ENGINE

SECTION
ENGINE MECHANICAL
EM EM

E
CONTENTS
PRECAUTION ............................................... 3 SPARK PLUG ................................................... 16 F
Exploded View .........................................................16
PRECAUTIONS ................................................... 3
Precaution for Supplemental Restraint System REMOVAL AND INSTALLATION ............... 17 G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 3 DRIVE BELT AUTO TENSIONER AND IDLER
Precautions Necessary for Steering Wheel Rota- PULLEY ............................................................. 17
Exploded View .........................................................17 H
tion After Battery Disconnection ................................ 3
Precaution for Procedure without Cowl Top Cover...... 4
Precaution for Drain Engine Coolant and Engine
AIR CLEANER AND AIR DUCT ....................... 18
Exploded View .........................................................18 I
Oil .............................................................................. 4
Precaution for Disconnecting Fuel Piping ................. 4 INTAKE MANIFOLD ......................................... 19
Precaution for Handling High Pressure Fuel Sys- Exploded View .........................................................19
tem ............................................................................ 4 J
Precaution for Removal and Disassembly ................ 4 EXHAUST MANIFOLD ...................................... 21
Precaution for Inspection, Repair and Replace- Exploded View .........................................................21
ment .......................................................................... 4
OIL PAN (LOWER) ........................................... 23 K
Precaution for Assembly and Installation .................. 4
Precaution for Angle Tightening ................................ 5 Exploded View .........................................................23
Precaution for Liquid Gasket ..................................... 5
HIGH PRESSURE FUEL PUMP AND FUEL L
PREPARATION ............................................ 7 HOSE ................................................................. 25
Exploded View .........................................................25
PREPARATION ................................................... 7 Removal and Installation .........................................25
M
Special Service Tools ................................................ 7 Inspection ................................................................29
Commercial Service Tools ........................................ 9
FUEL INJECTOR AND FUEL TUBE ................ 30
BASIC INSPECTION ................................... 10 Exploded View .........................................................30 N
Removal and Installation .........................................30
CAMSHAFT VALVE CLEARANCE ...................10 Inspection ................................................................35
Inspection and Adjustment ...................................... 10
IGNITION COIL, SPARK PLUG AND ROCK- O
COMPRESSION PRESSURE ............................13 ER COVER ........................................................ 36
Inspection ................................................................ 13 Exploded View .........................................................36
P
PERIODIC MAINTENANCE ......................... 14 UNIT REMOVAL AND INSTALLATION ...... 38
DRIVE BELT .......................................................14 ENGINE ASSEMBLY ........................................ 38
Checking ................................................................. 14 Exploded View .........................................................38
AIR CLEANER FILTER ......................................15 Removal and Installation .........................................39
Exploded View ........................................................ 15 UNIT DISASSEMBLY AND ASSEMBLY ... 42

Revision: 2012 August EM-1 C26

ENGINE STAND SETTING ................................ 42 OIL PAN (UPPER) ............................................. 56
Setting .................................................................... 42 Exploded View ........................................................ 56

DRIVE PLATE .................................................... 43 CYLINDER BLOCK ........................................... 58

Exploded View ........................................................ 43 Exploded View ........................................................ 58

TIMING CHAIN .................................................. 44 SERVICE DATA AND SPECIFICATIONS

Exploded View ........................................................ 44 (SDS) .......................................................... 63
CAMSHAFT ....................................................... 48 SERVICE DATA AND SPECIFICATIONS
Exploded View ........................................................ 48 (SDS) ................................................................. 63
OIL SEAL ........................................................... 51 General Specification .............................................. 63
Drive Belt ................................................................ 63
VALVE OIL SEAL ..................................................... 51 Air Cleaner Filter ..................................................... 63
VALVE OIL SEAL : Removal and Installation ......... 51 Spark Plug .............................................................. 64
Exhaust Manifold .................................................... 64
FRONT OIL SEAL ..................................................... 51 Camshaft ................................................................. 64
FRONT OIL SEAL : Removal and Installation ........ 51 Cylinder Head ......................................................... 66
Cylinder Block ......................................................... 68
REAR OIL SEAL ....................................................... 51
Connecting Rod Bearing ......................................... 72
REAR OIL SEAL : Removal and Installation .......... 51
Main Bearing ........................................................... 72
CYLINDER HEAD .............................................. 52
Exploded View ........................................................ 52

Revision: 2012 August EM-2 C26

 PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
PRE-TENSIONER" INFOID:0000000008758981

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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 “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING: D
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by E
an authorized NISSAN/INFINITI dealer.
• 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
F
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors. G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING: H
Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never 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 I
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. J
Precautions Necessary for Steering Wheel Rotation After Battery Disconnection
INFOID:0000000008758982

K
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition switch to the LOCK position,
then disconnect both battery cables. L
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing M
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro- N
cedure below before starting the repair operation.
OPERATION PROCEDURE
O
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the ignition switch to ACC position. P
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.

Revision: 2012 August EM-3 C26

 PRECAUTIONS
< PRECAUTION >
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.
Precaution for Procedure without Cowl Top Cover INFOID:0000000008758983

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

PIIB3706J

Precaution for Drain Engine Coolant and Engine Oil INFOID:0000000008758984

Drain engine coolant and engine oil when the engine is cooled.
Precaution for Disconnecting Fuel Piping INFOID:0000000008758985

• 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.
Precaution for Handling High Pressure Fuel System INFOID:0000000008758986

• High pressure fuel system components are between high pressure fuel pump and fuel injector.
• Always release fuel pressure and never start the engine when performing removal and installation.
• When removing or installing parts without releasing fuel pressure, fuel may be splashed and, if fuel contacts
skin or eyes, it may cause inflammation.
Precaution for Removal and Disassembly INFOID:0000000008758987

• When instructed to use SST, use the 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 the 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.
Precaution for Inspection, Repair and Replacement INFOID:0000000008758988

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and Installation INFOID:0000000008758989

• 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.
• 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.

Revision: 2012 August EM-4 C26

 PRECAUTIONS
< PRECAUTION >
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage. A
• 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.
EM
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Precaution for Angle Tightening INFOID:0000000008758990
C
• Use the angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
- Cylinder head bolts
- Main bearing cap bolts D
- Connecting rod cap bolts
- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle
tightening) E
• Never 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.
F
Precaution for Liquid Gasket INFOID:0000000008758991

REMOVAL OF LIQUID GASKET SEALING G

• After removing mounting nuts and bolts, separate the mating sur-
face using the seal cutter [SST: KV10111100] (A) and remove old
liquid gasket sealing.
H
CAUTION:
Be careful not to damage the mating surfaces.
• Tap (B) the seal cutter [SST: KV10111100] to insert it, and then
slide (C) it by tapping on the side as shown in the figure. I
• In areas where the seal cutter [SST: KV10111100] is difficult to use,
use a plastic hammer to lightly tap the parts, to remove it.
CAUTION: J
If for some unavoidable reason tool such as a screwdriver is
JPBIA0052ZZ
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE K
1. Using a scraper (A), remove old liquid gasket adhering to the
gasket application surface and the mating surface.
• Remove liquid gasket completely from the groove of the gas- L
ket 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
M
adhering moisture, grease and foreign materials.

N
JPBIA0053ZZ

3. Attach liquid gasket tube to the tube presser (commercial ser- O

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

EMA0622D

Revision: 2012 August EM-5 C26

 PRECAUTIONS
< PRECAUTION >
• As for bolt holes, normally apply liquid gasket inside the holes.
Occasionally, it should be applied outside the holes. Check to
read the text of this manual.
• Within 5 minutes of liquid gasket application, install the mating
component.
• If liquid gasket protrudes, wipe it off immediately.
• Never retighten mounting bolts or nuts after the installation.
• After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe
SEM159F
them.

Revision: 2012 August EM-6 C26

 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000008758992
EM

Name Description
C

Seal cutter Removing parts attached with liquid D

KV10111100 gasket

E
ZZA0013D

F
Heated oxygen sensor wrench
KV10113700
Removing and installing A/F sensor 1
or
KV10117100 G

ZZA1007D

H
Compression gauge set
EG15050001
(Set composed of 1 and 2)
1. Compression gauge Measuring compression pressure I
2. Compression gauge adapter
Compression gauge adapter
EG15050300
ZZA0008D J

K
Pulley puller
Removing crankshaft pulley
KV11103000

L
ZZA0010D

Angle wrench
Checking tightening angle
KV10112100
N

ZZA0120D

O
Valve spring compressor set
KV10116200
1. Attachment
Removing and installing valve collet
P
KV10115900
2. Adapter
KV10109220
PBIC1650E

Revision: 2012 August EM-7 C26

 PREPARATION
< PREPARATION >
Name Description

Valve oil seal puller

Removing valve oil seal
KV10107902

ZZA0015D

Valve oil seal drift

Installing valve oil seal
KV10115600

ZZA0996D

Manual-type lift table caddy Removing and installing engine as-

GW86490800 sembly

ZZA1210D

Stopper plate Removing and installing crankshaft

KV11105210 pulley

ZZA0009D

Pilot bushing puller

Removing pilot converter
ST16610001

ZZA0046D

Pulley holder Removing and installing crankshaft

KV10109300 pulley bolts

ZZA1010D

Revision: 2012 August EM-8 C26

 PREPARATION
< PREPARATION >
Name Description
A

Injector remover EM
Removing and installing fuel injector
KV10119600

C
JPBIA3746ZZ

D
Injector seal drift set
Installing fuel injector seal
KV101197S0
E

JPBIA3281ZZ

Commercial Service Tools INFOID:0000000008758993

F

Name Description G
Quick connector release
Disconnecting the fuel feed hose (fuel tube side)
16441 6N210
Engine slinger H
10005 EN21A: Front
10006 EN20A: Rear
Supporting and hoisting engine
Engine slinger mounting bolt I
11916 EN21A: Front (2 bolts)
01125 E8031 : Rear (2 bolts)
Dowel pin
Positioning of crankshaft and signal plate J
12313 ED000

Revision: 2012 August EM-9 C26

 CAMSHAFT VALVE CLEARANCE
< BASIC INSPECTION >
BASIC INSPECTION
CAMSHAFT VALVE CLEARANCE
Inspection and Adjustment INFOID:0000000008758994

INSPECTION
Check valve clearance according to the following procedure, when the camshaft and valve-related parts are
removed and installed or replaced, or symptoms due to changes in valve clearance as a result of aging (poor
starting, rough idle, unusual noise) are obvious.
1. Remove rocker cover. Refer to EM-36, "Exploded View".
2. Follow the procedure below and measure the valve clearance.
a. Position the No. 1 cylinder at compression-stroke TDC.
• Rotate the crankshaft pulley (1) clockwise as viewed from the
front, and align the TDC engraved line (no color) (B) with the
timing indicator (A).

C : Engraved line (white)

PBIC3960E

• Check that the camshaft noses of No. 1 cylinder are posi-

tioned as shown in the figure.

1 : Camshaft (INT)
2 : Camshaft (EXH)
: Engine front

NOTE:
If camshaft noses are not at the specified positions, rotate the
crankshaft pulley one more turn. Alternatively, it is also permit-
ted to inspect the No. 4 cylinder compression-stroke TDC JPBIA4347ZZ
check position (Step 5) first.

b. Refer to the figure, and measure valve clearance for the table
item below with an ×, using a feeler gauge.

Valve clearance : Refer to EM-64, "Camshaft".

standard

PBIC3192J

Revision: 2012 August EM-10 C26

 CAMSHAFT VALVE CLEARANCE
< BASIC INSPECTION >
• Refer to the figure, and measure valve clearance for the table
item below with an ×, using a feeler gauge. A

A : Exhaust side
B : No. 1 cylinder EM
C : No. 2 cylinder
D : No. 3 cylinder
E : No. 4 cylinder C
F : Intake side
: Engine front JPBIA5120ZZ

D
Measuring position No. 1 cylinder No. 2 cylinder No. 3 cylinder No. 4 cylinder

No. 1 cylinder at TDC on its compression EXH × ×

stroke E
INT × ×

c. Turn crankshaft 360 degrees to set No. 4 cylinder at TDC of its compression stroke.
• Refer to the figure, and measure valve clearance for the table F
item below with an ×, using a feeler gauge.

A : Exhaust side G
B : No. 1 cylinder
C : No. 2 cylinder
D : No. 3 cylinder H
E : No. 4 cylinder
F : Intake side
: Engine front JPBIA5121ZZ
I

Measuring position No. 1 cylinder No. 2 cylinder No. 3 cylinder No. 4 cylinder
EXH × ×
J
No. 4 cylinder at TDC on its compres-
sion stroke INT × ×

3. If the value is outside the standard, refer to “Adjustment” and adjust. K

ADJUSTMENT
NOTE: L
Adjust by selecting the head thickness of the valve lifter. (Adjustment shims are not used.)
1. Remove camshaft. Refer to EM-48, "Exploded View".
2. Remove the valve lifters for parts that are outside the standard. M
3. Measure thickness of the removed valve lifter center part using
a micrometer (A).
N

P
PBIC3195J

4. Measure the thickness of the replacement valve lifter using the following formula. (Units: mm)

Formula for determining valve lifter t = t1 + (C1 – C2)

thickness:
t = Thickness of replacement valve lifter

Revision: 2012 August EM-11 C26

 CAMSHAFT VALVE CLEARANCE
< BASIC INSPECTION >
t1 = Thickness of removed valve lifter
C1 = Valve clearance measurement value
C2 = Standard valve clearance
INT : 0.28 mm
EXT : 0.30 mm
• New valve lifter thickness (B) can be identified by stamp mark
(A) on the reverse side (inside of cylindrical part).
NOTE:
• “302H” stamp indicates a valve lifter thickness of 3.02 mm.
• Valve lifter thickness settings: Thickness 3.00 - 3.50 mm
(0.02 mm intervals), 26 types (set at time of shipping from
the plant) Refer to EM-64, "Camshaft".

PBIC3196J

5. Install selected valve lifter.

6. Install camshaft. Refer to EM-48, "Exploded View".
7. Install parts related to the timing chain. Refer to EM-44, "Exploded View".
8. Rotate crankshaft at least 2 rotations using the manual tool.
9. Measure the valve clearance again and check that it is within the valve clearance standard.
10. Install removed parts in the reverse order of removal.
11. Start engine and check for any unusual noise and vibration.

Revision: 2012 August EM-12 C26

 COMPRESSION PRESSURE
< BASIC INSPECTION >
COMPRESSION PRESSURE
A
Inspection INFOID:0000000008758995

COMPRESSION PRESSURE INSPECTION EM

1. Warm up engine and then stop it.
2. Release fuel pressure. Refer to EC-83, "Work Procedure".
• Eliminate the fuel pressure using the method listed under “If CONSULT is not used”. C
CAUTION:
Leave the fuel pump fuse off after removing the fuel pressure and until the compression pres-
sure inspection is complete. D
3. Remove ignition coil and spark plug from all cylinders. Refer to EM-36, "Exploded View".
4. Attach a rev counter or CONSULT to the engine.
5. Attach the adapter (SST: EG15050300) (A) to the compression E
gauge (SST: EG15050001) (B), and insert into the plug hole.

JPBIA5122ZZ
H

6. Fully depress the accelerator pedal and crank the engine. After the gauge indication stabilizes, read com-
pression pressure and engine speed. Repeat the measurement on each cylinder. I

Compression pressure : Refer to EM-63, "General Specification".

• If engine speed is not within the standard, check the battery and measure again in normal conditions. J
• If compression pressure is at or below the limit, check valve clearance and system components around
the combustion chamber (valve, valve seat, piston, piston rings, cylinder bore, cylinder head, cylinder
head gasket, etc.), and measure again.
• If the compression pressure in a few of the cylinders is low, add some engine oil through the spark plug K
mounting holes, and check again.
- It is possible that piston ring is worn or damaged if compression pressure is improved by adding engine
oil. Check piston ring, and replace it if necessary. L
- There may be a valve malfunction if compression pressure is not improved by adding engine oil. Check
valve. If damaged, replace valve or cylinder head.
• If compression pressures of adjacent two cylinders are low, and if pressures cannot be improved by
M
adding engine oil, gasket is leaking. Replace cylinder head gasket.
7. After inspection, install removed parts.
8. Start engine and check that the engine runs smoothly. N
9. Perform diagnosis and check for any indicated problems. Refer to EC-65, "Work Flow".

Revision: 2012 August EM-13 C26

 DRIVE BELT
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE
DRIVE BELT
Checking INFOID:0000000008758996

INSPECTION

JPBIA5123ZZ

1. Sub-starter & generator 2. Water pump 3. Crankshaft pulley

4. A/C compressor 5. Drive belt auto tensioner 6. Idler pulley
7. Drive belt
A. Usable range B. Range for installation of new drive C: INDICATOR
belt

• Check that the indicator of drive belt auto tensioner is within the usable range (A).
NOTE:
The range when installing a new drive belt is (B).
• Visually check belts to check that there is no wear, damage, or cracks on inside and sides.
• If outside the usable range or if the belt is malfunctioning, replace the belt.
ADJUSTMENT
The tension is automatically adjusted by the drive belt auto tensioner. Tension adjustment is not necessary.
CAUTION:
• Never place hand in a position where it may be pinched, in the event that the fixing tool becomes dis-
connected.
• Always use a hexagon socket wrench (WAF: 19 mm).
CAUTION:
• Check that the drive belt path is correct.
• Check that the drive belt is securely inside the groove on each pulley.
• Check that there is no engine oil, engine coolant, or other oil or grease on the drive belt and sur-
rounding locations.

Revision: 2012 August EM-14 C26

 AIR CLEANER FILTER
< PERIODIC MAINTENANCE >
AIR CLEANER FILTER
A
Exploded View INFOID:0000000008758997

EM

J
JPBIA6268GB

1. Resonator 2. Clamp 3. PCV hose K

4. Inlet air duct (upper) 5. Mounting rubber 6. Inlet air duct (lower)
7. Mounting rubber 8. Air cleaner case (lower) 9. Mounting rubber
10. Collar 11. Air cleaner element 12. Atmospheric pressure sensor L
13. Air cleaner case (upper) 14. Clamp 15. Air duct
16. Clamp 17. Mass air flow sensor 18. Gasket
A. To electric throttle control actuator B. To rocker cover M
: Not reusable
: N·m (kg-m, in-lb)
N
: N·m (kg-m, ft-lb)

Revision: 2012 August EM-15 C26

 SPARK PLUG
< PERIODIC MAINTENANCE >
SPARK PLUG
Exploded View INFOID:0000000008758998

JPBIA5144GB

1. Clamp 2. PCV hose (PCV) 3. O-ring

4. Positive crank ventilation (PCV) valve 5. Rocker cover gasket 6. Rocker cover
7. Clamp 8. PCV hose (atmosphere) 9. Oil filler cap
10. Spark plug 11. Ignition coil
Follow the installation procedure
A. To intake manifold B. C: To resonator
when tightening.
: Not reusable
: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

CAUTION:
Handle cooling fan control module carefully and never subject it to impact.

Revision: 2012 August EM-16 C26

 DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION A
DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
Exploded View INFOID:0000000008758999
EM

JPBIA5129GB
H
1. Cover (front) 2. Idler pulley 3. Collar
4. Cover (rear) 5. Stopper 6. Drive belt auto tensioner
: N·m (kg-m, ft-lb) I

Revision: 2012 August EM-17 C26

 AIR CLEANER AND AIR DUCT
< REMOVAL AND INSTALLATION >
AIR CLEANER AND AIR DUCT
Exploded View INFOID:0000000008759000

JPBIA6268GB

1. Resonator 2. Clamp 3. PCV hose

4. Inlet air duct (upper) 5. Mounting rubber 6. Inlet air duct (lower)
7. Mounting rubber 8. Air cleaner case (lower) 9. Mounting rubber
10. Collar 11. Air cleaner element 12. Atmospheric pressure sensor
13. Air cleaner case (upper) 14. Clamp 15. Air duct
16. Clamp 17. Mass air flow sensor 18. Gasket
A. To electric throttle control actuator B. To rocker cover
: Not reusable
: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

CAUTION:
• Never subject it to impact.
• Never disassemble the sensor. (Disassembly of this part is prohibited.)
• Never touch sensor part.
CAUTION:
Check that the grommet is in the installation position, and check that it does not become displaced
when the air cleaner case (lower) is installed.
CAUTION:
Check that there is no lint or other foreign material on the mounting points of the air duct and each
mating part.

Revision: 2012 August EM-18 C26

 INTAKE MANIFOLD
< REMOVAL AND INSTALLATION >
INTAKE MANIFOLD
A
Exploded View INFOID:0000000008759001

EM

J
JPBIA5131GB

1. Clamp 2. PCV hose 3. Bracket K

4. Bracket 5. Gasket 6. Intake manifold
7. Gasket 8. Electric throttle control actuator 9. EVAP hose
EVAP canister purge volume control sole- L
10. Clamp 11.
noid valve
A. To brake booster
: Not reusable M

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb) N

CAUTION:
After removing, block the oil level gauge guide openings with tape so that no foreign materials get
inside engine. O
CAUTION:
• Handle cooling fan control module carefully and never subject it to impact.
• Never disassemble or adjust. (Disassembly of this part is prohibited.) P
CAUTION:
Handle cooling fan control module carefully and never subject it to impact.
CAUTION:
Block the openings with tape so that no foreign materials get inside engine.
CAUTION:

Revision: 2012 August EM-19 C26

 INTAKE MANIFOLD
< REMOVAL AND INSTALLATION >
• Handle the tumble control valve motor (1) carefully and never
subject it to impact.
• Never remove tumble control valve motor. (Disassembly of
this part is prohibited.)
CAUTION:
• If the electronically controlled throttle harness connector is
disconnected, perform throttle fully-closed position learning
after reconnecting it. Refer to EC-71, "Work Procedure".
• Always perform the following items when the electronically
controlled throttle is replaced.
JPBIA5134ZZ

Throttle valve closed position learning EC-71, "Work Procedure"

Idle air intake amount learning EC-72, "Work Procedure"
Air/fuel ratio initial learning EC-74, "Work Procedure"

Revision: 2012 August EM-20 C26

 EXHAUST MANIFOLD
< REMOVAL AND INSTALLATION >
EXHAUST MANIFOLD
A
Exploded View INFOID:0000000008759002

EM

I
JPBIA5135GB

1. Exhaust manifold cover 2. Air-fuel ratio sensor 1 3. Stay J

4. Exhaust manifold 5. Gasket 6. Stud bolt
: Part which cannot be reused
: N·m (kg-m, in-lb) K

: N·m (kg-m, ft-lb)

L
CAUTION:
Handle cooling fan control module carefully and never subject it to impact.
CAUTION:
Always replace stud bolt, nut, and gasket with new ones. M
• Use a torx socket (size: E8).
• Refer to the figure and remove the gasket.
N
A : Identifying point
: Engine front

JPBIA5141ZZ

• Follow the procedure below and remove the exhaust manifold.

Revision: 2012 August EM-21 C26

 EXHAUST MANIFOLD
< REMOVAL AND INSTALLATION >
- Tighten nuts in the numerical order shown in the figure.

: Engine front

NOTE:
• Use a hexagonal socket wrench (WAF: 12 mm).
• Bolts 1, 2, and 3 are tightened in two stages. Bolts 6, 7, and 8 are
tightened at the second stage of tightening.
- Tighten the mounting nuts again in the numerical order shown in
the figure.
• If air/fuel ratio sensor 1 is replaced, perform air/fuel ratio initial
learning after the new sensor is reinstalled. Refer to EC-74, "Work JPBIA5137ZZ

Procedure".

Revision: 2012 August EM-22 C26

 OIL PAN (LOWER)
< REMOVAL AND INSTALLATION >
OIL PAN (LOWER)
A
Exploded View INFOID:0000000008759003

EM

J
JPBIA5235GB

1. Rear oil seal 2. O-ring 3. Oil pan (upper) K

4. Oil pump drive chain tensioner 5. Oil pump drive chain 6. Crankshaft sprocket
7. Oil pump sprocket 8. Oil pan drain plug 9. Drain plug washer
10. Oil pan (lower) 11. Plain washer 12. Fluid temperature sensor L
13. Oil filter 14. Oil filter stud 15. O-ring
16. Oil level gauge 17. Oil level gauge guide
A. Refer to LU-3. B. Oil pan side M
: Not reusable
: N·m (kg-m, in-lb)
N
: N·m (kg-m, ft-lb)

: Sealing point
O
: Apply lubricant

CAUTION: P
Engine oil must be added at least 30 minutes after the oil pan is attached.
CAUTION:
• Never damage the mounting surface.
• A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not
be forced off using a screwdriver, etc.
• Install oil pan (lower) according to the following procedure.

Revision: 2012 August EM-23 C26

 OIL PAN (LOWER)
< REMOVAL AND INSTALLATION >
- Evenly apply liquid gasket (A) (Three Bond 1217H or equivalent) to
the position shown in the figure, so that there are no gaps or over-
laps. Refer to EM-5, "Precaution for Liquid Gasket".

1 : Oil pan (lower)

: Engine outside

PBIC3611J

- Tighten the mounting bolts in numerical order as shown in the fig-

ure.

: Engine front

PBIC3146J

Revision: 2012 August EM-24 C26

 HIGH PRESSURE FUEL PUMP AND FUEL HOSE
< REMOVAL AND INSTALLATION >
HIGH PRESSURE FUEL PUMP AND FUEL HOSE
A
Exploded View INFOID:0000000008759004

CAUTION: EM
Never remove or disassemble parts unless instructed as shown in the figure.

JSBIA1672GB K

1. High pressure fuel pump insulator 2. High pressure fuel pump 3. O-ring
4. High pressure fuel pump lifter 5. Fuel rail connector 6. Fuel tube L
7. Bracket 8. Fuel pump connector protector 9. Fuel feed hose
A. To centralized under-floor piping
: Engine front M
: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

N
: Always replace after every disassembly.

: Should be lubricated with oil.

O
: Indicates that the parts is connected at points with same symbols in actual vehicle.

Removal and Installation INFOID:0000000008759005

P

REMOVAL
WARNING:
• Be sure to read EM-4, "Precaution for Handling High Pressure Fuel System" when working on the
high pressure fuel system.
• 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.

Revision: 2012 August EM-25 C26

 HIGH PRESSURE FUEL PUMP AND FUEL HOSE
< REMOVAL AND INSTALLATION >
• 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. Release fuel pressure. Refer to EC-83, "Work Procedure".
2. Remove fuel pump connector protector, and remove high pressure fuel pump insulator.
3. Disconnect quick connector (A) with the following procedure.
a. Disconnect fuel feed hose (1) from bracket hose clamp (2).

JPBIA4376ZZ

b. Disengage (A) and pull up (B) the pawl of the fuel feed hose
connector retainer (C) to disconnect the fuel feed hose from high
pressure fuel pump.
NOTE:
If the fuel feed hose is stuck, hold the fuel pipe by hand and dis-
connect it by pushing and pulling.
CAUTION:
• Keep parts away from heat source. Especially, be careful
when welding is performed around them.
• Never expose parts to battery electrolyte or other acids.
• Never bent or twist connection between quick connector
and fuel feed hose (with damper) during installation/
removal.
• Pull quick connector holding (D).
• Never remove the retainer.
• Prepare a tray and waste beforehand as fuel leaks out.
• Never pull with lateral force applied. O-ring inside quick
connector may be damaged.

Retainer color : Red

JPBIA4377ZZ

• To prevent damage to each joint and protect it from the

entry of foreign matter, cover the joint with plastic bag (A)
or an equivalent.

JPBIA4378ZZ

4. Remove fuel tube.

5. Remove fuel rail connector.

Revision: 2012 August EM-26 C26

 HIGH PRESSURE FUEL PUMP AND FUEL HOSE
< REMOVAL AND INSTALLATION >
6. Remove high pressure fuel pump (1) and lifter.
CAUTION: A
To prevent damage to high pressure fuel pump and cam-
shaft bracket, loosen bolt (A) alternately by one turn at a
time until the reaction force applied on the high pressure
EM
fuel pump disappears.

JSBIA1673ZZ

D
INSTALLATION
CAUTION:
• Do not reuse O-rings.
• To prevent damage to parts due to generated abnormal stress and eccentric load, always observe E
the installation procedure.
1. Install high pressure fuel pump according to the following procedure.
a. Check the orientation of pump cam from the mounting area F
(view arrow) of high pressure fuel pump.

JPBIA4379ZZ
I

b. Aim pump cam at the BDC area (arrow position).

J
1 : Camshaft (EXH)
NOTE:
For BDC area, anywhere within the area indicated by arrow can K
be accepted.

JPBIA4380ZZ M

c. Install O-ring to high pressure fuel pump. When handing new O-ring, paying attention to the following cau-
tion items: N
CAUTION:
• Do not reuse O-ring.
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil. O
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• Never damage O-ring with tools and fingernails during the installation. In addition, twisting or P
stretching O-ring is not allowed. If O-ring is stretched during the installation to high pressure
fuel pump, never install high pressure fuel pump immediately.
d. Install high pressure fuel pump lifter.
e. Apply oil to the fitting area of high pressure fuel pump O-ring and camshaft bracket side to install high
pressure fuel pump.
f. Install high pressure fuel pump. To prevent damage to high pressure fuel pump and camshaft bracket, the
following instructions must be observed.

Revision: 2012 August EM-27 C26

 HIGH PRESSURE FUEL PUMP AND FUEL HOSE
< REMOVAL AND INSTALLATION >
CAUTION:
• Temporarily tighten bolt (A) by hand. Alternately tighten
bolt by one turn at a time until high pressure fuel pump
reaches camshaft bracket.

1 : High pressure fuel pump

• After a pump flange sitting, tighten the bolts to the speci-
fied torque.

JSBIA1673ZZ

2. Connect fuel feed hose with the following procedure, and them install the fuel feed hose.
a. Check no foreign substances are deposited in and around matching pipe and quick connector, and no
damage on them.
b. Quick connector shall be inserted gradually, aligning with the axis of the matching pipe.
c. Insert the retainer until it clicks and check the retainer is locked.
After insertion, pull the connector and check that the connector
is locked.

A : Lock position
B : Unlock position
CAUTION:
If retainer cannot be installed smoothly, quick connector
may be have not been installed correctly. Check connection
again.
JPBIA4381ZZ

d. After attaching the quick connector and fix the hose to the clamp.
3. Install new fuel rail connector (1).

2 : O-ring
CAUTION:
• Never reuse fuel rail connector.
• 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
material.
• Never scratch O-ring with tools or fingernails when JSBIA1674ZZ

installing fuel rail connector.

• Insert new fuel rail connector straight into fuel rail. Never decenter or twist the fuel rail connec-
tor during insertion.

4. Install the fuel tube with the following procedure.

CAUTION:
• When removing fuel tube, always replace fuel rail connector together with fuel tube.
• Never reuse fuel tube.
• Never use fuel tube if its terminal tip is damaged.
• Observe the tightening order and the tightening torque.

Revision: 2012 August EM-28 C26

 HIGH PRESSURE FUEL PUMP AND FUEL HOSE
< REMOVAL AND INSTALLATION >
a. Temporarily tighten flare nut (A) and (B) of fuel tube (3) until
seated. A

1 : High pressure fuel pump

2 : Fuel rail connector EM
CAUTION:
When temporarily tightening flare nut, place pipe in the cen-
ter of the nut inner diameter. C
b. Temporarily tighten bolt (4) until the seat of bracket is seated.
c. Tighten flare nut (A) and (B) in alphabetical order. JPBIA5808ZZ
CAUTION: D
Always fit the tool completely with the nut.
d. Tighten bolt (4).
e. Retighten flare nut (A) and (B) in alphabetical order. E
CAUTION:
Always fit the tool completely with the nut.
5. Install in the reverse order of removal after this step. F
Inspection INFOID:0000000008759006

INSPECTION AFTER INSTALLATION G

Fuel Leakage Inspection
Check for fuel leakage according to the following procedure.
H
1. Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at the locations where parts are removed and reinstalled.
NOTE:
Use a mirror or other means to check locations which cannot be seen directly. I
2. Start the engine, and at a high speed, check again to see if there is any fuel leakage at the locations
where parts are removed and reinstalled.
CAUTION: J
Be careful to prevent burns while checking.

Revision: 2012 August EM-29 C26

 FUEL INJECTOR AND FUEL TUBE
< REMOVAL AND INSTALLATION >
FUEL INJECTOR AND FUEL TUBE
Exploded View INFOID:0000000008759007

JPBIA5893GB

1. Holder 2. Seal ring (white) 3. Backup ring

4. O-ring (blue) 5. Fuel injector 6. Stud bolt
7. Fuel rail 8. Fuel rail insulator 9. Fuel rail cover
10. Fuel rail pressure sensor 11. Gasket
To fuel rail connector and fuel tube.
A.
Refer to EM-25.
Comply with the assembly procedure
B.
when tightening. Refer to EM-30.
: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

: Should be lubricated with oil.

CAUTION:
Never remove or disassemble parts unless instructed as shown in the figure.
Removal and Installation INFOID:0000000008759008

WARNING:
• Be sure to read EM-4, "Precaution for Handling High Pressure Fuel System" when working on the
high pressure fuel system.
• 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.

Revision: 2012 August EM-30 C26

 FUEL INJECTOR AND FUEL TUBE
< REMOVAL AND INSTALLATION >
• 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. A
REMOVAL
1. Release the fuel pressure. Refer to EC-83, "Work Procedure".
EM
2. Remove oil level gauge. Refer to EM-23, "Exploded View".
3. Remove intake manifold. Refer to EM-19, "Exploded View".
4. Remove sub starter & generator. Refer to CHG-10, "Exploded View" C
5. Remove oil level gauge guide. Refer to EM-23, "Exploded View".
6. Remove fuel rail cover, and then remove fuel rail insulator.
7. Remove fuel tube and fuel rail connector. Refer to EM-25, "Exploded View". D
8. Disconnect fuel pressure sensor harness connector.
9. Disconnect fuel injector harness connector.
10. Remove fuel pressure sensor, if necessary. E
11. Remove fuel rail.
• Loosen mounting bolts in reverse order as shown in the figure.
F
: Engine front

CAUTION: G
• When removing, be careful to avoid any interference with fuel
injector.
• Use a shop cloth to absorb any fuel leakage from fuel rail.
H

JPBIA4388ZZ
I
12. Remove fuel injector from cylinder head as per the following.
CAUTION:
• Be careful with remaining fuel that may go out from fuel rail. J
• Be careful not to damage injector nozzles during removal.
• Never bump or drop fuel injector.
• Never disassemble fuel injector. K
a. Remove injector holder.
b. Install an remover [SST: KV10119600 (—)] (A) to the injector
connector side so that cutout (B) of injector remover faces the L
injector connector side.

JPBIA4382ZZ

Revision: 2012 August EM-31 C26

 FUEL INJECTOR AND FUEL TUBE
< REMOVAL AND INSTALLATION >
• Hook pawl portion (B) of injector remover [SST: KV10119600
(—)] (A) to groove portion (C) of injector

JSBIA0343ZZ

c. Press down body portion of injector remover [SST: KV10119600

(—)] (A) until it contacts cylinder head.

JPBIA4383ZZ

d. Tighten injector remover [SST: KV10119600 (—)] clockwise and

remove injector from cylinder head.

JPBIA4384ZZ

e. Cut seal ring (1) while pinching it. Be careful not to damage
injector.

JSBIA0346ZZ

Revision: 2012 August EM-32 C26

 FUEL INJECTOR AND FUEL TUBE
< REMOVAL AND INSTALLATION >
INSTALLATION
CAUTION: A
Do not reuse O-rings.
1. Install seal ring to fuel injector as per the following:
CAUTION: EM
• Handle seal ring with bare hands. Never wear gloves.
• Never apply engine oil to seal ring.
• Never clean seal ring with solvent.
C
a. Install an injector seal drift set [SST: KV101197S0 (—)] (A) to
fuel injector (1).
D

F
JPBIA4386ZZ

b. Set seal ring (1) to injector seal drift set [SST: KV101197S0 (—)]
(A). G

JSBIA0348ZZ
J
c. Straightly insert seal ring (1), which is set in step 2, to fuel injec-
tor as shown in the figure and install.
CAUTION: K
Be careful that seal ring does not exceed the groove portion
of fuel injector.
L

M
JSBIA0350ZZ

d. Insert injector seal drift set [SST: KV101197S0 (—)] (A) to injec- N
tor and rotate clockwise and counterclockwise by 90° while
pressing seal ring to fit it.
NOTE:
Compress seal ring, because this operation is for rectifying O
stretch of seal ring caused by installation and for preventing
sticking when inserting injector into cylinder head.
P

JSBIA0351ZZ

2. Install O-ring and backup ring to fuel injector. When handing new O-ring and backup ring, paying attention
to the following caution items:
CAUTION:

Revision: 2012 August EM-33 C26

 FUEL INJECTOR AND FUEL TUBE
< REMOVAL AND INSTALLATION >
• Do not reuse O-ring.
• 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 material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch 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 rail. Never decenter or twist it.
• Always install the back up ring (1) in the right direction as
instructed.

JPBIA3864ZZ

3. Install fuel injector (1) to fuel rail (2) as per the following:

3 : O-ring (blue)
4 : Backup ring
a. Install fuel injector holder (5) to fuel injector.
CAUTION:
• Never reuse fuel injector holder. Replace it with a new
one.
• Be careful to keep fuel injector holder from interfering
with O-ring. If interference occurs, replace O-ring.
b. Insert fuel injector into fuel rail with fuel injector holder attached.
• Insert it while matching it to the axial center.
• Insert so that protrusion (A) of fuel injector is aligned to cutout
(B).
c. Check that installation is complete by checking that fuel injector
does not rotate or come off.
• Check that protrusions of fuel injectors and fuel rail are aligned
with cutouts of clips after installation.

JPBIA4387ZZ

4. Install fuel rail and fuel injector assembly to cylinder head.

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

: Engine front

1st step : 10.0 N·m (1.0 kg-m, 89 in-lb)

2nd step : 20.5 N·m (2.1 kg-m, 15 ft-lb)

JPBIA4388ZZ

5. Connect injector harness connector.

6. Install fuel pressure sensor, if removed.

Revision: 2012 August EM-34 C26

 FUEL INJECTOR AND FUEL TUBE
< REMOVAL AND INSTALLATION >
7. Install fuel rail insulator.
CAUTION: A
• As covering part of fuel tube connector at the back end of common rail can easily move because
of its shape, do not remove it before installation.
• Install the insulator so that it is placed under lower side of intake manifold flange.
EM
8. Install in the reverse order of removal after this step.
Inspection INFOID:0000000008759009

C
INSPECTION AFTER INSTALLATION
Fuel Leakage Inspection
D
Check for fuel leakage according to the following procedure.
1. Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at the locations where parts are removed and reinstalled.
NOTE: E
Use a mirror or other means to check locations which cannot be seen directly.
2. Start the engine, and with the engine running at a high speed, check that there is no fuel leakage at the
locations where parts are removed and reinstalled. F
CAUTION:
Be careful to prevent burns while checking.
G

Revision: 2012 August EM-35 C26

 IGNITION COIL, SPARK PLUG AND ROCKER COVER
< REMOVAL AND INSTALLATION >
IGNITION COIL, SPARK PLUG AND ROCKER COVER
Exploded View INFOID:0000000008759010

JPBIA5144GB

1. Clamp 2. PCV hose (PCV) 3. O-ring

Positive Crank Ventilation (PCV)
4. 5. Rocker cover gasket 6. Rocker cover
valve
7. Clamp 8. PCV hose (atmosphere) 9. Oil filler cap
10. Spark plug 11. Ignition coil
Follow the installation procedure
A. To intake manifold B. C: To resonator
when tightening.
: Not reusable
: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

CAUTION:
Handle cooling fan control module carefully and never subject it to impact.
CAUTION:
Check that the gasket is not dropped.

Revision: 2012 August EM-36 C26

 IGNITION COIL, SPARK PLUG AND ROCKER COVER
< REMOVAL AND INSTALLATION >
• Tighten bolts evenly in two steps in the order shown in the figure,
tightening the mounting bolts to the specified torque. A

: Engine front
EM
First tightening : 1.96 N·m (0.20 kg-m)
torque
Second tighten- : 8.33 N·m (0.85 kg-m) C
ing torque
JPBIA4392ZZ

Revision: 2012 August EM-37 C26

 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >
UNIT REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
Exploded View INFOID:0000000008759011

JPBIA5145GB

1. Dynamic damper 2. Engine mount insulator RH 3. Pull-down rod bracket

4. Pulling down rod 5. Rear torque rod bracket 6. Rear torque rod
7. Engine mount insulator LH
A. AWD models
: N·m (kg-m, ft-lb)

CAUTION:
• Always pay attention to safety.
• Never remove engine until exhaust system and engine coolant are completely cooled off.
• Support the vehicle at the specified lift points.
• Use 2-pole or separate type lift whenever available. If only a board-on type lift is available, support
the rear axle jack-up points with a transmission jack because the center of gravity of the vehicle
moves rearward during operation.

Revision: 2012 August EM-38 C26

 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >
Removal and Installation INFOID:0000000008759012

A
REMOVAL
[Left Side of Engine Room]
EM
1. Disconnect all connections of engine room harness around the engine mount LH, and then temporarily
secure the engine room harness into the engine side.
CAUTION:
Protect connectors against foreign materials using a plastic bag during the operation. C

2. Disconnect the fuel feed hose on the engine side and temporarily fasten it on the vehicle side. Refer to
EM-30, "Exploded View". D
CAUTION:
After disconnecting, cover the opening with a plastic bag or similar item to prevent fuel leakage.
3. Disconnect the heater hose on the engine side. Refer to CO-9, "Exploded View". E
CAUTION:
After disconnecting, attach a plug to the hose to prevent coolant leakage.
[Removal Work] F
1. Raise the lift to a height that is convenient for work, and securely
support the bottom of the engine with a manual-type lift table
caddy [SST: GW86490800], 2 transmission jacks, or an equiva- G
lent.
CAUTION:
Check that the front-rear and left-right balance is stable.
H

I
JPBIA5146ZZ

2. Loosen mounting bolts in the reverse numerical order of the J

numbers shown in the figure, then remove the engine mount
insulator RH.

: Vehicle front K

JPBIA5151ZZ M
3. Remove engine mount insulator LH mounting bolts (A).

: Vehicle front N
CAUTION:
Never remove bolts (B) shown in the figure. (Disassembly
of this part is prohibited.) O

P
JPBIA5147ZZ

4. Carefully lower the manual lift table caddy (SST: GW86490800) or the transmission jack, (or carefully
lower the lift), and remove the engine and transaxle assembly from the vehicle.
CAUTION:
• Never allow it to come in contact with the vehicle.
• Check that all connections are disconnected while proceeding.

Revision: 2012 August EM-39 C26

 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >
• During engine transaxle assembly removal, always be careful to prevent the vehicle from falling
off the lift due to changes in the center of gravity.
• If necessary, support the vehicle rear with jack to prevent the vehicle from falling off.
[Separating Engine]
1. Remove exhaust manifold. Refer to EM-21, "Exploded View".
2. Install the engine slingers (service parts) onto the upper left side
of the front cover (A) and the rear right side of the cylinder head
(B).

: Engine front

Tightening torque for engine slinger mounting

bolts
Front cover LH upper : 32.9 N·m (3.4 kg-
m) JPBIA4422ZZ

Cylinder head rear right : 25.0 N·m (2.6 kg-

side m)
CAUTION:
During work, securely support bottom of the engine and transaxle assembly by placing a piece of
wood or an equivalent. Securely support the engine slingers using a hoist.

INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Never allow oil to get on the engine mount insulator. Never damage the engine mount insulator.
• Be sure that all engine mount insulators are seated properly, and then tighten bolts and nuts.
• For parts with a designated installation direction, check the mark which indicates the front before
installing.
Installing the Engine Mount Insulator LH

Installing the vehicle side

1. Temporarily tighten in the numerical order shown in the figure.

Vehicle front

2. Tighten in the numerical order shown in the figure to the speci-

fied torque.

JPBIA5149ZZ

Installing the transaxle side

Revision: 2012 August EM-40 C26

 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >
1. Temporarily tighten in the numerical order shown in the figure.
A
Vehicle front

2. Tighten in the numerical order shown in the figure to the speci-

fied torque. EM

JPBIA5150ZZ

D
Installing the Pull-Down Rod Bracket
1. Temporarily tighten in the numerical order shown in the figure.
E
Vehicle front

2. Tighten in the numerical order shown in the figure to the speci-

fied torque. F

JPBIA5152ZZ

Revision: 2012 August EM-41 C26

 ENGINE STAND SETTING
< UNIT DISASSEMBLY AND ASSEMBLY >
UNIT DISASSEMBLY AND ASSEMBLY
ENGINE STAND SETTING
Setting INFOID:0000000008759013

CAUTION:
Before releasing the engine hoisting, apply the engine load to the engine stand and check that it is in
the supporting status.

Revision: 2012 August EM-42 C26

 DRIVE PLATE
< UNIT DISASSEMBLY AND ASSEMBLY >
DRIVE PLATE
A
Exploded View INFOID:0000000008759014

EM

JPBIA5162GB
I
1. Pilot converter 2. Drive plate 3. Reinforcement plate
4. Transaxle 5. O-ring 6. Crankshaft position sensor 2
A. Chamfer J
: Crankshaft side
: Not reusable
K
: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

L
: Should be lubricated with oil.

CAUTION: M
Be careful of the installation direction (front/back).
• Press-fit the pilot converter using a φ33 mm diameter drift (commercial service tool) until it stops.
• Follow the procedure below and tighten the drive plate mounting bolts.
- Using a stopper plate (SST: KV11105210), secure and tighten the crankshaft. N
- Use a torx socket (size: E20).
- Tighten bolts diagonally in several steps.
O

Revision: 2012 August EM-43 C26

 TIMING CHAIN
< UNIT DISASSEMBLY AND ASSEMBLY >
TIMING CHAIN
Exploded View INFOID:0000000008759015

JPBIA5154GB

1. Timing chain slack guide 2. Chain tensioner 3. Timing chain

4. Oil pump drive chain 5. Crankshaft sprocket 6. Crankshaft pulley key
7. Oil pump sprocket 8. Front cover 9. O-ring
10. O-ring 11. VTC cover 12. O-ring
Exhaust valve timing control solenoid Intake valve timing control solenoid
13. 14. 15. Crankshaft pulley bolt
valve valve
16. Crankshaft pulley 17. Front oil seal 18. Oil pump drive chain tensioner

Revision: 2012 August EM-44 C26

 TIMING CHAIN
< UNIT DISASSEMBLY AND ASSEMBLY >
19. O-ring 20. Timing chain tension guide 21. Camshaft sprocket (INT)
22. Camshaft sprocket (EXH) 23. O-ring A
Follow the installation procedure when Follow the installation procedure
A. B.
tightening. when tightening.
: Not reusable EM
: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb) C

: Sealing point

: Should be lubricated with oil. D

CAUTION:
• When the pulley holder is secured, use a piece of wood or an equivalent so that the pulley holder
E
does not contact any surrounding parts.
• Secure the pulley holder so as to locate it at a right angle to the crankshaft pulley.
CAUTION:
Never remove the crankshaft pulley bolts as they are used as a supporting point for the pulley puller. F
CAUTION:
A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not
be forced off of any position not specified. G
CAUTION:
After removing the timing chain, never rotate camshaft and crankshaft individually to prevent valve
from contacting piston.
• Cut liquid gasket by prying the position shown in the figure ( ), H
and then remove the front cover.

JPBIA4394ZZ
K

Revision: 2012 August EM-45 C26

 TIMING CHAIN
< UNIT DISASSEMBLY AND ASSEMBLY >
• Hold the WAF part of the oil pump shaft (WAF: 19 mm) (A), and
then loosen the oil pump sprocket mounting bolts and remove
them.

1 : Oil pan (upper)

: Engine front

CAUTION:
• Be sure to hold the shaft by the WAF portion.
• The chain tension must not loosen the oil pump sprocket
mounting bolts.

JPBIA4398ZZ

• The figure shows the component location, the matching mark loca-
tion, and the link color.

1 : Timing chain
2 : Camshaft sprocket (EXH)
3 : Timing chain slack guide
4 : Chain tensioner
5 : Crankshaft sprocket
6 : Oil pump drive chain
7 : Oil pump sprocket
8 : Oil pump drive chain tensioner
9 : Timing chain tension guide
10 : Camshaft sprocket (INT)
A : Matching mark (dark blue link)
B : Matching mark (stamp)
C : Crankshaft key position (straight up)
D : Matching mark (stamp)
E : Matching mark (white link)
CAUTION:
Check matching mark position of each sprocket and oil pump
drive chain again after installing the oil pump drive chain to JPBIA5157ZZ

make sure they have not deviated.

CAUTION:
Check matching mark position of each sprocket and timing chain again after installing the timing
chain.
CAUTION:
Always replace O-ring with a new one.

Revision: 2012 August EM-46 C26

 TIMING CHAIN
< UNIT DISASSEMBLY AND ASSEMBLY >
• Evenly apply liquid gasket (A) (Three Bond 1217H or equivalent) to
the position shown in the figure, checking that there are no gaps or A
overlaps. Refer to EM-5, "Precaution for Liquid Gasket".

: Cylinder head, cylinder block, and oil pan

1
(upper)
EM
2 : Front cover
A : Liquid gasket application point
b : 4.0 - 5.6 mm
C
c : φ3.4 - 4.4 mm
: Engine outside
D
CAUTION:
Install within 5 minutes after liquid gasket application.
CAUTION: E
• Never contact other parts to the liquid gasket applied area.
• Install O-ring so that it does not move.

G
JPBIA5143ZZ

Revision: 2012 August EM-47 C26

 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY >
CAMSHAFT
Exploded View INFOID:0000000008759016

JSBIA1181GB

Exhaust valve timing control position

1. 2. O-ring 3. Camshaft bracket
sensor
4. Camshaft (EXH) 5. Camshaft sprocket (EXH) 6. Camshaft sprocket (INT)
7. Camshaft (INT) 8. Valve lifter (EXH) 9. Valve lifter (INT)
10. Signal plate (INT) 11 Signal plate (EXT) 12. O-ring
13. Camshaft position sensor (PHASE)
Follow the installation procedure when
A.
tightening.
: Not reusable
: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Sealing point

: Should be lubricated with oil.

: Select correct part.

Revision: 2012 August EM-48 C26

 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY >
CAUTION:
The rotation direction indicated in the text indicates all directions seen from the engine front direction. A
CAUTION:
Never rotate crankshaft and camshaft separately to prevent valve from contacting piston during the
procedure.
EM
CAUTION:
Handle cooling fan control module carefully and never subject it to impact.
CAUTION:
• After removing the timing chain, never rotate camshaft and crankshaft individually to prevent valve C
from contacting piston.
• Be sure to hold the camshaft hexagonal part so that the chain tension does not loosen the sprocket
mounting bolts. D
• Cut liquid gasket by prying the position shown in the figure ( ),
and then remove the camshaft bracket.

: Engine front
E

CAUTION:
A more adhesive liquid gasket is applied compared to previ-
F
ous types when shipped, so it should not be forced off of any
position not specified.

G
JPBIA4407ZZ

• Distinguish between the intake and the exhaust by looking at the H

different shapes of the front and rear ends of the camshaft or by
using the identification colors (A) and (B).

I
Identification color A B
Camshaft (EXH) (1) — Green
Camshaft (INT) (2) Green — J

JPBIA4408ZZ
K

• Evenly apply liquid gasket (A) (Three Bond 1217H or equivalent) to

the position shown in the figure. Be careful that there are no gaps
or overlaps. L

b : 4.0 - 5.6mm
c : φ3.4 - 4.4 mm M
: Engine front
: Engine outside
N
: Inner side of plug hole

JPBIA5234ZZ

Revision: 2012 August EM-49 C26

 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY >
• Tighten camshaft bracket bolts evenly in three steps in the order
shown in the figure.

: Engine front

NOTE:
There are two types of bolts. Refer to the following when installing
bolts.

M6 bolt (length under head: : 13, 14, 15 in the

57.5 mm) figure
JPBIA4406ZZ
M6 bolt (length under head: : Other than the
35.0 mm) above

First tightening : 1.96 N·m (0.20 kg-m)

torque
Second tightening : 5.88 N·m (0.60 kg-m)
torque
Third tightening : 9.5 N·m (0.97 kg-m)
torque
CAUTION:
After tightening the mounting bolts, wipe off any liquid gasket that is squeezed out.
• Tighten the camshaft sprocket mounting bolt.
CAUTION:
Hold the camshaft hexagonal part, and then secure the camshaft.

: 35.0 N·m (3.6 kg-m, 26 ft-lb)

• Tighten an additional 30°. (angle tightening)

1 : Camshaft sprocket
A : Camshaft hexagonal part
CAUTION:
Check tightening angle with an angle wrench (SST:
KV10112100) (B) or a protractor. Never estimate tightening
angle.

JPBIA4412ZZ

Revision: 2012 August EM-50 C26

 OIL SEAL
< UNIT DISASSEMBLY AND ASSEMBLY >
OIL SEAL
A
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation INFOID:0000000008759017
EM
CAUTION:
• Never damage the valve lifter hole while working.
• Align the attachment [SST: KV10115900] (A) with the center of C
the valve spring retainer (1), and press it into place.

JPBIA4477ZZ
F

CAUTION:
Never remove valve spring seat from valve spring. (Assembly parts) G
FRONT OIL SEAL
FRONT OIL SEAL : Removal and Installation INFOID:0000000008759018
H
CAUTION:
• Never damage the front cover or the crankshaft.
• Never touch the grease applied to the oil seal lip. I
• Press-fit straight and be careful that the oil seal does not curl or tilt.
REAR OIL SEAL
J
REAR OIL SEAL : Removal and Installation INFOID:0000000008759019

CAUTION:
• Never touch the grease applied to the oil seal lip. K
• Never damage the rear oil seal mounting part of oil pan (upper) and cylinder lock or the crankshaft.
• Press-fit straight and be careful that the oil seal does not curl or tilt.
L

Revision: 2012 August EM-51 C26

 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY >
CYLINDER HEAD
Exploded View INFOID:0000000008759020

REMOVAL

JPBIA4316ZZ

1. Cylinder head assembly 2. Cylinder head bolt 3. Cylinder head gasket

Follow the installation procedure when
A.
tightening.
: Not reusable
: N·m (kg-m, ft-lb)

: Should be lubricated with oil.

DISASSEMBLY

Revision: 2012 August EM-52 C26

 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY >

EM

I
JPBIA4317GB

1. Valve collet 2. Valve spring retainer 3. Valve spring (EXH)

J
4. Valve spring seat 5. Valve oil seal 6. Valve guide (EXH)
7. Valve seat (EXH) 8. Valve (EXH) 9. Valve (INT)
10. Valve seat (INT) 11. Cylinder head 12. Valve guide (INT)
K
13. Spark plug 14. Valve spring (INT)
To replace, follow the procedures for
A.
disassembly and assembly.
L
: Not reusable
: N·m (kg-m, ft-lb)

: Should be lubricated with oil. M

CAUTION:
Always replace cylinder head gasket with a new one. N
INSTALLATION
1. Follow the procedure below and tighten cylinder head bolts in
the numerical order shown in the figure. O

: Engine front
P
• Use a torx socket (size: E18).
CAUTION:
• If the cylinder head bolt is reused, check the outer diame-
ter in advance.
Cylinder Head Bolts Outer Diameter
JPBIA4415ZZ

Revision: 2012 August EM-53 C26

 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY >
- Cylinder head bolts are tightened by plastic zone tighten-
ing method. Whenever the size difference between “d1”
and “d2”exceeds the limit, replace them with new ones.

Limit (“d1”−“d2”) : 0.15 mm (0.0059 in)

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

PBIC3994E

• In step (4), loosen all bolts in the reverse of the numerical order shown in the figure.
a. Apply new engine oil to the threads and seat surfaces of cylinder head bolts.
b. Tighten the cylinder head bolts.

: 40.0 N·m (4.1 kg-m, 30 ft-lb)

c. Tighten an additional 100°. (angle tightening)
• When using a protractor, mark the cylinder and bolt heads and check the tightening angle.
CAUTION:
Check tightening angle with an angle wrench (SST:
KV10112100) (A) or a protractor. Never estimate tightening
angle.
d. Fully loosen the cylinder head bolts.

: 0 N·m (0 kg-m, 0 ft-lb)

CAUTION:
Reverse order of tightening
e. Tighten the cylinder head bolts.
JPBIA4435ZZ

: 40.0 N·m (4.1 kg-m, 30 ft-lb)

f. Tighten an additional 95°. (angle tightening)
g. Tighten 95°. (angle tightening)
CAUTION:
Handle cooling fan control module carefully and never subject it to impact. (Use of pneumatic tools
and power tools is prohibited.)
CAUTION:
• Never damage the valve lifter hole while working.

• Align the attachment [SST: KV10115900] (A) with the center of

the valve spring retainer (1), and press it into place.

JPBIA4477ZZ

CAUTION:
Never remove valve spring seat from valve spring. (Assembly parts)
CAUTION:

Revision: 2012 August EM-54 C26

 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY >
Never scratch the cylinder head.
CAUTION: A
Whenever the valve guide is removed, replace it with 0.2 mm oversize valve guide.
CAUTION:
Whenever the valve seat is removed, replace it with 0.5 mm oversize valve seat.
EM
CAUTION:
• Never touch chilled valve seat with bare hands.
• Use protective gloves so as to prevent burns because the cylinder head is hot.
CAUTION: C
When using a valve seat cutter, hold the cutter handle securely with both hands and press the cutter
to cut the entire periphery of the contacting face in one motion without stopping. If the cutter is not
pressed correctly, or if the cutter is taken away and pressed again on the surface multiple times, a step D
may be formed in the valve seat.
• Face the narrower pitch side [valve spring seat (1) press-fitted
side] toward cylinder head (B).
E
A : Identification color
• Bolts of intake and exhaust are different. When installing them,
refer to the identification colors. F

Intake : White
Exhaust : Orange G
CAUTION: JPBIA4479ZZ

• Never damage the valve lifter hole while working.

H
• Align the attachment [SST: KV10115900] (A) with the center of
the valve spring retainer (1), and press it into place.
I

JPBIA4477ZZ

Revision: 2012 August EM-55 C26

 OIL PAN (UPPER)
< UNIT DISASSEMBLY AND ASSEMBLY >
OIL PAN (UPPER)
Exploded View INFOID:0000000008759021

JPBIA5235GB

1. Rear oil seal 2. O-ring 3. Oil pan (upper)

4. Oil pump drive chain tensioner 5. Oil pump drive chain 6. Crankshaft sprocket
7. Oil pump sprocket 8. Oil pan drain plug 9. Drain plug washer
10. Oil pan (lower) 11. Plain washer 12. Fluid temperature sensor
13. Oil filter 14. Oil filter stud 15. O-ring
16. Oil level gauge 17. Oil level gauge guide
A. Refer to LU-3. B. Oil pan side
: Not reusable
: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Sealing point

: Should be lubricated with oil.

CAUTION:
The oil pan (upper) is integrated with the oil pan and the balancer unit. Never disassemble them.
CAUTION:
Always replace O-ring with a new one.

Revision: 2012 August EM-56 C26

 OIL PAN (UPPER)
< UNIT DISASSEMBLY AND ASSEMBLY >
• Insert a flat-bladed offset screwdriver into the part indicated by the
arrow ( ) in the figure and open up a crack between the oil pan A
(upper) and cylinder block.

: Engine front EM
CAUTION:
• Never damage the mounting surface.
• A more adhesive liquid gasket is applied compared to previ- C
ous types when shipped, so it should not be forced off of
any position not specified using a screwdriver, etc.
JPBIA5159ZZ
1. Evenly apply liquid gasket (C) (Three Bond 1217H or equiva- D
lent) to the position shown in the figure, taking care that there
are no gaps or overlaps. Refer to EM-5, "Precaution for Liquid
Gasket".
E
1 : Oil pan (upper)
A : 2 mm or more protruded to outside
B : 2 mm or more protruded to rear oil seal mounting side F
d : 5.5 – 7.5 mm
e : φ4.0 – 5.0 mm
G
: Engine front
: Engine outside

CAUTION: H
• Apply liquid gasket to the outside of the bolt hole at the
position indicated by ( ) in the figure.
• After applying liquid gasket, install quickly without wait- I
ing. (Install within 5 minutes.)

JPBIA5160ZZ

K
2. Tighten the mounting bolts in numerical order as shown in the
figure.

: Engine front L

N
JPBIA5158ZZ

CAUTION:
• Complete installation of the rear oil seal within 5 minutes after installing the oil pan (upper). O
• Always replace rear oil seal with new one.
• Never touch the grease applied to the oil seal lip.
• Never damage the rear oil seal mounting part of oil pan (upper) and cylinder lock or the crankshaft. P
• Press-fit straight and be careful that the oil seal does not curl or tilt.
• Engine oil should be added within at least 30 minutes after the oil pan (lower) is attached.

Revision: 2012 August EM-57 C26

 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
Exploded View INFOID:0000000008759022

JPBIA5161GB

1. Cylinder block 2. O-ring 3. Crankshaft position sensor 1

4. Cover 5. Oil filter 6. Knock sensor
7. Oil pressure sensor 8. Top ring 9. Second ring

Revision: 2012 August EM-58 C26

 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
10. Oil ring 11. Snap ring 12. Piston
13. Piston pin 14. Connecting rod 15. Thrust bearing A
16. Connecting rod bearing (upper) 17. Main bearing (upper) 18. Crankshaft key
19. Main bearing (lower) 20. Connecting rod bearing (lower) 21. Connecting rod cap
22. Connecting rod cap bolt 23. Main bearing cap 24. Main bearing cap bolt EM
25. Crankshaft 26. Signal plate 27. Rear oil seal
Follow the installation procedure when
A.
tightening. C
: Not reusable
: N·m (kg-m, in-lb)
D
: N·m (kg-m, ft-lb)

: Sealing point
E
: Should be lubricated with oil.

: Select correct part.

F
CAUTION:
Never subject knock sensor to impact while handling it.
CAUTION: G
• Never damage mating surface with connecting rod.
• Never place the drive plate with mating surface of connecting rod facing down.
CAUTION:
• Never damage mating surface with connecting rod cap. H
• Never place the drive plate with mating surface of connecting rod cap facing down.
• Never damage cylinder inner wall and crankshaft pin by contact with the large end of the connecting
rod. I
CAUTION:
When removing, check location of each part, and arrange them in a manner that prevents them from
becoming mixed up.
CAUTION: J
• Never damage piston.
• Never expand piston rings excessively. It can damage piston rings.
CAUTION: K
When removing, never scratch the main bearing cap mounting surface.
CAUTION:
• Never deform or damage the signal plate (1) of crankshaft rear
L
end (A).
• If the crankshaft is put on the flat area directly, the signal plate
contacts the floor. Maintain a clearance using a block of wood.
• Never remove the signal plate unless necessary. M

PBIC3234J
O
ASSEMBLY

Revision: 2012 August EM-59 C26

 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
1. Refer to the figure and install each plug into the cylinder block.

1 : Plug
2 : Plain washer
3 : Plug
4 : Engine coolant drain plug
: Engine front

: Part which cannot be reused

: Sealing point
PBIC3999E

Plug Liquid gasket Plain washer Tightening torque

Liquid gasket
1 Yes 54.0 N·m (5.5 kg-m)
(TB1215 or an equivalent)
3 Not necessary None 19.6 N·m (2.0 kg-m)
Liquid gasket
4 None 9.8 N·m (1.0 kg-m)
(TB1215 or an equivalent)
CAUTION:
Be sure to remove dowel pin.
2. Tighten main bearing cap bolts in the numerical order shown in
the figure with the following steps.

: Engine front

PBIC3235J

CAUTION:
If the main bearing cap bolt is reused, check the outer diameter in advance.
MAIN BEARING CAP BOLT OUTER DIAMETER
• Measure the outer diameters (“d1”, “d2”) at two positions
as shown in the figure.

A : “d1” measuring position

B : “d2” measuring position
• If reduction appears in places other than “B” range,
regard it as “d2”.

Limit (“d1”–“d2”) : 0.15 mm (0.0059 in)

PBIC4015E

• Torx socket (size: E14) can be used.

a. Lubricate threads and seat surface of each bolt with new engine oil.
b. Tighten the mounting bolts.

: 34.3 N·m (3.5 kg-m)

c. Tighten an additional 60°. (angle tightening)

Revision: 2012 August EM-60 C26

 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
• Use an angle wrench (SST: KV10112100) (A) to check tighten-
ing angle. A
• If angle wrench is not available, put a matching mark on main
bearing cap bolts before turning them, and check turning angle
with a protractor.
EM
CAUTION:
Confirm tightening angle using an angle wrench or a pro-
tractor. Never estimate tightening angle.
• After tightening main bearing cap bolts, rotate crankshaft by C
hand and check that it turns smoothly.
• Check crankshaft side clearance. Refer to EM-68, "Cylinder
PBIC3240J
Block". D
CAUTION:
Check that snap ring is securely seated in the piston groove.
3. Install piston rings using a piston ring expander (commercial service tool). E
CAUTION:
• Never damage piston.
• Be careful that the piston ring does not spread out too much and break.
• Position end gaps of each piston ring as shown in the figure. F

A : On oil ring or on lower rail end gap (either location)

B : Front mark G
C : Second ring end gap, roil ring spacer end gap
D : Top ring end gap
E : Stamp (Second ring) H
CAUTION:
Never contact the rail end gap under the oil ring with the
oil drain cast groove of piston. PBIC3242J
I
• Install top ring and second ring with stamp mark side facing
up.
CAUTION: J
• Never damage mating surface with connecting rod cap.
• Never damage cylinder inner wall or crankshaft pin by contact with connecting rod big end.
K
4. Tighten connecting rod bolts with the following procedure.
CAUTION:
• Check that there is no gap in the thrust surface (A) of the
joint between connecting rod (1) and connecting rod cap L
(2) and that these parts are in the correct positions. And
then, tighten the connecting rod bolts.
M

PBIC3510J
O
• If the control rod bolt is reused, check the outer diameter in advance.
CONNECTING ROD CAP BOLT OUTER DIAMETER
P

Revision: 2012 August EM-61 C26

 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
- Measure the outer diameter “d” at position as shown in
the figure.
- If 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 cap bolt with a new one.

PBIC4016E

a. Apply new engine oil to the main bearing cap bolt threads and seat surfaces.
b. Tighten at 27.4 N·m (2.8 kg-m).
c. Loosen all the way to 0 N·m (0 kg-m).
d. Tighten at 19.6 N·m (2.0 kg·m).
e. Put a matching mark on each bolt and connecting rod cap in the same direction. (When using a protractor)
f. Tighten an additional 60°. (angle tightening)
CAUTION:
Check tightening angle with an angle wrench (SST:
KV10112100) (A) or a protractor. Never estimate tightening
angle.
• Check that the crankshaft rotates smoothly by hand after tight-
ening the main bearing cap bolt.
• Check the connecting rod side clearance. Refer to EM-68,
"Cylinder Block".

PBIC3245J

5. Install knock sensor (1) in the direction shown in the figure.

A : Left side of cylinder block

: Engine front

CAUTION:
• Handle it carefully to avoid impact. If any impact is
applied, replace it.
• Check that no foreign material adheres to cylinder block
and knock sensor mounting surfaces.
• Install connectors so that they are positioned towards the
JPBIA5163ZZ
rear of the engine.
• Be sure to use specified bolts.
• Never hold connector when tightening bolts.
• Check that installed sensor connector is not contacting other parts.

Revision: 2012 August EM-62 C26

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000008759023
EM

SPECIFICATION
C
Engine model MR20DD
Basic structure In-line 4 cylinders
Total displacement (liters) 1.997 D
Cylinder bore × stroke (mm) 84.0×90.1
Valve layout DOHC
E
Firing order 1-3-4-2
Top ring
Piston ring configuration (3 rings) Second ring F
Oil ring
Main bearing configuration 5
Compression ratio 11.2
G
Standard 1.53 (15.6)
Repair limit 1.17 (11.9) H
Compression pressure MPa (kg/cm2) /200 rpm
Difference limit among cylin-
0.1 (1.0)
ders

Valve timing
: Intake valve
K
: Exhaust valve

L
JPBIA4992ZZ

a b c d e f
18 (−27) 78 (33) 0 (60) 40 (-20) M
220 240
ATDC ABDC ATDC BBDC
( ): Indicates the value when valve timing control is ON.
N
Drive Belt INFOID:0000000008759024

DRIVE BELT
O
The tension is automatically adjusted by the drive belt auto tensioner. Tension adjustment is not neces-
Belt tension adjustment
sary.
P
Air Cleaner Filter INFOID:0000000008759025

AIR CLEANER ELEMENT

Replacement Interval Every 60,000 km

Revision: 2012 August EM-63 C26

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Spark Plug INFOID:0000000008759026

SPARK PLUG

Manufacturer NGK
Standard specification DILKAR7D11H
Standard 1.1 mm
Plug gap
Repair limit 1.3 mm
Spark plug (iridium) replacement interval Every 100,000 km

Exhaust Manifold INFOID:0000000008759027

EXHAUST MANIFOLD
Unit: mm
Repair limit
Each port 0.3
Distortion limit
Entire part 0.7

Camshaft INFOID:0000000008759028

CAMSHAFT
Unit: mm
Standard Repair limit
No. 1 0.045 - 0.086
Camshaft oil clearance 0.15
No. 2, 3, 4, 5 0.030 - 0.071
No. 1 28.000 - 28.021 —
Camshaft bracket inner diameter
No. 2, 3, 4, 5 25.000 - 25.021 —
No. 1 27.935 - 27.955 —
Camshaft journal outer diameter
No. 2, 3, 4, 5 24.950 - 24.970 —
Camshaft end play 0.075 - 0.153 0.24
Intake 45.265 - 45.455 45.085
Camshaft nose height (A)
Exhaust 43.775 - 43.965 43.575
Camshaft runout 0.02 or less 0.05
Camshaft sprocket runout — 0.15

SEM671

VALVE LIFTER
Unit: mm
Standard
Intake 33.977 - 33.987
Valve lifter outer diameter
Exhaust 29.977 - 29.987

Revision: 2012 August EM-64 C26

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Intake 34.000 - 34.021
Valve lifter hole diameter A
Exhaust 30.000 - 30.021
Valve lifter clearance 0.013 - 0.044

VALVE CLEARANCE EM
Unit: mm
Cold (Approx. 20°C) Warm reference value (Approx. 80°C)
Intake 0.24 - 0.32 0.304 - 0.416
C

Exhaust 0.26 - 0.34 0.308 - 0.432

LIST OF VALVE LIFTERS D

Unit: mm
Stamp mark (A)
Valve lifter thickness (B) E
Intake Exhaust

JPBIA0170ZZ
I
300H 3.00
302H 3.02
304H 3.04 J
306H 3.06
308H 3.08
K
310H 3.10
312H 3.12
314H 3.14 L
316H 3.16
318H 3.18
320H 3.20 M
322H 3.22
324H 3.24
N
326H 3.26
328H 3.28
330H 3.30 O
332H 3.32
334H 3.34
P
336H 3.36
338H 3.38
340H 3.40
342H 3.42
344H 3.44
346H 3.46

Revision: 2012 August EM-65 C26

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Stamp mark (A)
Valve lifter thickness (B)
Intake Exhaust
348H 3.48
350H 3.50

Cylinder Head INFOID:0000000008759029

CYLINDER HEAD
Unit: mm
Standard Repair limit
Cylinder head distortion — 0.1
Cylinder head height (H) 130.9 —

PBIC0924E

VALVE DIMENSIONS
Unit: mm

EMR0133D

Measuring point Standard

Intake 106.42
(a)
Exhaust 105.41
Intake 1.2
(b)
Exhaust 1.4
Intake 2.55 - 2.95
(c)
Exhaust 3.15 - 3.55
Intake 3.35
(c′)
Exhaust —
Intake 5.465 - 5.480
(φd)
Exhaust 5.455 - 5.470
Intake 33.8 - 34.1
(φD)
Exhaust 27.6 - 27.9

Revision: 2012 August EM-66 C26

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Intake
(α) 45°15′ - 45°45′ A
Exhaust

VALVE GUIDE
Unit: mm EM

KBIA0252J

Standard Repair limit F

Intake 0.020 - 0.053
Valve guide clearance 0.1
Exhaust 0.030 - 0.063
G
Valve guide press-fit height (A) 13.35 - 13.65 —

VALVE SEAT
Unit: mm H

PBIC2745E

Measuring point Standard processing dimensions L

Intake 35.200 - 35.227
Inner diameter of cylinder head installation part “D”
Exhaust 29.200 - 29.227
M
Intake 35.308 - 35.324
Valve seat outer diameter “d”
Exhaust 29.308 - 29.324
Intake 31.8 N
“d1” (Diameter of boundary circle between α1 and α2)
Exhaust 25.3
Intake 33.1 - 33.6
“d2” Diameter of boundary circle between (α2 and α3) O
Exhaust 26.9 - 27.4
Intake 70°
Angle “α1”
Exhaust 45° P
Intake
Angle “α2” 88°45′ - 90°15′
Exhaust
Intake
Angle “α3” 120°
Exhaust

Revision: 2012 August EM-67 C26

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Intake 1.0 - 1.4
Contact surface “W”
Exhaust 1.2 - 1.6
Intake 5.0 - 5.1
Height “h”
Exhaust 4.95 - 5.05
Intake 6.04
Depth “H”
Exhaust 6.05

VALVE SPRING

Standard
Intake Exhaust
Free length (mm) 49.50 53.00
Length when installed (mm) 38.46 38.46
Load when installed [N (kg)] 151 – 175 (15.4 – 17.9) 139 – 157 (14.2 – 16.0)
Length when valve is open (mm) 28.86 30.40
Load when valve is open [N (kg)] 344 – 392 (35.1 – 40.0) 277 – 311 (28.3 – 31.7)
Identification color White Orange

Valve spring squareness Repair limit 1.0 mm

Cylinder Block INFOID:0000000008759030

CYLINDER BLOCK
Unit: mm

PBIC4017E

Cylinder block upper surface distortion Repair limit 0.1

Grade 1 84.000 - 84.010
Standard
Grade 2 84.010 - 84.020
Cylinder bore Inner diameter
Out-of-round limit 0.015
Taper limit 0.010

Revision: 2012 August EM-68 C26

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Grade A 55.997 - 55.998
A
Grade B 55.998 - 55.999
Grade C 55.999 - 56.000
Grade D 56.000 - 56.001 EM
Grade E 56.001 - 56.002
Grade F 56.002 - 56.003
Grade G 56.003 - 56.004 C
Grade H 56.004 - 56.005
Grade J 56.005 - 56.006
D
Grade K 56.006 - 56.007
Cylinder block main bearing housing inner diameter
Grade L 56.007 - 56.008
Grade M 56.008 - 56.009 E
Grade N 56.009 - 56.010
Grade P 56.010 - 56.011
F
Grade R 56.011 - 56.012
Grade S 56.012 - 56.013
Grade T 56.013 - 56.014 G
Grade U 56.014 - 56.015
Grade V 56.015 - 56.016
H
Grade W 56.016 - 56.017

PISTON
Unit: mm I
Standard

PBIC0188E M
Grade 1 83.970 - 83.980
Piston outer diameter (A)
Grade 2 83.980 - 83.990
N
Standard Repair limit
Position for measurement of piston outer diameter (H) 39.2 —
Piston pin hole inner diameter 19.993 - 19.999 — O
Piston and cylinder bore clearance 0.020 - 0.040 0.08

PISTON RING P
Unit: mm
Standard Repair limit
Top ring 0.040 - 0.080 0.11
Piston ring side clearance Second ring 0.030 - 0.070 0.10
Oil ring 0.055 - 0.155 —

Revision: 2012 August EM-69 C26

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Standard Repair limit
Top ring 0.20 - 0.30 0.49
Piston ring end gap Second ring 0.50 - 0.65 0.81
Oil ring 0.15 - 0.45 0.76

PISTON PIN
Unit: mm
Standard
Piston pin outer diameter 19.989 - 19.995
Piston and piston pin clearance 0.002 - 0.006
Connecting rod bushing oil clearance (at small end) 0.005 - 0.023

CONNECTING ROD
Unit: mm
Standard Repair limit
Distance between centers 139.02 —
Bend (per 100 mm) — 0.15
Twisting (per 100 mm) — 0.30
Connecting rod bushing inner diameter (at small end) 20.000 - 20.012 —
Connecting rod side clearance 0.20 - 0.35 0.40
Grade A 47.000 - 47.001
Grade B 47.001 - 47.002
Grade C 47.002 - 47.003
Grade D 47.003 - 47.004
Grade E 47.004 - 47.005
Grade F 47.005 - 47.006
Connecting rod large end diameter Grade G 47.006 - 47.007
Grade H 47.007 - 47.008
Grade J 47.008 - 47.009
Grade K 47.009 - 47.010
Grade L 47.010 - 47.011
Grade M 47.011 - 47.012
Grade N 47.012 - 47.013

CRANKSHAFT
Unit: mm

JPBIA0550ZZ PBIC3459J

Revision: 2012 August EM-70 C26

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Grade A 51.978 - 51.979
A
Grade B 51.977 - 51.978
Grade C 51.976 - 51.977
Grade D 51.975 - 51.976 EM
Grade E 51.974 - 51.975
Grade F 51.973 - 51.974
Grade G 51.972 - 51.973 C
Grade H 51.971 - 51.972
Grade J 51.970 - 51.971
D
Grade K 51.969 - 51.970
Crankshaft journal outer diameter grade (Dm)
Grade L 51.968 - 51.969
Grade M 51.967 - 51.968 E
Grade N 51.966 - 51.967
Grade P 51.965 - 51.966
F
Grade R 51.964 - 51.965
Grade S 51.963 - 51.964
Grade T 51.962 - 51.963 G
Grade U 51.961 - 51.962
Grade V 51.960 - 51.961
H
Grade W 51.959 - 51.960
Grade A 43.970 - 43.971
Grade B 43.969 - 43.970 I
Grade C 43.968 - 43.969
Grade D 43.967 - 43.968
Grade E 43.966 - 43.967
J

Grade F 43.965 - 43.966

Grade G 43.964 - 43.965
K
Grade H 43.963 - 43.964
Grade J 43.962 - 43.963
Crankshaft pin outer diameter grade (Dp)
Grade K 43.961 - 43.962 L
Grade L 43.960 - 43.961
Grade M 43.959 - 43.960
M
Grade N 43.958 - 43.959
Grade P 43.957 - 43.958
Grade R 43.956 - 43.957 N
Grade S 43.955 - 43.956
Grade T 43.954 - 43.955
O
Grade U 43.953 - 43.954
Standard Repair limit
Out-of-round — 0.0035 P
Taper — 0.0035
Crankshaft runout 0.05 0.10
Crankshaft side clearance 0.10 - 0.26 0.30

Revision: 2012 August EM-71 C26

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Connecting Rod Bearing INFOID:0000000008759031

CONNECTING ROD BEARING GRADE TABLE

When grade numbers are 0, 1, 2, 3, and 4
Grade number 0 1 2 3 4
Thickness of upper (mm) 1.494/1.497 1.497/1.500 1.500/1.503 1.503/1.506 1.506/1.509
Lower side thickness
1.494/1.497 1.497/1.500 1.500/1.503 1.503/1.506 1.506/1.509
(mm)
Color (Upper/Lower) Black/Black Brown/Brown Green/Green Yellow/Yellow Blue/Blue

When grade numbers are 01, 12, 23, and 34

Grade number 01 12 23 34
Thickness of upper (mm) 1.494/1.497 1.497/1.500 1.500/1.503 1.503/1.506
Lower side thickness
1.497/1.500 1.500/1.503 1.503/1.506 1.506/1.509
(mm)
Color (Upper/Lower) Black/Brown Brown/Green Green/Yellow Yellow/Blue

AVAILABLE UNDERSIZE BEARINGS

Unit: mm
Size Bearing thickness
US 0.25 1.623 - 1.631

CONNECTING ROD BEARING OIL CLEARANCE

Unit: mm
Standard Repair limit
Connecting rod bearing oil clearance 0.037 - 0.047 0.07

Main Bearing INFOID:0000000008759032

MAIN BEARING GRADE TABLE

When grade numbers are 1, 2, 3, 4, 5, 6, and 7
Grade number 0 1 2 3 4 5 6 7
Thickness of up- 1.996/ 1.999/ 2.002/ 2.005/ 2.008/ 2.011/ 2.014/ 2.017/
per (mm) 1.999 2.002 2.005 2.008 2.011 2.014 2.017 2.020
Lower side thick- 1.996/ 1.999/ 2.002/ 2.005/ 2.008/ 2.011/ 2.014/ 2.017/
ness (mm) 1.999 2.002 2.005 2.008 2.011 2.014 2.017 2.020
Brown/ Green/ Yellow/Yel- Purple/Pur- White/
Identification color Black/Black Blue/Blue Pink/Pink
Brown Green low ple White

When grade numbers are 01, 12, 23, 34, 45, 56, and 67
Grade number 01 12 23 34 45 56 67
Thickness of up-
1.996/ 1.999 1.999/ 2.002 2.002/2.005 2.005/ 2.008 2.008/ 2.011 2.011/ 2.014 2.014/2.017
per (mm)
Lower side thick-
1.999/ 2.002 2.002/ 2.005 2.005/ 2.008 2.008/ 2.011 2.011/ 2.014 2.014/2.017 2.017/ 2.020
ness (mm)
Identification col-
Black/Brown Brown/Green Green/Yellow Yellow/Blue Blue/Pink Pink/Purple Purple/White
or

AVAILABLE UNDERSIZE BEARINGS

Unit: mm
Size Bearing thickness
US 0.25 2.126 - 2.134

MAIN BEARING OIL CLEARANCE

Revision: 2012 August EM-72 C26

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm
Standard Repair limit A
No. 1, 4, 5 journals 0.024 - 0.034
Main bearing oil clearance 0.065
No. 2, 3 journals 0.012 - 0.022
EM

Revision: 2012 August EM-73 C26