT & CVT Models Leakage Level / Leakage Leakage
fluid MT Models Level / Leakage Leakage Level / Leakage
Other oils and fluids* Level Leakage Level EM
Fuel Leakage Leakage Leakage
Exhaust gas — Leakage —
* Power steering fluid, brake fluid, etc. C

EM-103
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
CYLINDER BLOCK
Component INFOID:0000000005447668

PBIC3892E

1. Reinforcement plate 2. Drive plate (A/T models) 3. Flywheel (M/T models)

4. Rear oil seal 5. Sub harness 6. Knock sensor
7. Water connector 8. Cylinder block 9. Oil jet

EM-104
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
10. Thrust bearing 11. Pilot converter (A/T models) 12. Pilot bushing (M/T models)
13. Main bearing 14. Crankshaft 15. Crankshaft key A
16. O-ring 17. Lower cylinder block bolt 18. Lower cylinder block
19. Connecting rod bolt 20. Connecting rod bearing cap 21. Connecting rod bearing
22. Connecting rod 23. Snap ring 24. Piston pin EM
25. Piston 26. Oil ring 27. Second ring
28. Top ring
A. Refer to EM-105 B. Chamfered C
: Crankshaft side

• Refer to GI-9, "Component" for symbol marks except in the above. D

Disassembly and Assembly INFOID:0000000005447669

E
DISASSEMBLY
1. Remove engine assembly from vehicle. Refer to EM-100.
2. Remove both exhaust manifolds. Refer to EM-23. F
3. Install engine to engine stand as follows.
a. Remove clutch cover and clutch disc (M/T models). Refer to CL-20.
b. Remove flywheel (M/T models) or drive plate (A/T models). Fix G
crankshaft with ring gear stopper (SST), and remove mounting
bolts.
• Loosen mounting bolts in diagonal order. H
• Use TORX socket for flywheel mounting bolts (size: T55)
(commercial service tool).

PBIC1617E J

CAUTION:
• Never disassemble flywheel (M/T models) or drive plate K
(A/T models).
• Never place drive plate (A/T models) with signal plate
facing down. L
• When handling signal plate, take care not to damage or
scratch it.
• Handle signal plate in a manner that prevents it from
becoming magnetized. M

PBIC2938E N

c. Remove pilot bushing (M/T models) or pilot converter (A/T mod-

els) using pilot bushing puller (A) [SST: 16610001] as necessary. O

PBIC3893E

EM-105
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
d. Hoist engine and install it to the engine stand (commercial ser-
vice tool).
CAUTION:
Use engine stand that has a load capacity [approximately
220 kg (485 lb) or more] large enough for supporting the
engine weight.
NOTE:
The figure shows an example of general-purpose engine stand
that can hold mating surface of transmission with flywheel (M/T
models) or drive plate (A/T models) removed.
PBIC0085E

4. Drain engine oil. Refer to LU-7, "Changing Engine Oil".

5. Drain engine coolant by removing water drain plugs from cylin-
der block left side at “A” and cylinder block front side at “B” as
shown in the figure.

C : Plug
D : Plug
E : Plug

PBIC2937E

6. Remove cylinder head. Refer to EM-88.

7. Remove sub harness, and remove knock sensors.
CAUTION:
Carefully handle sensor avoiding shocks.
8. Remove piston and connecting rod assembly as follows:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-119, "Inspection After Disassembly".
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod bearing cap.
c. Using hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.

PBIC2940E

EM-106
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
9. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION: A
Identify installation position, and store them without mixing them up.
10. Remove piston rings from piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-119, "Inspection After EM
Disassembly".
• Use piston ring expander (commercial service tool).
CAUTION:
C
• When removing piston rings, be careful not to damage
piston.
• Be careful not to damage piston rings by expanding them
excessively. D

PBIC0087E

F
11. Remove piston from connecting rod as follows:
a. Using snap ring pliers, remove snap rings.
G

PBIC1638E

b. Heat piston to 60 to 70°C (140 to 158°F) with industrial use drier J

or equivalent.

M
PBIC1639E

c. Push out piston pin with stick of outer diameter approximately 20

mm (0.79 in). N

PBIC0262E

12. Remove lower cylinder block bolts.

• Before loosening lower cylinder block bolts, measure the crankshaft end play. Refer to EM-119, "Inspec-
tion After Disassembly".

EM-107
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• Loosen lower cylinder block bolts in reverse order as shown in
the figure in several different steps.
NOTE:
Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).

PBIC2941E

13. Remove lower cylinder block.

• Use seal cutter [SST: KV10111100] to cut liquid gasket for removal. Refer to EM-6, "Precaution for Liq-
uid Gasket".
CAUTION:
Be careful not to damage the mounting surfaces.
14. Remove crankshaft.
15. Pull rear oil seal out from rear end of crankshaft.
NOTE:
When replacing rear oil seal without removing lower cylinder block, use a screwdriver to pull the rear oil
seal installed between crankshaft and cylinder block out.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
16. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
• Be careful not to drop main bearing, and to scratch the surface.
• Identify installation positions, and store them without mixing them up.
17. Remove oil jet.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
2. Install each plug to cylinder block as shown in the figure.
• Apply sealant to the thread of water drain plugs “A” and “B”.
Use Genuine Liquid Gasket or equivalent.
• Apply sealant to the thread of plugs “C” and “E”.
Use Genuine Thread Locking Sealant or equivalent.
• Apply sealant to the thread of plug “D”.
Use Anaerobic Liquid Gasket or equivalent.
• Replace washers with new one.

PBIC2937E

EM-108
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• Tighten each plug as specified below.
A
Part Washer Tightening torque
A No 19.6 N·m (2.0 kg-m, 14 ft-lb)
EM
Reuse: 9.8 N·m (1.0 kg-m, 87 in-lb)
B No
New: 6.0 N·m (0.61 kg-m, 53 in-lb)
C Yes 78.0 N·m (8.0 kg-m, 58 ft-lb) C
D Yes 62.0 N·m (6.3 kg-m, 46 ft-lb)
E Yes 12.3 N·m (1.3 kg-m, 9 ft-lb)
D
3. Install oil jet.
• Insert oil jet dowel pin into cylinder block dowel pin hole, and
tighten mounting bolts.
E

G
PBIC0898E

4. Install main bearings and thrust bearings as follows: H

a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block.
b. Install thrust bearings to the both sides of the No. 3 journal hous-
ing on cylinder block. I
• Install thrust bearings with the oil groove facing crankshaft arm
(outside).
• Install thrust bearing with a projection on one end on cylinder J
block, and thrust bearing with a projection at center on lower
cylinder block. Align each projection with mating notch.
K

PBIC2968E
L
c. Install main bearings paying attention to the direction.
• Main bearing with oil hole and groove goes on cylinder block.
The one without them goes on lower cylinder block. M
• Before installing main bearings, apply engine oil to the bearing
surface (inside). Do not apply engine oil to the back surface,
but thoroughly clean it.
• When installing, align main bearing stopper protrusion to cut- N
out of cylinder block and lower cylinder block.
• Ensure the oil holes on cylinder block and those on the corre-
sponding bearing are aligned. O
PBIC2969E

5. Install crankshaft to cylinder block. P

• While turning crankshaft by hand, check that it turns smoothly.
6. Inspect the outer diameter of lower cylinder block bolt. Refer to EM-119, "Inspection After Disassembly".
7. Install lower cylinder block as follows:
NOTE:
Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder
block.

EM-109
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
a. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to lower cylinder block as shown in the
figure.
Use Genuine Liquid Gasket or equivalent.
CAUTION:
After liquid gasket is applied, rear oil seal installation must
be finished within 5 minutes. Therefore, the following pro-
cedure must be performed quickly.
b. Tighten lower cylinder block mounting bolt as follows:
i. Apply new engine oil to threads and seat surfaces of the mount-
ing bolts. PBIC2942E

ii. Tighten M8 bolts in numerical order from No. 17 to 24 in the fig-

ure.

: 22.1 N·m (2.3 kg-m, 16 ft-lb)

CAUTION:
Wipe off completely any protruding liquid gasket on rear oil
seal installation surface.
NOTE:
There are more processes to complete the tightening of mount-
ing bolts. However stop procedure here to install rear oil seal.
PBIC2941E

c. Install rear oil seal. Refer to EM-86, "Removal and Installation of Rear Oil Seal".
d. Restart tightening of lower cylinder block bolts as follows:
i. Tighten M10 bolts in numerical order from No. 1 to 16 in the fig-
ure.
NOTE:
Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).

: 35.3 N·m (3.6 kg-m, 26 ft-lb)

PBIC2941E

ii. Turn M10 bolts 90 degrees clockwise (angle tightening) in

numerical order from No. 1 to 16 in the figure.
CAUTION:
Use angle wrench [SST: KV10112100] (A) to check tighten-
ing angle. Never make judgement by visual inspection.

PBIC3894E

• After installing the mounting bolts, check that crankshaft can be rotated smoothly by hand.
• Wipe off completely any protruding liquid gasket on front side of the engine.
• Check the crankshaft end play. Refer to EM-119, "Inspection After Disassembly".
8. Inspect the outer diameter of connecting rod bolt. Refer to EM-119, "Inspection After Disassembly".
9. Install piston to connecting rod as follows:
a. Using snap ring pliers, install new snap ring to the groove of piston rear side.
• Insert it fully into groove to install.
b. Install piston to connecting rod.

EM-110
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• Using industrial use drier or similar tool, heat piston until piston pin can be pushed in by hand without
excess force [approx. 60 to 70 °C (140 to 158 °F)]. From the front to the rear, insert piston pin into piston A
and connecting rod.
• Assemble so that the front mark on the piston head and the
cylinder number on connecting rod are positioned as shown in
EM
the figure.
c. Install new snap ring to the groove of the piston front side.
• Insert it fully into groove to install.
• After installing, check that connecting rod moves smoothly. C

SEM838F

E
10. Using piston ring expander (commercial service tool), install pis-
ton rings.
CAUTION:
• When installing piston rings, be careful not to damage F
piston.
• Be careful not to damage piston rings by expending them
excessively.
G

H
PBIC0087E

• If there is stamped mark on ring, mount it with marked side up.

I
NOTE:
If there is no stamp on ring, no specific orientation is required
for installation.
J
Stamped mark:
Top ring :—
Second ring : R K

SEM757G
L

• Position each ring with the gap as shown in the figure referring
to the piston front mark.
M

PBIC0808E

P
• Check the piston ring side clearance. Refer to EM-119, "Inspection After Disassembly".
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
• Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply
engine oil to the back surface, but thoroughly clean it.

EM-111
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• When installing, align connecting rod bearing stopper protru-
sion with cutout of connecting rods and connecting rod bearing
caps to install.
• Ensure the oil hole on connecting rod and that on the corre-
sponding bearing are aligned.

PBIC2067E

12. Install piston and connecting rod assembly to crankshaft.

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
• Match the cylinder position with the cylinder number on connecting rod to install.
• Be sure that front mark on piston head is facing front of engine.
• Using piston ring compressor (A) [SST: EM03470000] or suit-
able tool, install piston with the front mark on the piston head
facing the front of engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.

PBIC3895E

13. Install connecting rod bearing cap.

• Match the stamped cylinder number marks on connecting rod
with those on connecting rod bearing cap to install.
• Be sure that front mark on connecting rod bearing cap is fac-
ing front of engine.

PBIC0809E

14. Tighten connecting rod bolts as follows:

a. Apply engine oil to the threads and seats of connecting rod bolts.
b. Tighten connecting rod bolts.

: 19.6 N·m (2.0 kg-m, 14 ft-lb)

c. Then tighten all connecting rod bolts 90 degrees clockwise
(angle tightening).
CAUTION:
Always use angle wrench [SST: KV10112100] (A). Avoid
tightening based on visual check alone.
• After tightening connecting rod bolts, check that crankshaft
rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-119,
"Inspection After Disassembly".

PBIC3896E

EM-112
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
15. Install pilot bushing (M/T models) or pilot converter (A/T mod-
els). A
• With drift of the following outer diameter, press-fit as far as it
will go.
EM
Pilot bushing : Approx. 17 mm (0.67 in)
Pilot converter : Approx. 33 mm (1.30 in)
C

PBIC2947E
D
• Press-fit pilot bushing (1) as the dimension in the figure. (M/T
models)
E
2 : Crankshaft (Rear end surface)
: 10.20 - 10.85 mm (0.416 - 0.4272 in)
a
[Target: 10.20 mm (0.416 in)]
F

G
JPBIA1457ZZ

• Press-fit pilot converter with its chamfer facing crankshaft as H

shown in the figure. (A/T models)

SEM537E
K

16. Install knock sensors.

• Install knock sensor so that connector faces rear of engine. L
• After installing knock sensor, connect harness connector, and
lay it out to rear of engine.
CAUTION:
• Never tighten mounting bolts while holding connector. M
• If any impact by dropping is applied to knock sensor,
replace it with new one.
NOTE: N
• Check that there is no foreign material on the cylinder block
mating surface and the back surface of knock sensor.
• Check that knock sensor does not interfere with other parts.
O

PBIC2948E

EM-113
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
17. Note the following, assemble in the reverse order of disassembly after this step.
Flywheel (M/T models)
• When installing flywheel to crankshaft, be sure to correctly
align crankshaft side dowel pin and flywheel side dowel pin
hole.

PBIC1110E

• There is a mating mark (B) on the clutch cover side of fly-

whee(4). Refer it during installation.

1 : Dowel pin
2 : Rear oil seal
3 : Crankshaft
A : Dowel pin hole

PBIC3897E

• Holding ring gear with ring gear stopper (SST), tighten secur-
ing bolts with TORX socket (size: T55) (commercial service
tool).
• Tighten mounting bolts crosswise over several times.

PBIC1617E

Drive plate (A/T models)

• Install drive plate and reinforcement plate as shown in the fig-
ure.
• Holding ring gear with ring gear stopper [SST: KV10117700].
• Tighten mounting bolts crosswise over several times.

PBIC0910E

How to Select Piston and Bearing INFOID:0000000005447670

DESCRIPTION

EM-114
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]

Selection points Selection parts Selection items Selection methods A

Determined by match of cylin-
der block bearing housing
Between cylinder block and Main bearing grade grade (inner diameter of hous-
Main bearing EM
crankshaft (bearing thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for C
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection.
D
Piston and piston pin assembly
Between cylinder block and pis- Piston grade Piston grade = cylinder bore
(Piston is available together
ton (piston skirt diameter) grade (inner diameter of bore) E
with piston pin as assembly.)
Between piston and connecting
— — —
rod*
*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is available.) The F
information at the shipment from the plant is described as a reference.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts. G
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
H
selective fitting parts, refer to the text.
HOW TO SELECT PISTON
When New Cylinder Block is Used I
Check the cylinder bore grade (“1”, “2”, or “3”) on rear side of cylin-
der block, and select piston of the same grade.
NOTE: J
Piston is available with piston pin as a set for the service part. (Only
“0” grade piston pin is available.)
K

L
PBIC2949E

When Cylinder Block is Reused

M
1. Measure the cylinder bore inner diameter. Refer to EM-119, "Inspection After Disassembly".
2. Determine the bore grade by comparing the measurement with
the values under the cylinder bore inner diameter of the “Piston
N
Selection Table”.

PBIC2950E

3. Select piston of the same grade.

Piston Selection Table

EM-115
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
Unit: mm (in)

Grade 1 2 (or no mark) 3

95.500 - 95.510 95.510 - 95.520 95.520 - 95.530
Cylinder bore inner diameter
(3.7598 - 3.7602) (3.7602 - 3.7606) (3.7606 - 3.7610)
95.480 - 95.490 95.490 - 95.500 95.500 - 95.510
Piston skirt diameter
(3.7590 - 3.7594) (3.7594 - 3.7598) (3.7598 - 3.7602)
NOTE:
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no pis-
ton pin grades can be selected. (Only “0” grade is available.)
• No second grade mark is available on piston.
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used
Check pin journal grade (“0”, “1”, or “2”) on front of crankshaft, and
select connecting rod bearing of the same grade.
NOTE:
There is no grading for connecting rod big end diameter.

PBIC2951E

When Crankshaft and Connecting Rod are Reused

1. Measure the connecting rod big end diameter. Refer to EM-119, "Inspection After Disassembly".
2. Check that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to EM-119, "Inspection After Disassembly".
4. Determine the grade of crankshaft pin journal grade by corresponding to the measured dimension in
“Crankshaft pin journal diameter” column of “Connecting Rod Bearing Selection Table”.
5. Select connecting rod bearing of the same grade.
Connecting Rod Bearing Selection Table
Unit: mm (in)

Connecting rod big end diameter 57.000 - 57.013 (2.2441 - 2.2446)

Unit: mm (in)

Crankshaft Connecting rod bearing

Crankshaft pin journal diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
53.968 - 53.974 (2.1247 - 2.1250) 0 1.500 - 1.503 (0.0591 - 0.0592) STD 0 Black
53.962 - 53.968 (2.1245 - 2.1247) 1 1.503 - 1.506 (0.0592 - 0.0593) STD 1 Brown
53.956 - 53.962 (2.1242 - 2.1245) 2 1.506 - 1.509 (0.0593 - 0.0594) STD 2 Green

Undersize Bearings Usage Guide

• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.
• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:

EM-116
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)]. A

EM

PBIC1908E

Bearing undersize table

D
Unit: mm (in)

Size Thickness
E
US 0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643)

HOW TO SELECT MAIN BEARING

When New Cylinder Block and Crankshaft are Used F
1. “Main Bearing Selection Table” rows correspond to bearing
housing grade on rear left side of cylinder block.
G

PBIC2949E

2. “Main Bearing Selection Table” columns correspond to journal J

diameter grade on front side of crankshaft.

M
PBIC2951E

3. Select main bearing grade at the point where selected row and column meet in “Main Bearing Selection
Table”. N
When Cylinder Block and Crankshaft are Reused
1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer
to EM-119, "Inspection After Disassembly". O
2. Correspond the measured dimension in “Cylinder block main bearing housing inner diameter” row of
“Main Bearing Selection Table”.
3. Correspond the measured dimension in “Crankshaft main journal diameter” column of “Main Bearing P
Selection Table”.
4. Select main bearing grade at the point where selected row and column meet in following selection table.

EM-117
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
Main Bearing Selection Table

WBIA0625E

Main Bearing Grade Table (All Journals)

EM-118
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
Unit: mm (in)

Grade number Thickness Width Identification color Remarks A

0 2.500 - 2.503 (0.0984 - 0.0985) Black
1 2.503 - 2.506 (0.0985 - 0.0987) Brown
EM
2 2.506 - 2.509 (0.0987 - 0.0988) Green
3 2.509 - 2.512 (0.0988 - 0.0989) Yellow Grade is the same for
upper and lower bear-
4 2.512 - 2.515 (0.0989 - 0.0990) Blue ings. C
5 2.515 - 2.518 (0.0990 - 0.0991) Pink
6 2.518 - 2.521 (0.0991 - 0.0993) Purple
D
7 2.521 - 2.524 (0.0993 - 0.0994) White
UPR 2.503 - 2.506 (0.0985 - 0.0987) Brown
01
LWR 2.500 - 2.503 (0.0984 - 0.0985) Black E
UPR 2.506 - 2.509 (0.0987 - 0.0988) 19.9 - 20.1 Green
12
LWR 2.503 - 2.506 (0.0985 - 0.0987) (0.783 - 0.791) Brown
UPR 2.509 - 2.512 (0.0988 - 0.0989) Yellow
F
23
LWR 2.506 - 2.509 (0.0987 - 0.0988) Green
UPR 2.512 - 2.515 (0.0989 - 0.0990) Blue Grade is different for
34 upper and lower bear- G
LWR 2.509 - 2.512 (0.0988 - 0.0989) Yellow ings.
UPR 2.515 - 2.518 (0.0990 - 0.0991) Pink
45
LWR 2.512 - 2.515 (0.0989 - 0.0990) Blue H
UPR 2.518 - 2.521 (0.0991 - 0.0993) Purple
56
LWR 2.515 - 2.518 (0.0990 - 0.0991) Pink
I
UPR 2.521 - 2.524 (0.0993 - 0.0994) White
67
LWR 2.518 - 2.521 (0.0991 - 0.0993) Purple

Undersize Bearing Usage Guide J

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-
side (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and K
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft main journal to use undersize bearings, L
keep the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].

PBIC1908E
O
Bearing undersize table
Unit: mm (in)

Size Thickness P
US 0.25 (0.0098) 2.633 - 2.641 (0.1037 - 0.1040)

Inspection After Disassembly INFOID:0000000005447671

CRANKSHAFT END PLAY

EM-119
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with dial
indicator.

Standard : 0.14 - 0.22 mm (0.0055 - 0.0087 in)

Limit : 0.30 mm (0.0118 in)
• If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft
also.
PBIC2953E

CONNECTING ROD SIDE CLEARANCE

• Measure the side clearance between connecting rod and crank-
shaft arm with feeler gauge.

Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in)

Limit : 0.40 mm (0.0157 in)
• If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the limit, replace crankshaft
also.

PBIC2954E

PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with inside microme-
ter.

Standard : 21.993 - 22.005 mm (0.8659 - 0.8663 in)

PBIC0116E

Piston Pin Outer Diameter

Measure the outer diameter of piston pin with micrometer.

Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 in)

PBIC0117E

Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

Standard : 0.002 - 0.006 mm (0.0001 - 0.0002 in)

• If the calculated value is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly, refer to EM-114, "How to Select Piston and Bearing".
NOTE:
• Piston is available together with piston pin as assembly.
EM-120
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
piston pin grades can be selected. (Only “0” grade is available.) A
PISTON RING SIDE CLEARANCE
• Measure side clearance of piston ring and piston ring groove with
feeler gauge. EM

Standard:
Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in) C
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in)
D
Limit:
Top ring : 0.11 mm (0.0043 in)
SEM024AA
E
2nd ring : 0.10 mm (0.0039 in)

• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, F
replace piston also.
PISTON RING END GAP
G
• Check that the cylinder bore inner diameter is within the specifica-
tion. Refer to "Cylinder Bore Inner Diameter".
• Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and measure H
the piston ring end gap with feeler gauge.

Standard: I
Top ring : 0.23 - 0.33 mm (0.0091 - 0.0130 in)
2nd ring : 0.33 - 0.48 mm (0.0130 - 0.0189 in)
Oil ring : 0.20 - 0.50 mm (0.0079 - 0.0197 in) J
PBIC0118E

Limit:
Top ring : 0.56 mm (0.0220 in)
K

2nd ring : 0.68 mm (0.0268 in)

L
Oil ring : 0.85 mm (0.0335 in)
• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
re-bore cylinder and use oversize piston and piston rings. M
CONNECTING ROD BEND AND TORSION
N

EM-121
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• Check with connecting rod aligner.

Bend:
Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion:
Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
• If it exceeds the limit, replace connecting rod assembly.

PBIC2077E

CONNECTING ROD BIG END DIAMETER

• Install connecting rod bearing cap without installing connecting rod
bearing, and tightening connecting rod bolts to the specified
torque. Refer to EM-105, "Disassembly and Assembly" for the
tightening procedure.
• Measure the inner diameter of connecting rod big end with inside
micrometer.

Standard : 57.000 - 57.013 mm (2.2441 - 2.2446 in)

• If out of the standard, replace connecting rod assembly.

PBIC1641E

CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with inside
micrometer.

Standard : 22.000 - 22.012 mm (0.8661 - 0.8666 in)

PBIC0120E

Piston Pin Outer Diameter

EM-122
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
Measure the outer diameter of piston pin with micrometer.
A
Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 in)

EM

PBIC0117E

D
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
E
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit : 0.030 mm (0.0012 in)
F
• If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly, refer to EM-114, "How to Select Piston and Bearing".
• If replacing connecting rod assembly, refer to "CONNECTING G
ROD BEARING OIL CLEARANCE" to select the connecting rod
bearing.
H

PBIC0809E
J

Factory installed parts grading:

• Service parts apply only to grade “0”. K
Unit: mm (in)
Grade 0 1
Connecting rod bushing 22.000 - 22.006 22.006 - 22.012
L
inner diameter * (0.8661 - 0.8664) (0.8664 - 0.8666)
21.993 - 21.999 21.999 - 22. 005
Piston pin hole diameter
(0.8659 - 0.8661) (0.8661 - 0.8663) M
21.989 - 21.995 21.995 - 22.001
Piston pin outer diameter
(0.8657 - 0.8659) (0.8659 - 0.8662)
N
*: After installing in connecting rod PBIC2950E

CYLINDER BLOCK DISTORTION

• Using scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or O
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
P

EM-123
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• Measure the distortion on the cylinder block upper face at some
different points in six directions with straightedge and feeler gauge.

Limit : 0.1 mm (0.004 in)

• If it exceeds the limit, replace cylinder block.

SEM123C

MAIN BEARING HOUSING INNER DIAMETER

• Install lower cylinder block without installing main bearings, and
tighten lower cylinder block bolts to the specified torque. Refer to
EM-105, "Disassembly and Assembly" for the tightening proce-
dure.
• Measure the inner diameter of main bearing housing with bore
gauge.

Standard : 74.993 - 75.017 mm (2.9525 - 2.9534 in)

• If out of the standard, replace cylinder block and lower cylinder
block as assembly.
NOTE: PBIC2012E

Cylinder block cannot be replaced as a single part, because it is

machined together with lower cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
• Using bore gauge, measure cylinder bore for wear, out of round
and taper at six different points on each cylinder. (“X” and “Y” direc-
tions at “A”, “B” and “C”) (“X” is in longitudinal direction of engine)

Standard inner diameter:

95.500 - 95.530 mm (3.7598 - 3.7610 in)
Out-of-round (Difference between “X” and “Y”):
0.015 mm (0.0006 in)
Taper limit (Difference between “A” and “C”):
PBIC2955E
0.01 mm (0.0004 in)
• If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or re-bore the inner
wall.
• Oversize piston is provided. When using oversize piston, re-bore
cylinder so that the clearance of the piston to cylinder bore satis-
fies the standard.
CAUTION:
When using oversize piston, use oversize pistons for all cylin-
ders with oversize piston rings.

Oversize (O/S) : 0.2 mm (0.008 in) SEM843E

Piston Skirt Diameter

EM-124
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
Measure the outer diameter of piston skirt with micrometer.
A
Measure point
: Distance from the top 43.03 mm (1.6941 in)
Standard EM
: 95.480 - 95.510 mm (3.7590 - 3.7602 in)

PBIC2956E

D
Piston to Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter (direction “Y”, position “B”).
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter).
E
Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit : 0.08 mm (0.0031 in)
F
• If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to EM-114, "How to
Select Piston and Bearing".
Re-boring Cylinder Bore G
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.

Re-bored size calculation: D = A + B – C H

where,
D: Bored diameter
I
A: Piston skirt diameter as measured
B: Piston to cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in) J
2. Install lower cylinder block, and tighten lower cylinder block bolts to the specified torque. Otherwise, cylin-
der bores may be distorted in final assembly.
3. Cut cylinder bores. K
NOTE:
• When any cylinder needs boring, all other cylinders must also be bored.
• Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a L
time.
4. Hone cylinders to obtain the specified piston to cylinder bore clearance.
5. Measure finished the cylinder bore for out-of-round and taper. M
NOTE:
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER N
• Measure the outer diameter of crankshaft main journals with micrometer.

Standard : 69.951 - 69.975 mm (2.7540 - 2.7549 in) dia. O

• If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to "MAIN
BEARING OIL CLEARANCE".
CRANKSHAFT PIN JOURNAL DIAMETER P

EM-125
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• Measure the outer diameter of crankshaft pin journal with
micrometer.

Standard : 53.956 - 53.974 mm (2.1242 - 2.1250 in) dia.

• If out of the standard, measure the connecting rod bearing oil
clearance. Then use undersize bearing. Refer to "CONNECTING
ROD BEARING OIL CLEARANCE".

PBIC0127E

CRANKSHAFT OUT-OF-ROUND AND TAPER

• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with micrometer.
• Out-of-round is indicated by the difference in the dimensions
between “X” and “Y” at “A” and “B”.
• Taper is indicated by the difference in the dimensions between “A”
and “B” at “X” and “Y”.

Limit:
Out-of-round (Difference between “X” and “Y”)
: 0.002 mm (0.0001 in)
SBIA0535E
Taper (Difference between “A” and “B”)
: 0.002 mm (0.0001 in)
• If the measured value exceeds the limit, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
the main bearing and/or connecting rod bearing. Refer to "MAIN BEARING OIL CLEARANCE" and/or
"CONNECTING ROD BEARING OIL CLEARANCE".
CRANKSHAFT RUNOUT
• Place V-block on precise flat table, and support the journals on the
both end of crankshaft.
• Place dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on
dial indicator. (Total indicator reading)

Standard : Less than 0.05 mm (0.0020 in)

Limit : 0.10 mm (0.0039 in)
• If it exceeds the limit, replace crankshaft.
SEM346D

CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation
• Install connecting rod bearings to connecting rod and cap, and
tighten connecting rod bolts to the specified torque. Refer to EM-
105, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of connecting rod bearing with inside
micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter) –
(Crankshaft pin journal diameter)

Standard : 0.034 - 0.059 mm (0.0013 - 0.0023 in) (actu-

al clearance)
Limit : 0.070 mm (0.0028 in) PBIC1642E

EM-126
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to A
EM-114, "How to Select Piston and Bearing".
Method of Using Plastigage
• Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely. EM
• Cut plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified C
torque. Refer to EM-105, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
Never rotate crankshaft.
• Remove connecting rod bearing cap and bearing, and using scale D
on plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is E
same as that described in the “Method by Calculation”.

PBIC1149E G
MAIN BEARING OIL CLEARANCE
Method by Calculation H
• Install main bearings to cylinder block and lower cylinder block,
and tighten lower cylinder block bolts to the specified torque. Refer
to EM-105, "Disassembly and Assembly" for the tightening proce-
I
dure.
• Measure the inner diameter of main bearing with bore gauge.
(Bearing clearance) = (Main bearing inner diameter) – (Crankshaft
main journal diameter) J

Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 in)

(actual clearance) K
Limit : 0.065 mm (0.0026 in) PBIC2204E

• If the calculated value exceeds the limit, select proper main bearing according to main bearing inner diame-
ter and crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-114, "How to L
Select Piston and Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely. M
• Cut plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block bolts to the N
specified torque. Refer to EM-105, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
Never rotate crankshaft.
O
• Remove lower cylinder block and main bearings, and using scale
on plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is P
same as that described in the “Method by Calculation”.

PBIC1149E

EM-127
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
CRUSH HEIGHT OF MAIN BEARING
• When lower cylinder block is removed after being tightened to the
specified torque with main bearings installed, the tip end of bearing
must protrude. Refer to EM-105, "Disassembly and Assembly" for
the tightening procedure.

Standard : There must be crush height.

• If the standard is not met, replace main bearings.

SEM502G

CRUSH HEIGHT OF CONNECTING ROD BEARING

• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings installed, the
tip end of bearing must protrude. Refer to EM-105, "Disassembly
and Assembly" for the tightening procedure.

Standard : There must be crush height.

• If the standard is not met, replace connecting rod bearings.

PBIC1646E

LOWER CYLINDER BLOCK BOLT OUTER DIAMETER

• Measure the outer diameters (“d1”, “d2”) at two positions as shown
in the figure.
• If reduction appears in “A” range, regard it as “d2”.

Limit (“d1” – “d2”) : 0.11 mm (0.0043 in)

• If it exceeds the limit (large difference in dimensions), replace
lower cylinder block bolt with new one.

PBIC0911E

CONNECTING ROD BOLT OUTER DIAMETER

• Measure the outer diameter “d” at position shown in the figure.
• If the reduction appears in a position other than “d”, regard it as “d”.

Limit : 7.75 mm (0.3051 in)

• When “d” exceeds the limit (when it becomes thinner), replace
connecting rod bolt with new one.

PBIC0912E

FLYWHEEL DEFLECTION (M/T MODELS)

EM-128
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• Measure the deflection of flywheel contact surface to clutch with
dial indicator. A
• Measure the deflection at 250 mm (9.84 in) dia.

Standard : 0.45 mm (0.0177 in) or less EM

• If the measured value is out of the standard, replace flywheel.

PBIC2168E

D
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)
CAUTION:
Never disassemble double mass flywheel.
E
Movement Amount of Thrust (Fore-and-Aft) Direction
• Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added
at the portion of 125 mm (4.92 in) radius from the center of flywheel.
F
Standard : 1.3 mm (0.051 in) or less
• If the measured value is out of the standard, replace flywheel.
G
Movement Amount of Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction as follows:
1. Install bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel H
center line.
• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel I
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction, J
and mark the movement amount on the mass on the transmis-
sion side.
4. Measure dimensions of movement amounts “A” and “B” on cir-
cumference of flywheel on the transmission side. K

Standard : 24 mm (0.94 in) or less

PBIC1046E L
• If the measured value is out of the standard, replace flywheel.
DRIVE PLATE (A/T MODELS)
• Check drive plate and signal plate for deformation or cracks. M
CAUTION:
• Never disassemble drive plate.
• Never place drive plate with signal plate facing down. N
• When handling signal plate, take care not to damage or
scratch it.
• Handle signal plate in a manner that prevents it from becom-
ing magnetized. O
• If anything is found, replace drive plate.

PBIC2938E P
OIL JET
• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs.
• If it is not satisfied, clean or replace oil jet.
OIL JET RELIEF VALVE

EM-129
 CYLINDER BLOCK
< SERVICE INFORMATION > [VQ]
• Using clean plastic stick, press check valve in oil jet relief valve.
Check that valve moves smoothly with proper reaction force.
• If it is not satisfied, replace oil jet relief valve.

EMU0468D

EM-130
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [VQ]
SERVICE DATA AND SPECIFICATIONS (SDS)
A
Standard and Limit INFOID:0000000005447672

GENERAL SPECIFICATIONS EM

Cylinder arrangement V-6

Displacement cm3 (cu in) 3,954 (241.27) C

Bore and stroke mm (in) 95.5 × 92.0 (3.760 × 3.622)
Valve arrangement DOHC
D
Firing order 1-2-3-4-5-6
Compression 2
Number of piston rings
Oil 1 E
Number of main bearings 4
Compression ratio 9.7
F
Standard 1,275 (13.0, 185)
Compression pressure
Minimum 981 (10.0, 142)
kPa (kg/cm2, psi)/300 rpm
Differential limit between cylinders 98 (1.0, 14) G

Cylinder number I

SEM713A

Valve timing
(Intake valve timing control - “OFF”)
M

N
PBIC0187E

Unit: degree
a b c d e f
O
244 240 −4 64 6 58

DRIVE BELT P

Tension of drive belts Auto adjustment by auto tensioner

INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD

EM-131
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [VQ]
Unit: mm (in)

Items Limit
Intake manifold 0.1 (0.004)
Surface distortion
Exhaust manifold 0.3 (0.012)

SPARK PLUG

Make NGK
Standard type PLFR5A-11
Hot type PLFR4A-11
Cold type PLFR6A-11
Gap (Nominal) 1.1 mm (0.043 in)

CAMSHAFT AND CAMSHAFT BEARING

Unit: mm (in)

Items Standard Limit

No. 1 0.045 - 0.086 (0.0018 - 0.0034)
Camshaft journal oil clearance 0.15 (0.0059)
No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030)
No. 1 26.000 - 26.021 (1.0236 - 1.0244) —
Camshaft bracket inner diameter
No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) —
No. 1 25.935 - 25.955 (1.0211 - 1.0218) —
Camshaft journal diameter
No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) —
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)
Intake 45.465 - 45.655 (1.7900 - 1.7974) 45.265 (1.7821)
Camshaft cam height “A”
Exhaust 45.075 - 45.265 (1.7746 - 1.7821) 44.875 (1.7667)

Camshaft runout [TIR*1] Less than 0.02 mm (0.0008) 0.05 (0.0020)

Camshaft sprocket runout [TIR*2] — 0.15 (0.0059)

SEM671

*1: Total indicator reading

Valve Lifter
Unit: mm (in)

Items Standard
Valve lifter outer diameter 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter hole diameter 34.000 - 34.016 (1.3386 - 1.3392)
Valve lifter clearance 0.013 - 0.039 (0.0005 - 0.0015)

Valve Clearance

EM-132
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [VQ]
Unit: mm (in)

Items Cold Hot* (reference data) A

Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)
EM
*: Approximately 80°C (176°F)

Available Valve Lifter

Unit: mm (in) C
Identification (stamped) mark
Thickness
Intake Exhaust
D
788U N788 7.88 (0.3102)
790U N790 7.90 (0.3110)
792U N792 7.92 (0.3118) E
794U N794 7.94 (0.3126)
796U N796 7.96 (0.3134)
F
798U N798 7.98 (0.3142)
800U N800 8.00 (0.3150)
802U N802 8.02 (0.3157) G
804U N804 8.04 (0.3165)
806U N806 8.06 (0.3173)
808U N808 8.08 (0.3181)
H
810U N810 8.10 (0.3189)
812U N812 8.12 (0.3197)
I
814U N814 8.14 (0.3205)
816U N816 8.16 (0.3213)
818U N818 8.18 (0.3220) J
820U N820 8.20 (0.3228)
822U N822 8.22 (0.3236)
K
824U N824 8.24 (0.3244)
826U N826 8.26 (0.3252)
828U N828 8.28 (0.3260) L
830U N830 8.30 (0.3268)
832U N832 8.32 (0.3276)
M
834U N834 8.34 (0.3283)
836U N836 8.36 (0.3291)
838U — 8.38 (0.3299) N
840U — 8.40 (0.3307)

SEM758G

EM-133
 SERVICE DATA AND SPECIFICATIONS (SDS)
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CYLINDER HEAD
Unit: mm (in)

Items Standard Limit

Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Normal cylinder head height “H” 126.3 - 126.5 (4.97 - 4.98) —

PBIC0924E

Valve Dimensions
Unit: mm (in)

SEM188

Intake 37.0 - 37.3 (1.457 - 1.469)

Valve head diameter “D”
Exhaust 31.2 - 31.5 (1.228 - 1.240)
Intake 96.46 (3.7976)
Valve length “L”
Exhaust 93.99 (3.7004)
Intake 5.965 - 5.980 (0.2348 - 0.2354)
Valve stem diameter “d”
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Intake
Valve seat angle “α” 45°15′ - 45°45′
Exhaust
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 1.3 (0.051)

Valve Guide

EM-134
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [VQ]
Unit: mm (in)
A

EM

D
SEM950E

Items Standard Oversize (Service) [0.2 (0.008)]

E
Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
F
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Items Standard Limit
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031) G
Valve guide clearance
Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.09 (0.0035)
Projection length “L” 12.6 - 12.8 (0.496 - 0.504)
H
Valve Seat
Unit: mm (in)
I

L
PBIC2745E

Items Standard Oversize (Service) [0.5 (0.02)]

Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164)
M
Cylinder head seat recess diameter “D”
Exhaust 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880)
Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202)
Valve seat outer diameter “d” N
Exhaust 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2905 - 1.2912)
Intake 0.081 - 0.113 (0.0032 - 0.0044)
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038) O
Intake 35 (1.38)
Diameter “d1”*1
Exhaust 28.7 (1.130)
P
Intake 36.3 - 36.8 (1.429 - 1.449)
2
Diameter “d2”*
Exhaust 30.3 - 30.8 (1.193 - 1.213)
Intake 60°
Angle “α1”
Exhaust 60°
Intake 88°20′ - 89°50′
Angle “α2”
Exhaust 88°20′ - 89°50′

EM-135
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [VQ]
Intake 120°
Angle “α3”
Exhaust 120°
Intake 1.0 - 1.4 (0.039 - 0.055)
Contacting width “W”*3
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Intake 5.9 - 6.0 (0.232 - 0.236) 5.05 - 5.15 (0.1988 - 0.2028)
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)
Depth “H” 6.0 (0.236)

*1: Diameter made by intersection point of conic angles “α1” and “α2”
*2: Diameter made by intersection point of conic angles “α2” and “α3”
*3: Machining data

Valve Spring

Free height mm (in) 47.07 (1.8531)

Installation 166 - 188 (16.9 - 19.2, 37 - 42) at 37.00 (1.4567)
Pressure N (kg, lb) at height mm (in)
Valve open 373 - 421 (38.0 - 42.9, 84 - 95) at 27.20 (1.0709)
Squareness mm (in) Limit 2.1 (0.083)

CYLINDER BLOCK
Unit: mm (in)

PBIC2955E

Standard Less than 0.03 (0.0012)

Surface flatness
Limit 0.1 (0.004)
Main bearing housing inner diameter Standard 74.993 - 75.017 (2.9525 - 2.9534)
Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602)
Cylinder bore Inner diameter Standard Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606)
Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610)
Out-of-round (Difference between “X” and “Y”) 0.015 (0.0006)
Limit
Taper (Difference between “A” and “C”) 0.01 (0.0004)

EM-136
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [VQ]
Grade No. A 74.993 - 74.994 (2.9525 - 2.9525)
Grade No. B 74.994 - 74.995 (2.9525 - 2.9526) A
Grade No. C 74.995 - 74.996 (2.9526 - 2.9526)
Grade No. D 74.996 - 74.997 (2.9526 - 2.9526)
Grade No. E 74.997 - 74.998 (2.9526 - 2.9527)
Grade No. F 74.998 - 74.999 (2.9527 - 2.9527) EM
Grade No. G 74.999 - 75.000 (2.9527 - 2.9528)
Grade No. H 75.000 - 75.001 (2.9528 - 2.9528)
Grade No. J 75.001 - 75.002 (2.9528 - 2.9528)
Grade No. K 75.002 - 75.003 (2.9528 - 2.9529)
C
Grade No. L 75.003 - 75.004 (2.9529 - 2.9529)
Grade No. M 75.004 - 75.005 (2.9529 - 2.9529)
Main bearing housing inner diameter (Without bearing)
Grade No. N 75.005 - 75.006 (2.9529 - 2.9530) D
Grade No. P 75.006 - 75.007 (2.9530 - 2.9530)
Grade No. R 75.007 - 75.008 (2.9530 - 2.9531)
Grade No. S 75.008 - 75.009 (2.9530 - 2.9531)
Grade No. T 75.009 - 75.010 (2.9531 - 2.9531) E
Grade No. U 75.010 - 75.011 (2.9531 - 2.9532)
Grade No. V 75.011 - 75.012 (2.9532 - 2.9532)
Grade No. W 75.012 - 75.013 (2.9532 - 2.9533)
Grade No. X 75.013 - 75.014 (2.9533 - 2.9533) F
Grade No. Y 75.014 - 75.015 (2.9533 - 2.9533)
Grade No. 4 75.015 - 75.016 (2.9533 - 2.9534)
Grade No. 7 75.016 - 75.017 (2.9534 - 2.9534)
G
Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)

PISTON, PISTON RING AND PISTON PIN

H
Available Piston
Unit: mm (in)

L
SEM882E

Items Standard Oversize (Service) [0.2 (0.008)]

Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) — M
Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) —
Piston skirt diameter “A”
Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602) —
N
Service — 95.680 - 95.710 (3.7669 - 3.7681)
Items Standard Limit
“a” dimension 43.03 (1.6941) — O
Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) —
Piston pin hole diameter
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) —
Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031) P

Piston Ring
Unit: mm (in)
Items Standard Limit

EM-137
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [VQ]
Top 0.045 - 0.080 (0.0018 - 0.0031) 0.11 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.065 - 0.135 (0.0026 - 0.0053) —
Top 0.23 - 0.33 (0.0091 - 0.0130) 0.56 (0.0220)
End gap 2nd 0.33 - 0.48 (0.0130 - 0.0189) 0.68 (0.0268)
Oil (rail ring) 0.20 - 0.50 (0.0079 - 0.0197) 0.85 (0.0335)

Piston Pin
Unit: mm (in)

Items Standard Limit

Grade No. 0 21.989 - 21.995 (0.8657 - 0.8659) —
Piston pin outer diameter
Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
Connecting rod bushing oil clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.030 (0.0012)

CONNECTING ROD
Unit: mm (in)

Items Standard Limit

Center distance 165.82 - 165.92 (6.53 - 6.53) —
Bend [per 100 (3.94)] — 0.15 (0.0059)
Torsion [per 100 (3.94)] — 0.30 (0.0118)
Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664) —
Connecting rod bushing inner diameter*
Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666) —
Connecting rod big end diameter (Without bearing) 57.000 - 57.013 (2.2441 - 2.2446) —
Side clearance 0.20 - 0.35 (0.0079 - 0.0138) 0.40 (0.0157)
*: After installing in connecting rod

CRANKSHAFT

EM-138
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [VQ]
Unit: mm (in)
A

EM

D
SEM645 SBIA0535E

Grade No. A 69.975 - 69.974 (2.7549 - 2.7549)

Grade No. B 69.974 - 69.973 (2.7549 - 2.7548) E
Grade No. C 69.973 - 69.972 (2.7548 - 2.7548)
Grade No. D 69.972 - 69.971 (2.7548 - 2.7548)
Grade No. E 69.971 - 69.970 (2.7548 - 2.7547)
Grade No. F 69.970 - 69.969 (2.7547 - 2.7547) F
Grade No. G 69.969 - 69.968 (2.7547 - 2.7546)
Grade No. H 69.968 - 69.967 (2.7546 - 2.7546)
Grade No. J 69.967 - 69.966 (2.7546 - 2.7546)
Grade No. K 69.966 - 69.965 (2.7546 - 2.7545) G
Grade No. L 69.965 - 69.964 (2.7545 - 2.7545)
Grade No. M 69.964 - 69.963 (2.7545 - 2.7544)
Main journal diameter. “Dm” grade Standard
Grade No. N 69.963 - 69.962 (2.7544 - 2.7544) H
Grade No. P 69.962 - 69.961 (2.7544 - 2.7544)
Grade No. R 69.961 - 69.960 (2.7544 - 2.7543)
Grade No. S 69.960 - 69.959 (2.7543 - 2.7543)
Grade No. T 69.959 - 69.958 (2.7543 - 2.7542) I
Grade No. U 69.958 - 69.957 (2.7542 - 2.7542)
Grade No. V 69.957 - 69.956 (2.7542 - 2.7542)
Grade No. W 69.956 - 69.955 (2.7542 - 2.7541)
Grade No. X 69.955 - 69.954 (2.7541 - 2.7541) J
Grade No. Y 69.954 - 69.953 (2.7541 - 2.7540)
Grade No. 4 69.953 - 69.952 (2.7540 - 2.7540)
Grade No. 7 69.952 - 69.951 (2.7540 - 2.7540)
K
Grade No. 0 53.968 - 53.974 (2.1247 - 2.1250)
Pin journal diameter. “Dp” grade Standard Grade No. 1 53.962 - 53.968 (2.1245 - 2.1247)
Grade No. 2 53.956 - 53.962 (2.1242 - 2.1245) L
Center distance “r” 45.96 - 46.04 (1.8094 - 1.8126)
Taper (Difference between “A” and “B”) 0.002 (0.0001)
Limit M
Out-of-round (Difference between “X” and “Y”) 0.002 (0.0001)
Standard Less than 0.05 (0.0020)
Crankshaft runout [TIR*]
Limit 0.10 (0.0039) N
Standard 0.14 - 0.22 (0.0055 - 0.0087)
Crankshaft end play
Limit 0.30 (0.0118)
*: Total indicator reading O

MAIN BEARING
P

EM-139
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [VQ]

PBIC2969E

Grade number UPR/LWR Thickness mm (in) Width mm (in) Identification color Remarks
0 — 2.500 - 2.503 (0.0984 - 0.0985) Black
1 — 2.503 - 2.506 (0.0985 - 0.0987) Brown
2 — 2.506 - 2.509 (0.0987 - 0.0988) Green
3 — 2.509 - 2.512 (0.0988 - 0.0989) Yellow Grade is the same
for upper and lower
4 — 2.512 - 2.515 (0.0989 - 0.0990) Blue bearings.
5 — 2.515 - 2.518 (0.0990 - 0.0991) Pink
6 — 2.518 - 2.521 (0.0991 - 0.0993) Purple
7 — 2.521 - 2.524 (0.0993 - 0.0994) White
UPR 2.503 - 2.506 (0.0985 - 0.0987) Brown
01
LWR 2.500 - 2.503 (0.0984 - 0.0985) Black
UPR 2.506 - 2.509 (0.0987 - 0.0988) 19.9 - 20.1 Green
12
LWR 2.503 - 2.506 (0.0985 - 0.0987) (0.783 - 0.791) Brown
UPR 2.509 - 2.512 (0.0988 - 0.0989) Yellow
23
LWR 2.506 - 2.509 (0.0987 - 0.0988) Green
UPR 2.512 - 2.515 (0.0989 - 0.0990) Blue Grade is different for
34 upper and lower
LWR 2.509 - 2.512 (0.0988 - 0.0989) Yellow bearings.
UPR 2.515 - 2.518 (0.0990 - 0.0991) Pink
45
LWR 2.512 - 2.515 (0.0989 - 0.0990) Blue
UPR 2.518 - 2.521 (0.0991 - 0.0993) Purple
56
LWR 2.515 - 2.518 (0.0990 - 0.0991) Pink
UPR 2.521 - 2.524 (0.0993 - 0.0994) White
67
LWR 2.518 - 2.521 (0.0991 - 0.0993) Purple

Undersize
Unit: mm (in)

Items Thickness Main journal diameter

0.25 (0.0098) 2.633 - 2.641 (0.1037 - 0.1040) Grind so that bearing clearance is the specified value.

Main Bearing Oil Clearance

Unit: mm (in)

Items Standard Limit

Main bearing oil clearance 0.035 - 0.045 (0.0014 - 0.0018)* 0.065 (0.0026)
*: Actual clearance

CONNECTING ROD BEARING

EM-140
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [VQ]
Unit: mm (in)

Grade number Thickness Identification color (mark) A

0 1.500 - 1.503 (0.0591 - 0.0592) Black
1 1.503 - 1.506 (0.0592 - 0.0593) Brown
EM
2 1.506 - 1.509 (0.0593 - 0.0594) Green

Undersize
Unit: mm (in) C
Items Thickness Crank pin journal diameter
0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643) Grind so that bearing clearance is the specified value.
D
Connecting Rod Bearing Oil Clearance
Unit: mm (in)

Items Standard Limit E

Connecting rod bearing oil clearance 0.034 - 0.059 (0.0013 - 0.0023)* 0.070 (0.0028)
*: Actual clearance
F

EM-141
 PRECAUTIONS
< SERVICE INFORMATION > [YD]

SERVICE INFORMATION
PRECAUTIONS
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000006109138

NOTE:
• This Procedure is applied only to models with Intelligent Key system and NVIS/IVIS (NISSAN/INFINITI
VEHICLE IMMOBILIZER SYSTEM - NATS).
• Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing work. If
DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NVIS/IVIS, an electrically controlled steering lock
mechanism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT.
Precaution for Procedure without Cowl Top Cover INFOID:0000000006109139

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

PIIB3706J

Precautions For Engine Service INFOID:0000000008180051

DISCONNECTING FUEL PIPING

• Before starting work, check no fire or spark producing items are in the work area.
• Release fuel pressure before disconnecting and disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.

DRAINING ENGINE COOLANT

Drain engine coolant and engine oil when the engine is cooled.

INSPECTION, REPAIR AND REPLACEMENT

EM-142
 PRECAUTIONS
< SERVICE INFORMATION > [YD]
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary. A

REMOVAL AND DISASSEMBLY

• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin- EM
structed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins, C
check that dowel pins are installed in the original position.
• Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally D
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
E
ASSEMBLY AND INSTALLATION
• Use torque wrench to tighten bolts or nuts to specification.
• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the F
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for G
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well. H
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
I

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000006109140 J

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SUPPLEMENTAL K
RESTRAINT SYSTEM” and “SEAT BELTS” of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in L
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal M
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SUPPLEMENTAL RESTRAINT SYSTEM”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har- N
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
O
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly P
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Parts Requiring Angle Tightening INFOID:0000000006109146

• Use an angle wrench [SST: KV10112100] for the final tightening of the following engine parts:

EM-143
 PRECAUTIONS
< SERVICE INFORMATION > [YD]
- Cylinder head bolts
- Main bearing cap bolts
- Connecting rod cap nuts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000006109147

REMOVAL OF LIQUID GASKET

• After removing the mounting bolts and nuts, separate the mating
surface using the seal cutter (SST) and remove the old liquid gas-
ket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
• Tap seal cutter to insert it, and then slide it by tapping on the side
as shown in the figure.
• In areas where seal cutter (SST) is difficult to use, use plastic ham-
mer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason tool such as screwdriver is
PBIC0275E
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
• Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.

PBIC0003E

3. Attach the liquid gasket tube to the tube presser (commercial

service tool).
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
• If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.

EMA0622D

EM-144
 PRECAUTIONS
< SERVICE INFORMATION > [YD]
• As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes. A
Check to read the text of this manual.
• Within five minutes of liquid gasket application, install the mat-
ing component.
EM
• If the liquid gasket protrudes, wipe it off immediately.
• Do not retighten mounting bolts or nuts after the installation.
• After 30 minutes or more have passed from the installation, fill
the engine oil and engine coolant. C
CAUTION:
If there are instructions in this manual, observe them.
SEM159F

EM-145
 PREPARATION
< SERVICE INFORMATION > [YD]
PREPARATION
Special Service Tool INFOID:0000000006109148

Tool number
Description
Tool name
KV10115600 Installing valve oil seal
Valve oil seal drift Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
NT603
f: 5 (0.20)
Unit: mm (in)
KV10107902 Removing valve oil seal
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapter

S-NT605

KV11103000 Removing crankshaft pulley

Pulley puller

NT676

KV11300QAM Checking compression pressure

Compression gauge adapter

ZZA1188D

KV101056S0 Preventing crankshaft from rotating

Ring gear stopper a: 3 (0.12)
1. KV10105630 b: 6.4 (0.252)
Adapter c: 2.8 (0.110)
2. KV10105610 d: 6.6 (0.260)
Plate e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
NT617
h: 14 (0.55) dia.
Unit: mm (in)
KV101151S0 Changing adjusting shim
Lifter stopper set
1. KV10115110
Camshaft pliers
2. KV10115120
Lifter stopper

NT041

EM-146
 PREPARATION
< SERVICE INFORMATION > [YD]
Tool number
Description
Tool name A
KV10116200 Disassembling and assembling valve mecha-
Valve spring compressor nism
1. KV10115900 Part (1) is a component of KV10116200, but EM
Attachment Part (2) is not so.
2. KV10109220
Adapter
C
PBIC1650E

ST16610001 Removing crankshaft pilot bush

Pilot bushing puller D

NT045
F
KV10111100 Removing oil pan upper, oil pan lower and rear
Seal cutter chain case, etc.

H
NT046

KV10112100 Tightening bolts for bearing cap, cylinder

Angle wrench head, etc.
I

NT014

EM03470000 Installing piston assembly into cylinder bore K

Piston ring compressor

NT044 M
KV11106010 Removing and installing chain tensioner
Hexagon wrench a: 5 mm (0.20 in) (Face to face)
b: 20 mm (0.79 in)
N

O
NT801

KV11106020 Removing and installing slack guide

Hexagon wrench a: 6 mm (0.24 in) (Face to face) P
b: 20 mm (0.79 in)

NT803

EM-147
 PREPARATION
< SERVICE INFORMATION > [YD]
Tool number
Description
Tool name
KV11106030 Fixing fuel pump sprocket
Positioning stopper pin a: 6 mm (0.24 in) dia.
b: 80 mm (3.15 in)

NT804

KV11106040 Removing and installing fuel pump sprocket

TORX wrench nut
a: T70
b: 26 mm (1.02 in)

NT805

KV11106050 Removing and installing fuel pump sprocket

Hexagonal wrench a: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)

SBIA0224E

KV11106060 Holding fuel pump sprocket

Sprocket holder

SBIA0225E

Commercial Service Tool INFOID:0000000006109149

Tool name Description

Tube presser Pressing the tube of liquid gasket

NT052

Valve seat cutter set Finishing valve seat dimensions

NT048

EM-148
 PREPARATION
< SERVICE INFORMATION > [YD]
Tool name Description
A
Piston ring expander Removing and installing piston ring

EM

C
NT030

Valve guide reamer Reaming valve guide with (1) or hole for over-
size valve guide with (2)
Intake and Exhaust: D
d1 = 6.0 mm (0.236 in) dia.
d2 = 10.2 mm (0.402 in) dia.
E

NT016

Valve guide drift Removing and installing valve guide F

Intake and Exhaust:
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia.
G

NT015
H
TORX socket Loosening and tightening fuel pump mounting
bolt
Size: E10
I

J
NT807

TORX socket Loosening and tightening flywheel mounting

bolt K
Size: T55

PBIC1113E

TORX socket Loosening and tightening drive plate mounting M

bolt
Size: E20
N

NT807
O
Cylinder head bolt wrench Loosening and tightening cylinder head bolt,
and used with angle wrench [SST:
KV10112100] P
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
NT583

EM-149
 PREPARATION
< SERVICE INFORMATION > [YD]
Tool name Description
TORX socket Loosening and tightening main bearing cap
bolt
Size: E14

NT807

Pully holder Crankshaft pulley removing and instalingl

ZZA1010D

EM-150
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SERVICE INFORMATION > [YD]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
A
NVH Troubleshooting - Engine Noise INFOID:0000000007042363

EM

E1BIA0268GB O

Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000007042364
P
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.

EM-151
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SERVICE INFORMATION > [YD]

Operating condition of engine

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-206
gine clicking noise
Rocker
cover Camshaft
Camshaft oil clearance EM-271
Cylinder Rattle C A — A B C bearing
Camshaft runout EM-206
head noise

Piston to piston pin

Slap or Piston pin clearance EM-237
— A — B B —
knock noise Connecting rod bushing EM-271
oil clearance
Piston to cylinder bore
Crank- clearance
shaft pul- Piston ring side clear-
Slap or Piston EM-237
ley A — — B B A ance
rap slap noise EM-271
Cylinder Piston ring end gap
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-265
Knock A B C B B B
bearing Connecting rod bearing EM-271
noise oil clearance (Big end)
Main bearing oil clear-
Main bear- EM-265
Knock A B — A B C ance
ing noise EM-271
Crankshaft runout
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear
A A — B B B chain ten- EM-230
Timing ticking Timing chain tensioner
sioner
chain case operation
noise
Drive belts
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belts deflection
or slip-
ing EM-271
ping)
Front of
Drive belts Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water
Squall
A B — B A B pump Water pump operation CO-51
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related

EM-152
 DRIVE BELTS
< SERVICE INFORMATION > [YD]
DRIVE BELTS
A
Checking Drive Belts INFOID:0000000007042365

EM

E1BIA0262ZZ
E
1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump
A/C compressor (Models with A/C)
4. Crankshaft pulley 5. 6. Alternator F
Dummy pulley (Models without A/C)
7. Idler pulley 8. Fan pulley 9. Automatic tensioner
10. Drive belt
G
• Before inspecting engine, check engine has cooled down, wait approximately 30 minutes after engine has
been stopped.
• Visually inspect all belts for wear, damage or cracks on contacting surfaces and edge areas.
• Measure deflection at the marked point ( ). H
CAUTION:
• When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation I
in deflection between pulleys.
• Tighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection: J
Belt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
Applied belt
New Adjusted Limit for re-adjusting
K
Alternator and water pump belt or A/C
compresseor, alternator and water Automatic adjustment. Refer to EM-154, "Deflection Adjustment"
pump belt
4.6 - 5.4 7.1 - 7.7 L
Power steering oil pump belt 11.3 (0.445)
(0.181 - 0.213) (0.280 - 0.303)
*: When engine is cold.
M
Belt Frequency:

Belt frequency (Hertz)

Applied belt
New Adjusted Limit for re-adjusting N
Power steering oil pump belt 290±7 245±7 162
*: When engine is cold.
O

EM-153
 DRIVE BELTS
< SERVICE INFORMATION > [YD]
Deflection Adjustment INFOID:0000000007042366

E1BIA0352ZZ

1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump
Dummy pulley (Models without A/C)
4. Crankshaft pulley 5. 6. Alternator
A/C compressor (Models with A/C)
7. Idler pulley 8. Water pump pulley 9. Automatic tensioner
10. A/C compressor, alternator and wa- A. Adjusting bolt B. Idler pulley lock nut
ter pump belt

• Adjust belts with the parts shown below.

Applied belt Belt adjustment method

Power steering oil pump belt Adjusting bolt on idler pulley (A)
Alternator and water pump belt or A/C compressor, alternator and
Automatic adjustment
water pump belt
CAUTION:
• When a new belt is installed as a replacement, adjust it to the specified value under “New” value
because of insufficient adaptability with pulley grooves.
• If the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
• When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid varia-
tion in deflection between pulleys.
• Check the belts are fully fitted into the pulley grooves during installation.
• Handle with care to avoid smearing the belts with engine oil or engine coolant.
• Never twist or bend the belts with strong force.
POWER STEERING OIL PUMP BELT
1. Remove engine undercover front. Refer to EI-12.
2. Loosen idler pulley lock nut (B).
3. Turn adjusting bolt (A) to adjust.
4. Tighten idler pulley lock nut (B).

Nut B:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)

A/C COMPRESSOR, ALTERNATOR AND WATER PUMP BELT

EM-154
 DRIVE BELTS
< SERVICE INFORMATION > [YD]

EM

E1BIA0285ZZ

D
1. Water Pump 2. Automatic tensioner 3. Idler pulley
Dummy pulley (Models without A/C)
4. Alternator 5. Crankshaft pulley 6.
A/C compressor (Models with A/C)
E
A/C compressor, alternator and wa- Range when new drive belt is in-
7. Retaining pin 8. A.
ter pump belt stalled
B. Possible use range C. Indicator D. View
F
WARNING:
Be sure to perform this step when the engine is stopped.
• Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range
(B). G
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (A) in the fig- H
ure.
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
I
CAUTION:
• Replace the drive belt that has been removed with a new one.
• Never run the engine without the drive belt to avoid damaging the crankshaft pulley.
J
REMOVAL
1. Insert a stopper pin (A) in diameter such as short-length screw-
driver into the hole of the retaining boss to fix drive belt auto-ten-
K
sioner pulley.
• Keep drive belt auto-tensioner pulley arm locked after drive
belt is removed.
NOTE: L
Use approximately 3.0 mm (0.118 in) dia. hard metal pin as a
stopper pin.
M

JPBIA0661ZZ

N
2. Remove drive belt.
INSTALLATION
O
1. Install drive belt.
CAUTION:
• Check that drive belt is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each P
pulley groove.
2. Release drive belt auto-tensioner, and apply tension to drive belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Check that the indicator (notch on fixed side) of drive belt auto-tensioner is within the range when new
drive belt is installed. Refer to EM-154, "Deflection Adjustment".

EM-155
 DRIVE BELTS
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042367

REMOVAL
1. Loosen each belt. Refer to EM-154, "Deflection Adjustment".
2. Remove power steering oil pump belt. Refer to EM-154, "Deflection Adjustment".
3. Remove A/C compressor, alternator and water pump belt. Refer to EM-154, "Deflection Adjustment".
INSTALLATION
1. Install each belt on pulley in the reverse order of removal.
2. Adjust belt deflection. Refer to EM-154, "Deflection Adjustment".
3. Tighten nuts provided for adjustment to the specified torque.
4. Check again that each belt deflection is as specified.

EM-156
 AIR CLEANER AND AIR DUCT
< SERVICE INFORMATION > [YD]
AIR CLEANER AND AIR DUCT
A
Component INFOID:0000000007042368

EM

L
E1BIA0288GB

1. Clean side duct 2. Blow by 3. Mounting rubber M

4. Mass air flow sensor 5. O-ring 6. Air cleaner cover
7. Air cleaner filter 8. Air cleaner body 9. Air duct side
A. To rocker cover B. To turbocharger N
• Refer to GI-9, "Component" for symbol marks in the figure.
Removal and Installation INFOID:0000000007042369
O

REMOVAL
1. Remove mass air flow sensor harness clamp from air cleaner cover. P
2. Disconnect harness connector from mass air flow sensor.
3. Remove air cleaner cover and air cleaner filter.
• Add marks as necessary for easier installation.
4. Remove mass air flow sensor from air cleaner case (upper).
CAUTION:
• Never shock mass air flow sensor.
• Never disassemble mass air flow sensor.

EM-157
 AIR CLEANER AND AIR DUCT
< SERVICE INFORMATION > [YD]
• Never touch mass air flow sensor.
5. Remove air duct with ventilation hose and vacuum hoses disconnected.
• Add marks as necessary for easier installation.
6. Remove air cleaner body and air duct side.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Align marks. Attach each joint. Screw clamps firmly.
- Install vacuum hose by referring to paint marks avoiding twisting.
- When an insert stopper is not provided with the pipe, insert the hose up to dimension A. When the pipe is
shorter than dimension A, insert hose fully until it reaches the end.

Dimension A : 15 - 20 mm (0.59 - 0.79 in)

- When an insert stopper is provided on the pipe side, insert the hose until it reaches the stopper.
CHANGING AIR CLEANER FILTER
Removal
1. Remove mass air flow sensor harness clamp from air cleaner cover.
2. Disconnect harness connector from mass air flow sensor.
3. Unfasten clips and lift up air cleaner cover.
4. Remove air cleaner filter.
Installation
Installation is the reverse order of removal.

EM-158
 EGR SYSTEM
< SERVICE INFORMATION > [YD]
EGR SYSTEM
A
Exploded View INFOID:0000000007042370

EM

E1BIA0286GB

P
1. EGR cooler 2. Heat plate 3. Bolt
4. Bolt 5. Gasket 6. Stud
7. Nut 8. Cover 9. EGR guide tube
10. Washer 11. Nut 12. Bolt
13. Gasket 14. Bolt 15. EGR tube
16. Gasket 17. Nut 18. Gasket
19. Gasket 20. Egr control valve 21. Gasket

EM-159
 EGR SYSTEM
< SERVICE INFORMATION > [YD]
22. Bolt 23. Bolt
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000007042371

REMOVAL
1. Drain engine coolant. Refer to CO-38, "Changing Engine Coolant".
CAUTION:
Perform this step when the engine is cold.
2. Remove battery. Refer to SC-11, "Removal and Installation".
3. Remove Air duct. Refer to EM-157, "Component".
4. Disconnect water hoses from EGR cooler tube.
5. Remove EGR tube (front) and EGR volume control valve assembly.
CAUTION:
• Handle carefully to avoid any shock to EGR volume control valve.
• Never disassemble EGR volume control valve.
• Cover engine openings to avoid entry of foreign materials.
6. Remove Exhaust pressure sensor tube and bracket. Refer to EM-167, "Component".
7. Remove Turbocharger heat cover. Refer to EM-167, "Component".
8. Disconnect and put aside the vaccum hose.
9. Remove EGR guide tube. Refer to EM-159, "Exploded View".
10. Remove EGR cooler. Refer to EM-159, "Exploded View"
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Clean each joint surface before installation.
EGR Volume Control Valve
Perform “EGR Volume Control Valve Closed Position Learning Value Clear” and “EGR Volume Control Valve
Closed Position Learning” after repair when removing or replacing EGR volume control valve. Refer to EC-
1044, "Description" .

EM-160
 CHARGE AIR COOLER
< SERVICE INFORMATION > [YD]
CHARGE AIR COOLER
A
Component INFOID:0000000007042372

EM

I
E1BIA0273GB

1. Turbocharger boost sensor 2. Grommet 3. Vacuum hose J

4. Air inlet hose 5. Charge air cooler 6. Mounting rubber
7. Bracket 8. Bracket 9. Air inlet hose
10. Bracket 11. Air inlet tube 12. Air inlet hose K
13. Bracket 14. Air inlet tube 15. Air inlet hose
Turbocharger boost control solenoid
16. Turbocharger 18. 18. Bracket
valve L
19. Bracket A. To throttle chamber

• Refer to GI-9, "Component" for symbol marks in the figure.

M
Removal and Installation INFOID:0000000007042373

REMOVAL N
1. Remove front grille. Refer to EI-16.
2. Disconnect harness connector from turbocharger boost sensor.
3. Remove turbocharger boost control solenoid valve. O
4. Remove air inlet tube and air inlet hose.
• Add marks as necessary for easier installation.
5. Remove charge air cooler. P
6. Remove turbocharger boost sensor if necessary.
CAUTION:
When removing charge air cooler, close opening on turbocharger and on intake manifold with shop
cloth or other suitable material.
INSPECTION AFTER REMOVAL

EM-161
 CHARGE AIR COOLER
< SERVICE INFORMATION > [YD]
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
• Be careful not to deform core fins.
• For cleaning procedure of charge air cooler core, refer to EI-16, "Removal and Installation".
INSTALLATION
Note the following, and install in the reverse order of removal.
• Pay attention to identification mark color and direction when installing air inlet hose.
• Align marks. Attach each joint. Screw clamps firmly.

EM-162
 INTAKE MANIFOLD
< SERVICE INFORMATION > [YD]
INTAKE MANIFOLD
A
Component INFOID:0000000007042374

EM

E1BIA0353GB

P
1. Cylinder head 2. Gasket 3. Intake manifold
4. Gasket 5. Collector intake manifold 6. Air intake temperature sensor
7. Gasket 8. Electric throttle control actuator 9. Gasket
10. Bracket 11. Bracket 12. EGR tube

• Refer to GI-9, "Component" for symbol marks in the figure.

EM-163
 INTAKE MANIFOLD
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042375

REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Remove engine cover (1).
CAUTION:
Be careful not to damage engine cover surface.

PBIC3409E

2. Disconnect air inlet hose from throttle chamber. Refer to EM-161.

3. Remove fuel filter. Refer to FL-16.
4. Remove oil level gauge guide. Refer to EM-173.
5. Remove fuel hoses and fuel gallery. Refer to EM-186, "Component".
• To prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
• Add marks as necessary for easier installation.
6. Remove vacuum hoses.
• Add marks as necessary for easier installation.
7. Disconnect heater feed hose, water hoses, and remove heater feed pipe.
8. Remove intake manifold bracket, and put aside wire.
9. Remove EGR tube.
10. Remove injection tube center. Refer to EM-182, "Removal and Installation".
CAUTION:
Be careful not to spill fuel in the engine component.
11. Disconnect air intake temperature sensor.
12. Remove collector intake manifold.
13. Loosen bolts and nuts in the reverse order of that shown in the figure, and remove intake manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.

E1BIA0282ZZ

14. Remove throttle chamber from intake manifold.

INSPECTION AFTER REMOVAL
Surface Distortion

EM-164
 INTAKE MANIFOLD
< SERVICE INFORMATION > [YD]
• Check distortion on the mounting surface with a straightedge and
feeler gauge. A

Limit : 0.1 mm (0.004 in)

• If it exceeds the limit, replace intake manifold. EM

PBIC3411E

D
INSTALLATION
Note the following, and install in the reverse order of removal.
1. Install intake manifold.
E
• Tighten fixing bolts and nuts in numerical order as shown in
the figure.
• If stud bolts were removed, tighten them to the specified
torque. F

: 10.8 N·m (1.1 kg-m, 8 ft-lb)

G

H
E1BIA0282ZZ

2. Before starting engine, bleed air from fuel piping. Refer to FL-17, "Air Bleeding".
I
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
CAUTION:
J
Never touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:
Use mirrors for checking at points out of clear sight.
K

EM-165
 CATALYST
< SERVICE INFORMATION > [YD]
CATALYST
Component INFOID:0000000007042376

E1BIA0276GB

1. Catalyst 2. Bracket 3. Bracket

4. Catalyst cover (upper) 5. Catalyst cover (lower) 6. Catalyst cover (lower
7. Gasket

• Refer to GI-9, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000007042377

REMOVAL
1. Remove engine undercover.
2. Remove catalyst cover.
3. Remove exhaust front tube. Refer to EX-6, "Checking Exhaust System".
4. Remove air inlet hose and air inlet tube. Refer to EM-157, "Component".
5. Remove catalyst and exhaust outlet.
INSTALLATION
Note the following, and install in the reverse order of removal.
• If stud bolts of turbocharger were removed, tighten them to the specified torque.

: 25.5 N·m (2.6 kg-m, 19 ft-lb)

• If stud bolts of catalyst were removed, tighten them to the specified torque.

: 45.0 N·m (4.6 kg-m, 33 ft-lb)

• Pushing bracket against the cylinder block and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque.

EM-166
 TURBO CHARGER
< SERVICE INFORMATION > [YD]
TURBO CHARGER
A
Component INFOID:0000000007042378

EM

L
E1BIA0284GB

1. Turbocharger 2. Exhaust manifold 3. Nut M

4. Gasket 5. Stud 6. Stud
7. Heat insulator 8. Clip 9. Turbocharger pressure sensor
10. Clamp 11. Hose 12. Bracket N
13. Bolt 14. Tube 15. Bolt
16. Gasket 17. Oil pipe 18. Eye-bolt
19. Gasket 20. Clamp 21. Oil connector O
22. Gasket 23. Clamp 24. Clamp
25. Clamp 26. Water pipe return 27. Clamp
28. Water hose feed 29. Clamp 30. Gasket P
31. Water pipe feed 32. Gasket 33. Nut
34. Catalyst
A. To air inlet hose B. To cylinder block C. To cylinder block
D. To Water outlet E. To water pipe

• Refer to GI-9, "Component" for symbol marks in the figure.

EM-167
 TURBO CHARGER
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042379

REMOVAL
• After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and then
loosen the nuts to remove.
1. Drain engine coolant. Refer to CO-38, "Changing Engine Coolant"
2. Remove air inlet hose and air inlet pipe. Refer to EM-161.
3. Remove air duct and air inlet pipes. Refer to EM-157, "Removal and Installation".
4. Remove exhaust manifold cover. Refer to EM-171, "Removal and Installation".
5. Remove catalyst. Refer to EM-166, "Removal and Installation".
6. Remove eye bolts and water hose from water tube and oil feed tube and oil return tube.
7. Disconnect connector from turbocharger.
8. Remove turbocharger with water tube and oil feed tube and oil return tube.
CAUTION:
• Be careful not to deform water tube and oil-feed-and-return tube.
• Never disassemble or adjust the turbocharger.
• Be careful not to contact with the vehicle.
• Never hold turbocharger boost control actuator and actuator rod.
9. Remove water tube and oil feed tube and oil return tube from turbocharger.
10. Remove turbocharger.
CAUTION:
• Never disassemble or adjust the turbocharger.
• Never hold turbocharger boost control actuator and actuator rod.
Oil Tube and Water Tube
• Clean inside of oil feed tube and oil return tube and water tube, and check tubes for clogging.
• Replace oil feed tube and oil return tube and/or water tube if clogging still exists after cleaning.
INSPECTION AFTER REMOVAL

E1BIA0289ZZ

1. Compressor housing 2. Turbocharger boost control actuator 3. Turbine housing

A. Check for charge air pressure leaks B. Check for exhaust gas leaks C. Check for engine coolant leaks
D. Check for engine oil leaks

CAUTION:
When the compressor wheel turbine, wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:

Suction side : Between turbocharger and charge air cooler

Exhaust side : Between turbocharger and catalyst
Rotor Shaft Clearance
EM-168
 TURBO CHARGER
< SERVICE INFORMATION > [YD]
• Check that the rotor shaft (1) rotates smoothly without any resis-
tance when it is rotated by your fingertips. A
• Check that the rotor shaft is not loose when it is moved vertically or
horizontally.
• Measure looseness with a dial gauge inserting its measuring rod
EM
through oil drain hole of turbocharger.

Standard : 0.086 - 0.111 mm (0.0034 - 0.0044 in)

C
• Replace turbocharger if out of standard.

E1BIA0290ZZ

D
Rotor Shaft End Play
• Place a dial gauge (A) at the rotor shaft (1) end in the axial direc-
tion to measure the end play.
E
Standard : 0.030 - 0.111 mm (0.0012 - 0.0044 in)
• Replace turbocharger if out of standard.
F

G
E1BIA0292ZZ

Turbine Wheel H
• Check that there is no engine oil adhesion.
• Check that there is no carbon accumulation.
• Check that blades of turbine wheel (1) are not bent or broken.
• Check that turbine wheel does not interfere with turbine housing I
(2).

K
E1BIA0291ZZ

Compressor Wheel
• Check that there is no engine oil adhesion inside the air inlet. L
• Check that compressor wheel (1) does not interfere with compres-
sor housing (2).
• Check that compressor wheel is not bent or broken.
M

E1BIA0293ZZ O
Turbocharger Boost Control Actuator :
Inspect turbocharger boost control actuator. Refer to EC-924, "Turbocharger Boost Control Actuator"
P
TROUBLE DIAGNOSIS OF TURBOCHARGER
Preliminary check:
• Check that the engine oil level is between MIN and MAX of the oil level gauge. (When engine oil amount is
more than MAX, engine oil flows into the inlet duct through blow-by gas passage, and turbocharger is mis-
judged malfunction.)
• Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.

EM-169
 TURBO CHARGER
< SERVICE INFORMATION > [YD]
• Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.
• If no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunction.
Check the other parts again.

Symptom
Inspection item Inspection result
(when each inspection item meets each inspection result)
Engine oil Insufficient power/accel-
Smoke Noise
leakage eration malfunction
Engine oil leaks C A C C
Carbon is accumulated C A B B
Turbine wheel
Friction with housing C B A B
Blades are bent or broken — — A A
Inside the air inlet is seriously contam-
B B — —
inated by engine oil.
Compressor wheel
Friction with housing C B A B
Blades are bent or broken — — A A
There is resistance when the rotor
— C C B
shaft is rotated by your fingertips.
After checking both turbine and
compressor, inspect rotor shaft The rotor shaft sometimes does not
— — — A
end play. rotate by your fingertips.
There is too much play in the bearing. C C B C
Carbon or sludge is accumulated in
Oil return port C A C C
the waste oil hole.
A: Large possibility
B: Medium possibility
C: Small possibility

INSTALLATION
• When a stud bolt is pulled out, replace it with a new one and tighten it to the following torque.

: 25.5 N·m (2.6 kg-m, 19 ft-lb)

EM-170
 EXHAUST MANIFOLD
< SERVICE INFORMATION > [YD]
EXHAUST MANIFOLD
A
Component INFOID:0000000007042380

EM

I
E1BIA0271GB

1. Turbocharger 2. Exhaust manifold cover 3. Exhaust manifold cover J

4. Cylinder head 5. Gasket 6. EGR cooler
7. Gasket 8. Exhaust manifold 9. Gasket
10. Exhaust temperature sensor K
A. No. 1 port B. No. 2 port C. No. 3 port
D. No. 4 port E. Alignment protrusion
: Vehicle front L

• Refer to GI-9, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000007042381 M

REMOVAL
1. Drain engine coolant. Refer to CO-38, "Changing Engine Coolant". N
2. Remove exhaust manifold cover.
3. Remove turbocharger. Refer to EM-167, "Component".
O
4. Remove EGR cooler. Refer to EM-159, "Exploded View".

EM-171
 EXHAUST MANIFOLD
< SERVICE INFORMATION > [YD]
5. Loosen exhaust manifold mounting nuts in the reverse order in
the figure.

: Vehicle front

E1BIA0272ZZ

6. Remove exhaust temperature sensor.

7. Remove exhaust manifold.
INSPECTION AFTER REMOVAL
Surface Distortion
• Use a reliable straight edge and feeler gauge to check the flatness
of exhaust manifold fitting surface.

Limit : 0.3 mm (0.012 in)

• If it exceeds the limit, replace exhaust manifold.

PBIC2210E

INSTALLATION
• If stud bolts were removed, replace them with new ones, and tighten them to the specified torque:

: 14.7 N·m (1.5 kg-m, 11 ft-lb)

• Tighten the exhaust manifold mounting nuts in the following procedure:
1. Install gasket so that the alignment protrusion faces the No. 4 port. Refer to "Removal and Installation".
2. Tighten the nuts in order specified in the figure.

: Vehicle front

3. Re-tighten the nuts 1 to 8.

4. Install in the reverse order of removal.

E1BIA0272ZZ

INSPECTION AFTER INSTALLATION

Start engine and raise engine speed to check no exhaust gas and engine oil leaks.

EM-172
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [YD]
OIL PAN AND OIL STRAINER
A
Component INFOID:0000000007042382

EM

J
PBIC3424E

1. Oil level gauge 2. Oil level gauge guide 3. Oil level sensor K
4. O-ring 5. O-ring 6. O-ring
7. Oil pan upper 8. Crankshaft position sensor 9. O-ring
10. Rear plate 11. Rear plate cover 12. Oil strainer L
13. Oil pan drain plug 14. Drain plug washer 15. Oil pan lower

• Refer to GI-9, "Component" for symbol marks in the figure. M

Removal and Installation INFOID:0000000007042383

REMOVAL N
WARNING:
To avoid the danger of being scalded, never drain engine oil when engine is hot.
1. Remove engine undercover front and engine undercover middle. Refer to EI-12, "Removal and Installa- O
tion"
2. Drain engine oil. Refer to LU-20, "Changing Engine Oil".
P

EM-173
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [YD]
3. Remove oil pan lower bolts. Loosen bolts in the reverse order of
that shown in the figure.

: Vehicle front

PBIC3425E

4. Remove oil pan lower.

a. Insert the seal cutter (SST) between oil pan upper and oil pan
lower.
CAUTION:
• Be careful not to damage aluminum mating surface.
• Never insert screwdriver, or oil pan flange will be
deformed.
b. Slide the seal cutter by tapping on the side of the seal cutter with
a hammer.
c. Remove oil pan lower.

SEM365EA

5. Remove oil strainer.

6. Remove radiator lower shroud. Refer to CO-41, "Component"
7. Remove power steering oil pump belt. Refer to EM-153.
8. Remove power steering oil pump bracket and move power steering oil pump aside with its piping con-
nected. Temporarily secure it on the vehicle side with a rope to avoid putting load on it. Refer to PS-24.
9. Disconnect oil return hose (vacuum pump) from oil pan upper. Refer to EM-179.
10. Remove the oil level gauge guide. Refer to EM-248, "Component"

11. Remove A/C compressor bracket mounting bolts (A).

1 : Oil pan upper

2 : A/C compressor bracket
: Vehicle front

PBIC3426E

12. Remove the drive belt. Refer to EM-156, "Removal and Installation"
13. Remove the crankshaft pulley. Refer to EM-219, "Component".
14. Remove the front cross member. Refer to MT-19, "Removal and Installation from Vehicle" (M/T models),
Refer to AT-259, "Removal and Installation (YD25DDTi Models)" (A/T models).
15. Remove the oil level sensor.
CAUTION:
• Avoid impacts such as a dropping.
• Never disassemble.
• Keep it away from metal particles.
• Never place sensor close to magnetic materials.
16. Remove front propeller shaft. Refer to PR-3.

EM-174
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [YD]
17. Remove RH and LH front drive shaft. Refer to FAX-7.
18. Remove front final drive assembly. Refer to FFD-16. A
19. Remove rear plate cover and transmission joint bolts.
20. Loosen bolts in the reverse order of illustration to remove oil pan
upper. EM

: Vehicle front
C

PBIC3431E
E
21. Remove oil pan upper.
• Insert the seal cutter (SST) between oil pan upper and cylinder
block. Slide the seal cutter by tapping on the side of the seal F
cutter with a hammer. Remove oil pan upper.
CAUTION:
• Be careful not to damage aluminum mating surface.
G
• Never insert screwdriver, or oil pan flange will be
deformed.

SEM365EA

I
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
J
INSTALLATION
Note the following, and install in the reverse order of removal.
• Install oil pan upper with the following procedure.
- Use the scraper (A) to remove old liquid gasket from mating sur- K
face of oil pan upper (1).
CAUTION:
• Also remove old liquid gasket from mating surface of cylin- L
der block and rear chain case.
• Remove old liquid gasket from the bolt hole and thread.
M

PBIC3432E
N

- Apply a continuous bead of liquid gasket with the tube presser

(commercial service tool) to areas shown in the figure. O

: Vehicle front
P
Use Genuine Liquid Gasket or equivalent.
CAUTION:
• At the 2 bolt holes marked , liquid gasket should be
applied outside holes.
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) or
4.5 to 5.5 mm (0.177 to 0.217 in) wide. (Be careful that the
PBIC3433E
diameter of the liquid gasket bead is different around the
front.)
EM-175
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [YD]
• Attaching should be done within 5 minutes after coating.
- Install oil pan upper.
CAUTION:
Install avoiding misalignment of O-ring.
• Tighten bolts in numerical order to the specified torque.

: Vehicle front

• Bolt dimensions vary depending on the installation location. Refer

to the following and use appropriate bolts.

M6 x 30 mm (1.18 in) : Bolt No. 15, 16

M8 x 25 mm (0.98 in) : Bolt No. 2, 4, 5, 8, 9, 10, 14
M8 x 60 mm (2.36 in) : Bolt No. 1, 3, 6, 7, 11, 12, 13, 17
PBIC3431E
• The shank length under the bolt neck above is the length of the
threaded part (pilot portion not included).
• Install oil pan lower with the following procedure.
- Use a scraper (A) to remove old liquid gasket from mating surface
of oil pan lower (1).
CAUTION:
• Also remove old liquid gasket from mating surface of oil pan
upper.
• Remove old liquid gasket from bolt hole and thread.

PBIC3430E

- Apply a continuous bead of liquid gasket with the tube presser

(commercial service tool) as shown in the figure.

: Vehicle front

Use Genuine Liquid Gasket or equivalent.

CAUTION:
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
• Attaching should be done within 5 minutes after coating.
PBIC3434E

SEM159F

- Install oil pan lower.

EM-176
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [YD]
• Tighten bolts in numerical order to the specified torque.
A
: Vehicle front

NOTE:
Pour engine oil or start engine at least 30 minutes after oil pan is EM
installed.

PBIC3425E

D
INSPECTION AFTER INSTALLATION
1. Check engine oil level and add engine oil. Refer to LU-19.
2. Check for leakage of engine oil when engine is warmed. E
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-19.
F

EM-177
 GLOW PLUG
< SERVICE INFORMATION > [YD]
GLOW PLUG
Component INFOID:0000000007042384

JPBIA3689GB

1. Glow plug
: Engine front
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000007042385

REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Remove extension cowl top. Refer to EI-18, "Removal and Installation".
2. Remove engine cover.
3. Disconnect air inlet hose from electric throttle control actuator.
4. Disconnect glow plug connector.
5. Remove glow plug.
CAUTION:
• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a reamer.
2. Install glow plug.
3. Install remaining parts in the reverse order of removal.

EM-178
 VACUUM PUMP
< SERVICE INFORMATION > [YD]
VACUUM PUMP
A
Component INFOID:0000000007042386

EM

I
PBIC3435E

1. O-ring 2. Vacuum pump 3. Bracket J

4. Oil feed tube 5. Cooper washer 6. Eye-bolt
7. Oil return hose
: Vehicle front K

• Refer to GI-9, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000007042387 L

INSPECTION BEFORE REMOVAL

1. Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector. M
• Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connec-
tor.
2. Start engine and measure generated vacuum at idle speed. N

Standard:
–94.0 to –96.1 kPa (–940 to –961 mbar, –705 to –721 mmHg, –27.76 to –28.38 inHg) O
• If out of standard, check for air suction in vacuum route, and measure again.
• If still outside of standard, replace vacuum pump.
P
REMOVAL
1. Drain engine oil. Refer to LU-20, "Changing Engine Oil".
2. Remove primary timing chain. Refer to EM-220, "Removal and Installation".
3. Disconnect vacuum hose from vacuum pump side.
4. Remove oil feed tube and oil return hose.
5. Remove bracket.

EM-179
 VACUUM PUMP
< SERVICE INFORMATION > [YD]
6. Remove vacuum pump and O-ring.
INSTALLATION
Note the following, and install in the reverse order of removal.
Bracket
Tighten fixing bolts in numerical order as shown in the figure.

: Cylinder block side

PBIC4907E

EM-180
 INJECTION TUBE AND FUEL INJECTOR
< SERVICE INFORMATION > [YD]
INJECTION TUBE AND FUEL INJECTOR
A
Exploded View INFOID:0000000007042388

EM

L
JPBIA3691GB

1. Nozzle oil seal 2. Injection tube No. 1 - 4 3. Protector M

4. Cooper washer 5. Eye-bolt 6. Spill tube
7. Gasket 8. Fuel rail 9. Connector tube
10. Gasket 11. Clamp 12. Return hose N
13. Injection tube 14. Clip 15. Spill hose
16. Clamp 17. Spill tube retaining bolt 18. Clamp
19. Fuel feed hose 20. Fuel pump 21. Clamp O
22. Spill hose 23. Fuel gallery 24. Clamp
25. Air bleed hose 26. Air bleed tube 27. Quick connector
28. Nozzle gasket 29. O-ring 30. Nozzle support P
31. Fuel injector 32. Rocker cover
A. To fuel filter
: Engine front
Refer to GI-9, "Component" for symbols in the figure.

EM-181
 INJECTION TUBE AND FUEL INJECTOR
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042389

REMOVAL
1. Remove engine cover
2. Remove injection tube. Refer to EM-181, "Exploded View".
CAUTION:
Be careful not to spill fuel in the engine component.
3. Disconnect harness connector from fuel injector.
4. Remove spill hose.
5. Following steps below, remove injection tubes.
a. Put a paint mark or tag on injection tubes to identify each cylinder.
• Use a fuel-resistant method.
b. Remove injection tubes in order of 3-2-1-4 individually.
CAUTION:
Be careful not to allow leaked fuel to contaminate engine
room. Especially, ensure to keep engine mounting insulator
clear of fuel.

: Engine front

JPBIA3753ZZ

6. Remove nozzle oil seal.

• Using the flat-bladed screwdriver, pry flange to remove oil
seal.
NOTE:
Nozzle oil seal seals between fuel injector and rocker cover. If
only injection tube shall be removed and installed, nozzle oil
seal replacement is not required.

PBIC0944E

7. Remove rocker cover. Refer to EM-196, "Component".

EM-182
 INJECTION TUBE AND FUEL INJECTOR
< SERVICE INFORMATION > [YD]
8. Remove spill tube mounting bolts and nut.
• Loosen bolts and nut to the reverse order in the figure and A
remove them.
CAUTION:
When loosening nut, fix spill tube retaining bolt with span-
EM
ner.

B : Gasket position
C : Spill tube retaining bolt C
: Engine front

G
JPBIA3889ZZ

9. Remove fuel injector as follows.

H
1 : Fuel injector
2 : O-ring
3 : Nozzle gasket I
4 : Nozzle support
a. Remove nozzle support.
b. Remove fuel injector. While rotating it to left and right, raise it to J
remove.
CAUTION: PBIC4852E
• Handle fuel injector carefully without giving any impact. K
• Never disassemble fuel injector.
c. If nozzle gasket remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out.
d. Remove O-ring from fuel injector. L
INSTALLATION
1. Record “INJECTOR ADJUSTMENT VALUE” on the top surface when replacing fuel injector.
• Refer to EC-1040, "Description" . M

JPBIA3754ZZ
P
Example: Injector Adjustment value = D021ABCD1A061234000000000000E6
2. Following steps below, install fuel injector.
a. Install O-ring and nozzle gasket to fuel injector, and insert them into cylinder head.
b. Tighten injection tubes temporarily in the order of 1-2-3-4.
c. Be sure to fit nozzle support and pin without looseness.
d. Tighten nozzle support bolts.

EM-183
 INJECTION TUBE AND FUEL INJECTOR
< SERVICE INFORMATION > [YD]
e. Loosen injection tubes in the order of 3-2-1-4.
3. Connect spill tube.
• Tighten fixing bolts and nut in numerical order shown in the fig-
ure.
CAUTION:
When tightening nut, fix spill tube retaining bolt with
spanner.
NOTE:
Connection of spill tube gasket may be broken, even if it is
tighten to the specified torque. It does not affect performance.

B : Gasket position
C : Spill tube retaining bolt
: Engine front

JPBIA3889ZZ

4. Perform air tightness test for spill tube.

• Connect a handy vacuum pump to spill connector. Check that
vacuum is retained while applying following vacuum.

Standard:
–53.3 to –66.7 kPa (–533 to –667 mbar, –400 to –
500 mmHg, –15.75 to –19.69 inHg)
• If outside of standard, reconnect spill tube. (Replace gasket in
this case.)
5. Install rocker cover. Refer to EM-196, "Removal and Installa- JEF250Z
tion".
6. Install nozzle oil seal.
• Apply engine oil to the rocker cover nozzle oil seal contact surface and the nozzle oil seal fuel injector
contact surface before installation.
• Insert it straight until its flange fully contacts rocker cover.
CAUTION:
• Check gutter spring in nozzle oil seal on fuel injector for missing.
7. Connect injection tubes individually to each cylinder in order of
1-2-3-4.

: Engine front

JPBIA3753ZZ

8. Install in the reverse order of removal after this step.

EM-184
 INJECTION TUBE AND FUEL INJECTOR
< SERVICE INFORMATION > [YD]
Inspection INFOID:0000000007042390

A
INSPECTION AFTER INSTALLATION
• Input “INJECTOR ADJUSTMENT VALUE” to ECM after installing to the vehicle when replacing fuel injector.
Refer to EC-1040, "Description". EM

JPBIA3754ZZ E
Example: Injector Adjustment value = D021ABCD1A061234000000000000E6
• Start engine and increase engine speed to check for fuel leak.
CAUTION:
Never touch engine immediately after stopped as engine becomes extremely hot. F

EM-185
 FUEL PUMP
< SERVICE INFORMATION > [YD]
FUEL PUMP
Component INFOID:0000000007042395

E1BIA0274GB

1. Washer 2. Fuel pump sprocket 3. Seal washer

4. O-ring 5. Adjusting shim 6. Sprocket nut
7. Coupling 8. Oil seal 9. Spacer
10. Key 11. Fuel pump 12. Fuel pump bracket
13. Fuel pump bracket
: Engine front

• Refer to GI-9, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000007042396

CAUTION:
• Before removing and installing fuel pump, be sure to remove sprocket. Never loosen or remove
installation nut in the center of fuel pump. If loosened or removed, replace fuel pump.
• After removing timing chain, never turn crankshaft and camshaft separately, or valves will strike pis-
ton heads.
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
• When fuel pump is replaced with new one or another one, perform fuel pump learning value clearing
before starting engine. Refer to EC-1043, "Description" .
REMOVAL
1. Remove engine cover, vacuum gallery and heater feed pipe. Refer to EM-163, "Component" .
2. Remove fuel hose and spill hose from fuel pump. Refer to EM-193, "Component".
CAUTION:
Be careful not to spill fuel in the engine component.
3. Disconnect harness connectors from fuel pump.
4. Remove injection tube center, clip and insert rubber. Refer to EM-182, "Removal and Installation".

EM-186
 FUEL PUMP
< SERVICE INFORMATION > [YD]
CAUTION:
Be careful not to spill fuel in the engine component. A

5. Remove secondary timing chain. Refer to EM-213, "Component".

6. Hold fuel pump sprocket and remove bolt. EM
a. Insert the positioning stopper pin (SST) into the hole 6 mm (0.24
in) in the diameter on the fuel pump sprocket.
b. Using the TORX wrench (SST), turn pump shaft little by little to C
adjust the position of fuel pump sprocket so that the holes align.
c. Push the positioning stopper pin (SST) through fuel pump
sprocket to fuel pump body to hold fuel pump sprocket. D

MBIA0049E E

• Insert the positioning stopper pin until its flange contacts the fuel
pump sprocket.
F

PBIC2535E

I
7. Using the hexagon wrench (SST) remove tightening bolts of fuel
pump sprocket.
J

L
PBIC2404E

MBIA0074E P

EM-187
 FUEL PUMP
< SERVICE INFORMATION > [YD]
8. Using the sprocket holder (SST), hold fuel pump sprocket to pre-
vent falling.
• Rework sprocket holder (SST) to use, as shown in the figure.

SBIA0217E

• When the sprocket holder is installed, if the positioning stopper

pin (SST) interferes, pull out the positioning stopper pin
approximately 10 mm (0.39 in), then install it.
• After the sprocket holder is installed temporarily, tighten the
sprocket holder after making extension bar and TORX socket
(size: E10) (commercial service tool) insert into the machined
bore.
• The length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).
• Check that the a- and b-faces of the sprocket holder contact
the bottom side of the sprocket (small diameter side).
PBIC2534E
CAUTION:
Never remove the sprocket holder (SST) until fuel pump is installed.
• After the sprocket holder is installed, pull out the positioning
stopper pin from fuel pump sprocket.

MBIA0075E

9. Using the extension bar and the TORX socket (size: E10) (com-
mercial service tool), remove the tightening bolts.
CAUTION:
Never disassemble or adjust fuel pump.

PBIC2405E

10. Remove the fuel pump toward the rear of engine.

CAUTION:
For removal, be careful not to drop the seal washer into the engine.
NOTE:
The seal washer of the tightening bolts cannot be reused.
11. Remove adjusting shim.
12. Attach a suitable tool in the M8 bolt hole on coupling.

EM-188
 FUEL PUMP
< SERVICE INFORMATION > [YD]
13. Loosen sprocket nut with the TORX wrench (SST).
A

EM

MBIA0013E

D
14. Remove coupling with a suitable puller.

G
MBIA0014E

15. Remove spacer from fuel pump.

H
16. Remove oil seal from spacer.
INSPECTION AFTER REMOVAL
I
Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.
J

SEM984C

INSTALLATION M
1. Install new oil seal to spacer.

P
MBIA0045E

2. Install spacer to fuel pump.

EM-189
 FUEL PUMP
< SERVICE INFORMATION > [YD]
3. Install coupling to fuel pump of spacer.
• Using the TORX wrench (SST), tighten the sprocket nut to fix
the coupling.

MBIA0013E

4. Install adjusting shim.

• For shim adjustment, measure dimension L [Distance between
front surface of coupling and the fuel pump flange (spacer)] at
two opposing points near the coupling bolt center. Use the
average of these two measurements to select the shim grade
that marked on adjusting shim.

MBIA0077E

• The shim adjustment is required only when the fuel pump is

replaced.

PBIC3439E

Part No. of adjusting shim Grade number Measuring dimension L mm (in) Type
16614 8H800 0.5 t 39.23 - 39.77 (1.5445 - 1.5657) A
16614 8H810 1.0 t 38.76 - 39.23 (1.5260 - 1.5445) B
16614 8H860 1.2 t 38.57 - 38.76 (1.5185 - 1.5260) C
16614 8H820 1.6 t 38.18 - 38.57 (1.5031 - 1.5185) D
16614 8H800 + 16614 8H860 0.5 t + 1.2 t 38.09 - 38.18 (1.4996 - 1.5031) A+C
16614 8H810 + 16614 8H810 1.0 t + 1.0 t 37.80 - 38.09 (1.4882 - 1.4996) B+B
16614 8H860 + 16614 8H810 1.2 t + 1.0 t 37.60 - 37.80 (1.4803 - 1.4882) C+B
16614 8H820 + 16614 8H810 1.6 t + 1.0 t 37.21 - 37.60 (1.4650 - 1.4803) D+B

EM-190
 FUEL PUMP
< SERVICE INFORMATION > [YD]
5. Before fuel pump is installed, check that spacer and the 6 mm
(0.24 in) dia. hole on coupling are aligned. A

EM

MBIA0016E

D
6. Insert fuel pump to the mounting position from the rear side of
the engine, and install the tightening bolts with seal washer.
CAUTION:
E
Be careful not to drop the seal washer into engine.

G
PBIC2438E

7. Using the extension bar and the TORX socket (size: E10) (com-
H
mercial service tool), tighten the tightening bolts of fuel pump.
8. Remove the sprocket holder (SST).
I

PBIC2405E
K
9. Using the TORX wrench (SST), turn the pump shaft gradually to
adjust the position of fuel pump sprocket. Then, insert the posi-
tioning stopper pin (SST) to the 6 mm (0.24 in) dia. hole of the L
fuel pump sprocket through the pump body.
10. Remove the TORX wrench (SST).
M

N
MBIA0049E

11. Using the hexagon wrench (SST), tighten the sprocket tighten- O
ing bolt.
• When the washer of the fuel pump sprocket is removed, install
it with the marking “F” (front) facing the front of the engine. P
12. Pull out the positioning stopper pin (SST).

PBIC2404E

EM-191
 FUEL PUMP
< SERVICE INFORMATION > [YD]
13. Install secondary timing chain. Refer to EM-213, "Removal and Installation".
14. Following steps below, install injection tube center. Refer to EM-185, "Inspection".
a. Pre-set clip and insert rubber to injection tube center.
b. Pre-tight nut of injection tube center to fuel pump and fuel rail by hand. (until seal surface touched)
c. Adjust clip dimension and tight bolt for clip to intake manifold by tool.
d. Tight nut of injection tube center to fuel pump by tool.
e. Tight nut of injection tube center to fuel rail by tool.
15. Connect the harness connector to fuel pump.
16. Install fuel hoses. Refer to EM-181, "Exploded View".
17. Hereafter, install in the reverse order of removal.
CAUTION:
When fuel pump is replaced with new one or another one, perform fuel pump learning value clear-
ing before starting engine. Refer to EC-1043, "Description" .

EM-192
 FUEL PUMP SUCTION CONTROL VALVE
< SERVICE INFORMATION > [YD]
FUEL PUMP SUCTION CONTROL VALVE
A
Component INFOID:0000000007042393

EM

E1BIA0296GB

1. Suction control valve 2. Bolt 3. Small O-ring G

4. Gasket 5. O-ring

• Refer to GI-9, "Component" for symbol marks in the figure. H

Removal and Installation INFOID:0000000007042394

REMOVAL I
1. Disconnect wiring harness from Fuel pump suction control valve.
J
1 : Fuel pump suction control valve

E1BIA0297ZZ
M
2. Take note of the connector's orientation. The new valve will have to be fitted in the same way as the old
one.
N
3. Clean the pump with brake cleaner around fuel pump suction control valve contact surface.
4. Remove fixating bolt of the suction valve and remove the suction valve.
NOTE:
O
• The large O-ring says inside. Do not pull the valve with twisting or try pying it out with any tool. Carefully pull
the valve straight up.
• Do not use work gloves to prevent foreign substances entering the fuel injection pump.
NOTE: P
The seal washer of the tightening bolts cannot be reused.
INSTALLATION
1. Remove large O-ring.

EM-193
 FUEL PUMP SUCTION CONTROL VALVE
< SERVICE INFORMATION > [YD]

1 : Large O-ring
NOTE:
• Do not use any tool to remove the O-ring.
• Do not allow any foreign substances to enter into the fuel
injection pump.

E1BIA0298ZZ

2. Ensure that the groove of the pump side housing is contamination free, then place the large new O-ring
into the groove.

1 : Large O-ring
NOTE:
• Apply clean engine oil around the small O-ring, then fit it to the
groove. Otherwise the O-ring may fall off.

E1BIA0299ZZ

3. Insert the new gasket.

4. Apply clean engine oil around the small O-ring on the new suction control valve for sealing.

1 : Small O-ring
NOTE:
• Make sure the suction control valve is clean and no debris
sticks to the [Link] contamination or damage to the O-
ring will cause the fuel injection pump not to work properly.

E1BIA0300ZZ

5. Insert the new suction control valve by hand until you feel a click. Make sure the connector faces into the
same direction as before removal.

NOTE:
• Do not try to twist the suction control valve in, just push it straight.

E1BIA0301ZZ

6. Tighten bolt by hand and then use the torque wrench. Refer to EM-193, "Component".
7. Connect the suction control valve to the wiring harness.

EM-194
 FUEL PUMP SUCTION CONTROL VALVE
< SERVICE INFORMATION > [YD]
8. Clean the suction control valve fitting area with a degreasing spray.
9. Bleed the air from fuel lines. Refer to FL-17, "Air Bleeding". A
10. Start engine and check there is no fuel leakage.

EM

EM-195
 ROCKER COVER
< SERVICE INFORMATION > [YD]
ROCKER COVER
Component INFOID:0000000007042397

E1BIA0358ZZ

1. Nozzle oil seal 2. Oil filler cap 3. Rocker cover

4. Gasket
A. Refer to EM-196, "Removal and Installation" B. To Intake air duct

• Refer to GI-9, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000007042398

REMOVAL
1. Remove engine cover.
2. Remove vacuum gallery and engine cover bracket on rocker cover and ventilation hose.
3. Disconnect harness connector from fuel injector. Refer to EM-181, "Exploded View".
4. Following steps below, remove injection tube. Refer to EM-182, "Removal and Installation".
a. Put a paint mark or tag on injection tubes to identify each cylinder.
• Use a fuel-resistant method.
b. Remove injection tubes in order of 2-1-4-3 individually.

JPBIA3753ZZ

EM-196
 ROCKER COVER
< SERVICE INFORMATION > [YD]

CAUTION: A
Be careful not to allow leaked fuel to contaminate engine room. Especially, ensure to keep engine
mounting insulator clear of fuel.
5. Remove injection nozzle oil seal.
• Using the flat-bladed screwdriver, pry flange to remove nozzle EM
oil seal.

E
PBIC0944E

6. Remove rocker cover.

• Loosen holding bolts in the reverse order of that shown in the F
figure and remove.

: Engine front G

JPBIA3760ZZ I

7. Remove gasket from rocker cover.

INSTALLATION J
1. Install new gasket to rocker cover.
2. Apply liquid gasket with tube presser (commercial service tool)
K
on locations shown in the figure.

1 : Cylinder head
2 : Cylinder head rear cover L
a : 10 mm (0.394 in)
b : φ 3.0 mm (0.118 in)
M
: Engine front

• Use Genuine Liquid Gasket or equivalent.

JPBIA3761ZZ
N
3. Tighten holding bolts.
• Tighten all bolts in numerical order as shown in the figure.
O
: Engine front

P
: 7.8 N·m (0.8 kg-m, 69 in-lb)
• Re-tighten to the same torque in the same order as above.

JPBIA3760ZZ

EM-197
 ROCKER COVER
< SERVICE INFORMATION > [YD]
4. Install nozzle oil seal.
• Insert it straight until flange fully contacts rocker cover.
5. Install remaining parts in the reverse order of removal.
6. Before starting engine, bleed air from fuel piping. Refer to FL-17, "Air Bleeding".
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak and engine oil leak.
CAUTION:
Never touch the engine immediately after stopped as engine becomes extremely hot.

EM-198
 CAMSHAFT
< SERVICE INFORMATION > [YD]
CAMSHAFT
A
Component INFOID:0000000007042399

EM

J
JPBIA3695GB

1. Camshaft bracket 2. Intake camshaft 3. Exhaust camshaft K

4. Adjusting shim 5. Valve lifter 6. Knock pin
7. Camshaft sprocket 8. Cylinder head 9. O-ring
10. Camshaft position sensor 11. Bracket 12. Cylinder head rear cover L
13. Rubber washer 14. Signal plate
A. Comply with the installation proce-
dure when tightening. Refer to EM- M
199, "Removal and Installation"
Refer to GI-9, "Component" for symbols in the figure.
N
Removal and Installation INFOID:0000000007042400

REMOVAL
O
1. Drain engine oil. Refer to LU-20, "Changing Engine Oil".
2. Remove the following parts:
• Collector (upper and lower). Refer toEM-157, "Component".
P
• Vacuum pump. Refer to EM-179, "Component".
• Fuel injector. Refer to EM-181, "Exploded View".
• Rocker cover. Refer to EM-196, "Component".
• Secondary timing chain. Refer to EM-213, "Component".
3. Remove cylinder head rear cover, camshaft position sensor and rubber washer.

EM-199
 CAMSHAFT
< SERVICE INFORMATION > [YD]
Loosen cylinder head rear cover mounting bolts in the reverse
order shown in the figure.

JPBIA3893ZZ

4. Remove camshaft sprockets and signal plate.

• Loosen the camshaft sprocket mounting bolts and signal plate
mounting bolt by fixing the hexagonal portion of camshaft.

JEM159G

5. Remove camshaft.
• Place distinguishing marks on the right and left sides with paint.
• Loosen and remove the camshaft sprocket bolts in the reverse
order shown in the figure.

: Engine front

JPBIA3771ZZ

6. Remove adjusting shim and valve lifter.

• Remove by taking notice of the installation position, and place outside engine in order to prevent confu-
sion.
INSPECTION AFTER REMOVAL
Visual Check of Camshaft
• Check the camshaft for one sided wear or scratches.
• Replace the camshaft if there are abnormalities.
Camshaft Runout
• Prepare V-block on a flat surface and secure camshaft journals No.
2 and No. 5.
• Set the dial gauge (A) vertically on journal No. 3.
• Rotate camshaft in one direction by hand, then read needle move-
ment on dial gauge. (Total indicator reading)

Limit : Refer to EM-271, "Standard and Limit".

• If it exceeds the limit, replace camshaft.

JPBIA3895ZZ

EM-200
 CAMSHAFT
< SERVICE INFORMATION > [YD]
Height of Cam Nose
• Measure the height of cam nose using the micrometer. A

Standard : Refer to EM-271, "Standard

and Limit". EM
• If out of the standard, replace camshaft.

SEM549A D
Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL OUTER DIAMETER E

• Measure outer diameter of camshaft journal with micrometer.

Standard : Refer to EM-271, "Standard

F
and Limit".

H
SEM012A

CAMSHAFT BRACKET INNER DIAMETER

I
• Install camshaft bracket and tighten bolts to the specified torque. Refer to "INSTALLATION" for the tighten-
ing procedure.
• Measure inner diameter of camshaft bracket using the inside
micrometer. J

Standard : Refer to EM-271, "Standard

and Limit". K

JEM162G
M
CAMSHAFT OIL CLEARANCE CALCULATIONS
• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal outer diameter)
N
Standard : Refer to EM-271, "Standard
and Limit".
• If out of standard, refer to the standard value of each unit, then replace the camshaft and/or cylinder head. O
NOTE:
As the camshaft bracket is manufactured with the cylinder head, it is impossible to replace only the camshaft
bracket.
P
Camshaft End Play

EM-201
 CAMSHAFT
< SERVICE INFORMATION > [YD]
• Install dial gauge in thrust direction on front end of camshaft. Mea-
sure end play of dial gauge when camshaft is moved forward/back-
ward (in direction to axis).

Standard : Refer to EM-271, "Standard

and limit and Limit".

PBIC0366E

• Measure the following parts if out of the standard.

- Dimension “A” for camshaft

Standard : 6.882 - 6.930 mm (0.2709 - 0.2728 in)

- Dimension “B” for cylinder head

Standard : 7.000 - 7.030 mm (0.2756 - 0.2768 in)

• Refer to the standards above, and then replace camshaft and/or
cylinder head.
PBIC2320E

Camshaft Sprocket Runout

1. Install camshaft in cylinder head. Refer to "INSTALLATION" for the tightening procedure.
2. Install sprocket on camshaft. Refer to "INSTALLATION".
3. Measure camshaft sprocket runout. (Total indicator reading)

Limit : Refer to EM-271, "Standard

and Limit".
• If it exceeds the limit, replace camshaft sprocket.

JEM164G

Visual Inspection of Valve Lifter and Adjusting Shim

Check if surface of valve lifter and adjusting shim has any wear or
cracks.
• If anything above is found, replace valve lifter or adjusting shim.

SEM160D

Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER

EM-202
 CAMSHAFT
< SERVICE INFORMATION > [YD]
• Measure the outer diameter of the valve lifter with the micrometer.
A
Standard : Refer to EM-271, "Standard
and Limit".
EM

SEM961E

D
VALVE LIFTER BORE DIAMETER
• Measure the bore diameter of the cylinder head valve lifter with the
inside micrometer. E

Standard : Refer to EM-271, "Standard

and Limit".
F

PBIC0367E

H
VALVE LIFTER CLEARANCE CALCULATIONS
• (Clearance) = (Valve lifter bore diameter) – (Valve lifter outer diameter)

Standard : Refer to EM-271, "Standard I

and Limit".
• If out of standard, refer to the outer diameter and bore diameter standard values and replace valve lifter and/ J
or cylinder head.
INSTALLATION
1. Install valve lifter and adjusting shim. K
• Check that these are installed in the same position as before the removal process.
2. Install camshaft.
L
1 : Intake camshaft
2 : Exhaust camshaft
: Engine front M
• Identify camshafts by the paint position.

A : White N
B : Green
JPBIA3894ZZ

EM-203
 CAMSHAFT
< SERVICE INFORMATION > [YD]
• Install so that knock pins (A) are positioned in the directions
shown in the figure.

B : Intake camshaft
C : Exhaust camshaft
d : Approx. 65°
: Up

JPBIA3909ZZ

3. Install camshaft brackets.

• Completely remove any foreign material on back surfaces of camshaft brackets and top surface of cylin-
der head.
• Install correctly, identifying brackets by the journal No. and
front mark on top surface.

JEM175G

4. Tighten camshaft bolts in numerical order as shown in the figure

according to the following procedure:

: Engine front

a. Tighten No. 13 to 15.

: 1.96 N·m (0.20 kg-m, 1 ft-lb)

• Check camshaft thrusting parts (on rear side) securely fit in
their mating parts on the cylinder head.
JPBIA3771ZZ
b. Tighten No. 1 to 12.

: 1.96 N·m (0.20 kg-m, 1 ft-lb)

c. Tighten all bolts.

: 5.88 N·m (0.60 kg-m, 4 ft-lb)

d. Tighten all bolts.

: 12.8 N·m (1.3 kg-m, 9 ft-lb)

5. Install camshaft sprockets and signal plate.
• Camshaft sprockets are commonly used for right side and left side.
• Align camshaft sprocket and knock pin on camshaft, and install.
• Holding the hexagonal part of camshaft with a wrench, tighten bolt securing camshaft sprockets and sig-
nal plate.
6. Install rubber washer to cylinder head rear side.

EM-204
 CAMSHAFT
< SERVICE INFORMATION > [YD]
7. Apply liquid gasket to cylinder head rear cover as shown in the
figure. A
Use Genuine Liquid Gasket or Equivalent.

a : 4.0 - 5.6 mm (0.157 - 0.220 in)

EM
b : φ 3.4 - 4.4 mm (0.134 - 0.173 in)

JPBIA3772ZZ

D
8. Install cylinder head rear cover and tighten mounting bolts in
numerical order shown in the figure.

M8 × 50 mm (1.97 in) : Bolt No. 1 E

M8 × 20 mm (0.79 in) : Bolt No. 2 - 6
F

G
JPBIA3893ZZ

9. Before installing spill tube after installing secondary timing chain, check and adjust valve clearance. Refer
to EM-206, "Valve Clearance". H
10. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
I
Inspection for Leakage

The following are procedures for checking fluid leakage, lubricant leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the J
required quantity, fill them to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping, K
check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE: L
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises. M
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
N
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
O

Engine coolant Level Leakage Level

Engine oil Level Leakage Level P
Transmission / AT Models Leakage Level / Leakage Leakage
transaxle fluid MT Models Level / Leakage Leakage Level / Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.

EM-205
 CAMSHAFT
< SERVICE INFORMATION > [YD]
Valve Clearance INFOID:0000000007042401

INSPECTION
• When the camshaft or parts in connection with valves are removed or replaced, and a malfunction has
occurred (poor starting, idling, or other malfunction) due to the miss adjustment of the valve clearance,
inspect as follows.
• Inspect and adjust when the engine is cool (at normal temperature).

1. Remove rocker cover. Refer to EM-196, "Component".

2. Remove fuel injector. Refer to EM-181, "Exploded View".
3. Set the No. 1 piston to TDC on its compression stroke.
• Turn crankshaft pulley clockwise so that the cam nose (A) on
exhaust camshaft (1) faces straight above ( ). (No position
indicator, etc. is provided on the crankshaft pulley.)

JPBIA4521ZZ

4. While referring to the figure, measure the valve clearance

marked in the table below.

: Vehicle front

Measuring position No.1 No.2 No.3 No.4

No. 1 cylinder at compression INT (A) (D)

TDC EXH (B) (C)

JPBIA3758ZZ

NOTE:
Use a feeler gauge (A), measure the clearance between valve
lifter and camshaft.

JPBIA3759ZZ

5. Set the No. 4 cylinder at TDC by rotating the crankshaft clockwise once. (360 degrees)

EM-206
 CAMSHAFT
< SERVICE INFORMATION > [YD]
6. While referring to the figure, measure the valve clearance
marked in the table below. A

: Vehicle front
EM
Measuring position No.1 No.2 No.3 No.4

No. 4 cylinder at compression INT (A) (D)

C
TDC EXH (B) (C)

JPBIA3787ZZ

D
7. If the valve clearance is outside the specification, adjust as follows.
ADJUSTMENTS
• Remove adjusting shim for parts which are outside the specified valve clearance. E
1. Extract engine oil on the upper side of the cylinder head (for the air blowing in step 6).
2. Rotate crankshaft to face the camshaft for adjusting shims that
are to be removed upward. F

1 : Round hole
: Facing straight above G

JPBIA3883ZZ

I
3. Grip camshaft with the camshaft pliers (A) [SST: KV10115110],
then using camshaft as a support point, push adjusting shim
downward to compress valve spring. Then move the camshaft
J
pliers handle in the direction of arrow ( ).
CAUTION:
Never damage camshaft, cylinder head and the outer cir-
cumference of valve lifter. K

L
JPBIA3884ZZ

4. With valve spring in a compressed state, remove the camshaft

pliers (A) [SST: KV10115110] by securely setting the outer cir- M
cumference of the valve lifter with the end of the lifter stopper (B)
[SST: KV10115120].
• Hold the lifter stopper by hand until the shim is removed. N
CAUTION:
Never retrieve the camshaft pliers forcefully, as camshaft
will be damaged.
O

JPBIA3885ZZ
P
5. Move the round hole of adjusting shim to the front with the very thin screwdriver or like that.
• When adjusting shim on valve lifter will not rotate smoothly, restart from step 3 to release the end of the
lifter stopper [SST: KV10115120] from touching adjusting shim.

EM-207
 CAMSHAFT
< SERVICE INFORMATION > [YD]
6. Remove adjusting shim from valve lifter by blowing air through
the round hole (1) of the adjusting shim with the air gun (B).

A : Lifter stopper
CAUTION:
To prevent any remaining engine oil from being blown
around, thoroughly wipe the area clean and wear protective
goggles.

JPBIA3886ZZ

7. Remove adjusting shim (1) by using the magnet hand (B).

A : Lifter stopper

JPBIA3887ZZ

8. Measure the thickness of adjusting shim using the micrometer.

• Measure near the center of the shim (the part that touches
camshaft).

FEM032

9. Select the new adjusting shim from the following methods.

Calculation method of the adjusting shim thickness:

R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake
N = R + [M - 0.28 mm (0.0110 in)]
Exhaust
N = R + [M - 0.30 mm (0.0118 in)]
• New adjusting shims have the thickness stamped (A) on the
rear side.
• Shims are available in 33 size from 2.10 mm (0.0827 in) to
2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in). Refer to
EM-271, "Standard and Limit".

B : Thickness

JPBIA3912ZZ

EM-208
 CAMSHAFT
< SERVICE INFORMATION > [YD]

10. Fit the selected adjusting shim to valve lifter. A

A : Lifter stopper
B : Suitable tool
EM
CAUTION:
Place the stamped side of adjusting shim to valve lifter.
C

JPBIA3888ZZ
D
11. Compress valve spring using the camshaft pliers [SST: KV10115110] and remove the lifter stopper [SST:
KV10115120].
E
12. Rotate crankshaft 2 to 3 turns by hand.
13. Confirm that the valve clearance is within the specification.
14. Install remaining parts in the reverse order of removal.
F
15. Warm up engine, and check for unusual noise and vibration.

EM-209
 OIL SEAL
< SERVICE INFORMATION > [YD]
OIL SEAL
Removal and Installation of Valve Oil Seal INFOID:0000000007042402

REMOVAL
1. Turn crankshaft until the cylinder requiring new valve oil seals is at TDC. This will prevent valve from drop-
ping into cylinder.
2. Remove camshafts. Refer to EM-199.
3. Remove adjusting shims and valve lifters. Refer to EM-199.
• Check the installation positions, and keep them to avoid being confused.
4. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
5. Remove valve collet.
• Compress the valve spring with valve spring compressor,
attachment and adapter (SST). Remove valve collet with a
magnet hand.
CAUTION:
When working, be careful not to damage valve lifter holes.

PBIC2388E

6. Remove valve spring retainer and valve spring.

7. Remove valve oil seal with the valve oil seal puller (SST).

JEM153G

INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Using the valve oil seal drift (SST), install valve oil seals refer-
ring to the dimension shown in the figure.

JEM165G

3. Install in the reverse order of removal.

Removal and Installation of Front Oil Seal INFOID:0000000007042403

REMOVAL

EM-210
 OIL SEAL
< SERVICE INFORMATION > [YD]
1. Remove the following parts.
• Splash guard (RH). Refer to EI-25, "Removal and Installation". A
• Drive belt. Refer to EM-161, "Component".
• Crankshaft pulley. Refer to EM-248, "Component".
2. Remove front oil seal with a suitable tool. EM
CAUTION:
Be careful not to damage oil pump housing and crankshaft.
C

JPBIA3762ZZ E

INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip. F
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
G
A : Oil seal lip
B : Dust seal lip
: Engine inside H
: Engine outside

I
JPBIA0054ZZ

• Using the suitable drift [60 mm (2.36 in) dia.] (A), press fit the J
oil seal (2) so that the dimension is as specified in the figure.

1 : Oil pump housing

K

b : 0 - 0.5 mm (0 - 0.020 in)

CAUTION: L
Never touch lips of oil seal. Check seal surfaces are free
of foreign materials.
M

JPBIA3763ZZ

3. Install in the reverse order of removal.

Removal and Installation of Rear Oil Seal INFOID:0000000007042404

REMOVAL
EM-211
 OIL SEAL
< SERVICE INFORMATION > [YD]
1. Remove engine and transaxle from vehicle. Refer to EM-244, "Component".
2. Remove transaxle.
3. Remove drive plate.
4. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.

A : Oil seal lip

B : Dust seal lip
: Engine inside
: Engine outside

JPBIA0054ZZ

• Press in rear oil seal (2) to rear oil seal retainer (1) as shown in
the figure.

b : 0 - 0.5 mm (0 - 0.020 in)

• Using the drift [100 mm (3.94 in) dia.] (A), press fit so that the
dimension is as specified in the figure.
• Avoid inclined fitting. Force fit perpendicularly.

JPBIA3764ZZ

3. Install in the reverse order of removal after this step.

EM-212
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
SECONDARY TIMING CHAIN
A
Component INFOID:0000000007042405

EM

I
JPBIA3694GB

1. Chain tensioner 2. Slack guide 3. Front chain case J

4. Tension guide 5. Gasket 6. Secondary timing chain
7. Tension guide
A. Oil pump housing side B. Comply with the installation proce- K
dure when tightening. Refer to EM-
213, "Removal and Installation"
Refer to GI-9, "Component" for symbols in the figure.
L
Removal and Installation INFOID:0000000007042406

CAUTION: M
• After removing timing chain, never turn crankshaft and camshaft separately, or valves will strike pis-
ton heads.
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil. N

REMOVAL
1. Remove RH engine mounting bracket (lower). Refer to EM-244, "Component". O
2. Remove front chain case.

EM-213
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
• Loosen fixing bolts in reverse order of that shown in the figure
and remove them.
CAUTION:
• While front chain case is removed, cover openings to
prevent entry of foreign material into engine.

JPBIA3769ZZ

• Never remove mass damper (2) on the back of cover.

1 : Tension guide

JPBIA3892ZZ

3. Set the No. 1 piston to TDC on its compression stroke.

• Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
shown in the figure.
• No position indicator is provided on crankshaft pulley.
• When installing, color coded links on secondary timing
chain can be used as alignment marks. Marking may not
be necessary for removal, however, make alignment
marks as required because the alignment mark on fuel
pump sprocket may not be easy to see.

SEM515G

4. Remove chain tensioner.

a. Push the plunger of chain tensioner and keep it pressed with a
push pin.

JEM124G

EM-214
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
b. Using the hexagon wrench [SST: KV11106010], remove bolts to
remove chain tensioner. A

EM

SBIA0227E

D
5. Remove slack guide.
• Using the hexagon wrench [SST: KV11106020], remove bolt to
remove slack guide.
E

SBIA0228E

H
6. Remove tension guide.
7. Remove secondary timing chain.
• Timing chain alone can be removed without removing sprock-
ets. I

K
JEM127G

INSTALLATION
1. Install secondary timing chain. L

EM-215
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
• When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the timing
chain.

1 : Secondary timing chain

2 : Chain tensioner
3 : Slack guide
4 : Fuel pump sprocket
5 : Tension guide
6 : Camshaft sprocket
A : Alignment mark (dark blue link)
B : Alignment mark (punched mark)
C : Alignment mark (yellow link)
2. Install tension guide.
• The upper bolt has a longer shank than the lower bolt.

PBIC4048E

3. Using the hexagon wrench [SST: KV11106020], install slack

guide.

SBIA0228E

4. Install chain tensioner.

a. Push the plunger of chain tensioner. While holding it with a push
pin, install chain tensioner.
b. Using the hexagon wrench [SST: KV11106010], tighten bolts.
c. Pull out the push pin, etc. holding the plunger.
• Check again that the alignment marks on the sprockets
and the colored alignment marks on the timing chain are
aligned.

SBIA0227E

5. Install front chain case.

EM-216
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
a. Install tension guide (1) on the back surface of front chain case.
A
2 : Mass damper
• Hold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted. EM

JPBIA3892ZZ

D
b. Apply a continuous bead of liquid gasket on both ends of arched area (locations where rear chain case is
adjoined) as shown in the figure.
E

I
JPBIA3770ZZ

1. Oil pump housing 2. Rear chain case J

b. φ 19 mm (0.75 in) c. 10 mm (0.39 in) e. φ 3.4 - 4.4 mm (0.13 - 0.17 in)
f. 5 mm (0.20 in)
K
CAUTION:
• For (A), the overlap of the liquid gasket starting point and end-point must be minimized and
faced outward.
Use Genuine Liquid Gasket or equivalent. L

c. Install front chain case.

• When installing, align dowel pin on oil pump housing with the pin hole. M
• Install No. 6, 10 and 11 bolts with the rubber washer to front chain case.
d. Tighten fixing bolts in numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order. N

JPBIA3769ZZ

6. Install in the reverse order of removal after this step.

EM-217
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
Inspection INFOID:0000000007042407

INSPECTION AFTER REMOVAL

Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.

SEM984C

INSPECTION AFTER INSTALLATION

Inspection for Leakage

The following are procedures for checking fluid leakage, lubricant leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the
required quantity, fill them to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping,
check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises.
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level

Transmission / AT & CVT Models Leakage Level / Leakage Leakage

transaxle fluid MT Models Level / Leakage Leakage Level / Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.

EM-218
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
PRIMARY TIMING CHAIN
A
Component INFOID:0000000007042408

EM

JPBIA3696GB

N
1. Fuel pump 2. O-ring 3. Rear chain case
4. O-ring 5. Fuel pump sprocket 6. Washer
7. Tension guide 8. Primary timing chain 9. Chain tensioner O
10. Slack guide 11. Crankshaft sprocket 12. Crankshaft pulley
13. Front oil seal 14. Oil pump housing 15. Crankshaft gear
16. Key 17. Balancer unit 18. Seal washer P
A. Comply with the installation proce- B. Comply with the installation proce-
dure when tightening. Refer to EM- dure when tightening. Refer to EM-
220, "Removal and Installation". 220, "Removal and Installation".
Refer to GI-9, "Component" for symbols in the figure.

EM-219
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042409

CAUTION:
• After removing timing chain, never turn crankshaft and camshaft separately, or valves will strike pis-
ton heads.
• When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
surfaces with new engine oil.
REMOVAL
1. Drain engine oil. Refer to LU-20, "Changing Engine Oil".
2. Remove the following parts:
• Drive belt auto-tensioner and idler pulley. Refer to EM-156, "Removal and Installation".
• Collector (upper and lower). Refer to EM-157, "Component".
• Vacuum pump. Refer to EM-179, "Component".
• Fuel injector. Refer to EM-181, "Exploded View".
• Rocker cover. Refer to EM-196, "Component".
• Secondary timing chain. Refer to EM-213, "Component".
• Oil pan (upper and lower). Refer to EM-173, "Component".
3. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (commercial ser-
vice tool).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt approx-
imately 10 mm (0.39 in).

PBIC3469E

c. Using the pulley puller [SST: KV11103000], remove crankshaft

pulley.
• Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.

JEM132G

4. Remove oil pump housing.

• Loosen bolts in reverse order of that shown in the figure and
remove them.
• Use the seal cutter [SST: KV10111100] etc. for removal.

JPBIA3773ZZ

EM-220
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
5. Remove crankshaft gear (1) with the following procedure.
a. Check that No.1 piston is TDC on its compression stroke. A
b. Turn the idler sub gear (3) counterclockwise with snap ring plier
(B) or suitable tool for aligning idler sub gear and idler main gear
(2). EM
• If idler gear rotates, hold the flat faces on balancer drive shaft
front end (4).
c. Install internal mechanism securing bolt and plate (Service part: C
13012 EB30A and 13013 EB30A) (A) and tighten to the speci-
fied torque.
D
: 4.0 N·m (0.41 kg-m, 35 in-lb)

CAUTION:
• Never loosen idler gear mounting bolt (5). E
• Only use the genuine internal mechanism securing bolt
and plate, or the idler gear and will be damaged.
• Never remove internal mechanism securing bolt and plate
F
from idler gear and until crankshaft gear and all of the
parts in connection have been installed.
• If internal mechanism securing bolt and plate is not
installed, internal mechanism of idler gear and will disen- G
gage after crankshaft gear is removed. This will prohibit JPBIA3914ZZ

the balancer unit from being reusable.

d. Apply mating marks (C) to crankshaft gear and idler sub gear. H
e. Remove crankshaft gear.
6. Remove front oil seal from oil pump housing.
• Punch out the seal off from the back surface of the oil pump housing using a flat-bladed screwdriver. I
CAUTION:
Be careful not to damage oil pump housing.
J
7. Remove chain tensioner (1).
• When removing chain tensioner, push the plunger of chain
tensioner and keep it pressed with a push pin (2).
8. Remove slack guide (3). K

M
JPBIA3774ZZ

9. Hold fuel pump sprocket (1) and remove bolt.

a. Insert positioning stopper pin (A) [SST: KV11106030] on fuel N
pump sprocket.

c : φ 6 mm (0.24 in) O
d : 80 mm (3.15 in)
b. Using the TORX wrench (B) [SST: KV11106040], turn pump
shaft little by little to adjust the position of fuel pump sprocket so P
that the holes align.
JPBIA3775ZZ

e : 26 mm (1.02 in)
c. Push positioning stopper pin through fuel pump sprocket to fuel pump body to hold fuel pump sprocket.

EM-221
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
• Insert the positioning stopper pin [SST: KV11106030] until its
flange contacts fuel pump sprocket.

PBIC2535E

10. Using the hexagon wrench [SST: KV11106050] remove tighten-

ing bolts to fuel pump sprocket.

PBIC2404E

MBIA0074E

11. Remove primary timing chain (2) with fuel pump sprocket (1)
and crankshaft sprocket (3).

JPBIA3776ZZ

EM-222
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
12. Remove tension guide (1).
A

EM

JPBIA3777ZZ

D
13. Remove fuel pump. Refer to EM-186, "Component".
14. Remove camshaft sprockets. Refer to EM-199, "Component".
15. Remove rear chain case. E
• Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
• Use the seal cutter [SST: KV10111100] for removal.
F

JPBIA3778ZZ

L
16. Remove balancer unit.
• Loosen mounting bolts in the reverse order as shown in the
figure.
M
: Engine front

PBIC4049E

INSTALLATION P
NOTE:
The figure shows the relationship between the mating mark on each timing chain and that on the correspond-
ing sprocket, with the components installed.

EM-223
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]

JPBIA3779ZZ

1. Secondary timing chain 2. Chain tensioner 3. Slack guide

4. Fuel pump sprocket 5. Chain tensioner 6. Slack guide
7. Primary timing chain 8. Crankshaft sprocket 9. Tension guide
10. Tension guide 11. Camshaft sprocket 12. Tension guide
13. Front chain case
A. Alignment mark (dark blue link) B. Alignment mark (yellow link) C. Alignment mark (punched mark)
D. Alignment mark (punched mark) E. Alignment mark (punched mark)

CAUTION:
Before starting work, check that No. 1 piston is on its compression stroke.
1. Install balancer unit, and tighten mounting bolts in numerical
order as shown in the figure.

: Engine front

CAUTION:
If mounting bolts are re-used, check their outer diameter
before installation. Refer to "Balancer Unit Mounting Bolt
Outer Diameter".
a. Apply new engine oil to threads and seat surfaces of mounting
bolts.
PBIC4049E
b. Tighten all bolts.

: 29.4 N·m (3.0 kg-m, 22 ft-lb)

c. Turn all bolts 65 degrees clockwise (angle tightening).

1 : Balancer unit
CAUTION:
Check tightening angle with an angle wrench [SST:
KV10112100] (A) or a protract. Never make judgement by
visual check alone.
d. Completely loosen.

: 0 N·m (0 kg-m, 0 ft-lb) PBIC3474E

CAUTION:
In this step, loosen bolts in the reverse order as shown in the figure.
e. Tighten all bolts.

EM-224
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]

: 29.4 N·m (3.0 kg-m, 22 ft-lb) A

f. Turn them another 65 degrees clockwise (angle tightening).

CAUTION:
EM
Check tightening angle with an angle wrench [SST: KV10112100] or a protractor. Never make judg-
ment by visual check alone.
2. Install rear chain case.
C
a. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) on locations shown in the figure.
Use Genuine Liquid Gasket or equivalent.
CAUTION: D
• Never allow liquid gasket to stick out to the oil passage
(C).
• For (A), the overlap of the liquid gasket starting point and E
end-point must be minimized and faced outward.
• For (B), the starting point and the end-point of the liquid
gasket must stick out from the case rim.
F
1 : O-ring
d : 4.0 - 5.6 mm (0.16 - 0.22 in)
e : φ3.4 - 4.4 mm (0.13 - 0.17 in) G

JPBIA3780ZZ

J
b. Install new O-ring (1) to the grooves of fuel pump bracket.

M
JPBIA3781ZZ

c. Install rear chain case.

• When installing, align the dowel pin with the pin hole. N

EM-225
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
d. Tighten bolts in numerical order shown in the figure.
• Install the following two types of bolts, referring to the figure.

M8 × 16 mm (0.63 in) : Bolt No. 1, 2, 8, 9, 10, 11, 12, 13,

17, 18
M8 × 20 mm (0.79 in) : Bolt No. 3, 4, 5, 6, 7, 14, 15, 16,
19, 20
• The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.

JPBIA3778ZZ

3. Install fuel pump. Refer to EM-186, "Component".

• Before installing, check that spacer and the hole 6 mm (0.24 in) in diameter on coupling are aligned.
4. Install tension guide (1).

JPBIA3777ZZ

5. Install crankshaft sprocket (3), aligning it with crankshaft key on

the far side.
6. Install primary timing chain (2) with fuel pump sprocket (1).
• When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on primary timing
chain.
• Install fuel pump sprocket washer with the surface marked “F”
(front mark) facing the front of the engine.

JPBIA3776ZZ

EM-226
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
7. Use the positioning stopper pin (A) [SST: KV11106030] to hold
the fuel pump sprocket (1) and install the bolt. A

c : φ 6 mm (0.24 in)
d : 80 mm (3.15 in) EM
• Using the TORX wrench (B) [SST: KV11106040], turn the fuel
pump shaft little by little to adjust the position of the fuel pump
sprocket. Insert positioning stopper pin into the hole 6 mm C
(0.24 in) in diameter on fuel pump sprocket so that the stopper
pin goes through the fuel pump body. While the stopper pin is
in place, install the bolt. JPBIA3775ZZ

D
e : 26 mm (1.02 in)

PBIC2404E
H

8. Install timing chain slack guide (3).

9. Install chain tensioner (1). I
• Push the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin (2), install chain ten-
sioner.
• After installation, pull out the push pin holding the plunger. J
CAUTION:
Check again that the alignment marks on sprockets and the
colored alignment marks on timing chain are aligned. K

JPBIA3774ZZ

10. Install front oil seal (1) to oil pump housing (2). L
• Using the suitable drift (A) [62 mm (2.44 in) dia.], force fit the
seal until it hits the bottom.
CAUTION: M
Never touch lips of oil seal. Check seal surfaces are free of
foreign materials.
N

O
PBIC3448E

11. Install crankshaft gear.

P

EM-227
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
• Align crankshaft gear (1) mating mark and idler sub gear (3)
mating mark (C).

2 : Idler main gear

4 : Balancer drive shaft front end
5 : Idler gear mounting bolt (do not loosen)
B : Snap ring plier
• Remove internal mechanism securing bolt and plate (Service
part: 13012 EB30A and 13013 EB30A) (A).

JPBIA3914ZZ

- If new balancer unit (2) is used, align matching marks (B) of

each gear as shown in the figure.
- Remove securing-bolt-and-plate (A) and securing pin (C) after
installing crankshaft gear (1).

PBIC3475E

12. Install oil pump housing.

EM-228
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
a. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) as shown in the figure. A
• Leave the start and end areas (A) of the bead slightly protrud-
ing from the surface.
• Apply liquid gasket along upper end surface of oil pump hous-
EM
ing.

b : φ3.4 - 4.4 mm (0.13 - 0.17 in)

c : 4.0 - 5.6 mm (0.16 - 0.22 in) C
d : 0.5 - 2.1 mm (0.02 - 0.08 in)

G
JPBIA3782ZZ

b. Install new O-rings into the groove of rear chain case.

H
c. Install oil pump housing.
• When installing, align the inner rotor in the direction of the two facing flats of oil pump drive spacer.
• When installing, align the dowel pin with the pin hole.
I
d. Tighten fixing bolts in numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order.
J

L
JPBIA3773ZZ

13. Check gaps on upper oil pan mounting surface.

• Using straightedge and feeler gauge, measure gaps between M
the locations of the following parts:

Oil pump housing and rear chain case: N

Standard : (–0.09) – (+0.09) mm [(–0.0035) – (+0.0035)
in]
Rear chain case and cylinder block: O
Standard : (–0.19) – (+0.07) mm [(–0.0075) – (0.0028)
in] JEM146G
P
• If the measured value is out of the standard, install again.

14. Install crankshaft pulley, refer to the following:

CAUTION:
Be careful not to damage front oil seal.
a. Install crankshaft pulley to crankshaft.
b. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.

EM-229
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
c. Hold crankshaft pulley with the pulley holder (commercial ser-
vice tool).
d. Tighten crankshaft pulley fixing bolt.

: 75.0 N·m (7.7 kg-m, 55 ft-lb)

e. Completely loosen.

: 0 N·m (0 kg-m, 0 ft-lb)

PBIC3469E
f. Tighten crankshaft pulley bolt.

: 75.0 N·m (7.7 kg-m, 55 ft-lb)

g. Put an alignment mark on crankshaft pulley that aligns with one of the punched marks on the bolt.

h. Tighten fixing bolt another 120 degrees (angle tightening) (turn

by 2 notch).

A : Indicate embossments
B : Alignment mark

PBIC3476E

15. Install in the reverse order of removal.

Inspection INFOID:0000000007042410

INSPECTION AFTER REMOVAL

Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.

SEM984C

Balancer Unit Mounting Bolt Outer Diameter

• Measure the outer diameters (“d1”, “d2”) at two positions as shown
in the figure.
• If reduction appears in “A” range, regard it as “d2”.

Limit (“d1” - “d2”) : 0.15 mm (0.0059 in)

• If it exceeds the limit (large difference in dimensions), replace it
with a new one.

PBIC1137E

EM-230
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
INSPECTION AFTER INSTALLATION
A
Inspection for Leakage

The following are procedures for checking fluid leakage, lubricant leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the EM
required quantity, fill them to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping,
check for fuel leakage at connection points. C
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE: D
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises.
E
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to F
the specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped G
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
H
Transmission / AT & CVT Models Leakage Level / Leakage Leakage
transaxle fluid MT Models Level / Leakage Leakage Level / Leakage
Other oils and fluids* Level Leakage Level I
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
J
*: Power steering fluid, brake fluid, etc.

EM-231
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
CYLINDER HEAD
On-Vehicle Service INFOID:0000000007042411

CHECKING COMPRESSION PRESSURE

1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT, check no error codes are indicated for self-diagnosis items. Refer to EC-1036, "Work
Procedure".
• Do not disconnect CONSULT until the end of this operation, it will be used to check engine rpm and for
error detection at the end of this operation.
3. Disconnect the battery cable from the negative terminal.
4. Remove the engine cover and bracket. Refer to EM-157, "Component"
5. To prevent fuel from being injected during inspection, disconnect
all the connectors of the fuel injector.

A : Connector
B : Injector

JPBIA3881ZZ

6. Wind the insulating tape around the electrode of the discon-

nected connectors. Tie them together and fix them on the har-
ness side.

A : Connector

PBIC4772E

7. Remove glow plugs from all the cylinders. Refer to EM-178, "Component".
CAUTION:
• Before removal, clean the surrounding area to prevent entry of any foreign materials into engine.
• Carefully remove glow plugs to prevent any damage or breakage.
• Handle with care to avoid applying any shock to glow plugs.

8. Install compression gauge adapter [SST: ED19600610] to instal-

lation holes of glow plugs and connect compression gauge for
diesel engine.

: 20.0 N·m (2.0 kg-m, 15 ft-lb)

9. Connect the battery cable to the negative terminal.
10. Turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and engine
rpm. Perform these steps to check each cylinder.
• Always use a fully-charged battery to obtain specified engine SEM112G
speed.

Compression pressure : Refer to EM-271, "Standard and Limit".

EM-232
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
• When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions. A
• If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
EM
• If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
- If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring. C
- If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.
• If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be leak- D
ing from gasket. In this case, replace cylinder head gasket.
11. Complete this operation as follows:
a. Turn the ignition switch to “OFF”. E
b. Disconnect the battery cable from the negative terminal.
c. Install glow plug and install all the parts removed in step 4.
d. Connect all the connectors of the fuel injector. F
e. Connect the battery cable to the negative terminal.
f. Check DTC. If DTC is displayed, erase it. Refer to EC-1034, "Diagnostic Work Sheet".
G
Exploded View INFOID:0000000007042412

REMOVAL H

JPBIA3698GB

P
1. Bracket 2. Slinger bracket 3. Cylinder head assembly
4. Gasket 5. Dowel pin
A. Comply with the installation proce-
dure when tightening. Refer to EM-
234, "Removal and Installation".
Refer to GI-9, "Component" for symbols in the figure.

EM-233
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
DISASSEMBLY

JPBIA3699GB

1. Adjusting shim 2. Valve lifter 3. Valve collet

4. Valve spring retainer 5. Valve spring (intake) 6. Valve oil seal
7. Valve spring seat 8. Valve guide 9. Cylinder head
10. Valve seat 11. Valve (intake) 12. Valve (exhaust)
13. Valve spring (exhaust)
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000007042413

REMOVAL
1. Drain engine coolant from radiator and cylinder block. Refer to CO-38, "Changing Engine Coolant" and
CO-38, "Inspection".
2. Remove the following parts:
• EGR system. Refer to EM-159, "Exploded View".
• Turbocharger. Refer to EM-167, "Component".
• Exhaust manifold. Refer to EM-171, "Component".
• Intake manifold. Refer to EM-163, "Component".
• Vacuum pump. Refer to EM-179, "Component".
• Glow plug. Refer to EM-178, "Component".
• Injection tube and fuel injector. Refer to EM-181, "Exploded View".
• Rocker cover. Refer to EM-196, "Component".
• Secondary timing chain. Refer to EM-213, "Component".
• Camshaft. Refer to EM-199, "Component".
3. Remove cylinder head assembly.
• Remove bolts between rear chain case and cylinder head. Refer to EM-233, "Exploded View".

EM-234
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
• Remove cylinder head bolts in the reverse order as shown in
the figure with the cylinder head bolt wrench (commercial ser- A
vice tool).

: Engine front
EM
• Lift up cylinder head assembly to avoid interference with dowel
pins located between the cylinder block and cylinder head,
and remove cylinder head assembly. C
CAUTION:
Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of cylinder JPBIA3785ZZ

head, or, place wood blocks beneath both ends of cylin- D

der head to keep the cylinder bottom from any contact.
• For glow plug removal, the following shall be noted.
CAUTION: E
• To avoid breakage, never remove glow plug unless necessary.
• Perform continuity test with glow plug installed.
• Keep glow plug from any impact. [Replace if dropped from a height 10 cm (3.94 in) or higher.]
• Never use air impact wrench. F

INSTALLATION
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts. G
1. Install cylinder head gasket.
• Cylinder head gasket to be installed is selected by its thickness through the following procedure.
- When replacing gasket alone:
H
• Install a gasket with same thickness as that of the one removed.
• Identify the thickness of gasket by the number of ID marks on
the front LH side.
I
: Engine front

J
Gasket thickness* mm (in) Number of grade Number of ID marks
0.900 (0.0354) 1 0
0.925 (0.0364) 2 1 K
0.950 (0.0374) 3 1+2
JPBIA3786ZZ

0.975 (0.0384) 4 1+2+3

1.000 (0.0394) 5 1+2+3+4
L

1.025 (0.0404) 6 1+2+3+4+5

*: Measured with head bolts tightened
M

• Heater return tube is omitted for explanation.

NOTE: N
Use mirrors for checking at points out of clear sight.
- When the following parts have been repaired/replaced:
• With cylinder block upper surface and/or crankshaft pin journal ground.
• With cylinder block, pistons, connecting rods, and/or crankshaft replaced. O
a. Set piston at a point close to TDC.

EM-235
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
b. Set the dial gauge at the location as shown in the figure. Turning
crankshaft gradually, set the gauge scale to “0” where the piston
protrusion is maximized.
c. Move the dial gauge stand so that the tip of dial gauge can con-
tact cylinder block. Read the difference.
d. Measure two points from each cylinder in order to obtain each
mean value of them. Choose a properly thick gasket corre-
sponding the highest number of the four values.

SEM507G

Identification
Piston protrusion mm (in) Gasket thickness* mm (in)
Number of ID marks
0.161 - 0.186 (0.0063 - 0.0073) 0.900 (0.0354) 0
0.186 - 0.211 (0.0073 - 0.0083) 0.925 (0.0364) 1
0.211 - 0.236 (0.0083 - 0.0093) 0.950 (0.0374) 1+2
0.236 - 0.261 (0.0093 - 0.0103) 0.975 (0.0384) 1+2+3
0.261 - 0.286 (0.0103 - 0.0113) 1.000 (0.0394) 1+2+3+4
0.286 - 0.331 (0.0113 - 0.0130) 1.025 (0.0404) 1+2+3+4+5
*: Measured with head bolts tightened
e. If out of above protrusion, check replaced parts.
2. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) as shown in the figure.
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external loca-
tion but cannot be viewed externally after engine is assembled.

PBIC1256E

3. Install cylinder head assembly.

• Tighten bolts in numerical order as shown in the figure accord-
ing to the following procedure:

: Engine front

a. Apply engine oil to bolt threads and seat surfaces.

b. Tighten all bolts.

: 39.2 N·m (4.0 kg-m, 29 ft-lb)

JPBIA3785ZZ

EM-236
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
c. Tighten all cylinder head bolts (clockwise).
A
Angle tightening : 180 degrees
CAUTION:
• When the angle wrench [SST: KV10112100] is not used, EM
paint an alignment mark on the head of cylinder head bolt
and cylinder head surface before tightening. Check the
angle with a protractor. C
d. Loosen completely in the reverse order of that shown in the fig-
ure.
JEM166G

D
: 0 N·m (0 kg-m, 0 ft-lb)
e. Tighten all bolts.
E

: 39.2 N·m (4.0 kg-m, 29 ft-lb)

f. Tighten all cylinder head bolts (clockwise). F

Angle tightening : 90 degrees

G
g. Tighten all cylinder head bolts (clockwise).

Angle tightening : 90 degrees

H
CAUTION:
• When the angle wrench [SST: KV10112100] is not used, paint an alignment mark on the head of
cylinder head bolt and cylinder head surface before tightening. Check the angle with a protrac-
tor. I
4. Tighten bolts between rear chain case and cylinder head. Refer to EM-233, "Exploded View".
5. After installing cylinder head, measure dimension from the front
J
end surface of cylinder block to that of cylinder head (If rear
chain case is removed).

Standard : 23.53 - 24.07 mm (0.9264 - 0.9476 in) K

• If out of the standard, check fitting of dowel pins and cylinder
head.
L

JEM172G
M
6. Install glow plug.
CAUTION:
• To avoid damage, glow plugs should be removed only when required. N
• Handle with care to avoid applying shock. When dropped from approx. 10 cm (3.94 in) or higher,
always replace with a new one.
• Before installing, remove carbon depositing on mounting hole of glow plug with a reamer. O
7. Install engine coolant temperature sensor. Refer to EM-233, "Exploded View".
8. Install in the reverse order of removal.
Disassembly and Assembly INFOID:0000000007042414
P

DISASSEMBLY
1. Remove adjusting shims and valve lifters.
• Check the installation positions, and keep them to avoid being confused.

EM-237
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
2. Remove valve collet.
• Using the valve spring compressor [SST: KV10116200], com-
press valve spring. Using magnet hand, remove valve collets.

PBIC2388E

3. Remove valve spring retainers and valve springs.

4. Remove valves as pressing valve stems toward combustion chamber.
• Before removing valve, check the valve guide clearance. Refer to EM-239, "Inspection".

5. Remove valve oil seals using the valve oil seal puller [SST:
KV10107902].
6. Remove valve spring seats.
7. Remove valve seats.
• Before removing valve seats, perform valve seat contact
check. Refer to EM-239, "Inspection".
8. Remove valve guides.

JEM153G

ASSEMBLY
1. Install valve guides. Refer to EM-239, "Inspection".
2. Install valve seats. Refer to EM-239, "Inspection".
3. Using the valve oil seal drift [SST: KV10115600], install valve oil
seals referring to the dimension shown in the figure.
4. Install valve spring seats.

JEM165G

5. Install valves.
• Install the valves with bigger outer diameter to intake valve side.

6. Install valve spring.

7. Install valve spring retainers.

EM-238
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
8. Using the valve spring compressor [SST: KV10116200], com-
press valve springs. A
Then install valve collets using magnet hand.
• After installing valve collets, tap the stem end using the plastic
hammer, and check the installation status.
EM

PBIC2388E

D
9. Install valve lifters and adjusting shims to the same positions as before.
Inspection INFOID:0000000007042415
E
INSPECTION AFTER REMOVAL
Cylinder Head Bolt Deformation F
• Using micrometer, measure the outer diameters “d1” and “d2” of
bolt thread as shown in the figure.
• If the necking point can be identified, set it as measuring point d1.
• Calculate the difference between “d1” and “d2”. G

Limit : 0.15 mm (0.0059 in)

H
• If it exceeds the limit, replace cylinder head bolt.

I
JEM171G

Cylinder Head Distortion

1. Wipe off oil and remove water scale (like deposit), gasket, sealer, carbon, etc. with scraper. J
CAUTION:
Use utmost care not to allow gasket debris to enter passages for oil or water.
2. At each of several locations on bottom surface of cylinder head, K
measure distortion in six directions (A - F).

Limit : Refer to EM-271, "Standard and Lim- L

it".
• If it exceeds the limit, replace cylinder head.
M

JPBIA0176ZZ N
INSPECTION AFTER DISASSEMBLY
Valve Dimension O
• Check dimensions of each valve. For dimensions, refer to EM-271,
"Standard and Limit".
• If dimensions are out of the standard, replace valve.
P

SEM188A

EM-239
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
Valve Guide Clearance

Valve Stem Diameter

• Measure diameter of valve stem with micrometer (A).

Standard : Refer to EM-271, "Standard and

Limit".

JPBIA0183ZZ

Valve Guide Inner Diameter

• Measure inner diameter of valve guide with inside micrometer.

Standard : Refer to EM-271, "Standard and

Limit" .

Valve Guide Clearance

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).

Standard and limit : Refer to EM-271, "Standard and

Limit".
• If it exceeds the limit, replace valve and/or valve guide.
Valve Guide Replacement
When removing valve guide, replace it with oversized [0.2 mm (0.008 in)] valve guide.
1. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A).

JPBIA0184ZZ

2. Using the valve guide drift (commercial service tool), tap valve
guides out from the combustion chamber side.
WARNING:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.

SEM931C

EM-240
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
3. Ream cylinder head valve guide hole with the valve guide
reamer (commercial service tool) (A). A

Valve guide hole diameter : Refer to EM-271, "Standard

(for service parts) and Limit". EM

JPBIA0185ZZ

D
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A).
E

G
JPBIA0184ZZ

5. Using the valve guide drift (commercial service tool), press fit
valve guides from camshaft side, referring to the dimension H
shown in the figure.

Projection (L) : Refer to EM-271, "Standard and Lim- I

it".
WARNING:
Cylinder head contains heat, when working, wear protective J
equipment to avoid getting burned.
PBIC2497E
K
6. Using the valve guide reamer (commercial service tool), perform
reaming to the press-fitted valve guides.
L
Reaming specifications : Refer to EM-271, "Stan-
dard and Limit".
M

N
JPBIA0185ZZ

Valve Seat Contact

O
• Before starting this check, confirm that the dimension of valve
guide and valves are as specified.

A : OK P
B : NG
• Apply red lead primer on contacting surfaces of valves seat and of
valve face to examine the conditions of contacting surfaces.
• Check that the paint on contacting surfaces is continuous along the
entire circumference.

JPBIA0187ZZ

EM-241
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
• If there are abnormal indications, grind the valve and check the contact again. If malfunction indications still
persist, replace valve seat.
Valve Seat Replacement
When removing valve seat, replace it with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-271, "Standard and Limit".
2. Ream cylinder head recess diameter (a) for service valve seat.

Oversize [0.5 mm : Refer to EM-271, "Standard and

(0.020 in)] Limit".
• Be sure to ream in circles concentric to the valve guide center.
• This will enable valve seat to fit correctly.

JPBIA0188ZZ

3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil (A).
4. After cooling valve seats sufficiently with dry ice, press fit it to
cylinder head.
WARNING:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
CAUTION:
Never touch the cooled valve seats directly by hand.

JPBIA0184ZZ

5. Using the valve seat cutter set (commercial service tool), finish
processing referring to the dimensions shown in the figure.
Refer to EM-271, "Standard and Limit".
CAUTION:
When using the valve seat cutter set, grasp cutter handle
with both hands, press cutter onto contacting face all
around, and cut thoroughly. If cutter is pressed unevenly or
repeatedly, the valve seat surface may be damaged.

SEM934C

6. Using compound, perform valve fitting.

7. Check again to check that contacting status is satisfactory.
For details, refer to "Valve Seat Contact".

8. Use the depth gauge to measure the distance between the

mounting surface of cylinder head spring seat and the valve
stem end. If the distance is shorter than specified, repeat step 5
above to adjust it. If it is longer, replace valve seat with a new
one.

Valve seat resurface : Refer to EM-271, "Standard and

limit (L) Limit".

JEM253G

Valve Spring Square

EM-242
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
• Position the try square to valve spring, turn the spring, and mea-
sure the maximum clearance value between top surface of spring A
and the try square.

Limit : Refer to EM-271, "Standard and Limit". EM

• If it exceeds the limit, replace valve spring.

PBIC0080E

D
Valve Spring Dimensions and Valve Spring Pressure Load
• Using intake valve spring tester, check the following.

Standard : Refer to EM-271, "Standard and E

Limit".
• If out of the standard, replace the valve spring.
F

G
SEM113

INSPECTION AFTER INSTALLATION H

Inspection for Leakage

The following are procedures for checking fluid leakage, lubricant leakage. I
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the
required quantity, fill them to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping, J
check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration. K
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises. L
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system. M
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary.
Summary of the inspection items: N
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level O
Transmission / AT & CVT Models Leakage Level / Leakage Leakage
transaxle fluid MT Models Level / Leakage Leakage Level / Leakage
P
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.

EM-243
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [YD]
ENGINE ASSEMBLY
Component INFOID:0000000007042416

JPBIA1398GB

1. Vacuum hose 2. Vacuum gallery 3. Vacuum hose

4. Vacuum hose 5. RH engine mounting insulator 6. RH engine mounting bracket
7. Engine mount control solenoid valve 8. Vacuum gallery 9. LH engine mounting bracket
10. Heat insulator 11. Vacuum hose 12. LH engine mounting insulator
13. Transmission cross member 14. Engine mounting insulator (rear) 15. RH engine mounting insulator
16. RH engine mounting bracket 17. LH engine mounting bracket 18. Heat insulator
19. LH engine mounting insulator
Models with electronic controlled en- Models without electronic controlled
A. B.
gine mount engine mount

• Refer to GI-9, "Component" for symbol marks in the figure.

EM-244
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042417

A
WARNING:
• Situate vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels. EM
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations. C
• Never start working until exhaust system and engine coolant are cool enough.
• If items or work required are not covered by the engine main body section, refer to the applicable
sections. D
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with transmission jack or similar tool before
E
starting work, in preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-42, "Pantograph Jack,
Garage Jack and Safety Stand".
F
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or openings to prevent fluid from spilling.
G
REMOVAL
Description of work
Remove transmission assembly from vehicle downward. Then hoist the engine from vehicle upward. H
Preparation
1. Disconnect battery cable from negative terminal. Refer to SC-11.
2. Drain engine coolant from radiator. Refer to CO-38, "Changing Engine Coolant". I
3. Remove the following parts.
• Engine undercover front, engine undercover middle, engine undercover rear: Refer to EI-12.
• Hood assembly: Refer to BL-14, "Removal and Installation of Hood Assembly". J
• Engine cover: Refer to EM-159, "Exploded View".
• Drive belts: Refer to EM-153.
• Cooling fan, fan coupling and water pump pulley: Refer to CO-49. K
• Air duct and air cleaner case: Refer to EM-157, "Component".
• Air inlet tube and air inlet hose: Refer to EM-161.
• Alternator: Refer to SC-25, "Removal and Installation".
• Radiator, radiator shroud (upper and lower) and cooling fan assembly: Refer to CO-41 and CO-45. L
4. Disconnect engine room harness from the engine side and set it aside for easier work.
5. Disconnect all the body-side vacuum hoses and air hoses at engine side.
M
Engine room RH
1. Disconnect fuel feed hose and return hose. Refer to EM-181, "Exploded View".
2. Remove fuel filter. Refer to FL-16. N
3. Disconnect heater hose. Refer to CO-37, "Cooling Circuit".
Engine room LH
O
1. Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to
avoid putting load on it. Refer to ATC-115, "Removal and Installation for Compressor (YD models)".
Vehicle underbody P
1. Remove exhaust front tube. Refer to EX-6, "Component (YD Engine Models without DPF)".
2. Remove front and rear propeller shaft. Refer to PR-3 and PR-7.
3. Remove clutch operating cylinder from transmission, and move it aside (M/T models). Refer to CL-13 and
CL-13, "MODELS WITH YD ENGINE : Component".
4. Disconnect power steering fluid piping at a point between body and engine. Refer to PS-40, "Component
(YD25DDTi Models)".

EM-245
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [YD]
5. Remove starter motor. Refer to SC-41, "Removal and Installation".
6. Remove transmission assembly. Refer to MT-19 (M/T models) or AT-259 (A/T models).
Removal
1. Install engine slingers into front right of cylinder head (A) and
rear left of cylinder head (B).

1 : Engine slinger (front)

2 : Engine slinger (rear)
: Engine front

Engine slinger bolts:

: 22.0 N·m (2.2 kg-m, 16 ft-lb)
PBIC3480E

2. Lift with hoist and secure engine in position.

3. Loosen LH and RH engine mounting insulator mounting nuts.
4. Remove engine.
CAUTION:
• During the operation, check that no part interferes with
body side.
• Before and during this lifting, always check if any har-
nesses are left connected.

SEM896G

INSTALLATION
Install in the reverse order of removal.
• Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
• When installation directions are specified, install parts according to the direction marks on them referring to
figure of components. Refer to EM-244.
• Check that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
• Insert vacuum hose to vacuum gallery until vacuum hose comes in contact with the stopper when a stopper
is provided at vacuum gallery.
• Insert vacuum hose up to 15 mm (0. 59 in) when a stopper is not provided at vacuum gallery.
INSPECTION AFTER INSTALLATION
Inspection for Leaks

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-25.
• Use procedure below to check for fuel leakage.
- Before starting engine, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.

EM-246
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [YD]
Summary of the inspection items:
Items A
Before starting engine Engine running After engine stopped

Engine coolant
Level Leakage Level
EM
Engine oil Level Leakage Level

Transmission / transaxle AT & CVT Models Leakage Level / Leakage Leakage

fluid MT Models Level / Leakage Leakage Level / Leakage C
Other oils and fluid (*) Level Leakage Level
Fuel Leakage Leakage Leakage
D
Exhaust gases — Leakage —
* Power steering fluid, brake fluid, etc.
E

EM-247
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
CYLINDER BLOCK
Component INFOID:0000000007042418

JPBIA3700GB

1. Cylinder block 2. Copper washer 3. Oil jet relief valve

4. Alternator bracket 5. Drain plug 6. Top ring
7. Second ring 8. Oil ring 9. Snap ring
10. Piston 11. Piston pin 12. Connecting rod
13. Connecting rod bearing 14. Connecting rod cap 15. Main bearing cap
16. Main bearing lower 17. Drive plate 18. Reinforcement plate
19. Crankshaft 20. Key 21. Main bearing upper
22. Thrust bearing 23. Oil jet 24. Rear oil seal retainer
25. Rear oil seal 26. Rear cover 27. Oil pressure switch
28. Knock sensor

EM-248
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
A. Comply with the installation proce- B. Comply with the installation proce-
dure when tightening. Refer to EM- dure when tightening. Refer to EM- A
249, "Disassembly and Assembly". 249, "Disassembly and Assembly".
Refer to GI-9, "Component" for symbols in the figure.
EM
Disassembly and Assembly INFOID:0000000007042419

DISASSEMBLY
C
1. Remove the following parts:
• EGR system. Refer to EM-159, "Exploded View".
• Turbocharger. Refer to EM-167, "Component".
• Exhaust manifold. Refer to EM-171, "Component". D
• Intake manifold. Refer to EM-163, "Component".
• Vacuum pump. Refer to EM-179, "Component".
• Glow plug. Refer to EM-178, "Component". E
• Injection tube and fuel injector. Refer to EM-181, "Exploded View".
• Rocker cover. Refer to EM-196, "Component".
• Secondary timing chain. Refer to EM-213, "Component".
• Camshaft. Refer to EM-199, "Component". F
• Cylinder head assembly. Refer to EM-233, "Exploded View".
• Oil pan and oil strainer: Refer to EM-173, "Component".
• Water pump. Refer to CO-51, "Removal and Installation". G
• Thermostat. Refer to CO-53, "Component".
• Water piping. Refer to CO-37, "Cooling Circuit".
• Fuel pump and fuel pump bracket. Refer to EM-186, "Component".
H
• Oil cooler. Refer to LU-25, "Component".
• A/C compressor. Refer to ATC-115, "Removal and Installation for Compressor (YD models)" or ATC-
242, "Removal and Installation for Compressor".
• Alternator. Refer to SC-41, "Removal and Installation". I
2. Remove rear oil seal retainer.
• Insert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer.
3. Remove rear oil seal from rear oil seal retainer. Refer to EM-211, "Removal and Installation of Rear Oil J
Seal".
• Punch out with a flat-bladed screwdriver.
CAUTION: K
Be careful not to damage rear oil seal retainer.
4. Remove piston and connecting rod assembly.
• Before removing piston and connecting rod assembly, check
L
connecting rod side clearance. Refer to EM-271, "Standard
and Limit".
a. Move crankshaft pin to be removed to approximately BDC.
M
b. Remove connecting rod caps.
c. Using the grip of a hammer, press the piston and connecting rod
assembly out to cylinder head side.
CAUTION: N
• Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod JEM195G

big end. O

EM-249
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• When removing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with
oil jet (1).

JPBIA3896ZZ

5. Remove connecting rod bearings from connecting rods and caps.

CAUTION:
• Be careful not to drop connecting rod bearing, and to scratch the surface.
• Identify installation positions, and store them without mixing them up.

6. Remove piston rings from pistons using the piston ring expander
(commercial service tool) (A).
CAUTION:
• When removing, prevent pistons from being damaged.
• Never expand piston rings excessively. This may damage
piston rings.

PBIC3233J

7. Remove pistons from connecting rods.

a. Using the snap ring pliers (A), remove snap rings.

PBIC3230J

b. Using the industrial use dryer (A), heat pistons up to 60 to 70°C

(140 to 158°F).

PBIC3231J

EM-250
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
c. Using rod with outer diameter of 26 mm (1.02 in), press piston
pins out. A

EM

EMM0072D

D
8. Loosen and remove main bearing cap bolts in reverse order as
shown in the figure.
E
: Engine front

• Use TORX socket (size: E14) (commercial service tool).

• Before loosening main bearing cap bolts, measure crankshaft F
end play. Refer to EM-256, "Inspection".

G
JPBIA3788ZZ

9. Remove main bearing caps.

H
• Insert bolts (1) into bolt holes, and then remove main bearing
cap (2) by lifting up and shaking forward and backward.
10. Remove crankshaft.
I
11. Remove main bearings and thrust bearings from cylinder block
and main bearing caps.
CAUTION:
Check the correct installation locations of removed parts. J
Store them so they never get mixed up.
12. Remove oil jet.
JPBIA2478ZZ
13. Remove oil jet relief valve. K

ASSEMBLY
1. Blow air sufficiently to inside engine coolant passage, engine oil passage, crankcase and cylinder bore to L
remove foreign matter.
CAUTION:
Use a goggles to protect your eye.
M
2. Install drain plug to cylinder block (1).
• Apply liquid gasket to drain plug (2).
Use Genuine Liquid Gasket or equivalent
• Tighten drain plug. N

: 46.6 N·m (4.8 kg-m, 34 ft-lb)

O

P
PBIC3483E

3. Install oil jet relief valve.

EM-251
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
4. Install oil jet.
• Align knock pin on back of oil jet with hole on block when
installing oil jet.

PBIC0389E

5. Install main bearings and thrust bearings.

a. Remove contamination, dust and engine oil from bearing mount-
ing positions on cylinder block and main bearing caps.
b. Install thrust bearings on both sides of No. 3 housing on cylinder
block.
• Install thrust bearings with oil groove facing to crankshaft arm
(outside).

JEM224G

c. Being careful with the direction, install main bearings.

• Install main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the main cap side.
• While installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply engine oil to rear surfaces, but clean
them completely.
• Align stopper notches on bearings to install them.
• Check that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.
6. Install crankshaft to cylinder block. JEM213G
• Check crankshaft rotates smoothly by hand.
7. Install main bearing caps.
• Identify main bearing caps by the punched mark. Install cor-
rectly matching the journal No. on the bearing cap and the
journal with the front mark facing forward.
• Main bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
8. Check the main bearing cap bolts for deformation. Refer to EM-
256, "Inspection".

JEM225G

9. With the TORX socket (size: E14) (commercial service tool),

tighten the main bearing cap bolts according to the following
procedure:

: Engine front

a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten all bolts in numerical order shown in the figure.

: 27.0 N·m (2.8 kg-m, 20 ft-lb) JPBIA3788ZZ

EM-252
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
c. Put alignment marks (with paint) on each bolt and the main bearing cap, all in the same direction. (When
using a protractor) A

d. Then, tighten 90 degrees. (angle tightening)

CAUTION:
Always use either the angle wrench [SST: KV10112100] or EM
protractor during angular tightening. Avoid tightening
based on visual checks alone.
• After tightening bolts to specified torque, check that crankshaft C
rotates smoothly.
• Check crankshaft end play. Refer to EM-256, "Inspection".
10. Check the outer diameter of connecting rod bolts. Refer to EM- D
256, "Inspection".
11. Install piston to connecting rod. JEM226G

a. Using the snap ring pliers, install snap rings to groove on piston E
rear side.
• Fit snap ring correctly into grooves.
b. Install pistons to connecting rods. F
• Using the industrial use dryer (A), heat pistons up to approx.
60 to 70°C (140 to 158°F) until piston pin can be pressed
down by finger touch. Then insert piston pin into piston and
connecting rod from front side of piston toward rear. G

I
PBIC3231J

• Assemble piston and connecting rod with front mark of piston J

head and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
c. Install snap ring to front side of piston.
K
• Refer to above step a for precaution on snap ring installation.
• After installation, check connecting rods for smooth move-
ment.
L

MBIA0024E M
12. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged. N
• Install top ring and second ring with punched mark surfaces
facing upward.
O
Punched mark:
Top ring : RTOP
Second ring : R2ND P
• Install rings so that three closed gap position 120 degrees
apart one another.
• Closed gaps do not need to face in a specific directions, as
long as each are positioned 120 degrees apart. JEM228G

EM-253
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
13. Install connecting rod bearing to connecting rod and cap.
• While installing connecting rod bearing, apply engine oil to
bearing surfaces (inside). Do not apply engine oil to rear sur-
faces, but clean them completely.
• Align protrusions on connecting rod bearings with connecting
rod cut-outs to install connecting rod bearings.

JEM229G

14. Install piston and connecting rod assembly to crankshaft.

• Move crankshaft pin to be assembled to BDC.
• Align cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
• Using the piston ring compressor [SST: EM03470000] or suit-
able tool, install piston and connecting rod assembly with front
mark on piston head facing toward the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with
oil jet.
PBIC1619E

15. Install connecting rod caps and mounting nuts.

• Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
• Check that the front mark on connecting rod cap faces
towards the front of the engine.

MBIA0024E

16. Tighten connecting rod nuts according to the following procedure:

a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten bolts.

: 29.4 N·m (3.0 kg-m, 22 ft-lb)

c. Loosen completely.

: 0 N·m (0 kg-m, 0 in-lb)

d. Tighten bolts.

: 19.6 N·m (2.0 kg-m, 14 ft-lb)

e. Tighten bolts.

EM-254
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]

Angle tightening : 120 degrees A

• Always use either the angle wrench [SST: KV10112100] or
protractor during angular tightening. Avoid tightening
based on visual checks alone. EM
• After tightening nuts, check that crankshaft rotates smoothly.
• Check connecting rod side clearance. Refer to EM-256,
"Inspection".
C

JEM231G

D
17. Press fit rear oil seal into rear oil seal retainer.
• Using the drift [105 mm (4.13 in) dia.], press fit so that the
dimension is as specified in the figure.
E
• Avoid inclined fitting. Force fit perpendicularly.

G
JEM232G

18. Install rear oil seal retainer to cylinder block. H

• Apply new engine oil to the oil and dust seal lips.
• Apply liquid gasket to rear oil seal retainer using the tube
presser (commercial service tool) as shown in the figure. I
Use Genuine Liquid Gasket or equivalent.

JEM233G
K

19. Install fuel pump bracket (1).

• Align the bracket with the dowel pins (A) on cylinder block to L
install.

JPBIA3897ZZ

O
20. Assemble in the reverse order of disassembly.
21. Remove engine from engine stand in the reverse order of assembly.
P

EM-255
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
22. Install drive plate (1).

A : Rounded
: Engine front

• When installing drive plate to crankshaft (2), be sure to cor-

rectly align crankshaft side dowel pin and drive plate side
dowel pin hole.
CAUTION:
If these are not aligned correctly, engine runs roughly and
“MI” turns on.
JPBIA3915ZZ
• Install drive plate and reinforcement plate (3) as shown in the
figure.
• Holding ring gear with ring gear stopper [SST: KV10105630], tighten securing bolts with TORX socket
(size: E20) (commercial service tool).
• Tighten bolts uniformly in a crisscross manner.

23. Install in the reverse order of removal.

Inspection INFOID:0000000007042420

CRANKSHAFT END PLAY

• Using dial gauge, measure crankshaft travel amount by moving the
crankshaft forward or backward.

Standard and limit : Refer to EM-271, "Standard and

Limit".
• If the value exceeds the limit, replace thrust bearings with new
ones and measure again.
If the measurement exceeds the limit again, replace crankshaft
with a new one.
JEM202G

CONNECTING ROD SIDE CLEARANCE

• Using feeler gauge, measure side clearance between connecting
rod and crankshaft arm.

Standard and limit : Refer to EM-271, "Standard and

Limit".
• If measured value exceeds the limit, replace connecting rod and
repeat measurement.
If measured value still exceeds the limit, replace crankshaft.

JEM203G

PISTON TO PISTON PIN CLEARANCE

Piston Pin Bore Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer (A).

Standard : Refer to EM-271, "Standard and Limit".

JPBIA0217ZZ

EM-256
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer (A). A

Standard : Refer to EM-271, "Standard and Limit".

EM

JPBIA0218ZZ D
Calculation of Piston to Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) − (Piston pin outer diameter)
E
Standard : Refer to EM-271, "Standard and Limit".
• If out of the standard, replace piston/piston pin assembly.
NOTE: F
Piston is available together with piston pin as assembly.
PISTON RING SIDE CLEARANCE G
• Measure the side clearance of piston ring (1) and piston ring groove with a feeler gauge (C).

A : NG
B : OK
H

Standard and limit : Refer to EM-271, "Standard and

Limit". I

JPBIA2276ZZ

K
• Align top ring and external surface of piston. Measure lower side
clearance of top ring with top ring pressed onto upper side of ring
groove.
• If side clearance exceeds the limit, replace piston ring. L
• Check clearance again. If side clearance still exceeds the limit,
replace piston.
M

N
FEM100

PISTON RING END GAP

• Check that the cylinder bore inner diameter is within the specifica- O
tion.
• Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert piston ring until middle of cylinder with piston, and mea-
sure the piston ring end gap with a feeler gauge (B). P

A : Press-fit

Standard and limit : Refer to EM-271, "Standard and

Limit".
JPBIA2277ZZ

EM-257
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
re-bore cylinder and use oversize piston and piston rings.
CONNECTING ROD BEND AND TORSION
• Check with a connecting rod aligner.

A : Bend
B : Torsion
C : Feeler gauge

Bend limit : Refer to EM-271, "Standard and

Torsion limit Limit".
• If it exceeds the limit, replace connecting rod assembly.

JPBIA0221ZZ

CONNECTING ROD BIG END DIAMETER

• Install connecting rod bearing cap without installing connecting rod
bearing, and tighten connecting rod bolts to the specified torque.
Refer to EM-249, "Disassembly and Assembly" for the tightening
procedure.

1 : Connecting rod
• Measure the inner diameter of connecting rod big end with an
inside micrometer.

Standard : Refer to EM-271, "Standard and Limit".

JPBIA0222ZZ
• If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).

Standard : Refer to EM-271, "Standard and Limit".

JPBIA0223ZZ

Piston Pin Outer Diameter

EM-258
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
Measure the outer diameter of piston pin with a micrometer (A).
A
Standard : Refer to EM-271, "Standard and Limit".

EM

JPBIA0218ZZ

D
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
E
Standard and limit : Refer to EM-271, "Standard and Limit".
• If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin
assembly. F
• If replacing piston and piston pin assembly, refer to EM-249, "Disassembly and Assembly".
• If replacing connecting rod assembly, refer to EM-271, "Standard and Limit" to select the connecting rod
bearing. G
CYLINDER BLOCK DISTORTION
• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination. H
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
• Measure the distortion on the cylinder block upper face at some I
different points in six directions (C), (D), (E), (F), (G) and (H) with a
straightedge (A) and a feeler gauge (B).

Limit : Refer to EM-271, "Standard and Limit". J

• If it exceeds the limit, replace cylinder block.

K

JPBIA0224ZZ L
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap (2) without installing main bearings, and
tighten main bearing cap bolts to the specified torque. Refer to EM- M
249, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of main bearing housing with a bore
gauge. N
Standard : Refer to EM-271, "Standard and Limit".
• If out of the standard, replace cylinder block (1) and main bearing O
cap as assembly.
NOTE:
Cylinder block cannot be replaced as a single part, because it is JPBIA0225ZZ

machined together with main bearing cap. P

PISTON TO CYLINDER BORE CLEARANCE

Cylinder Bore Inner Diameter

EM-259
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• Using a bore gauge, measure the cylinder bore for wear, out-of
round and taper at six different points on each cylinder. [(A) and (B)
directions at (C), (D), and (E)] [(A) is in longitudinal direction of
engine]

f : 10 mm (0.39 in)
g : 85 mm (3.35 in)
h : 160 mm (6.30 in)

Standard and limit : Refer to EM-271, "Standard and

JPBIA2059ZZ
Limit".

• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or bore the inner wall.
• Oversize piston is provided. When using oversize piston, hone the cylinder so that the clearance between
piston and cylinder satisfies the standard.
CAUTION:
If oversize piston is used, use it for all cylinders with oversize piston rings.

Oversize (O/S) : Refer to EM-271, "Standard and

Limit".
Piston Outer Diameter
Measure the outer diameter of piston skirt with a micrometer (A).

Measurement position : Refer to EM-271, "Standard

Standard and Limit".

JPBIA0227ZZ

Piston to Cylinder Bore Clearance

• Calculate by piston skirt diameter and cylinder bore inner diameter
[direction (B), position (D)].

A : Direction A
C : Position C
E : Position E
f : 10 mm (0.39 in)
g : 85 mm (3.35 in)
h : 160 mm (6.30 in)
(Clearance) = (Cylinder bore inner diameter) − (Piston outer diam- JPBIA2059ZZ
eter)

Standard and limit : Refer to EM-271, "Standard and

Limit".
• If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-249, "Disassembly and Assem-
bly".
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.

EM-260
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]

Re-bore size calculation: A

D=A+B–C
Where,
EM
D: Bored diameter
A: Piston outer diameter as measured
B: Piston-to-cylinder bore clearance C
C: Honing allowance 0.02 mm (0.0008 in)
2. Install main bearing cap, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in
final assembly. D
3. Cut cylinder bore.
NOTE:
• When any cylinder needs boring, all other cylinders must also be bored. E
• Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a
time.
4. Hone cylinders to obtain the specified piston-to-cylinder bore clearance. F
5. Measure finished cylinder bore for the out-of-round and taper.
NOTE:
• Perform measurement after cylinder bore cools down. G
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals with a
micrometer. H

Standard : Refer to EM-271, "Standard and Limit".

• If out of the standard, measure the main bearing oil clearance. I
Then use the under size bearing. Refer to EM-265, "How to Select
Piston and Bearing".
J

FEM114
K
CRANKSHAFT PIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft pin journal with a
micrometer (A).
L
Standard : Refer to EM-271, "Standard and Limit".
• If out of the standard, measure the connecting rod bearing oil M
clearance. Then use under size bearing. Refer to EM-265, "How to
Select Piston and Bearing".

JPBIA0228ZZ

CRANKSHAFT OUT-OF-ROUND AND TAPER O

EM-261
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in the dimensions
between (d) and (c) at (a) and (b).
• Taper is indicated by the difference in the dimensions between.

Out-of-round (Difference : Refer to EM-271, "Stan-

between c and d) dard and Limit".
Taper (Difference between
a and b)
JPBIA0229ZZ
• If the measured value exceeds the limit, correct or replace crank-
shaft.
• If corrected, measure the bearing oil clearance of the corrected journal and/or pin. Then select the main
bearing or connecting rod bearing. Refer to EM-265, "How to Select Piston and Bearing" and/or EM-271,
"Standard and Limit".
CRANKSHAFT RUNOUT
• Place V-block on precise flat table, and support the journals on
both ends of crankshaft.
• Place a dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on a
dial indicator. (Total indicator reading)

Standard and limit : Refer to EM-271, "Standard and

Limit".
• If it exceeds the limit, replace crankshaft.
SEM346D

CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation
• Install connecting rod bearings (1) to connecting rod (2) and con-
necting rod cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-249, "Disassembly and Assembly" for the
tightening procedure.

JPBIA0230ZZ

• Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter)

Standard and limit : Refer to EM-271, "Standard and Limit".

• If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to
EM-256, "Inspection".
Method of Using Plastigage
• Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting
rod bolts to the specified torque. Refer to EM-249, "Disassembly and Assembly" for the tightening proce-
dure.
CAUTION:

EM-262
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
Never rotate crankshaft.
• Remove connecting rod bearing cap and bearings, and using the A
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is the
EM
same as that described in the “Method by Calculation”.

JPBIA0231ZZ D
MAIN BEARING OIL CLEARANCE
Method by Calculation E
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-249, "Disassembly and Assembly" for the tightening
procedure. F
• Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main
journal diameter) G

Standard and limit : Refer to EM-271, "Standard and

Limit". H
• If the calculated value exceeds the limit, select proper main bear- JPBIA0232ZZ

ing according to main bearing inner diameter and crankshaft main

journal diameter to obtain the specified bearing oil clearance. Refer to EM-256, "Inspection". I
Method of Using Plastigage
• Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil J
holes.
• Install main bearing to cylinder block and main bearing cap, and tighten main bearing cap bolts with main
bearing cap to the specified torque. Refer to EM-249, "Disassembly and Assembly" for the tightening proce-
dure. K
CAUTION:
Never rotate crankshaft.
• Remove main bearing cap and bearings, and using the scale on L
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is the
M
same as that described in the “Method by Calculation”.

JPBIA0231ZZ O
MAIN BEARING CRUSH HEIGHT
P

EM-263
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of
bearing must protrude. Refer to EM-237, "Disassembly and
Assembly" for the tightening procedure.

A : Crush height

Standard : There must be crush height.

• If the standard is not met, replace main bearings.
JPBIA0233ZZ

CONNECTING ROD BEARING CRUSH HEIGHT

• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings (1) installed,
the tip end of bearing must protrude. Refer to EM-237, "Disassem-
bly and Assembly" for the tightening procedure.

A : Crush height

Standard : There must be crush height.

• If the standard is not met, replace connecting rod bearings.
JPBIA0233ZZ

MAIN BEARING CAP BOLT DEFORMATION

• Measure the outer diameter of threaded area, “d1” and “d2”, at the
points specified in the figure.
• When the necked point is identified at a point other than where
specified, measure at the point as “d2”.
• Calculate the difference between “d1” and “d2”.

Limit : 0.13 mm (0.0051 in)

• If it exceeds the limit, replace main bearing cap bolt.

JEM219G

CONNECTING ROD BOLT DEFORMATION

• Install nuts to connecting rod bolts. Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread on the
bolt.
• If the nut does not screw in smoothly, measure the outer diameter
of the bolt thread at the point specified in the figure.
• If a necked point is identified, measure at that point.

Standard : 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.

Limit : 8.75 mm (0. 3445 in) dia.
• If it exceeds the limit, replace connecting rod bolts and nuts.
JEM220G

OIL JET

EM-264
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs. A

Standard : No deformation and no damage.

• If out of the standard, replace oil jet. EM

JEM221G

D
OIL JET RELIEF VALVE
• Using clean plastic stick, press check valve in oil jet relief valve.
Check that valve moves smoothly with proper reaction force.
E
Standard:
Valve moves smoothly with proper reaction force.
F
• If out of the standard, replace oil jet relief valve.

JEM222G

DRIVE PLATE H
• Check drive plate and signal plate for deformation or cracks.
CAUTION:
• Never disassemble drive plate.
I
• Never place drive plate with signal plate facing down.
• When handling signal plate, take care not to damage or
scratch it.
• Handle signal plate in a manner that prevents it from becom- J
ing magnetized.
• If anything is found, replace drive plate.
K
SEM760G

How to Select Piston and Bearing INFOID:0000000007042421

L
DESCRIPTION

Selection points Selection parts Selection items Selection methods M

Determined by match of cylin-
der block bearing housing
Between cylinder block to Main bearing grade (bearing grade (inner diameter of hous- N
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
O
Combining service grades for
connecting rod big end diame-
Between crankshaft to connect- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
ing rod (bearing thickness)
ameter determine connecting P
rod bearing selection.
Piston and piston pin assembly
Between cylinder block to pis- Piston grade (piston outer diam- Piston grade = cylinder bore
The piston is available together
ton eter) grade (inner diameter of bore)
with piston pin as an assembly.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.

EM-265
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON WHEN NEW CYLINDER BLOCK IS USED
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
2. Select piston of the same grade.
• The part No. of piston is specified together with piston pin as
an assembly.

JEM208G

HOW TO SELECT PISTON WHEN CYLINDER BLOCK IS REUSED

1. Measure cylinder bore inner diameter. Refer to EM-265, "How to Select Piston and Bearing".
2. Referring to “Cylinder bore inner diameter” in “Piston Selection Table”, determine the bore grade.

A : Identification code
B : Front mark
C : Piston grade number
3. Select piston of the same grade.

JPBIA3910ZZ

PISTON SELECTION TABLE

Unit: mm (in)

Grade (punched) 1 2 3
Cylinder bore in-
89.000 - 89.010 (3.5039 - 3.5043) 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
ner diameter
Piston outer di-
88.806 - 88.820 (3.4963 - 3.4968) 88.816 - 88.830 (3.4967 - 3.4972) 88.826 - 88.840 (3.4971 - 3.4976)
ameter

NOTE:
Piston is available together with piston pin as an assembly.
HOW TO SELECT CONNECTING ROD WHEN NEW CONNECTING ROD AND CRANKSHAFT
ARE USED
1. Identify the pin diameter grade on front surface of crankshaft.
2. Select connecting rod bearings of the same grade.
NOTE:
There is no grading for the inner diameter of the big end of the
connecting rod.

JEM215G

HOW TO SELECT CONNECTING ROD WHEN CONNECTING ROD AND CRANKSHAFT ARE RE-

EM-266
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
USED
1. Measure the inner diameter of the big end of connecting rod and check it is within the specified range. A
Refer to EM-256, "Inspection".
2. Measure the outer diameter of the crankshaft pin. Refer to EM-256, "Inspection".
3. Determine the crankshaft pin grade by comparing the measurement with the values under the column EM
“Crankshaft pin outer diameter” in “Selection Table of connecting Rod Bearing”.
4. Choose bearings of the same grade.
C
CONNECTING ROD BEARING SELECTION TABLE

JPBIA3907GB

N
UNDERSIZE BEARING USAGE GUIDE
• If bearing clearance is out of the specifications for connecting rod bearings in standard size, use under size
bearings. O
• When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft pins to adjust clearance to specification.

Connecting rod bearing under size : Refer to EM-271, "Standard and Limit". P

CAUTION:

EM-267
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
When grinding the crankshaft pin to use an under size bearing,
avoid damaging the fillet R.

Standard dimension R : 1.5 - 1.7 mm (0.059 - 0.067 in)

JEM216G

HOW TO SELECT MAIN BEARING WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE
USED
1. Identify the crank journal grade on LH surface at the rear of the
cylinder block, and locate the applicable grade on the “Grade”
row in the “Main Bearing Grade Table”.

JEM208G

2. Identify the journal grade on the front surface of crankshaft, and

locate the applicable grade under the “Grade” column in the
“Main Bearing Grade Table”.

JEM215G

3. The main bearing to be used can be located in the cell where the row and column cross.
HOW TO SELECT MAIN BEARING WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED
1. Measure the inner diameter of cylinder block main bearing housing. Refer to EM-256, "Inspection".
2. Locate the applicable cell where the measurement falls, on “Inner diameter of Cylinder block main bearing
housing” row in the “Main Bearing Grade Table”.
3. Measure the outer diameter of crankshaft journal. Refer to EM-256, "Inspection".
4. Locate the applicable cell where the measurement falls, under “Crankshaft journal outer diameter” column
in the “Main Bearing Grade Table”.
5. The main bearing to be used can be located in the cell where the row and column cross.

EM-268
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
MAIN BEARING SELECTION TABLE
A

EM

L
JPBIA3906GB

MAIN BEARING GRADE TABLE (ALL JOURNALS) M

Main bearing grade table (All journals) : Refer to EM-271, "Standard and
Limit". N
UNDERSIZE BEARING USAGE GUIDE
• If bearing clearance is out of the specifications for main bearings in standard size, use under size bearings.
• When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank- O
shaft journals to adjust clearance to the specification.

Main bearing under size : Refer to EM-271, "Standard and P

Limit".
CAUTION:

EM-269
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
When grinding crank journals to use under size bearings, keep
corners radius of fillet R. (All journals)

Standard dimension R : 1.5 - 1.7 mm (0.059 - 0.067 in)

JEM216G

EM-270
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
SERVICE DATA AND SPECIFICATIONS (SDS)
A
Standard and Limit INFOID:0000000007042422

GENERAL SPECIFICATIONS EM

Cylinder arrangement In-line 4

Displacement Unit: cm3 (cu in) 2,488 (151.82) C
Bore and stroke Unit: mm (in) 89.0 x 100 (3.504 x 3.937)
Valve arrangement DOHC
D
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1 E
Number of main bearings 5
Compression ratio 15
F
Standard 2,800 (28, 28.56, 406)
Compression pressure
Minimum 2,200 (22, 22.44, 319)
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Differential limit between cylinders 450 (4.5, 4.59, 65.3) G
Unit: degree
Intake valve open (BTDC) 2
H
Intake valve close (ABDC) 30
Valve timing
Exhaust valve open (BBDC) 46
Exhaust valve close (ATDC) -2 I
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
J
Items Limit
Intake manifold 0.1 (0.004)
Surface distortion
Exhaust manifold 0.3 (0.012) K
DRIVE BELTS
Belt Deflection:
L
Belt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
Applied belt
New Adjusted Limit for re-adjusting
A/C compressor, alternator and water M
Auto adjustment by auto-tensioner
pump belt
4.6 - 5.4 7.1 - 7.7
Power steering oil pump belt 11.3 (0.445)
(0.181 - 0.213) (0.280 - 0.303) N
*: When engine is cold.
Belt Frequency:
O
Belt frequency (Hertz)
Applied belt
New Adjusted Limit for re-adjusting
A/C compressor, alternator and water
Auto adjustment by auto-tensioner
P
pump belt
Power steering oil pump belt 290 245 162
*: When engine is cold.

CYLINDER HEAD

EM-271
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Unit: mm (in)
Items Standard Limit
Cylinder head distortion Less than 0.04 (0.0016) 0.1 (0.004)

JEM204G

VALVE
Valve Dimensions
Unit: mm (in)

SEM188

Intake 28.4 - 28.7 (1.1181 - 1.1299)

Valve head diameter “D”
Exhaust 25.8 - 26.1 (1.0157 - 1.0276)
Intake 105.93 (4.1705)
Valve length “L”
Exhaust 105.48 (4.1527)
Intake 5.965 - 5.98 (0.2348 - 0.2354)
Valve stem diameter “d”
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
Valve seat angle “α” Intake and exhaust 45 degrees 15′ - 45 degrees 45′
Intake 1.08 (0.0425)
Valve margin “T”
Exhaust 1.38 (0.0543)
Valve margin “T” limit More than 1.0 (0.039)
Valve stem end surface grinding limit Less than 0.2 (0.008)

Valve Clearance
Unit: mm (in)

Items Cold Hot* (Reference data)

Intake 0.24 - 0.32 (0.009 - 0.013) 0.274 - 0.386 (0.011 - 0.015)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)

Available Shims

EM-272
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]

Stamped mark (A) Thickness mm (in) A

2.10 2.10 (0.0827)
2.12 2.12 (0.0835)
EM
2.14 2.14 (0.0843)
2.16 2.16 (0.0850)
2.18 2.18 (0.0858) C
2.20 2.20 (0.0866)
2.22 2.22 (0.0874)
2.24 2.24 (0.0882) D
2.26 2.26 (0.0890)
2.28 2.28 (0.0898)
E
2.30 2.30 (0.0906)
2.32 2.32 (0.0913)
2.34 2.34 (0.0921) F
2.36 2.36 (0.0929)
2.38 2.38 (0.0937)
G
2.40 2.40 (0.0945)
2.42 2.42 (0.0953)
2.44 2.44 (0.0961) H
2.46 2.46 (0.0969)
2.48 2.48 (0.0976)
I
2.50 2.50 (0.0984)
2.52 2.52 (0.0992)
2.54 2.54 (0.1000) J
2.56 2.56 (0.1008)
2.58 2.58 (0.1016)
2.60 2.60 (0.1024) K
2.62 2.62 (0.1031)
2.64 2.64 (0.1039)
L
2.66 2.66 (0.1047)
2.68 2.68 (0.1055)
2.70 2.70 (0.1063) M
2.72 2.72 (0.1071)
2.74 2.74 (0.1079)
N

JPBIA3912ZZ

Valve Spring

EM-273
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]

Valve spring square mm (in) 1.9 (0.075)

Intake 43.7 (1.720)
Free height mm (in)
Exhaust 43.7 (1.720)
Pressure N (kg, lb) at height mm (in) 184 - 208 (18.77 - 21.22, 41.4 - 46.8) at 32.82 (1.2921)
Intake 24.95 (0.9823)
Height during valve open mm (in)
Exhaust 24.66 (0.9709)
Intake 250 - 274 (25.5 - 27.9, 56.2 - 61.6)
Load with valve open N (kg, lb)
Exhaust 308 - 336 (31.4 - 34.3, 69.2 - 75.5)

Valve Lifter
Unit: mm (in)

Items Standard
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801)
Valve lifter bore diameter 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.025 - 0.061 (0.0010 - 0.0024)

Valve Guide
Unit: mm (in)

JEM156G

Items Standard Service

Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Items Standard Limit
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Valve guide clearance
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.10 (0.0039)
Projection length 10.4 - 10.6 (0.409 - 0.417)

Valve Seat

EM-274
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Unit: mm (in)
A

EM

E1BIA0294ZZ

JEM253G
M
Items Standard Oversize (Service) [0.5 (0.020)]

Cylinder head seat (1) recess diame- Intake 30.4 - 30.416 (1.1968 - 1.1975) 30.9 - 30.916 (1.2165 - 1.2165)
ter “D” Exhaust 28.200 - 28.216 (1.1102 - 1.1109) 28.7 - 28.716 (1.1299 - 1.1305) N
Intake (A) 30.48 - 30.5 (1.2 - 1.2008) 30.98 - 31.0 (1.2197 - 1.2205)
Valve seat outer diameter “d”
Exhaust (B) 28.28 - 28.296 (1.1134 - 1.1140) 28.78 - 28.796 (1.1331 - 1.1337)
O
Intake (A) 0.064 - 0.100 (0.0025 - 0.0039)
Valve seat interference fit
Exhaust (B) 0.064 - 0.096 (0.0025 - 0.0038)
Intake (A) 27.7 - 28.2 (1.0689 - 1.0886) 27.7 - 28.2 (1.0689 - 1.0886) P
Diameter “d1”
Exhaust (B) 25.1 - 25.6 (0.9882 - 1.0079) 25.1 - 25.6 (0.9882 - 1.0079)
Angle “α” 89.5°±45′
Intake (A) 6.84 - 6.94 (0.269 - 0.273) 6.39 - 6.49 (0.252 - 0.256)
Height “h1”
Exhaust (B) 6.84 - 6.94 (0.264 - 0.268) 6.84 - 6.94 (0.269 - 0.273)

EM-275
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Intake (A) 2.25 - 2.45 (0.089 - 0.096) 2.15 - 2.55 (0.085 - 0.1004)
Height “h2”
Exhaust (B) 2.9 - 3.1 (0.1142 - 0.1220) 2.8 - 3.2 (0.1102 - 0.1260)
Intake 8.85 - 9.15 (0.3484 - 0.3602)
Depth “H”
Exhaust 9.29 - 9.59 (0.3657 - 0.3776)
Intake 36.18 - 36.78 (1.4382 - 1.4559)
Projection (L)
Exhaust 36.16 - 36.96 (1.4236 - 1.4551)

CAMSHAFT
Unit: mm (in)

Items Standard Limit

Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034)
No.1 30.500 - 30.521 (1.2008 - 1.2016)
Camshaft bracket inner diameter
No. 2, 3, 4, 5 24.000 - 24.021 (0.9449 - 0.9457) —
No. 1 30.435 - 30.455 (1.1982 - 1.1990)
Camshaft journal outer diameter
No. 2, 3, 4, 5 23.935 - 23.955 (0.9423 - 0.9431)
Camshaft runout [TIR*] — 0.02 (0.0008)
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.24 (0.0094)

SEM671

Intake 39.505 - 39.695 (1.5553 - 1.5628)

Cam height “A”
Exhaust 39.905 - 40.095 (1.5711 - 1.5785)
*: Total indicator reading

CYLINDER BLOCK
Unit: mm (in)

SEM899G

Standard Less than 0.03 (0.0012)

Top surface distortion
Limit 0.1 (0.004)

EM-276
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Grade No. 1 89.000 - 89.010 (3.5039 - 3.5043)
A
Standard Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047)
Cylinder bore Inner diameter
Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.07 (0.0028) EM
Out-of-round (Difference between X and Y) 0.015 (0.0006)
Limit
Taper (Difference between A and C) 0.010 (0.0004)
Main bearing housing inner diameter (Without bearing) 66.656 - 66.680 (2.6242 - 2.6252) C
Difference in inner diameter
Limit Less than 0.05 (0.0020)
between cylinders
D
PISTON, PISTON RING AND PISTON PIN
Available Piston
Unit: mm (in) E

E1BIA0295ZZ

Grade No. 1 88.806 - 88.820 (3.496 - 3.4968) I

Grade No. 2 88.816 - 88.830 (3.4967 - 3.4972)
Piston outer diameter “A” Standard Grade No. 3 88.826 - 88.840 (3.4971 - 3.4976) J
Oversize (Service) [0.25] 89.066 - 89.080 (3.5065 - 3.5071)
Oversize (Service) [0.5] 89.316 - 89.330 (3.5164 - 3.5169)
“a” dimension 43.0 (1.63) K
Piston pin bore diameter 28.008 - 28.013 (1.1027 - 1.1029)
Piston to cylinder bore clearance 0.18 - 0.204 (0.0071 - 0.008)
L
Piston Ring
Unit: mm (in)

Items Standard Limit M

Top 0.04 - 0.06 (0.0016 - 0.0024) 0.17 (0.007)
Side clearance 2nd 0.08 - 0.12 (0.0031 - 0.0047) 0.13 (0.005)
N
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
Top 0.18 - 0.28 (0.0071 - 0.0110)
End gap 2nd 0.32 - 0.47 (0.0126 - 0.0185) 1.0 (0.039) O
Oil ring 0.30 - 0.55 (0.0118 - 0.0217)

Piston Pin
P
Unit: mm (in)

Piston pin outer diameter 27.995 - 28.000 (1.1022 - 1.1024)

Piston to piston pin clearance 0.008 - 0.018 (0.0003 - 0.0007)
Standard 0.026 - 0.043 (0.0010 - 0.0017)
Connecting rod bushing clearance
Limit 0.057 (0.0022)

CONNECTING ROD
EM-277
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Unit: mm (in)

Center distance 154.47 - 154.53 (6.0815 - 6.0838)

Bend [per 100 (3.94)] Limit 0.12 (0.0047)
Torsion [per 100 (3.94)] Limit 0.12 (0.0047)
Connecting rod bushing inner diameter* 28.026 - 28.038 (1.1034 - 1.1039)
Connecting rod big end inner diameter* 55.000 - 55.013 (2.1654 - 2.1659)
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Side clearance
Limit 0.40 (0.0157)
*: After installing in connecting rod

CRANKSHAFT
Unit: mm (in)

Main journal dia. “Dm” 62.951 - 62.975 (2.4784 - 2.4793)

Pin journal dia. “Dp” 51.956 - 51.974 (2.0455 - 2.0462)
Center distance “r” 49.97 - 50.03 (1.9673 - 1.9697)

Out-of-round (Difference between X Standard 0.003 (0.0001)

and Y) Limit 0.005 (0.0002)
Standard 0.003 (0.0001)
Taper (Difference between A and B)
Limit 0.005 (0.0002)
Standard 0.05 (0.0020)
Runout [TIR*]
Limit 0.10 (0.0039)
Standard 0.085 - 0.25 (0.0033 - 0.0098)
End play
Limit 0.30 (0.0118)

SEM645 SBIA0535E

*: Total indicator reading

AVAILABLE MAIN BEARING

Main bearing

EM-278
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Unit: mm (in)
A

EM

D
SEM255G

Grade number Thickness Width Identification color Remarks

E
0 1.812 - 1.809 (0.0713 - 0.0712) Black
1 1.815 - 1.812 (0.0715 - 0.0713) Brown
2 1.818 - 1.815 (0.0716 - 0.0715) Green
F
3 1.821 - 1.818 (0.0717 - 0.0716) Yellow Grade and color are the
same for upper and
4 1.824 - 1.821 (0.0718 - 0.0717) Blue lower bearings.
5 1.827 - 1.824 (0.0719 - 0.0718) Pink G
6 1.830 - 1.827 (0.0720 - 0.0719) Purple
7 1.833 - 1.830 (0.0722 - 0.0720 Red
H
UPR 1.812 - 1.809 (0.0715 - 0.0712) Black
01
LWR 1.815 - 1.812 (0.0715 - 0.0713) Brown
UPR 1.815 - 1.812 (0.0715 - 0.0713) 19.9 - 20.1 Brown I
12
LWR 1.818 - 1.815 (0.0716 - 0.0715) (0.783 - 0.791) Green
UPR 1.818 - 1.815 (0.0716 - 0.0715) Green
23 J
LWR 1.821 - 1.818 (0.0717 - 0.0716) Yellow
UPR 1.821 - 1.818 (0.0717 - 0.0716) Yellow Grade and color are dif-
34 ferent between upper
LWR 1.824 - 1.821 (0.0718 - 0.0717) Blue and lower bearings. K
UPR 1.824 - 1.821 (0.0718 - 0.0717) Blue
45
LWR 1.827 - 1.824 (0.0719 - 0.0718) Pink
L
UPR 1.827 - 1.824 (0.0719 - 0.0718) Pink
56
LWR 1.830 - 1.827 (0.0720 - 0.0719) Purple
UPR 1.830 - 1.827 (0.0720 - 0.0719) Purple M
67
LWR 1.833 - 1.830 (0.0722 - 0.0720 Red

Undersize
Unit: mm (in) N
Size Thickness Main journal diameter “Dm”
Grind so that bearing clearance is the spec-
0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769) O
ified value.

AVAILABLE CONNECTING ROD BEARING

Connecting Rod Bearing P

Grade number Thickness mm (in) Width Identification color Remarks

EM-279
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
0 1.488 - 1.485 (0.0586 - 0.0585) Green
1 1.491 - 1.488 (0.0585 - 0.0587) Yellow
Grade and color are the same
2 1.494 - 1.491 (0.0588 - 0.0585) Blue
for upper and lower bearings.
3 1.497 - 1.494 (0.0589 - 0.0588) Pink
4 1.500 - 1.497 (0.0591 - 0.0589) Purple
UPR 1.488 - 1.485 (0.0586 - 0.0585) Green
01 22.9 - 23.1
LWR 1.491 - 1.488 (0.0585 - 0.0587) Yellow
(0.902 - 0.909)
UPR 1.491 - 1.488 (0.0585 - 0.0587) Yellow
12
LWR 1.494 - 1.491 (0.0588 - 0.0585) Blue Grade and color are different
between upper and lower
UPR 1.494 - 1.491 (0.0588 - 0.0585) Blue bearings.
23
LWR 1.497 - 1.494 (0.0589 - 0.0588) Pink
UPR 1.497 - 1.494 (0.0589 - 0.0588) Pink
34
LWR 1.500 - 1.497 (0.0591 - 0.0589) Purple

Undersize
Unit: mm (in)

Size Thickness Crank pin journal diameter “Dp”

UPR 1.534 - 1.542 (0.0604 - 0.0607)
0.08 (0.0031)
LWR 1.536 - 1.540 (0.0605 - 0.0606)
UPR 1.554 - 1.562 (0.0612 - 0.0615)
0.12 (0.0047) Grind so that bearing clearance is the specified value.
LWR 1.556 - 1.560 (0.0613 - 0.0614)
UPR 1.619 - 1.627 (0.0637 - 0.0641)
0.25 (0.0098)
LWR 1.621 - 1.625 (0.0638 - 0.0640)

MISCELLANEOUS COMPONENTS
Flywheel
Unit: mm (in)

Flywheel deflection [TIR]* Standard 0.45 (0.0177) or less

*: Total indicator reading

Bearing Clearance
Unit: mm (in)

Main bearing oil clearance Standard 0.056 - 0.066 (0.0022 - 0.0026)

Connecting rod bearing oil
Standard 0.051 - 0.061 (0.002 - 0.0024)
clearance

E M -2 8 0
 PRECAUTIONS
< PRECAUTION > [V9X]

PRECAUTION A
PRECAUTIONS
Precaution for Battery Service (for V9X Models) INFOID:0000000006466962
EM
When disconnect the battery cable, pay attention to the following.
• Always use a 12 volt battery as power source.
• Do not attempt to disconnect battery cables while engine is run- C
ning.
• Before disconnecting battery cables, turn ignition switch OFF
and wait at least 4 minutes. D
• After high-load driving, turn the ignition switch OFF and wait
for at least 15 minutes to remove the battery cable.
NOTE:
• Turbocharger cooling pump may operate in a few minutes after E
the ignition switch is turned OFF.
SEF289H
• Example of high-load driving
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more. F
- Driving for 30 minutes or more on a steep slope.
Precaution for Procedure without Cowl Top Cover INFOID:0000000006466963

G
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield. H

J
PIIB3706J

Precaution Necessary for Steering Wheel Rotation After Battery Disconnect

INFOID:0000000006466964
K

CAUTION:
Comply with the following cautions to prevent any error and malfunction. L
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-
THEFT SYSTEM).
• Remove and install all control units after disconnecting both battery cables with the ignition switch
in the LOCK position. M
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech- N
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before O
starting the repair operation.
OPERATION PROCEDURE
P
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ACC position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.

EM-281
 PRECAUTIONS
< PRECAUTION > [V9X]
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the LOCK position before connecting the
battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT.
Precautions For Engine Service INFOID:0000000008180054

DISCONNECTING FUEL PIPING

• Before starting work, check no fire or spark producing items are in the work area.
• Release fuel pressure before disconnecting and disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.

DRAINING ENGINE COOLANT

Drain engine coolant and engine oil when the engine is cooled.

INSPECTION, REPAIR AND REPLACEMENT

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.

REMOVAL AND DISASSEMBLY

• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin-
structed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position.
• Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.

ASSEMBLY AND INSTALLATION

• Use torque wrench to tighten bolts or nuts to specification.
• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000006466965

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SUPPLEMENTAL
RESTRAINT SYSTEM” and “SEAT BELTS” of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.

EM-282
 PRECAUTIONS
< PRECAUTION > [V9X]
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag A
Module, see the “SUPPLEMENTAL RESTRAINT SYSTEM”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
EM
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING: C
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
D
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
E
Parts Requiring Angular Tightening INFOID:0000000006466971

• Use an angle wrench for the final tightening of the following engine parts.
- Cylinder head bolts F
- Main bearing cap bolts
- Timing sprocket bolts
- Crankshaft pulley bolt G
- Wear compensation gear bolt
- Camshaft sprocket (for fuel pump) bolt
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step. H
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000006466972
I

REMOVAL OF LIQUID GASKET

• After removing mounting nuts and bolts, separate the mating sur- J
face using the seal cutter [SST:KV10111100 ( — )] (A) and remove
old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces. K
• Tap the seal cutter to insert it (B), and then slide it (C) by tapping
on the side as shown in the figure.
• In areas where the seal cutter is difficult to use, use a plastic ham- L
mer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
JPBIA0052ZZ
screwdriver is used, be careful not to damage the mating sur- M
faces.
LIQUID GASKET APPLICATION PROCEDURE
N
1. Using a scraper (A), remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
• Remove the liquid gasket completely from the groove of the
gasket application surface, mounting bolts and bolt holes. O
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials. P

JPBIA0053ZZ

EM-283
 PRECAUTIONS
< PRECAUTION > [V9X]
3. Attach the liquid gasket to the tube presser (commercial service
tool).
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
• If there is a groove for the liquid gasket application, apply the
gasket to the groove.

EMA0622D

• As for the bolt holes, normally apply the gasket inside the
holes. If specified, it should be applied outside the holes.
Check to read the instruction in this manual.

A : Groove
B : Bolt hole
: Inside

• Within five minutes of gasket application, install the mating

component.
• If the liquid gasket protrudes, wipe it off immediately. JPBIA0010ZZ
• Do not retighten after the installation.
• After 30 minutes or more have passed from the installation, fill the engine oil and coolant.
CAUTION:
If there are instructions in this manual, observe them.
Precaution for Diesel Equipment INFOID:0000000006466973

CLEANLINESS
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRES-
SURE DIRECT INJECTION SYSTEM
Risks relating to contamination
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
• Damage or destruction of the high pressure injection system and the engine
• Seizing or leaking of a component
All After-Sales operations must be performed under very clean conditions. This means that no impurities (par-
ticles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the fuel filter to the fuel injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:
• Metal or plastic chips
• Paint
• Fibers:
- Boxes
- Brushes
- Paper
- Clothing
- Cloths
• Foreign bodies such as hair
• Ambient air
• Etc.
WARNING:
It is not possible to clean the engine using a high pressure fuel pump because of the risk of damaging
connections. In addition, moisture may collect in the connectors and create electrical connection mal-
functions
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYS-
TEM
EM-284
 PRECAUTIONS
< PRECAUTION > [V9X]
• Check that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Nissan
part No. 16609 00Q0C, Renault part No. 77 01 479 091). Plugs are to be used once only. After use, they A
must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable).
Unused plugs must be thrown away.
• Check that you have hermetically resealable plastic bags for storing removed parts. Stored parts will there-
EM
fore be less subject to the risk of impurities. The bags must be used only once, and after use they must be
thrown away.
• Lint-free towelettes to be used for fuel pump related service purpose. The use of a normal cloth or paper for
cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of the system. C
Each lint-free cloth should only be used once.
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
• For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle. D
• For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
• Use a brush and thinners to clean the connections to be opened.
• Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and
injection system zone). Check that no bristles remain adhered. E
• Wash your hands before and during the operation if necessary.
• When wearing leather protective gloves, cover these with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION F
• As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system.
The plugs to be used are available from the Parts Stores - Nissan part No. 16609 00Q0C, Renault part No.
77 01 479 091. They must not, under any circumstances, be reused.
• Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries con- G
tamination.
• All components of the injection system that are removed must be stored in a hermetically sealed plastic bag
once the plugs have been inserted. H
• The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been
opened. These items are likely to allow impurities to enter the system.
• A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle. I
Instructions for Fitting the Plugs
Nissan part No. 16609 00Q0C
J

EM-285
 PRECAUTIONS
< PRECAUTION > [V9X]
(Renault part No. 77 01 479 091)

JPBIA0585ZZ

SPECIAL FEATURES
CAUTION:
• The engine must not operate with:
- Use diesel fuel required by the regulations for cetane number. Refer to GI-4, "Precaution for Fuel".
- Petrol, even in tiny quantities
• Before carrying out any work, check that the fuel rail is not under pressure and that the fuel temper-
ature is not too high. [The system can inject the diesel into the engine at a pressure up to 160,000
kPa (1,600 bar, 1,632 kg/cm2, 23,200 psi)].

EM-286
 PRECAUTIONS
< PRECAUTION > [V9X]
• Respect the cleaning and safety advice specified in this document for any work on the high pressure
injection system. A
• Remove of the interior of the fuel pump and fuel injectors is prohibited.
• For safety reasons, it is strictly forbidden to slacken an injection tube union when the engine is run-
ning.
EM
• It is not possible to remove the fuel pressure sensor from the fuel rail because this may cause circuit
contamination malfunctions. If the fuel pressure sensor fails, the fuel pressure sensor, the fuel rail
and the fuel injection tubes must be replaced.
• It is strictly forbidden to remove the fuel pump pulley. C
• Applying 12 volts directly to any component in the system is prohibited.
• Ultrasonic carbon removal and cleaning are prohibited.
• Never start the engine without the battery being connected correctly. D
CHECKING SEALING AFTER REPAIR
CAUTION:
After any operation, check that there is no diesel leakage.
• Start the engine and check for fuel leak for one minute after starting. E
• Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
• Once the engine coolant temperature is above 50°C (122°F) and provided there are no malfunctions
present, carry out a road test, taking the engine speed up to 4,000 rpm at least once to check that there is no F
leakage.
• Perform a visual inspection after the road test to check that there is no high pressure leakage.
• Clean off the tracing fluid.
G
Definitions of Bank Names INFOID:0000000006466974

• In this manual, each bank name is defined as follows:

H
A : Bank 1 (The conventional right bank)
B : Bank 2 (The conventional left bank)
: Engine front
I

• For cylinder numbers and bank layout, refer to the illustration.

J
Bank 1 : The bank side including cylinder No. 1
(odd-numbered cylinder side)
Bank 2 : The other bank side of the above JPBIA1135ZZ
K
(even-numbered cylinder side)

EM-287
 PREPARATION
< PREPARATION > [V9X]

PREPARATION
PREPARATION
Special Service Tools INFOID:0000000006466975

NISSAN tool number

(RENAULT tool No.) Description
Tool name
EM03470000 Installing piston assembly into cylinder bore
(—)
Piston ring compressor

NT044

KV10111100 Removing oil pan and front cover. etc

(—)
Seal cutter

NT046

KV10112100 Tightening bolts for bearing cap, cylinder

(—) head, etc. in angle
Angle wrench

NT014

KV10117100 Loosening or tightening air fuel ratio sensor

(—)
Heated oxygen sensor wrench

NT379

KV10116400 Installing front oil seal

(—)
Front oil seal fitting tool

JPBIA3552ZZ

KV10116500 To lock drive plate and flywheel

(—)
Ring gear stopper

JPBIA3544ZZ

EM-288
 PREPARATION
< PREPARATION > [V9X]
NISSAN tool number
(RENAULT tool No.) Description A
Tool name
— Removing front oil seal
(Mot. 1577) EM
Lip seal extractor

JPBIA3546ZZ

— To lock crankshaft pulley D

(Mot. 1770)
Crankshaft pulley locking tool
E

JPBIA0630ZZ F
— Connecting compression gauge and glow
(Mot. 1772) plug hole
Compression gauge adapter G

H
JPBIA0626ZZ

— To position the gear and apply for the right

(Mot. 1773) clearance (wear compensation gear) I
Positioning tool

JPBIA0625ZZ
K
— To lock engine at TDC
(Mot. 1874)
TDC set pin
L

M
JPBIA3550ZZ

— To lock camshaft when changing timing chain

(Mot. 1880)
N
Camshaft timing tool

JPBIA3551ZZ

EM-289
 PREPARATION
< PREPARATION > [V9X]
NISSAN tool number
(RENAULT tool No.) Description
Tool name
— Removing front oil seal used with lip seal ex-
(Mot. 1912) tractor (Mot. 1577)
Adapter

JPBIA3554ZZ

— Removing and installing drive plate

(Mot. 1959) Size: T55+
TORX Socket

E1BIA0349ZZ

Commercial Service Tools INFOID:0000000006466976

NISSAN tool number

(RENAULT tool No.) Description
Tool name
KV113B0040 Gauge stand used with KV113B0050 (Mot.
(Mot. 251-01) 252-01)
Dial indicator stand set

MBIB0360E

KV113B0050 Thrust plate for measuring the protrusion of

(Mot. 252-01) piston used with KV113B0040 (Mot. 251-01)
Dial indicator stand set

MBIB0361E

KV113B0090 Tool for removing valve oil seals

(Mot. 1335)
Valve seal remover

MBIB0370E

KV113B0180 Tool for installing valve oil seals

(Mot. 1511-01)
Valve seal drift

MBIB0378E

EM-290
 PREPARATION
< PREPARATION > [V9X]
NISSAN tool number
(RENAULT tool No.) Description A
Tool name
KV113B0200 Cylinder head and cylinder head housing sup-
(Mot. 1573) port EM
Cylinder head stand

MBIB0380E

Tube presser Pressing the tube of liquid gasket D

NT052 F
Valve spring compressor Disassembling valve mechanism

H
JPBIA0770ZZ

Manual lift table caddy Removing and installing engine

I

ZZA1210D
K
Piston ring expander Removing and installing piston ring

M
NT030

EM-291
 COMPRESSION PRESSURE
< BASIC INSPECTION > [V9X]

BASIC INSPECTION
COMPRESSION PRESSURE
Inspection INFOID:0000000006466977

1. Warm up engine thoroughly. Then stop it.

2. Disconnect the battery cable from the negative terminal.
3. Remove glow plugs from all cylinders.
CAUTION:
• Before removal, clean the surrounding area to prevent entry of any foreign materials into engine.
• Carefully remove glow plugs to prevent any damage or breakage.
• Handle with care to avoid applying any shock to glow plugs.
4. Disconnect fuel injector harness connectors to avoid fuel injection during measurement.
5. Install compression gauge (commercial service tool) with compression gauge adapter [SST: — (Mot.
1772)] to the hole for glow plug.
6. Turn ignition switch to START for cranking. When the gauge pointer stabilizes, read the compression
pressure and engine rpm. Perform these steps to check each cylinder.

Compression pressure : Refer to EM-393, "General Specification".

CAUTION:
Always use a fully-charged battery to obtain specified engine speed.
• When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
• If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again.
• If some cylinder has low compression pressure, pour small amount of engine oil into the glow plug hole
of the cylinder to re-check it for compression.
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-
ton rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
• If two adjacent cylinders have respectively low compression pressure and their compression remain
slow even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
7. After inspection is completed, install removed parts.
8. Start the engine, and check that the engine runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-1262, "Diagnosis Description".

EM-292
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [V9X]

SYMPTOM DIAGNOSIS A
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting - Engine Noise INFOID:0000000006466978
EM

JPBIA3931GB

EM-293
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [V9X]
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000006466979

1. Locate the area where noise occurs.

2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.

Operating condition of engine

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Hydraulic
Ticking or
Top of en- A C — B B — tappet Out of oil EM-377
clicking
gine noise
Cylinder Camshaft
head Camshaft journal oil
Rattle C A — A B C bearing EM-368
clearance
noise
Piston to piston pin oil
Slap or Piston pin clearance
— A — B B — EM-386
knock noise Connecting rod bushing
Crank- oil clearance
shaft pul- Piston ring side clear-
ley Slap or Piston
A — — B B A ance EM-386
Cylinder rap slap noise
Piston ring end gap
block
(Side of Connect- Connecting rod bushing
engine) ing rod oil clearance
Knock A B C B B B EM-386
Oil pan bearing Connecting rod bearing
noise oil clearance
Main bear- Main bearing oil clear-
Knock A B — A B C EM-386
ing noise ance
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear
A A — B B B chain ten- EM-322
Front cov- ticking Timing chain tensioner
sioner
er operation
noise
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-295
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water
Squall
A B — B A B pump Water pump operation CO-75
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related

EM-294
 DRIVE BELTS
< PERIODIC MAINTENANCE > [V9X]

PERIODIC MAINTENANCE A
DRIVE BELTS
Exploded View INFOID:0000000006466980
EM

JPBIA3567ZZ

1. Water pump 2. Idler pulley 3. Alternator

G
4. Power steering oil pump pulley 5. Drive belt auto-tensioner 6. Crankshaft pulley
7. Cooling fan pulley 8. A/C compressor 9. Idler pulley
H
10. Drive belt
A. Range when new drive belt is installed B. Possible use range C. Indicator
D. View
I
Refer to GI-9, "Component" for symbols in the figure.
Checking INFOID:0000000006466981
J
WARNING:
Be sure to perform this step when the engine is stopped.
• Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range K
(B).
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold. L
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (A) in the fig-
ure.
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt. M
CAUTION:
Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is
replaced. N
Tension Adjustment INFOID:0000000006466982

Refer to EM-393, "Drive Belts". O

Removal and Installation INFOID:0000000006466983

CAUTION: P
• Replace the drive belt that has been removed with a new one.
• Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is
replaced.
• Never run the engine without the drive belt to avoid damaging the crankshaft pulley.
REMOVAL
1. Remove engine front undercover.

EM-295
 DRIVE BELTS
< PERIODIC MAINTENANCE > [V9X]
2. Hold the hexagonal part of drive belt auto-tensioner pulley with a
hexagonal socket (A) securely. Then move the wrench handle in
the direction of arrow (loosening direction of tensioner).
CAUTION:
Never place hand in a location where pinching may occur if
the holding tool accidentally comes off.

JPBIA3628ZZ

3. Insert a stopper pin (A) in diameter such as hexagonale wrench

into the hole of the retaining boss to fix drive belt auto-tensioner
pulley.
• Keep drive belt auto-tensioner pulley arm locked after drive
belt is removed.
NOTE:
Use approximately 4.0 mm (0.157 in) dia. hard metal pin as a
stopper pin.

JPBIA3629ZZ

4. Remove drive belt.

INSTALLATION
1. Install drive belt.
CAUTION:
• Check that drive belt is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each
pulley groove.
2. Release drive belt auto-tensioner, and apply tension to drive belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Check that the indicator (notch on fixed side) of drive belt auto-tensioner is within the range when new
drive belt is installed. Refer to EM-295, "Checking".

EM-296
 AIR CLEANER FILTER
< PERIODIC MAINTENANCE > [V9X]
AIR CLEANER FILTER
A
Removal and Installation INFOID:0000000006466984

REMOVAL EM
1. Unhook clips and remove air cleaner upper case.
2. Remove air cleaner filter from air cleaner case.
C

E1BIA0314ZZ
F
INSTALLATION
Install in the reverse order of removal.
G

EM-297
 DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
< REMOVAL AND INSTALLATION > [V9X]

REMOVAL AND INSTALLATION

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
Exploded View INFOID:0000000006466985

JPBIA3594GB

1. Idler pulley 2. Drive belt auto-tensioner 3. Cooling fan pulley

4. Idler pulley 5. Idler pulley bracket
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006466986

CAUTION:
• Replace the drive belt that has been removed with a new one.
• Never disassemble drive belt auto-tensioner.
• Never run the engine without the drive belt to avoid damaging the crankshaft pulley.
REMOVAL
1. Remove engine undercover.
2. Remove drive belt. Refer to EM-295, "Removal and Installation".
• Keep drive belt auto-tensioner pulley arm locked after drive belt is removed.
3. Remove drive belt auto-tensioner.
4. Remove cover and idler pulley.
INSTALLATION
Note the following, and install in the reverse order of removal.
Idler pulley and cover
• When replacing idler pulley, replace the cover as well.

EM-298
 ENGINE COVER
< REMOVAL AND INSTALLATION > [V9X]
ENGINE COVER
A
Exploded View INFOID:0000000006466987

EM

G
E1BIA0304ZZ

1. Engine cover 2. Mounting rubber 3. Pin

Refer to GI-9, "Component" for symbols in the figure.
H

Removal and Installation INFOID:0000000006466988

I
REMOVAL
1. Remove engine cover following arrows.
CAUTION: J
• Never damage or scratch cover when installing or remov-
ing.
K

E1BIA0305ZZ
M
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
When installing, push the engine cover at the position on the pins. N

EM-299
 AIR CLEANER AND AIR DUCT
< REMOVAL AND INSTALLATION > [V9X]
AIR CLEANER AND AIR DUCT
Exploded View INFOID:0000000006466989

E1BIA0312GB

1. Air cleaner case (lower) 2. Air cleaner filter 3. Air cleaner case (upper)
4. clamp 5. clamp 6. Air duct
7. Resonator 8. Air duct 9. Mass air flow sensor (with intake air
temperature sensor)
10. clamp
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006466990

REMOVAL
1. Remove battery cable from negative terminal.
2. Remove engine cover. Refer to EM-299, "Exploded View".
3. Remove mass air flow sensor harness clamp from air cleaner case (upper).
4. Disconnect mass air flow sensor harness connector.
5. Remove air cleaner case (upper) and air cleaner filter.
• Add marks as necessary for easier installation.
6. Remove mass air flow sensor from air cleaner case (upper).
CAUTION:
• Never shock mass air flow sensor.
• Never disassemble mass air flow sensor.
7. Remove air cleaner case (lower).
8. Remove air duct and resonator.

EM-300
 AIR CLEANER AND AIR DUCT
< REMOVAL AND INSTALLATION > [V9X]
INSTALLATION
Note the following, and install in the reverse order of removal. A
• Align marks.
• Attach each joint.
• Screw clamps firmly. EM
Inspection INFOID:0000000006466991

INSPECTION AFTER REMOVAL C

Inspect air duct assembly for crack or tear.
• If anything found, replace air duct assembly.
D

EM-301
 VACUUM PUMP
< REMOVAL AND INSTALLATION > [V9X]
VACUUM PUMP
Exploded View INFOID:0000000006466992

E1BIA0347GB

1. Vacuum pump 2. O-ring 3. O-ring

4. Vacuum hose 5. Vacuum hose 6. Vacuum tube and bracket
7. Vacuum hose 8. Vacuum hose 9. Turbocharger boost control solenoid
valve bracket
10. Turbocharger boost control solenoid 11. Vacuum hose 12. EGR cooler bypass valve control so-
valve lenoid valve
A. To brake booster B. To engine mount solenoid valve C. To EGR
D. To resonator E. To turbocharger F. To engine mount solenoid valve
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006466993

REMOVAL
1. Remove engine cover. Refer to EM-299, "Exploded View".
2. Remove air inlet hose 4, 5 and air inlet tube 6. Refer to EM-307, "Exploded View".
3. Disconnect vacuum hoses from vacuum pump.
4. Remove vacuum pump.

EM-302
 VACUUM PUMP
< REMOVAL AND INSTALLATION > [V9X]
INSTALLATION
Note the following, and install in the reverse order of removal. A
CAUTION:
Be sure to check that the vacuum pump is in contact with the cylinder head before tightening the
mounting bolts. EM

EM-303
 FUEL PUMP
< REMOVAL AND INSTALLATION > [V9X]
FUEL PUMP
Exploded View INFOID:0000000006466994

E1BIA0348GB

1. Fuel pump bracket 2. Fuel pump bracket 3. Fuel pump protector

4. High pressure fuel pump 5. O-ring 6. Fuel pump drive spacer
7. Fuel inlet tube
A To fuel injector B To fuel tank
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006466995

REMOVAL
CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to EM-284, "Precaution for Diesel Equip-
ment".
• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• Never disassemble or adjust the fuel pump body.
1. Disconnect battery cable from negative terminal.
2. Remove engine cover. Refer to EM-299, "Exploded View".
3. Remove air duct assembly and air cleaner case. Refer to EM-300, "Exploded View".
4. Remove air inlet hose 1. Refer to EM-307, "Exploded View".

EM-304
 FUEL PUMP
< REMOVAL AND INSTALLATION > [V9X]
5. Remove mounting bolts (A) and nut (B), and then remove fuel
pump protector (1). A

EM

JPBIA3829ZZ

D
6. Remove mounting bolts (A), and then remove fuel pump
bracket (1).
E

G
JPBIA3830ZZ

7. Remove injection tube mounting bolt (A).

H
8. Disconnect injection tube (1) from fuel high pressure pump.
Refer to EM-315, "Exploded View".
9. Plug all the holes of the injection circuit. I

JPBIA3831ZZ
K
10. Remove mounting bolts (A), and then remove high pressure fuel
pump.
L

N
JPBIA3615ZZ

INSTALLATION O
Install in the reverse order of removal, for the rest of parts.
• Before starting engine, bleed air from fuel piping. Refer to FL-31, "Air Bleeding".
NOTE: P
Fill the fuel of at least 60 m (2.11 Imp fl oz).
Inspection INFOID:0000000006466996

INSPECTION AFTER INSTALLATION

• Start the engine and check for fuel leak for one minute after starting.
CAUTION:

EM-305
 FUEL PUMP
< REMOVAL AND INSTALLATION > [V9X]
After any operation, check that there are no diesel leaks. Refer to EM-284, "Precaution for Diesel
Equipment".

EM-306
 CHARGE AIR COOLER
< REMOVAL AND INSTALLATION > [V9X]
CHARGE AIR COOLER
A
Exploded View INFOID:0000000006466997

EM

L
E1BIA0303GB

1. Charge air cooler 2. Gasket 3. Air inlet tube 3 M

4. Clamp 5. Air inlet hose 2 6. Bracket
7. Air inlet tube 2 8. Air inlet hose 1 9. Bracket
10. Air inlet tube 1 11. Bracket 12. Turbocharger inlet and outlet tube N
13 Gasket 14. Air inlet hose 5 15. Bracket
16. Air inlet tube 6 17. Air inlet hose 4 18. Air inlet tube 5
19. Air inlet hose 3 20. Air inlet tube 4 21. gasket O
A. To electric throttle control actuator
Refer to GI-9, "Component" for symbols in the figure.
P
Removal and Installation INFOID:0000000006466998

REMOVAL
1. Remove front grille. Refer to EI-16, "Removal and Installation".
2. Remove front bumper. Refer to EI-12, "Removal and Installation".
3. Remove charge air cooler with the following procedure:
• Loosen air inlet hose clamp.
EM-307
 CHARGE AIR COOLER
< REMOVAL AND INSTALLATION > [V9X]
• Remove charge air cooler mounting bolts.
• Remove charge air cooler.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Apply a neutral detergent (fluid) to the joint between air inlet hoses and air inlet tubes (oil is not permissible).
• Align marks. Attach each joint. Screw clamps firmly.
Inspection INFOID:0000000006466999

INSPECTION AFTER REMOVAL

1. Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it
dry.
2. Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
• Do not deform core fins.
• For cleaning procedure of charge air cooler core, refer to CO-69, "Inspection".

EM-308
 ELECTRIC THROTTLE CONTROL ACTUATOR
< REMOVAL AND INSTALLATION > [V9X]
ELECTRIC THROTTLE CONTROL ACTUATOR
A
Exploded View INFOID:0000000006467000

EM

L
JPBIA3589GB

1. Intake manifold (bank 1) 2. Intake manifold gasket 3. O-ring M

4. Bracket 5. Intake manifold (center) 6. Gasket
7. Electric throttle control actuator 8. Gasket 9. Intake manifold gasket
10. Intake manifold (bank 2) 11. Gasket 12. Adaptor N
13. O-ring
Refer to GI-9, "Component" for symbols in the figure.
O
Removal and Installation INFOID:0000000006467001

REMOVAL
P
1. Disconnect battery cable from negative terminal. Refer to SC-11, "Removal and Installation".
2. Remove engine cover. Refer to EM-299, "Exploded View".
3. Remove air inlet hose 5. Refer to EM-307, "Exploded View".
4. Disconnect electric throttle control actuator harness connector.

EM-309
 ELECTRIC THROTTLE CONTROL ACTUATOR
< REMOVAL AND INSTALLATION > [V9X]
5. Loosen electric throttle control actuator mounting bolts in
reverse order as shown in the figure.
NOTE:
The figure shows the electric throttle control actuator viewed
from the air duct side.
CAUTION:
Handle carefully to avoid any shock to electric throttle con-
trol actuator.
6. Remove electric throttle control actuator.

JPBIA3610ZZ

INSTALLATION
Note the following, and install in the reverse order of removal.
Electric Throttle Control Actuator Gasket
• Install electric throttle control actuator gasket in direction shown in
the figure.

A : Triangle press
: Engine upper

JPBIA3609ZZ

Electric Throttle Control Actuator

• Tighten in numerical order as shown in the figure.
NOTE:
• The figure shows the electric throttle control actuator viewed
from the air duct side.
• Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is disconnected.
Refer to EC-1321, "Work Procedure".
• Perform the “Throttle Valve Closed Position Learning Value Clear”
when electric throttle control actuator is replaced. Refer to EC-
1320, "Work Procedure" and EC-1319, "Work Procedure".
JPBIA3610ZZ

EM-310
 CATALYST
< REMOVAL AND INSTALLATION > [V9X]
CATALYST
A
Exploded View INFOID:0000000006467002

EM

I
E1BIA0338GB

1. Turbocharger 2. Gasket 3. Air fuel ratio sensor J

4. Oxidation catalytic converter 5. Bracket 6. Bracket
7. Gasket 8. Exhaust front tube
Refer to GI-9, "Component" for symbols in the figure. K

Removal and Installation INFOID:0000000006467003

L
REMOVAL
1. Remove engine cover. Refer to EM-299, "Exploded View".
2. Remove engine undercover. M
3. Remove front right wheel.
4. Remove front right mudguard. Refer to EI-21, "Removal and Installation"
5. Remove front right fender protector. Refer to EI-19, "Removal and Installation of Front Fender Protector" N
6. Remove air fuel ratio sensor (1).
• Using heated oxygen sensor wrench [SST: KV10117100] (A),
remove air fuel ratio sensor. O
CAUTION:
Be careful not to impact or damage air fuel ratio sensor.
P
: Engine front

JPBIA3611ZZ

7. Remove oxidation catalytic converter from turbocharger.

EM-311
 CATALYST
< REMOVAL AND INSTALLATION > [V9X]
INSTALLTION
Note the following, and install in the reverse order of removal.
Air Fuel Ratio Sensor
CAUTION:
• Before installing a air fuel ratio sensor, clean catalyst thread.
• When installing, never use such tools as an air impact wrench.
Inspection INFOID:0000000006467004

INSPECTION AFTER INSTALLATION

Start engine and raise engine speed to check no exhaust emission leaks.

EM-312
 GLOW PLUG
< REMOVAL AND INSTALLATION > [V9X]
GLOW PLUG
A
Exploded View INFOID:0000000006467005

EM

G
JPBIA3584GB

1. Glow plug
Refer to GI-9, "Component" for symbols in the figure.
H

Removal and Installation INFOID:0000000006467006

I
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken. J
Bank 1 Side
1. Disconnect the battery cable from the negative terminal. Refer to SC-11, "Removal and Installation"
2. Remove engine cover. Refer to EM-299, "Exploded View". K
3. Remove vacuum tube and bracket. Refer to EM-302, "Exploded View"
4. Move aside main harness.
L
5. Disconnect harness connector from glow plug.
6. Remove glow plug.
CAUTION: M
• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal.
Bank 2 Side N
1. Remove engine cover. Refer to EM-299, "Exploded View".
2. Remove air inlet hose 1 and air inlet tube 1. Refer to EM-307, "Exploded View"
3. Remove engine cover pin bracket bank 2 side. O
4. Clamp EGR cooler hose and EGR cooler by pass hose to prevent fluid leakage.
5. Remove EGR cooler hose. Refer to EM-358, "Exploded View"
6. Remove EGR cooler by pass valve hose. Refer to EM-358, "Exploded View" P
7. Remove main harness.
8. Disconnect harness connector from glow plug.
9. Remove glow plug.
CAUTION:
• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal.

EM-313
 GLOW PLUG
< REMOVAL AND INSTALLATION > [V9X]
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a reamer.
2. Install glow plug.
3. Install in the reverse order of removal, for the rest of parts.

EM-314
 INJECTION TUBE AND FUEL INJECTOR
< REMOVAL AND INSTALLATION > [V9X]
INJECTION TUBE AND FUEL INJECTOR
A
Exploded View INFOID:0000000006467007

FEED SYSTEM EM

JPBIA3581GB
N

1. Injection transfer tube 2. Tube clamp 3. Tube clamp

4. Insulator 5. Fuel injector rail protector (bank 1) 6. Injection tube No.5 O
7. Injection tube No.3 8. Injection tube No.1 9. Fuel rail seal
10. Fuel rail (bank 1) 11. Fuel rail (bank 2) 12. Injection tube No.2
13. Injection tube No.4 14. Injection tube No.6 15. Fuel injector rail protector (bank 2) P
16. Fuel injector rail protector panel 17. Injection tube 18. Tube clamp
19. Fuel injector 20. Fuel injector support
A. View A
Refer to GI-9, "Component" for symbols in the figure.

RETURN SYSTEM

EM-315
 INJECTION TUBE AND FUEL INJECTOR
< REMOVAL AND INSTALLATION > [V9X]

JPBIA3582GB

1. Spill hose 2. fuel return hose

A. To fuel tank B. To fuel pump
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006467008

REMOVAL
CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to EM-284, "Precaution for Diesel Equip-
ment".
• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• It is forbidden to open an fuel injector. If you open an fuel injector by mistake, you will have to
change it.
NOTE:
It is possible to replace a single injection tube.
Bank 1 Side, Injector 1,3 and 5
1. Disconnect battery cable from negative terminal. Refer to SC-11, "Removal and Installation".
2. Remove engine cover. Refer to EM-299, "Exploded View".
3. Put aside turbocharger boost control. Refer to EM-302, "Exploded View".
4. Remove engine cover rear pin bracket bank 1.
5. Remove fuel injector rail protector.

EM-316
 INJECTION TUBE AND FUEL INJECTOR
< REMOVAL AND INSTALLATION > [V9X]
6. Remove spill hose (1).
• Lift the movable sections of the injector unions away from the A
spill hose.

EM

JPBIA0601ZZ

D
7. Remove injection tube (No. 1, 3, 5).
• Put a paint mark or tag on injection tubes to identify each cylinder.
8. Remove fuel injectors with the following procedure: E
a. Remove fuel injector support.
b. Remove fuel injector. While rotating it to left and right, raise it to remove.
• If fuel injector spacer remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out. F
CAUTION:
• Handle fuel injector carefully without giving an impact.
• Never disassemble fuel injector.
G
9. Plug all the holes in the injection circuit.
Bank 2 Side, Injector 2,4 and 6
1. Disconnect battery cable from negative terminal. Refer to SC-11, "Removal and Installation" H
2. Remove engine cover. Refer to EM-299, "Exploded View".
3. Remove air cleaner and air duct. Refer to EM-300, "Exploded View".
4. Remove air inlet hose 1 and tube 1. Refer to EM-307, "Exploded View". I
5. Remove fuel injector rail protector. Refer to EM-315, "Exploded View"
6. Remove fuel return hose (1).
J
: Engine front

JPBIA3639ZZ
M
7. Remove spill hose (1).
• Lift the movable sections of the injector unions away from the
spill hose. N

P
JPBIA0601ZZ

8. Remove injection tube (No. 2, 4, 6).

• Put a paint mark or tag on injection tubes to identify each cylinder.
9. Remove fuel injectors with the following procedure:
a. Remove fuel injector support.

EM-317
 INJECTION TUBE AND FUEL INJECTOR
< REMOVAL AND INSTALLATION > [V9X]
b. Remove fuel injector. While rotating it to left and right, raise it to remove.
• If fuel injector spacer remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out.
CAUTION:
• Handle fuel injector carefully without giving an impact.
• Never disassemble fuel injector.
10. Plug all the holes in the injection circuit.
Bank 1 and 2 side, fuel rail
1. Remove engine unit. Refer to EM-342, "Exploded View".
2. Remove turbocharger. Refer to EM-348, "Exploded View".
3. Remove EGR cooler. Refer to EM-358, "Exploded View".
4. Remove EGR cooler support bracket. Refer to EM-358, "Exploded View".
5. Remove fuel injector rail protector.
6. Remove fuel pump protector. Refer to EM-304, "Exploded View".
7. Remove fuel return hose (1).

: Engine front

JPBIA3639ZZ

8. Remove spill hose (1).

• Lift the movable sections of the injector unions away from the
spill hose.

JPBIA0601ZZ

9. Remove injection transfer tube. Refer to EM-315, "Exploded View"

10. Remove injection tubes.
11. Remove fuel rail and fuel rail seal.
12. Plug all the holes in the injection circuit.
INSTALLATION
1. Record “INJECTOR ADJUSTMENT VALUE” on the top surface
when replacing fuel injector. Refer to EC-1316, "Description".

Example: Injector adjustment valve (A) = AZSSCAG

JPBIA3640ZZ

2. Install fuel injector, injection tubes and fuel rail with the following procedure:

EM-318
 INJECTION TUBE AND FUEL INJECTOR
< REMOVAL AND INSTALLATION > [V9X]
a. Install new fuel injector spacer (1) to fuel injector, and insert
them into cylinder head. A
CAUTION:
• Completely remove any foreign material among fuel injec-
tor and cylinder head.
EM
• Never mix ring (B) location. Upper location is mandatory.

A :Fuel injector guide

C

JPBIA0984ZZ

D
b. Install fuel rail, fuel rail seal, injection tube (center) and mounting rubber (temporarily).
• Finger tighten until contact the injection tube nuts.
c. Install fuel injector support. Tighten mounting bolt (specified torque).
E
CAUTION:
Be sure to fit fuel injector support without looseness.
d. Install injection tube (No. 1, 2, 3, 4, 5, 6) in the original position (temporarily).
• Finger tighten until contact the injection tube nuts. F
CAUTION:
Never put injection tubes under stress.
e. Tighten fuel rail mounting bolts and all injection tube nuts (specified torque). G
3. Install spill hose onto fuel injectors.
• Align center to insert spill hose straightly into fuel injector.
4. Install in the reverse order of removal, for the rest of parts. H
• Before starting engine, bleed air from fuel piping. Refer to FL-31, "Air Bleeding".
NOTE:
Fill the fuel of at least 60 m (2.11 Imp fl oz). I
Inspection INFOID:0000000006467009

INSPECTION AFTER INSTALLATION J

• Input “INJECTOR ADJUSTMENT VALUE” to ECM after installing
to the vehicle when replacing fuel injector. Refer to EC-1316,
"Description". K

Example: Injector adjustment valve (A) = AZSSCAG

L

M
JPBIA3640ZZ

• Start the engine and check for fuel leak for one minute after starting. N
CAUTION:
After any operation, check that there are no diesel leaks. Refer to EM-284, "Precaution for Diesel
Equipment". O

EM-319
 OIL PAN
< REMOVAL AND INSTALLATION > [V9X]
OIL PAN
Exploded View INFOID:0000000006467010

E1BIA0335GB

1. Oil pan 2. Gasket 3. Oil pressure switch

4. Oil temperature/level sensor 5. Oil level gauge and guide 6. Oil strainer
7. Snap ring 8. Baffle plate 9. Oil pan gasket
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006467011

REMOVAL
1. Remove engine undercover.
2. Remove front final drive assembly. Refer to FFD-16, "Removal and Installation".
3. Remove oil cooler. Refer to LU-39, "Exploded View"
4. Remove transmission assembly. Refer to AT-527, "Exploded View".
5. Remove rear oil seal retainer. Refer to EM-340, "REAR OIL SEAL : Removal and Installation".
6. Remove front cover lower. Refert to EM-322, "Exploded View"
7. Remove oil pan with the following procedure:

EM-320
 OIL PAN
< REMOVAL AND INSTALLATION > [V9X]
• Loosen mounting bolts in reverse order as shown in the figure.
A
: Engine front

EM

E1BIA0334ZZ

D
INSTALLATION
1. Install oil pan with the following procedure:
• Tighten mounting bolts in numerical order as shown in the fig- E
ure.

: Engine front
F

E1BIA0334ZZ
H
2. Install rear oil seal retainer. Refer to EM-340, "REAR OIL SEAL : Removal and Installation".
3. Install in the reverse order of removal, for the rest of parts.
I

EM-321
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
TIMING CHAIN
Exploded View INFOID:0000000006467012

E1BIA0302GB

1. Wear compensation gear (bank 1) 2. Wear compensation spacer 3. Timing sprocket (bank 1)
4. Timing chain sprocket (bank 1) 5. Timing chain sprocket spacer (bank 1) 6. Vacuum pump drive spacer
7. Gasket 8. Front cover upper (bank 1) 9. Front cover upper (bank 2)
10. Gasket 11. Wear compensation spacer 12. Wear compensation gear (bank 2)
13. Timing sprocket (bank 2) 14. Timing chain sprocket (bank 2) 15. Timing chain sprocket spacer (bank 2)
16. Crankshaft sprocket 17. Timing chain tension guide (bank 2) 18. Timing chain
19. Timing chain slack guide (bank 2) 20. Timing chain tensioner 21. Timing chain slack guide (bank 1)

EM-322
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
22. Timing chain 23. Timing chain tension guide (bank 1) 24. Timing chain tensioner
25. Crankshaft spacer 26. Crankshaft pulley 27. Front oil seal A
28. Oil pump drive key 29. Front cover lower 30. Gasket
31. Fuel pump drive gear 32. Fuel pump drive gear shaft
Comply with the installation proce- EM
A. dure when tightening. Refer to EM-
323
Refer to GI-9, "Component" for symbols in the figure. C

Removal and Installation INFOID:0000000006467013

D
REMOVAL
CAUTION:
Never turn the engine in the direction opposite to that of normal operation.
E
1. Drain engine oil. Refer to LU-36, "Draining".
CAUTION:
Perform this step when the engine is cold.
2. Drain engine coolant. Refer to CO-65, "Draining". F
3. Disconnect the battery cable from the negative terminal.
4. Remove the following parts:
• Drive belt: Refer to EM-295, "Removal and Installation". G
• Drive belt auto-tensioner and idler pulley: Refer to EM-298, "Exploded View".
• Power steering oil pump and bracket: Refer to PS-35, "V9X : Removal and Installation".
• Alternator: Refer to SC-25, "Removal and Installation". H
• Water pump: Refer to CO-75, "Exploded View".
• A/C compressor: Refer to ATC-116, "Removal and Installation for Compressor (V9X models)".
• Vacuum pump: Refer to EM-302, "Exploded View".
I
• High pressure fuel pump: EM-304, "Exploded View".
• Air inlet tube and pipe: Refer to EM-307, "Exploded View".
5. Remove crankshaft pulley with the following procedure:
J
a. Set the crankshaft pulley locking tool [SST: — (Mot. 1770)] (A)
and loosen crankshaft pulley bolt.

M
JPBIA3641ZZ

b. Remove crankshaft pulley and spacer.

• Pull crankshaft pulley with both hands to remove it. N
CAUTION:
Be careful not to damage front oil seal lip.
6. Remove oil pump deive key (1). O

JPBIA3642ZZ

EM-323
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
7. Remove front oil seal. Refer to EM-339, "FRONT OIL SEAL : Removal and Installation".
8. Remove engine oil filter. Refer to LU-38, "Removal and Installation".
9. Remove front cover with the following procedure:
a. Loosen mounting bolts in the reverse of the order shown in the
figure.

JPBIA3579ZZ

b. Loosen mounting bolts in the reverse of the order shown in the

figure.

A : Bank 1
B : Bank 2

JPBIA3578ZZ

10. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft groove (A) to set it in the position shown in the
figure.

1 : Crankshaft
B : 45 degrees
: Engine front

E1BIA0306ZZ

EM-324
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
b. Remove TDC pin plug (A).
A
: Engine front

EM

JPBIA3834ZZ

D
c. Screw in the TDC set pin [SST: — (Mot. 1874)] (A). Turn the
engine clockwise until the crankshaft (1) touches the TDC set
pin.
E
: Engine front

G
E1BIA0307ZZ

d. Check that the camshaft are located as shown in the figure.

• Fit the notch (C) of camshaft RH (1) and plug (D) of cylinder H
head.
• Set the camshaft LH (2) with the offset side faced upward.
I
A : Bank 1
B : Bank 2

JPBIA3932ZZ

11. Remove vacuum pump drive spacer (1). O

JPBIA3645ZZ

EM-325
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
12. Remove the timing chain (bank 1) with the following procedure:
a. Set the camshaft timing tool [SST: — (Mot.1880)] (A), and
tighten mounting bolt [M6 × 50 mm (1.97 in)] (B).
b. Loosen timing sprocket mounting bolts (C) and wear compensa-
tion gear mounting bolt (D).
c. Remove the camshaft timing tool.

JPBIA3646ZZ

d. Remove timing sproket spacer (1).

JPBIA3832ZZ

e. Remove the timing chain tensioner.

• Compress the timing chain tensioner (1) with timing chain
slack guide (2), and then insert a stopper pin (A) into hole on
timing chain tensioner.
NOTE:
Use approximately 3.0 mm (0.118 in) dia. hard metal pin as a
stopper pin

JPBIA3647ZZ

f. Remove timing chain slack guide (1) and timing chain tension
guide (2).
g. Remove timing sprocket spacer, timing sprocket and timing
chain.
CAUTION:
Never rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.

JPBIA3803ZZ

EM-326
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
h. Insert a screwdriver (A) and lift it up to move the gear of wear
compensation gear (1). A
NOTE:
To align two gear teeth of wear compensation gear.
i. Remove timing gear (2) under the condition shown in Step “h”. EM
j. Remove wear compensation gear and spacer.

JPBIA3804ZZ

D
13. Remove the timing chain (bank 2) with the following procedure:
a. Set the camshaft timing tool [SST: — (Mot.1880)] (A), and
tighten mounting bolt [M6 × 50 mm (1.97 in) (B). E
b. Loosen timing sprocket mounting bolts (C) and wear compensa-
tion gear mounting bolt (D).
c. Loosen fuel pump drive gear mounting bolts. F
d. Remove the camshaft timing tool.

JPBIA3805ZZ

H
e. Remove the timing chain tensioner.
• Compress the timing chain tensioner (1) with timing chain
slack guide (2), and then insert a stopper pin (A) into hole on
timing chain tensioner. I
NOTE:
Use approximately 3.0 mm (0.118 in) dia. hard metal pin as a
stopper pin J

JPBIA3806ZZ

f. Remove timing sproket spacer (1). L

O
JPBIA3833ZZ

EM-327
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
g. Remove timing chain slack guide (1) and timing chain tension
guide (2).

JPBIA3807ZZ

h. Remove timing sprocket spacer, timing sprocket, fuel pump drive gear, crankshaft sprocket and timing
chain.
CAUTION:
Never rotate crankshaft or camshaft while timing chain is removed. It causes interference between
valve and piston.
i. Insert a screwdriver (A) and lift it up to move the gear of wear
compensation gear (1).
NOTE:
To align two gear teeth of wear compensation gear.
j. Remove timing gear (2) under the condition shown in Step “h”.
k. Remove wear compensation gear and spacer.

JPBIA3808ZZ

14. Remove fuel pump gear shaft.

INSTALLATION
1. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft groove (A) to set it in the position shown in the
figure.

1 : Crankshaft
B : 45 degrees
: Engine front

E1BIA0306ZZ

b. Remove TDC pin plug (A).

: Engine front

JPBIA3834ZZ

EM-328
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
c. Screw in the TDC set pin [SST: — (Mot. 1874)] (A). Turn the
engine clockwise until the crankshaft (1) touches the TDC set A
pin.

: Engine front
EM

E1BIA0307ZZ

D
d. Check that the camshaft are located as shown in the figure.
• Fit the notch (C) of camshaft RH (1) and plug (D) of cylinder
head.
• Set the camshaft LH (2) with the offset side faced upward. E

A : Bank 1
B : Bank 2 F

JPBIA3932ZZ K
2. Install fuel pump gear shaft.
3. Install wear compensation gear (bank 2) with the following procedure: L
a. Set the wear compensation gear (1) on base plate of positioning
tool [SST: — (Mot. 1773)] (A).
M

O
JPBIA0766ZZ

EM-329
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
b. Set the lever (B) in the lower gear teeth (A). Pivot the lever
counterclockwise until the two gear teeth are aligned.

1 : Wear compensation gear

JPBIA0594ZZ

c. Set a stopper pin (A) in the gear hole.

1 : Wear compensation gear

NOTE:
• Use approximately 4.0 mm (0.157 in) dia. hard metal pin as a
stopper pin

JPBIA0595ZZ

d. Install wear compensation gear and wear compensation gear spacer to the camshaft LH (bank 2).
e. Align matching mark (A) on wear compensation gear and boss
(B) of cylinder head.
f. Temporarily tighten mounting bolt.

JPBIA3836ZZ

4. Install timing gear with the following procedure:

a. Parallelize the groove (A) of camshaft LH to face the offset side
upward.
b. Center the timing gear openings on the camshaft RH hub
mounting holes (B).
c. Set the timing gear fully onto the camshaft RH hub.
d. Remove stopper pin (C).

JPBIA3837ZZ

5. Install timing sprocket (1), crankshaft sprocket (2), timing chain (3) and fuel pump drive gear (4).
• Align matching marks on each sprocket and timing chain.

EM-330
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]

EM

E
JPBIA3838ZZ

A : Matching mark (copper link) B : Matching mark (notched) F

6. Install timing chain slack guide (1) and timing chain tension
guide (2).
G

I
JPBIA3807ZZ

7. Install timing chain tensioner (1). J

• Check that the timing chain tensioner makes contact with the
cylinder block before tightening the bolts.
• Pull out stopper pin (A) after installing, and the release K
plunger.

JPBIA3806ZZ
M

8. Install timing sprocket spacer (1) on the timing gear and tempo-
rarily tighten mounting bolt. N
• Allow the timing sprocket to rotate freely.

JPBIA3833ZZ

9. Tighten mounting bolts (timing sprockets and wear compensation gear) with the following procedure:

EM-331
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
a. Set the tool collet (A) of the timing adjustment tool [SST: —
(Mot. 1880)] (B) in the camshaft RH groove.
b. Pivot the camshaft timing tool to align the axes of the spacer (C)
and the bolt hole.

JPBIA3840ZZ

c. Set tool pins (D) into the wear compensation gear holes.
d. Pivot the camshaft timing tool [SST: — (Mot. 1880)] (B) to align
the axes of the spacer (C) and the bolt hole.
e. Set the tool collet (A), without force, into the camshaft RH
groove.

JPBIA3841ZZ

f. Set the mounting bolt [M6 × 50 mm (1.97 in)] (B) onto spacer of
the timing adjustment tool [SST: — (Mot. 1880)] (A).
g. Tighten timing sprocket mounting bolts (C).

1st step : 10.0 N·m (1.0 kg-m, 7 ft-lb)

2nd step : Turn 40 degrees clockwise (angle
tightening)
h. Tighten wear compensation gear mounting bolt (D).
JPBIA3805ZZ
1st step : 20.0 N·m (2.0 kg-m, 15 ft-lb)
2nd step : Turn 35 degrees clockwise (angle
tightening)
CAUTION:
Check the tightening angle by using an angle wrench [SST: KV10112100 ( — )] or protractor. Never
judge by visual inspection without an angle wrench.
i. Remove timing adjustment tool.

10. Install wear compensation gear (bank 1) with the following procedure:
a. Set the wear compensation gear (1) on base plate of positioning
tool [SST: — (Mot. 1773)] (A).

JPBIA0766ZZ

EM-332
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
b. Set the lever (B) in the lower gear teeth (A). Pivot the lever
counterclockwise until the two gear teeth are aligned. A

1 : Wear compensation gear

EM

JPBIA0594ZZ

D
c. Set a stopper pin (A) in the gear hole.

1 : Wear compensation gear

E
NOTE:
• Use approximately 4.0 mm (0.157 in) dia. hard metal pin as a
stopper pin
F

G
JPBIA0595ZZ

d. Install wear compensation gear and wear compensation gear spacer to the camshaft LH (bank 1).
H
e. Align matching mark (A) on wear compensation gear and boss
(B) of cylinder head.
f. Temporarily tighten mounting bolt.
I

K
JPBIA3842ZZ

11. Install timing gear with the following procedure:

a. Parallelize the groove (A) of camshaft LH to face the offset side L
upward.
b. Center the timing gear openings on the camshaft RH hub
mounting holes (B). M
c. Set the timing gear fully onto the camshaft RH hub.
d. Remove stopper pin (C).
N

O
JPBIA3843ZZ

12. Install timing sprocket (1), crankshaft sprocket (2) and timing chain (3).
• Align matching marks on each sprocket and timing chain. P

EM-333
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]

JPBIA3844ZZ

A : Matching mark (copper link) B : Matching mark (notched)

13. Install timing chain slack guide (1) and timing chain tension
guide (2).

JPBIA3803ZZ

14. Install timing chain tensioner (1).

• Check that the timing chain tensioner makes contact with the
cylinder block before tightening the bolts.
• Pull out stopper pin (A) after installing, and the release
plunger.

JPBIA3845ZZ

15. Install timing sprocket spacer (1) on the timing gear and tempo-
rarily tighten mounting bolt.
• Allow the timing sprocket to rotate freely.

JPBIA3833ZZ

16. Tighten mounting bolts (timing sprockets and wear compensation gear) with the following procedure:

EM-334
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
a. Set the tool collet (A) of the timing adjustment tool [SST: —
(Mot. 1880)] (B) in the camshaft RH groove. A
b. Pivot the camshaft timing tool to align the axes of the spacer (C)
and the bolt hole.
EM

JPBIA3846ZZ

D
c. Set tool pins (D) into the wear compensation gear holes.
d. Pivot the camshaft timing tool [SST: — (Mot. 1880)] (B) to align
the axes of the spacer (C) and the bolt hole. E
e. Set the tool collet (A), without force, into the camshaft RH
groove.
F

G
JPBIA3847ZZ

f. Set the mounting bolt [M6 × 50 mm (1.97 in)] (B) onto spacer of
H
the timing adjustment tool [SST: — (Mot. 1880)] (A).
g. Tighten timing sprocket mounting bolts (C).
I
1st step : 10.0 N·m (1.0 kg-m, 7 ft-lb)
2nd step : Turn 40 degrees clockwise (angle
tightening) J
h. Tighten wear compensation gear mounting bolt (D).
JPBIA3646ZZ
1st step : 20.0 N·m (2.0 kg-m, 15 ft-lb) K
2nd step : Turn 35 degrees clockwise (angle
tightening)
L
CAUTION:
Check the tightening angle by using an angle wrench [SST: KV10112100 ( — )] or protractor. Never
judge by visual inspection without an angle wrench.
M
i. Remove timing adjustment tool.

17. Remove vacuum pump drive spacer (1).

N

JPBIA3645ZZ

18. Remove the TDC set pin [SST: — (Mot.1874)].

19. Apply liquid gasket to TDC pin plug, and tighten it.

EM-335
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]

Tightening torque : 25.0 N·m (2.6 kg-m, 18 ft-lb)

Use Genuine Liquid Gasket or equivalent.
20. Install oil pump drive key.
21. Install front cover lower with the following procedure:
a. Install gasket to front cover lower.
b. Apply liquid gasket to the front cover lower gasket (1), referring
to the application point shown in the figure.

A : Liquid gasket application point

Use Genuine Liquid Gasket or equivalent.
NOTE:
Liquid gasket should be applied to the front cover side because
the workspace is narrow.

JPBIA3644ZZ

c. Temporarily tighten mounting bolts in the following steps in

numerical order as shown in the figure.

JPBIA3564ZZ

d. Tighten mounting bolts in the following steps in numerical order

as shown in the figure.
i. Tighten No. 1 to 17 in numerical order as shown.

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

ii. Tighten No. 18 bolt.

: 10.0 N·m (1.0 kg-m, 89 in-lb)

JPBIA3579ZZ

22. Install front cover uppeer with the following procedure:

a. Install gasket to front cover upper.
b. Apply liquid gasket to the front cover upper gasket (1), referring
to the application point shown in the figure.

A : Liquid gasket application point

Use Genuine Liquid Gasket or equivalent.
NOTE:
Liquid gasket should be applied to the front cover side because
the workspace is narrow.

JPBIA3644ZZ

EM-336
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
c. Tighten mounting bolts in the following steps in numerical order
as shown in the figure. A

A : Bank 1
B : Bank 2 EM

M8 bolt
: 32.0 N·m (3.3 kg-m, 24 ft-lb) C
M10 bolt
: 64.0 N·m (6.5 kg-m, 47 ft-lb) D

G
JPBIA3578ZZ

23. Install engine oil filter. Refer to LU-38, "Removal and Installation".
24. Install front oil seal. Refer to EM-339, "FRONT OIL SEAL : Removal and Installation". H
25. Install crankshaft pulley with the following procedure:
a. Secure crankshaft pulley with a crankshaft pulley locking tool
[SST: — (Mot. 1770)] (A). I
b. Tighten crankshaft pulley bolt.

1st step : 50.0 N·m (5.1 kg-m, 37 ft-lb) J

2nd step : Turn 115 degrees clockwise (angle

tightening)
K
CAUTION:
Check the tightening angle by using an angle wrench [SST:
KV10112100 ( — )] or protractor. Never judge by visual JPBIA0730ZZ
L
inspection without an angle wrench.
c. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns
smoothly.
M
26. Install in the reverse order of removal, for the rest of parts.
Inspection INFOID:0000000006467014

N
INSPECTION AFTER INSTALLATION
Inspection for Leaks
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required O
quantity, fill to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
- Start engine. With engine speed increased, check again for fuel leakage at connection points. P
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.

EM-337
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
Summary of the inspection items:
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission / transaxle fluid
Leakage Level / Leakage Leakage

Other oils and fluid* Level Leakage Level

Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.

EM-338
 OIL SEAL
< REMOVAL AND INSTALLATION > [V9X]
OIL SEAL
A
FRONT OIL SEAL
FRONT OIL SEAL : Removal and Installation INFOID:0000000006467015
EM
REMOVAL
1. Remove the following parts.
• Engine cover. Refer to EM-299, "Exploded View". C
• Undercover.
• Fan shroud. Refer to CO-73, "Exploded View".
• Cooling fan. Refer to CO-73, "Exploded View". D
• Drive belt: Refer to EM-295, "Removal and Installation".
• Crankshaft pulley: Refer to EM-322, "Exploded View".
2. Remove oil pump drive key (1). E

JPBIA3642ZZ H

3. Remove front oil seal with the follwing procedure:

a. Remove end piece (A) of the seal extractor [SST: — (Mot. I
1577)] from the extractor.
b. Remove snap ring (B) from the seal extractor [SST: — (Mot.
1577)] using snap ring pliers.
J

JPBIA3960ZZ
L
c. Remove shaft (A) from the seal extractor [SST: — (Mot. 1577)].
d. Remove adapter (B), and then install adapter [SST: — (Mot.
M
1912)] from the seal extractor [SST: — (Mot. 1577)]
e. Install shaft on the seal extractor [SST: — (Mot. 1577)].
N

O
JPBIA3961ZZ

EM-339
 OIL SEAL
< REMOVAL AND INSTALLATION > [V9X]
f. Install snap ring (A) on the seal extractor [SST: — (Mot. 1577)]
using snap ring pliers.
g. Install end piece (B) onto the seal extractor [SST: — (Mot. 1577)]
from the extractor.

JPBIA3962ZZ

h. Remove front oil seal using the lip seal extractor [SST: — (Mot. 1577)].
i. Press the seal lip extractor (A) pawl toward the inner side of the
front oil seal.
ii. Tighten nut (B) and hold the front oil seal with the seal extractor
pawl.
iii. Rotate shaft (C) clockwise to remove the front oil seal.

JPBIA3643ZZ

INSTALLATION
1. Install front oil seal with the following procedure:
NOTE:
• This type of seal is extremely fragile.
• When handling, it is essential to grip protective piece.
• It is strictly forbidden to touch the seal, in order to prevent any oil leaks once the seal is fitted to theen-
gine.
a. Set the crackshaft seal fitting tool [SST: —] (A).
b. Install crankshaft pulley bolt (B) and tighten it until crackshaft
seal fitting tool touches the front cover lower.

JPBIA3934ZZ

2. Install in the reverse order of removal, for the rest of parts.

REAR OIL SEAL
REAR OIL SEAL : Removal and Installation INFOID:0000000006467016

REMOVAL
1. Remove A/T assembly. Refer to AT-527, "Exploded View".
2. Remove drive plate.
3. Remove rear oil seal retainer.
INSTALLATION
1. Install rear oil seal retainer with the following procedure:

EM-340
 OIL SEAL
< REMOVAL AND INSTALLATION > [V9X]
a. Set guide bolt (A) to rear oil seal retainer (1).
A
: Engine front

b. Move the rear oil seal retainer evenly by hand until it makes con-
EM
tact with the cylinder block.

JPBIA3813ZZ

D
c. Remove guide bolts and protector.
d. Tighten mounting bolts in two steps separately in numerical
order as shown in the figure. E

1st step : 5.0 N·m (0.51 kg-m, 44 in-lb)

2nd step F
: 10.0 N·m (1.0 kg-m, 89 in-lb)

JPBIA3814ZZ

H
2. Install in the reverse order of removal, for the rest of parts.

EM-341
 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [V9X]

UNIT REMOVAL AND INSTALLATION

ENGINE ASSEMBLY
Exploded View INFOID:0000000006467017

E1BIA0342GB

1. Engine mount insulator (Rear) 2. Transmission cross member 3. Engine mount insulator (LH)
4. Vacuum hose 5. Vacuum hose 6. Vacuum hose
7. Engine mounting bracket (RH) 8. Engine mounting insulator (RH) 9. Engine mounting bracket (LH)
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006467018

WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at the front and back of rear wheels.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• Always be careful to work safely, and avoid forceful or uninstructed operations.
• Never start working until exhaust system and engine coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.

EM-342
 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [V9X]
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as much as possible. If board-on type is used for A
unavoidable reasons, support at rear axle jacking point with transmission jack or similar tool before
starting work, in preparation for the backward shift of the center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-42, "Pantograph Jack,
EM
Garage Jack and Safety Stand".
REMOVAL
Outline C
At first, remove the engine, transmission, transfer and front final drive assembly with front suspension member
facing downward. Then separate the engine from transmission.
Preparation D
1. Remove battery. Refer to SC-11, "Removal and Installation".
2. Discharge refrigerant from A/C system. Refer to ATC-111, "HFC-134a (R-134a) Service Procedure" or
E
MTC-100, "HFC-134a (R-134a) Service Procedure".
3. Drain engine coolant from radiator. Refer to CO-65, "Draining".
CAUTION:
Perform this step when engine is cold. F
4. Remove the following parts:
• Engine undercover (power tool)
• Remove Hood assembly. Refer to BL-14, "Removal and Installation of Hood Assembly". G
• Remove front grille. Refer to EI-16, "Removal and Installation".
• Remove front bumper. Refer to EI-12, "Removal and Installation".
• Engine cover. Refer to EM-299, "Exploded View". H
• Air duct inlet. Refer to EM-300, "Exploded View".
• Charge air cooler, inlet tube and hose. Refer to EM-307, "Exploded View".
• Reservoir tank. Refer to CO-70, "Exploded View".
• Front road wheel and tires (power tool). I
• Front mudguard. Refer to EI-21, "Removal and Installation".
• Front fender. Refer to EI-19, "Removal and Installation of Front Fender Protector".
5. Remove radiator hoses (upper and lower). Refer to CO-70, "Exploded View". J
Engine Room
1. Disconnect heater hose at engine side, and fit a plug onto hose end to prevent engine coolant leakage.
K
2. Remove Radiator. Refer to CO-70, "Exploded View".
3. Remove A/C condenser. Refer to ATC-122, "Removal and Installation for Condenser".
4. Remove A/C piping from A/C compressor. L
5. Remove vacuum hose. Refer to EM-302, "Exploded View".
6. Disconnect ground cable.
7. Remove fan shroud (lower and Upper). Refer to CO-73, "Exploded View". M
8. Remove cooling fan. Refer to CO-73, "Exploded View".
9. Remove A/C compressor. Refer to ATC-116, "Removal and Installation for Compressor (V9X models)".
10. Remove alternator. Refer to SC-26, "Disassembly and Assembly". N
11. Remove steering oil pump. Refer to PS-34, "V9X : Exploded View".
12. Remove turbocharger heat shield on the body.
O
13. Disconnect all clips and connectors of the engine room harness.
14. Disconnect engine room harness connectors at unit sides and other locations.
15. Disconnect fuel feed hose from high pressure fuel pump. P
CAUTION:
Fit plugs onto disconnected hoses to prevent fuel leakage.
16. Remove reservoir tank of power steering oil pump and piping from vehicle, and temporarily secure them
on engine.
CAUTION:
When temporarily securing, keep the reservoir tank upright to avoid fluid leakage.
17. Pull out engine room harnesses to engine room side, and temporarily secure them on engine.

EM-343
 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [V9X]
CAUTION:
• When pulling out harnesses, take care not to damage harnesses and connectors.
• After temporarily securing, cover connectors with vinyl or similar material to protect against
adhesion of foreign materials.
Vehicle Underbody
1. Remove oil cooler. Refer to LU-39, "Exploded View".
2. Remove catalyst. Refer to EM-311, "Exploded View".
3. Remove starter. Refer to SC-41, "Removal and Installation".
4. Remove A/T fluid cooler and tube. Refer to AT-524, "Exploded View".
5. Remove exhaust front tube. Refer to EX-15, "WITHOUT DPF (DIESEL PARTICULATE FILTER) MODELS
: Exploded View".
6. Remove oxydation catalytic converter. Refer to EX-15, "WITHOUT DPF (DIESEL PARTICULATE FILTER)
MODELS : Exploded View".
7. Remove front propeller shaft. Refer to PR-3, "Removal and Installation".
8. Remove drive shaft. Refer to FAX-7, "Removal and Installation".
9. Remove front final drive assembly. Refer to FFD-16, "Removal and Installation".
Separation and removal work
1. Install engine slingers into front of cylinder head (bank 1) and
rear of cylinder head (bank 2).

1 : Engine front slinger (bank 1)

2 : Engine rear slinger (bank 2)
: Engine front

Slinger bolts:
Front : 19 N·m (1.9 kg-m, 14 ft-lb)
JPBIA2099ZZ
Rear : 24 N·m (2.4 kg-m, 18 ft-lb)

2. Lift the hoist of a two-point engine lifter (commercial service tool)

(A) from the front and rear engine slingers to support engine.
• CAUTION:
Always lift or support the engine by using a two-point
engine lifter (i.e. hoisting the front and rear slingers from
one point in the air), or the rocker cover and parts around
the engine may be damaged due to the fall of the engine
slinger.

JPBIA2509ZZ

3. Remove A/T bolts. Refer to AT-527, "Exploded View".

4. Remove engine mounting insulators bolts(RH and LH). Refer to EM-342, "Exploded View".
5. Lift with hoist and separate the engine from A/T.
CAUTION:
• Before and during this lifting, always check that any harnesses are left connected.
• Never damage engine mounting insulator and avoid oil/grease smearing or spills onto engine
mounting insulator.
INSTALLATION
Note the following item, and install in the reverse order of removal.
• Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
• For a location with a positioning pin, insert it securely into hole of matching part.
• For a part with a specified installation orientation, refer to component figure in EM-342, "Exploded View".
• Check that all engine mounting insulators are seated properly, then tighten mounting nuts and bolts.

EM-344
 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [V9X]
Inspection INFOID:0000000006467019

A
INSPECTION AFTER INSTALLATION
Inspection for Leaks
EM
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
- Start engine. With engine speed increased, check again for fuel leakage at connection points. C
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant. D
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
E
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
F
Engine oil Level Leakage Level
Transmission / AT & CVT Models Leakage Level / Leakage Leakage
transaxle fluid G
MT Models Level / Leakage Leakage Level / Leakage

Other oils and fluids* Level Leakage Level

Fuel Leakage Leakage Leakage H
Exhaust gas — Leakage —
*: Power steering fluid, brake fluid, etc.
I

EM-345
 ENGINE STAND SETTING
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

UNIT DISASSEMBLY AND ASSEMBLY

ENGINE STAND SETTING
Setting INFOID:0000000006467020

NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc.
1. Remove the engine assembly from the vehicle. Refer to EM-342, "Exploded View".
2. Install engine to engine stand with the following procedure:
a. Remove drive plate.
• Secure crankshaft using a ring gear stopper [SST: KV10116500 (—)], and remove mounting bolts.
CAUTION:
Never disassemble them.
b. Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
Use the engine stand that has a load capacity [approximately 225 kg (496 lb) or more] large
enough for supporting the engine weight.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-
tial risk of overturning stand.
- Intake manifold: Refer to EM-351, "Exploded View".
- Exhaust manifold: Refer to EM-355, "Exploded View".
- Oil separator: Refer to EM-361, "Exploded View".
NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with drive plate
removed.
CAUTION:
Before removing the hanging chains, check the engine
stand is stable and there is no risk of overturning.

PBIC3227J

3. Drain engine oil. Refer to LU-36, "Draining".

CAUTION:
Be sure to clean drain plug and install with new gasket.

EM-346
 ENGINE UNIT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
ENGINE UNIT
A
Disassembly INFOID:0000000006467021

1. Remove multifunction support bracket. Refer to EM-298, "Exploded View". EM

2. Remove intake manifold. Refer to EM-351, "Exploded View".
3. Remove exhaust manifold. Refer to EM-355, "Exploded View".
4. Remove oil pan (lower). Refer to EM-320, "Exploded View". C
5. Remove oil cooler. Refer to LU-39, "Exploded View".
6. Remove vacuum pump. Refer to EM-302, "Exploded View".
D
7. Remove fuel pump. Refer to EM-304, "Exploded View".
8. Remove timing chain. Refer to EM-322, "Exploded View".
9. Remove cylinder head housing. Refer to EM-363, "Exploded View". E
10. Remove water suction pipe. Refer to CO-82, "Exploded View".
11. Remove water outlet and thermostat assembly. Refer to CO-80, "Exploded View".
Assembly INFOID:0000000006467022
F

Assembly is the reverse order of disassembly.

G

EM-347
 TURBOCHARGER
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
TURBOCHARGER
Exploded View INFOID:0000000006467023

JPBIA3565GB

1. Exhaust gas pressure sensor 1 2. Exhaust gas temperature sensor 1 3. Turbocharger insulator
4. Turbocharger 5. Gasket 6. Oil tube
7. Gasket 8. Oil tube 9. Gasket
10. Oil tube 11. Gasket 12. Water tube
13. Water tube 14. Bracket
A. To turbocharger cooling water pump B. To exhaust fuel injector cooler C. To cylinder block
D. to cylinder block
Refer to GI-9, "Component" for symbols in the figure.

Disassembly and Assembly INFOID:0000000006467024

DISASSEMBLY
1. Remove oil feed tube from turbocharger. Refer to EM-348, "Exploded View".
2. Remove exhaust manifold. Refer to EM-355, "Exploded View".

EM-348
 TURBOCHARGER
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
3. Remove mounting bolt (A), and then remove EGR tube (1).
A
: Engine front

EM

JPBIA3606ZZ

D
4. Remove turbocharger.
CAUTION:
Never disassemble or adjust the turbocharger body.
E
5. Remove exhaust gas pressure sensor 1and exhaust gas temperature sensor 1.
CAUTION:
Be careful not to impact or damage exhaust gas pressure sensor 1 and exhaust gas temperature
sensor 1. F
ASSEMBLY
Note the following, and install in the reverse order of disassembly.
G
Exhaust Gas Temperature Sensor 1
CAUTION:
• Before installing a new exhaust gas temperature sensor, clean turbocharger thread.
• Be careful not to impact or damage exhaust gas temperature sensor 1. H
• When installing, never use such tools as an air impact wrench.
Inspection INFOID:0000000006467025
I

INSPECTION AFTER DISASSEMBLY

Turbocharger J

O
JPBIA3612GB

CAUTION:
When the compressor wheel, turbine wheel or rotor shaft is damaged, remove all the fragments and
P
foreign matter left in the following passages in order to prevent a secondary malfunction:

Suction side: Between turbocharger and air cleaner

Between turbocharger and charge air cooler
Exhaust side: Between turbocharger and catalyst
Between turbocharger and exhaust manifold

EM-349
 TURBOCHARGER
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
Turbocharger Boost Control
• Connect the handy vacuum pump (A) to the actuator, and check
that the rod strokes smoothly in compliance with the following
pressure.

Standard (value of vacuum/value of rod moving):

Refer to SDS.

JPBIA3828ZZ

INSPECTION AFTER INSTALLATION

Start engine and raise engine speed to check no exhaust emission leaks.

EM-350
 INTAKE MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
INTAKE MANIFOLD
A
Exploded View INFOID:0000000006467026

EM

L
JPBIA3589GB

1. Intake manifold (bank 1) 2. Intake manifold gasket 3. O-ring M

4. Bracket 5. Intake manifold (center) 6. Gasket
7. Electric throttle control actuator 8. Gasket 9. Intake manifold gasket
10. Intake manifold (bank 2) 11. Gasket 12. Adaptor N
13. O-ring
Refer to GI-9, "Component" for symbols in the figure.
O
Disassembly and Assembly INFOID:0000000006467027

DISASSEMBLY
P
1. Remove tubocharger. Refer to EM-348, "Exploded View".
2. Remove EGR assembly. Refer to EM-358, "Exploded View".

EM-351
 INTAKE MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
3. Remove injection tube No.1 (1) and injection transfer tube (2).

: Engine front

JPBIA3616ZZ

4. Disconnect glow plug harness connector.

5. Disconnect oil separator tube.
6. Remove mounting bolts (A), and then remove intake manifold
(center) and electric throttle control actuator (1).

: Engine front

JPBIA3633ZZ

7. Remove mounting bolts (A) between intake manifold (bank 1)

and intake manifold (bank 2).

: Engine front

JPBIA3634ZZ

8. Remove intake manifold (bank 2).

• Loosen mounting bolts in reverse order as shown in the figure.

: Engine front

JPBIA3635ZZ

9. Remove intake manifold (bank 1).

EM-352
 INTAKE MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Loosen mounting bolts in reverse order as shown in the figure.
A
: Engine front

EM

JPBIA3636ZZ

D
ASSEMBLY
Note the following, and install in the reverse order of disassembly.
CAUTION: E
Clean each joint surface before installation.
Intake Manifold
F
Bank 1
• Tighten mounting bolts in numerical order as shown in the figure.

: Engine front G

I
JPBIA3636ZZ

Bank 2 J
• Tighten mounting bolts in numerical order as shown in the figure.

: Engine front K

M
JPBIA3635ZZ

Intake Manifold Gasket

• Install intake manifold gasket to cylinder head in direction shown in N
the figure.

A : Triangle press O
: Engine upper

JPBIA3630ZZ

EM-353
 INTAKE MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Install intake manifold adaptor gasket to intake manifold (bank 2) in
direction shown in the figure.

: Engine upper

JPBIA3632ZZ

• Install intake manifold (center) gasket to intake manifold (bank 2) in

direction shown in the figure.

: Engine upper

JPBIA3631ZZ

Electric Throttle Control Actuator

• Tighten mounting bolts of electric throttle control actuator equally and diagonally in several steps.
• Perform “Throttle Valve Closed Position Learning” after repair when removing or replacing electric throttle
control actuator. Refer to EC-1321, "Work Procedure".
Inspection INFOID:0000000006467028

INSPECTION AFTER DISASSEMBLY

Surface Distortion
• Check the surface distortion of the intake manifold mating surface with a straightedge and a feeler gauge.

Standard : Refer to SDS.

• If it exceeds the standard, replace intake manifold.

EM-354
 EXHAUST MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
EXHAUST MANIFOLD
A
Exploded View INFOID:0000000006467029

EM

I
JPBIA3562GB

1. Gasket 2. Exhaust manifold (bank 2) 3. Front exhaust manifold cover (bank 2) J

4. Rear exhaust manifold cover (bank 2) 5. Clamp 6. Gasket
7. Gasket 8. Clamp 9. Front exhaust manifold cover (bank 1)
10. Rear exhaust manifold cover (bank 1) 11. Exhaust manifold (bank 1) 12. Gasket K
A. To turbocharger B. Comply with the assembly procedure
when tightening. Refer to EM-355,
"Disassembly and Assembly".
L
Refer to GI-9, "Component" for symbols in the figure.

Disassembly and Assembly INFOID:0000000006467030

M
DISASSEMBLY
1. Remove oil feed tube for turbocharger.
N
2. Remove EGR cooler tube insulator cover. Refer to EM-348, "Exploded View".
3. Remove exhaust manifold cover.
4. Remove exhaust manifold. O

EM-355
 EXHAUST MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Loosen mounting nuts in the reverse order as shown in the fig-
ure.

A : Bank 2
B : Bank 1
: Engine front

JPBIA3613ZZ

5. Remove gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
ASSEMBLY
1. Install gasket to cylinder head as shown in the figure.

A : Triangle press
: Engine upper

JPBIA3614ZZ

2. Install exhaust manifold.

EM-356
 EXHAUST MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Tighten the mounting nuts in two steps separately in numerical
order as shown in the figure. A

A : Bank 2
B : Bank 1 EM
: Engine front

1st step C
: 18.0 N·m (1.8 kg-m, 13 ft-lb)
2st step : 30.0 N·m (3.1 kg-m, 22 ft-lb)
D

G
JPBIA3613ZZ

3. Install in the reverse order of disassembly, for the rest of parts.

H
Inspection INFOID:0000000006467031

INSPECTION AFTER DISASSEMBLY

I
Surface Distortion
• Check the surface distortion of the exhaust manifold mating surface with a straightedge and a feeler gauge.
J
Standard : Refer to SDS.
• If it exceeds the standard, replace exhaust manifold.
K
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust emission leaks.
L

EM-357
 EGR SYSTEM
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
EGR SYSTEM
Exploded View INFOID:0000000006467032

JPBIA3590GB

1. EGR cooler 2. Turbocharger 3. EGR cooler tube insulator

4. Gasket 5. EGR cooler tube 6. Intake manifold assembly
7. EGR cooler support bracket 8. EGR volume control valve 9. Gasket
10. EGR tube 11. Gasket 12. Gasket
13. Water hose 14. Clamp
A. To EGR water pump B. To radiator
Refer to GI-9, "Component" for symbols in the figure.

Disassembly and Assembly INFOID:0000000006467033

DISASSEMBLY
1. Remove turbocharger. Refer to EM-348, "Exploded View".
2. Remove fuel injector rail protector. Refer to EM-315, "Exploded View"

EM-358
 EGR SYSTEM
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
3. Remove mounting bolts (A) and remove EGR tube (1).
A
: Engine front

EM

JPBIA3606ZZ

D
4. Remove EGR cooler and EGR volume control valve.
• Loosen mounting bolts in reverse order as shown in the figure.

: Engine front
E

JPBIA3607ZZ

H
• Remove EGR cooler (1) with the EGR cooler bypass valve (A)
pressed in the direction shown by the arrow.

K
JPBIA3992ZZ

5. Remove EGR support bracket.

• Loosen mounting bolts in reverse order as shown in the figure. L

: Engine front
M

JPBIA3608ZZ O

6. Separate EGR cooler and EGR volume control valve, if necessary.

ASSEMBLY P
Note the following, and install in the reverse order of removal.
CAUTION:
Clean each joint surface before installation.
EGR Support Bracket

EM-359
 EGR SYSTEM
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Tighten mounting bolts in numerical order as shown in the figure.

: Engine front

JPBIA3608ZZ

EGR Cooler Tube

• Tighten mounting bolts in numerical order as shown in the figure.

: Engine front

JPBIA3607ZZ

Inspection INFOID:0000000006467034

INSPECTION AFTER DISASSEMBLY

Perform “EGR Volume Control Valve Closed Position Learning Value Clear” and “EGR Volume Control Valve
Closed Position Learning” after installing to the vehicle when replacing EGR volume control valve.
• EGR volume control valve closed position learning value clear: Refer to EC-1318, "Work Procedure".
• EGR volume control valve closed position learning: Refer to EC-1319, "Work Procedure".

EM-360
 OIL SEPARATOR
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
OIL SEPARATOR
A
Exploded View INFOID:0000000006467035

EM

J
JPBIA3591GB

1. Oil separator 2. Gasket 3. Clamp K

4. PCV hose 5. PCV tube 6. PCV hose
7. PCV valve 8. Turbocharger inlet & outlet tube
Refer to GI-9, "Component" for symbols in the figure. L

Disassembly and Assembly INFOID:0000000006467036

M
DISASSEMBLY
1. Remove intake manifold. Refer to EM-351, "Exploded View".
2. Remove water outlet. Refer to CO-80, "Exploded View". N
3. Remove oil separator.
• Loosen mounting bolts in the reverse order as shown in the
figure. O

: Engine front
P

JPBIA3638ZZ

EM-361
 OIL SEPARATOR
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
ASSEMBLY
1. Install gasket to oil separator.
CAUTION:
Check the gasket is not dropped.
2. Install oil separator.
• Tighten mounting bolts in numerical order as shown in the fig-
ure.

: Engine front

JPBIA3638ZZ

3. Install water outlet. Refer to CO-80, "Exploded View".

NOTE:
• There are three types of mounting bolts.

Tightening torque
A, B : 12 N·m (1.2 kg-m, 9 ft-lb)
C : 10 N·m (1.0 kg-m, 89 in-lb)

JPBIA3637ZZ

4. Install in the reverse order of disassembly, for the rest of parts.

EM-362
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
CAMSHAFT
A
Exploded View INFOID:0000000006467037

EM

J
JPBIA3571GB

1. Cylinder head housing (bank 1) 2. Camshaft RH (bank 1) 3. Camshaft bracket K

4. Camshaft bracket 5. Wear compensation gear (bank 1) 6. Wear compensation gear spacer
7. Timing chain sprocket spacer 8. Timing chain sprocket (bank 1) 9. Timing gear (bank 1)
10. Camshaft LH (bank 1) 11. Wear compensation gear (bank 2) 12. Camshaft RH (bank 2) L
13. Timing chain sprocket spacer (bank 2) 14. Timing chain sprocket (bank 2) 15. Timing gear (bank 2)
16. Camshaft LH (bank 2) 17. Cylinder head housing (bank 2) 18. Camshaft position sensor
Comply with the installation procedure Comply with the installation procedure M
A. when tightening. Refer to EM-363, B. when tightening. Refer to EM-363,
"Disassembly and Assembly" "Disassembly and Assembly"
Refer to GI-9, "Component" for symbols shown in the figure. N
Disassembly and Assembly INFOID:0000000006467038

CAUTION: O
• This engine has a different valve arrangement from normal DOHC 4-valve type engines. As both
camshafts on this engine have intake and exhaust camshafts.
P

EM-363
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Refer to the figure for intake and exhaust valve arrangement.
(The camshafts have, alternately, either intake valve or an
exhaust valve.)

1. Camshaft (right side)

2. Camshaft (left side)
A. Intake cam
B. Exhaust cam
C. Bank 1
D. Bank 2
: Engine front

JPBIA3809ZZ

DISASSEMBLY
1. Remove turbocharger. Refer to EM-348, "Exploded View"
2. Remove timing chain. Refer to EM-323, "Removal and Installation".
3. Remove camshaft position sensor.
CAUTION:
• Handle camshaft position sensor carefully and avoid impacts.
• Never disassemble camshaft position sensor.
• Never place sensor where it is exposed to magnetism.
4. Remove cylinder head housing with the following procedure:
a. Loosen mounting bolts in reverse order as shown in the figure.

A : Bank 1
B : Bank 2
: Engine front

JPBIA3577ZZ

b. Remove the cylinder head housing (1) using a screwdriver (A).

EM-364
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

EM

JPBIA3810ZZ F

B : Screwdriver insertion point

CAUTION: G
Be careful not to damage the mating surface.

5. Remove camshafts with the following procedure: H

a. Install cylinder head housing (1) to cylinder head stand [com-
mercial service tool: KV113B0200 (Mot.1573)] (A).
b. Loosen mounting bolts, and remove camshaft brackets and I
camshafts.
• Mark camshafts and camshaft brackets so they are placed in
the same position and direction for installation. J

K
JPBIA3849ZZ

ASSEMBLY L
1. Install camshaft to cylinder head housing with the following procedure:
a. Clean camshaft journal to remove any foreign material.
M
b. Install camshafts.

EM-365
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
c. Refer to the figure to install camshaft bracket in its original.

A : Part marking ADM2

B : Part marking ADM1
C : Part marking ECH2
D : Part marking ECH1
E : Bank 1
F : Bank 2
: Engine front

JPBIA3811ZZ

d. Tighten camshaft bracket mounting bolts.

• Finger tighten the camshaft bracket mounting bolts, until they just make contact.
2. Install cylinder head housing with the following procedure:
a. Rotate crankshaft groove (A) to set it in the position shown in the
figure.

1 : Crankshaft
b : 45 degrees
: Engine front

E1BIA0306ZZ

b. Remove foreign material completely from cylinder head housing backside and cylinder head installation
face.

EM-366
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
c. Apply liquid gasket to cylinder head as shown in the figure.
A
B : Bank 1
C : Bank 2
a : 0.5 - 2.5 mm (0.020 - 0.098 in) EM
: Engine front

Use Genuine Liquid Gasket or equivalent.

C

G
JPBIA3812ZZ

d. Install so that camshafts are positioned in the directions shown

in the figure. H
• Set the camshaft RH (1) notch (C) at angle of 45 degrees.
• Set the camshaft LH (2) with the offset side faced upward.
I
A : Bank 1
B : Bank 2

N
JPBIA3848ZZ

EM-367
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
e. Tighten mounting bolts of cylinder head housing in numerical
order as shown in the figure.

A : Bank 1
B : Bank 2
: Engine front

1st step : 5.0 N·m (0.51 kg-m, 4 ft-lb)

2nd step : 12.0 N·m (1.2 kg-m, 9 ft-lb)
CAUTION:
After tightening mounting bolts of cylinder head housing,
be sure to wipe off excessive liquid gasket from the mating
surface of cylinder head.
3. Install timing chain and related parts. Refer to EM-323,
"Removal and Installation".

JPBIA3577ZZ

4. Install crankshaft position sensor. Refer to EM-363, "Exploded View".

5. Install in the reverse order of disassembly, for the rest of parts
Inspection INFOID:0000000006467039

INSPECTION AFTER DISASSEMBLY

CAMSHAFT JOURNAL DIAMETER
• Measure the camshaft journal with a micrometer (A).

Standard : Refer to SDS.

JPBIA0122ZZ

CYLINDER HEAD HOUSING AND CAMSHAFT BRACKET INNER DIAMETER

• Measure the inner diameter (A) of cylinder head housing and cam-
shaft bracket with a bore gauge.

Standard : Refer to SDS.

JPBIA3850ZZ

CAMSHAFT JOURNAL OIL CLEARANCE

• (Oil clearance) = (Bracket inner diameter) – (Camshaft journal diameter)

EM-368
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

Standard : Refer to SDS. A

• If it exceeds the standard, replace camshaft or/and cylinder head housing and cylinder head assembly.
HYDRORICK ADJUSTER
EM
• Check that the adjuster clip (1) are in place.

E
JPBIA3851ZZ

INSPECTION AFTER INSTALLATION

Inspection for Leaks F
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage. G
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
H
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary. I
Summary of the inspection items:
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
J

Engine oil Level Leakage Level

Transmission / transaxle fluid
Leakage Level / Leakage Leakage K

Other oils and fluid* Level Leakage Level

Fuel Leakage Leakage Leakage L
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.
M

EM-369
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
CYLINDER HEAD
Exploded View INFOID:0000000006467040

JPBIA3583GB

1. Rocker arm 2. Hydraulic tappet 3. Valve cotter

4. Valve spring retainer 5. Valve spring 6. Valve oil seal
7. Cylinder head (bank 1) 8. Cylinder head gasket (bank 1) 9. Exhaust valve
10. Intake valve 11. Cylinder head gasket (bank 2) 12. Valve oil seal
13. Cylinder head (bank 2)
Comply with the assembly procedure when
A. tightening. Refer to EM-370, "Disassembly and
Assembly".
Refer to GI-9, "Component" for symbols in the figure.

Disassembly and Assembly INFOID:0000000006467041

DISASSEMBLY
1. Remove the following components and related parts.
• Turbocharger: Refer to EM-348, "Exploded View" .
• Intake manifold: Refer to EM-351, "Exploded View".
• Exhaust manifold: Refer to EM-355, "Exploded View".
• Water inlet and thermostat assembly: Refer to CO-80, "Exploded View".
• Front cover, timing chain: Refer to EM-322, "Exploded View".
• Cylinder head housing: Refer to EM-363, "Exploded View".

EM-370
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
2. Remove mounting bolts (A).
A
: Engine front

EM

JPBIA3818ZZ

D
3. Remove cylinder head.
• Loosen mounting bolts in reverse order as shown in the figure.
E
A : Bank 1
B : Bank 2
: Engine front
F

JPBIA3819ZZ K

4. Remove cylinder head gasket.

5. Set the cylinder head assembly to the cylinder head support [commercial service tool: KV113B0200 L
(Mot.1573)].
6. Remove hydraulic tappet.
CAUTION: M
Be sure to immerse the hydraulic tappets in a bath of engine oil to ensure no air enters.
7. Remove valve collet (1).
• Compress valve spring with valve spring compressor (com- N
mercial service too) (A).

JPBIA0643ZZ

8. Remove valve spring retainer and valve spring.

9. Check dimension of valve oil seal mounting position before removing valve and valve oil seal with the fol-
lowing procedure:

EM-371
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
a. Install the push rod (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot.1511-01)] on the valve oil seal.
NOTE:
The inner diameter of the push rod must be identical to that of
the valve. In addition, the bottom of the push rod must come into
contact with the metal upper section of the valve oil seal.

JPBIA3936ZZ

b. Install the guide tube (B) over the push rod (A) until the guide
tube comes into contact with the cylinder head, locking the push
rod with the knurled wheel.
• Remove the guide tube assembly plus push rod, being careful
not to loosen the knurled wheel.

JPBIA3937ZZ

10. Push valve stem to combustion chamber side, and remove valve.
• Identify installation positions, and store them without mixing them up.
11. Remove valve oil seal (1) with a valve oil seal puller [commercial
service tool: KV113B0090 (Mot.1335)] (A).

JPBIA0663ZZ

ASSEMBLY
1. Install valve.
NOTE:
Install larger diameter to intake side.
2. Install valve oil seal with the following procedure:
a. Position the protector (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot.1511-01)] on the valve.

JPBIA3938ZZ

EM-372
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
b. Position a valve oil seal (1) on the protector (A). Move the valve
oil seal past the protector. A
CAUTION:
Never lubricate valve oil seal.
EM

JPBIA3939ZZ

D
c. Remove the protector.
d. Push in the push rod (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot. 1511-01)] with palm of the hand until the E
guide tube (B) makes contact with the cylinder head.

JPBIA3937ZZ

H
3. Install valve spring.
NOTE:
The intake and exhaust valve springs are identical.
I
4. Install valve spring retainer.
5. Install valve collet (1).
• Compress valve spring with a valve spring compressor (com-
mercial service tool) (A). J
• Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition.
K

JPBIA0643ZZ
M
6. Install hydraulic tappet.
• Check that the tappets are filled with oil before refitting them.
7. Install cylinder head gasket with the following procedure: N
CAUTION:
Before installing cylinder head, inspect piston protrusion.
O

EM-373
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
a. Apply liquid gasket to cylinder head as shown in the figure.

B : Bank 1
C : Bank 2
a : 5.0 mm (0.20 in)
: Engine front

Use Genuine Liquid Gasket or equivalent.

JPBIA3852ZZ

b. Install cylinder head gasket (1), and apply liquid gasket to cylin-
der head gasket as shown in the figure.

B : Bank 1
C : Bank 2
a : 5.0 mm (0.20 in)
: Engine front

Use Genuine Liquid Gasket or equivalent.

JPBIA3926ZZ

EM-374
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
8. Install cylinder head, and tighten mounting bolts in numerical
order as shown in figure with the following procedure: A

A : Bank 1
B : Bank 2 EM
: Engine front

a. Tighten all cylinder head bolts.

C
: 30.0 N·m (3.1 kg-m, 22 ft-lb)

G
JPBIA3819ZZ

b. Tighten all cylinder head bolts (clockwise).

H
Angle tightening: 300 degrees
CAUTION:
Check and confirm the tightening angle by using an angle I
wrench [SST: KV10112100] (A) or protractor. Never judge by
visual inspection without the tool.
J
: Engine front

JPBIA3927ZZ
K

9. Assemble in the reverse order of disassembly, for the rest of parts.

Inspection INFOID:0000000006467042 L

INSPECTION AFTER DISASSEMBLY

M
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checked.
N
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
Never allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head, O
measure the distortion in six directions (A - F).

Standard: Refer to EM-393, "Cylinder Head". P

• If it exceeds the standard, replace cylinder head and cylinder
head housing.
NOTE:
Cylinder head cannot be replaced as a single part, because it is
machined together with cylinder head housing. Replace whole
cylinder head housing and cylinder head assembly.
JPBIA0176ZZ

EM-375
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

VALVE DIMENSIONS
• Check the dimensions of each valve. For the dimensions, refer to EM-393, "Cylinder Head".
• If dimensions are out of the standard, replace valve and check valve seat contact.
VALVE GUIDE CLEARANCE

Valve Stem Diameter

• Measure the diameter of valve stem with micrometer (A).

Standard : Refer to EM-393, "Cylinder Head".

Valve Guide Inner Diameter

• Measure the inner diameter of valve guide with bore gauge.

Standard : Refer to EM-393, "Cylinder Head".

Valve Guide Clearance

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve
stem diameter) JPBIA0183ZZ

Standard : Refer to EM-393, "Cylinder Head".

• If it exceeds the standard, replace valve and/or cylinder head and cylinder head housing.
VALVE SEAT CONTACT
• After confirming that the dimensions of valve guides and valves are within the specifications, perform this
procedure.
• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve
contact on the surface.
• Check if the contact area band is continuous all around the circum-
ference.

A : OK
B : NG
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions even after the re-check, replace
cylinder head and cylinder head housing.

JPBIA0187ZZ

VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

• Check valve spring pressure with valve spring seat installed at the
specified spring height.

Standard : Refer to EM-393, "Cylinder Head".

• If the pressure height is out of the standard, replace valve spring.

SEM113

EM-376
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
CYLINDER BLOCK
A
Exploded View INFOID:0000000006467043

EM

JPBIA3580GB

1. Cylinder block closure panel 2. Rear oil seal retainer 3. Cylinder block
4. Oil jet 5. Side bolt 6. Thrust bearing
7. Main bearing (upper) 8. Crankshaft 9. Main bearing (lower)

EM-377
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
10. Main bearing cap 11. Main bearing cap bolt 12. Pilot converter
13. Connecting rod cap bolt 14. Connecting rod cap 15. Connecting rod bearing
16. Connecting rod 17. Snap ring 18. Piston pin
19. Piston 20. Oil ring 21. Second ring
22. Top ring 23. A/T assembly 24. Crankshaft position sensor
25. Drive plate 26. Rear oil seal retainer
A. Comply with the installation procedure B. Comply with the assembly procedure C. Chamfered
when tightening. Refer to EM-342, "Re- when tightening. Refer to EM-378,
moval and Installation". "Disassembly and Assembly".
D. Comply with the assembly procedure
when tightening. Refer to EM-378, "Dis-
assembly and Assembly".
Refer to GI-9, "Component" for symbols shown in the figure.

Disassembly and Assembly INFOID:0000000006467044

DISASSEMBLY
1. Remove engine oil temperature/level sensor.
CAUTION:
Handle it carefully and avoid impacts.
2. Remove rear oil seal retainer.
3. Remove oil pan. Refer to EM-320, "Exploded View".
4. Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-386, "Inspection".
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove mounting bolts (A), and then remove connecting rod
cap.
• Put a paint mark on cap to identify each cylinder.

: Engine front

JPBIA3816ZZ

c. Using a hammer handle (A) or similar tool, push piston and con-
necting rod assembly out to the cylinder head side.

: Engine front

JPBIA3817ZZ

CAUTION:

EM-378
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Be careful not to damage oil jets (1), cylinder wall and
crankshaft pin, resulting from an interference of the con- A
necting rod big end.
• Never disassemble oil jets.
EM
: Engine front

JPBIA3928ZZ

D
5. Remove connecting rod bearings.
CAUTION:
When removing them, note the installation position. Keep them in the correct.
E
6. Remove piston rings from piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-386, "Inspection".
• Use a piston ring expander (commercial service tool) (A).
CAUTION: F
• When removing piston rings, be careful not to damage
the piston.
• Be careful not to damage piston rings by expanding
G
them excessively.

JPBIA3929ZZ
I
7. Remove the snap rings (1) using a screwdriver (A), and then
release the piston pin by hand.
J
B : Channel

L
JPBIA3930ZZ

8. Remove main bearing cap mounting bolts with the following procedure:
• Measure crankshaft end play before loosening main bearing cap mounting bolts. Refer to EM-386, M
"Inspection".
a. Loosen mounting bolts in reverse order as shown in the figure.
N
: Engine front

JPBIA3821ZZ

b. Loosen side bolt (A).

EM-379
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

JPBIA3820ZZ

: Engine front

c. Remove main bearing caps using a screwdriver (A).

• Put a paint mark on main bearing caps to identify each cylin-
der.

: Engine front

CAUTION:
• Be careful not to damage the mounting surface.
• Identify installation positions, and store them without
mixing them up.
JPBIA3822ZZ

9. Remove crankshaft.
10. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION:
Identify installation positions, and store them without mixing them up.
11. Remove oil jet, if necessary.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in the cylinder block, cylinder bore and crankcase
to remove any foreign matter.
CAUTION:
Use a goggles to protect your eye.

EM-380
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
2. Install water drain plug (1) to cylinder block as shown in the fig-
ure. A

: Engine front
EM
Water drain plug
: 25.0 N·m (2.6 kg-m, 18ft-ib)
C

G
JPBIA4015ZZ

3. Install main bearings and thrust bearings with the following procedure:
CAUTION: H
Be careful not to drop main bearing, and to scratch the surface.
a. Remove dust, dirt, and engine oil from the bearing mating surfaces of the cylinder block and main bearing
cap. I
b. Install the main bearings paying attention to the direction.
• Ensure the oil hole on cylinder block and oil hole (A) on the
main bearings (upper) (1) are aligned. J
• Before installing main bearings, apply engine oil to the bearing
surface (inside). Do not apply engine oil to the back surface,
but thoroughly clean it.
K

JPBIA3940ZZ

M
• Adjust the position of the main bearings (upper) using a fleer
gauge.
N
a : 0.490 mm (0.019 in)
b : 0.580 mm (0.023 in)
c : 0.015 mm (0.001 in) O

: Engine front
P
JPBIA3942ZZ

EM-381
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Adjust the position of the main bearings (lower) (1) using a
fleer gauge (A).

Main bearing caps No.1, 2 and 3

b : 0.889 mm (0.035 in)
Main bearing caps No.4
b : 1.480 mm (0.058 in)

JPBIA3943ZZ

c. Install thrust bearings (1) to both sides of the No. 4 journal hous-
ing on the cylinder block.
• Install thrust bearings with the oil groove facing crankshaft arm
(outside).

JPBIA3941ZZ

4. Install crankshaft to cylinder block.

• While turning crankshaft by hand, check that it turns smoothly.
5. Install main bearing caps with the following procedure:
a. Tighten new main bearing cap bolts in numerical order as shown
in the figure with the following procedure:

: Engine front

i. Tighten main bearing cap bolts.

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

CAUTION:
Be sure to check that the main bearing cap is in contact
with the cylinder block before tightening the bolts. JPBIA3821ZZ

ii. Tighten main bearing cap bolts (clockwise).

Tightening angle: 100 degrees

CAUTION:
Confirm the tightening angle by using an angle wrench
[SST: KV10112100] (A) or protractor. Never judge by visual
inspection without the tool.

JPBIA3944ZZ

iii. Tighten side bolt (A).

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

EM-382
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

EM

JPBIA3820ZZ

D
: Engine front

• After installing mounting bolts, check that crankshaft can be rotated smoothly by hand.
E
• Check crankshaft end play. Refer to EM-386, "Inspection".
6. Install piston to connecting rod with the following procedure:
a. Install snap ring to the groove of the piston rear side.
F
• Insert it fully into the groove.
b. Assemble piston to connecting rod.
• Point the mark engraved (A) on the piston head facing as
shown in the figure. G

B : Bank 1
C : Bank 2 H
: Engine front

• Piston pin can be pushed in by hand without excessive force.

I
From the front to the rear, insert piston pin into piston and con-
necting rod.

M
JPBIA3945ZZ

c. Install snap ring to the groove of the piston front side. N

• Insert it fully into the groove.
• After installing, check that connecting rod moves smoothly.
7. Using a piston ring expander (commercial service tool), install piston rings.
CAUTION: O
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.
P

EM-383
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Position each ring with the gap as shown in the figure referring
to the piston front mark.

: Engine front

JPBIA3946ZZ

8. Install connecting rod bearing (upper) and connecting rod bearing (lower) to connecting rod and connect-
ing rod cap.
• When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Never
apply new engine oil to the back surface, but thoroughly clean the back surface.
• Adjust the position of the connecting rod bearing (1) using a
fleer gauge [1.4 mm (0.055 in)] (A).
NOTE:
Locate the bearing for the connecting rod cap side.

b : 1.4 mm (0.055 in)

JPBIA3947ZZ

9. Install piston and connecting rod assembly to crankshaft with the following procedure:
• Install removed parts in the same locations as before.
a. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
b. Install piston with the mark engraved (A) on the piston head fac-
ing the rear of the engine as shown in the figure.

B : Bank 1
C : Bank 2
: Engine front

JPBIA3945ZZ

EM-384
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
c. Using a piston ring compressor [SST: EM03470000 (—)] (A) or
suitable tool. A
CAUTION:
Be careful not to damage oil jets, cylinder wall and crank-
shaft pin, resulting from an interference of the connecting
EM
rod big end.

JPBIA3948ZZ

D
10. Install connecting rod cap with the following procedure:
CAUTION:
Check that there is no gap in the thrust surface (A) of the
E
joint between connecting rod (1) and connecting rod cap (2)
and that these parts are in the correct position. And then,
tighten the new bolts.
a. Tighten new connecting rod cap bolts. F

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

G
JPBIA3949ZZ

b. Tighten connecting rod cap bolts (clockwise).

H
Tightening angle: 55 degrees
CAUTION:
Confirm the tightening angle by using an angle wrench I
[SST: KV10112100 (—)] (A) or protractor. Never judge by
visual inspection without the tool.
J

JPBIA0846ZZ
K
• After tightening connecting rod cap bolt, check that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-386, "Inspection".
• Check the piston protrusion. Refer to EM-386, "Inspection". L
11. Install oil pan. Refer to EM-320, "Exploded View".
12. Install rear oil seal retainer with the following procedure:
M
a. Set guide bolt (A) to rear oil seal retainer (1).

: Engine front
N
b. Move the rear oil seal retainer evenly by hand until it makes con-
tact with the cylinder block.
O

P
JPBIA3813ZZ

EM-385
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
c. Tighten mounting bolts in numerical order as shown in the fig-
ure.
i. Tighten all mounting bolts.

: 5.0 N·m (0.51 kg-m, 44 in-lb)

ii. Tighten all mounting bolts.

: 10.0 N·m (1.0 kg-m, 89 in-lb)

JPBIA3814ZZ

13. Install drive plate.

a. Fix crankshaft using ring gear stopper [SST: KV10116500 (—].
b. Tighten bolts by using Torx wrench (size 55+) [SST: (Mot.1959)]
in numerical order as shown in the figure with the following pro-
cedure:
i. Tighten all mounting bolts.

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

ii. Tighten all mounting bolts (clockwise).

Tightening angle: 55 degrees

JPBIA3951ZZ

14. Install crankshaft position sensor.

CAUTION:
• Handle crankshaft position sensor carefully and avoid impacts.
• Never place crankshaft position sensor in a location where it is exposed to magnetism.
15. Install engine oil temperature/level sensor.
CAUTION:
Handle it carefully and avoid impacts.
16. Assemble in the reverse order of disassembly.
Inspection INFOID:0000000006467045

CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator (A).

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, replace thrust bearings, and measure
again. If it still exceeds the standard, also replace crankshaft.

JPBIA3823ZZ

CRANKSHAFT PIN JOURNAL DIAMETER

EM-386
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Measure the outer diameter of crankshaft pin journal with a
micrometer (A). A

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, measure the connecting rod bearing oil EM
clearance. Refer to “CONNECTING ROD BEARING OIL CLEAR-
ANCE”.
C

JPBIA0228ZZ

D
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals with a micrometer.

Standard : Refer to EM-393, "General Specification". E

• If it exceeds the standard, measure the main bearing oil clearance. Refer to “MAIN BEARING OIL CLEAR-
ANCE”.
F
CONNECTING ROD SIDE CLEARANCE
• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A). G

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, replace connecting rod, and measure H
again. If it still exceeds the standard, also replace crankshaft.

JPBIA3953ZZ

CONNECTING ROD BIG END DIAMETER J

• Install connecting rod cap without connecting rod bearing installed,
and tightening connecting rod cap bolts to the specified torque.
Refer to EM-378, "Disassembly and Assembly". K

1 : Connecting rod
• Measure the inner diameter of connecting rod big end with an L
inside micrometer.

Standard : Refer to EM-393, "General Specifica- M

tion".
JPBIA3954ZZ
• If it exceeds the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE N

Connecting Rod Bushing Inner Diameter

Measure the inner diameter of connecting rod bushing with an inside O
micrometer (A).

Standard : Refer to EM-393, "General Specifica-

tion". P

JPBIA0223ZZ

EM-387
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer (A).

Standard : Refer to EM-393, "General Specifica-

tion".

JPBIA0218ZZ

Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, replace connecting rod assembly and/or piston and piston pin assembly.
• If replacing piston and piston pin assembly. Refer to “PISTON PROTRUSION”.

PISTON PROTRUSION
Measure the protrusion of piston with the following procedure:
1. Set piston at a point close to the TDC. Refer to EM-323, "Removal and Installation".
2. Set the dial indicator stand set [commercial service tool:
KV113B0040 (Mot.251-01)] (B) and [commercial service tool:
KV113B0050 (Mot.252-01)] (A) at the location as shown in the
figure.
3. Set the indicator scale to “0” where the piston protrusion is max-
imized.
4. Move the dial indicator stand so that the tip of dial indicator can
contact the cylinder block. Read the difference.

Standard : Refer to EM-393, "General Specification".

JPBIA1803ZZ

5. If measured value is out of the standard, replace piston. Select a

piston in “Piston Protrusion Grade”.

A : Date of manufacture
B : Piston grade
C : Modification in production suffix
D : Mark engraved
: Engine front

Piston Protrusion Grade: JPBIA0589ZZ

Refer to EM-393, "General Specification".

PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter

EM-388
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
Measure the inner diameter of piston pin hole with an inside
micrometer (A). A

Standard : Refer to EM-393, "General Specification".

EM

JPBIA0217ZZ

D
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer (A).

Standard : Refer to EM-393, "General Specification". E

G
JPBIA0218ZZ

Piston to Piston Pin Oil Clearance H

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

Standard : Refer to EM-393, "General Specification". I

• If it exceeds the standard, replace piston and piston pin an assembly.
NOTE:
Piston is available together with piston pin as assembly. J
PISTON RING SIDE CLEARANCE
• Measure the side clearance of piston ring (1) and piston ring
groove with a feeler gauge (C). K

A : OK
B : NG L

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, replace piston ring, and measure again. M
If it still exceeds the standard, also replace piston.
JPBIA0219ZZ

N
PISTON RING END GAP
• Check that cylinder bore inner diameter is within specification. Refer to “PISTON TO CYLINDER BORE
CLEARANCE”.
• Lubricate with new engine oil to piston (1) and piston ring (2), and O
then insert (A) piston ring until middle of cylinder with piston, and
measure piston ring end gap with a feeler gauge (B).
P
C : Measuring point

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, replace piston ring, and measure again.
If it still exceeds the standard, replace cylinder block and piston
rings.
JPBIA0220ZZ

EM-389
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
CYLINDER BLOCK TOP SURFACE DISTORTION
• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
• Measure the distortion on the cylinder block upper face at different
points in six directions (C, D, E, F, G and H) with a straight edge
(A) and feeler gauge (B).

Standard : Refer to EM-393, "General Specifica-

tion".
• If it exceeds the standard, replace cylinder block.

JPBIA0224ZZ

MAIN BEARING HOUSING INNER DIAMETER

• Install main bearing cap without main bearings installed, and tighten main bearing cap mounting bolts to the
specified torque. Refer to EM-378, "Disassembly and Assembly".
• Measure the inner diameter of main bearing housing with a bore
gauge.

1 : Cylinder block
2 : Main bearing cap

Standard : Refer to EM-393, "General Specifica-

tion".
• If it exceeds the standard, replace cylinder block and main bearing
caps assembly. JPBIA3955ZZ
NOTE:
Main bearing caps cannot be replaced individually, because it is machined together with the cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
• Using a bore gauge, measure the cylinder bore for wear, out-of-round and taper at six different points on
each cylinder.

Standard:
Cylinder bore inner diameter
: Refer to EM-393, "General Specifica-
tion".
• If it exceeds the standard, or if there are scratches and/or seizure on the cylinder inner wall, replace cylinder
block.
Piston Skirt Diameter
Measure the outer diameter of piston skirt with a micrometer (A).

Standard : Refer to EM-393, "General Specification".

Measure point : Refer to EM-393, "General Specifica-

tion".

JPBIA0227ZZ

EM-390
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
Piston to Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter. A
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter)

Standard : Refer to EM-393, "General Specifica- EM

tion".
• If it exceeds the standard, replace piston and piston pin assembly and/or cylinder block.
CONNECTING ROD BEARING OIL CLEARANCE C

Method by Calculation
• Install connecting rod bearings (1) to connecting rod (2) and con- D
necting rod bearing cap, and tighten connecting rod cap bolts to
the specified torque. Refer to EM-378, "Disassembly and Assem-
bly".
• Measure the inner diameter of connecting rod bearing with an E
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter) F

Standard : Refer to SDS.

• If it exceeds the standard. Replace connecting rod bearing or/and JPBIA3956ZZ
G
connecting rod.
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely. H
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod cap bolts to the speci-
I
fied torque. Refer to EM-378, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.
• Remove connecting rod cap and bearing, and using the scale on J
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the standard is K
the same as that described in “Method by Calculation”.

JPBIA0231ZZ
M

MAIN BEARING OIL CLEARANCE

Method by Calculation N
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap mounting bolts to the specified
torque. Refer to EM-378, "Disassembly and Assembly".
O
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
P
Standard : Refer to SDS.
• If it exceeds the standard, select proper main bearing according to
main bearing inner diameter and crankshaft main journal diameter
to obtain specified bearing oil clearance. Refer to SDS. JPBIA3957ZZ

Method of Using Plastigage

• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.

EM-391
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Cut a plastigage slightly shorter than the bearing width, and place it in the crankshaft axial direction, avoiding
oil holes.
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap mounting bolts to
the specified torque. Refer to EM-378, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.
• Remove main bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the standard is
the same as that described in “Method by Calculation”.

JPBIA0231ZZ

EM-392
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [V9X]

SERVICE DATA AND SPECIFICATIONS (SDS) A

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000006467046
EM

GENERAL SPECIFICATIONS
C
Engine type V9X
Cylinder arrangement V-6
Displacement cm3 (cu in) 2,998 (182.93) D
Bore and stroke mm (in) 84.0 x 90.0 (3.307 x 3.543)
Valve arrangement DOHC
E
Firing order 1-2-3-4-5-6
Compression 2
Number of piston rings
Oil 1 F
Compression ratio 15.5

Drive Belts INFOID:0000000006467047 G

DRIVE BELT
H
Tension of drive belt Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Cylinder Head INFOID:0000000006467048

I

CYLINDER HEAD
Unit: mm (in)
J
Items Standard
Head surface distortion 0.05 (0.0020)
K

JPBIA3958ZZ N

Normal cylinder head height “a” 132.5 (5.22)

O
VALVE DIMENSIONS

EM-393
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [V9X]
Unit: mm (in)

E1BIA0064ZZ

Item Standard
Intake 27.58 - 27.82 (1.0858 - 1.0953)
Valve head diameter “D”
Exhaust 25.88 - 26.12 (1.0189 - 1.0283)
Intake 103.865 - 103.899 (4.089 - 4.091)
Valve length “L”
Exhaust 103.56 - 104.00 (4.077 - 4.094)
Intake 5.970 - 5.985 (0.2350 - 0.2356)
Valve stem diameter “d”
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Measuring point "X1" 35.0 (1.378)
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 0.94 (0.037)
Valve lift amount 8.0 (0.315)

VALVE SPRING

Free height 46.90 mm (1.8465 in)

200 - 220 N (20.4 - 22.4 kg, 45 - 49 lb) 34.90 mm (1.3740 in)
Pressure height
353 - 387 N (36.0 - 39.5 kg, 79 - 87 lb) 26.90 mm (1.0591 in)
Diameter of the wire 2.78 - 2.82 mm (0.1094 - 0.1110 in)
Inner diameter 13.90 - 14.30 mm (0.5472 - 0.5630 in)
Outer diameter 19.50 - 19.90 mm (0.7677 - 0.7835 in)
Valve spring squareness 1.2 mm (0.047 in)

EM-394