Engine Mechanical: Section
Engine Mechanical: Section
Engine Mechanical: Section
B ENGINE
EM
SECTION
ENGINE MECHANICAL C
E
CONTENTS
PRECAUTIONS .......................................................... 4 INTAKE MANIFOLD COLLECTOR .......................... 18 F
Precautions for Procedures without Cowl Top Cover..... 4 Removal and Installation ........................................ 18
Precautions for Battery Service ................................ 4 REMOVAL ........................................................... 18
Precautions for Drain Engine Coolant and Engine INSPECTION AFTER REMOVAL ....................... 20 G
Oil ............................................................................. 4 INSTALLATION ................................................... 21
Precautions for Disconnecting Fuel Piping .............. 4 INTAKE MANIFOLD ................................................. 23
Precautions for Removal and Disassembly ............. 4 Removal and Installation ........................................ 23
H
Precautions for Inspection, Repair and Replace- REMOVAL ........................................................... 23
ment ......................................................................... 4 INSPECTION AFTER REMOVAL ....................... 23
Precautions for Assembly and Installation ............... 4 INSTALLATION ................................................... 24
Parts Requiring Angle Tightening ............................. 5 EXHAUST MANIFOLD AND THREE WAY CATA- I
Precautions for Liquid Gasket .................................. 5 LYST .......................................................................... 25
REMOVAL OF LIQUID GASKET SEALING .......... 5 Removal and Installation ........................................ 25
LIQUID GASKET APPLICATION PROCEDURE..... 5 REMOVAL ........................................................... 25 J
PREPARATION ........................................................... 7 INSPECTION AFTER REMOVAL ....................... 27
Special Service Tools ............................................... 7 INSTALLATION ................................................... 27
Commercial Service Tools ........................................ 9 OIL PAN AND OIL STRAINER ................................. 29
K
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ........................................ 29
TROUBLESHOOTING .............................................. 12 REMOVAL ........................................................... 29
NVH Troubleshooting — Engine Noise .................. 12 INSPECTION AFTER REMOVAL ....................... 31
Use the Chart Below to Help You Find the Cause INSTALLATION ................................................... 32 L
of the Symptom. ..................................................... 13 INSPECTION AFTER INSTALLATION ................ 34
DRIVE BELTS ........................................................... 14 IGNITION COIL ......................................................... 35
Checking Drive Belts .............................................. 14 Removal and Installation ........................................ 35 M
Tension Adjustment ................................................ 14 REMOVAL ........................................................... 35
ALTERNATOR AND POWER STEERING OIL INSTALLATION ................................................... 35
PUMP BELT ........................................................ 15 SPARK PLUG (PLATINUM-TIPPED TYPE) ............. 36
A/C COMPRESSOR BELT ................................. 15 Removal and Installation ........................................ 36
Removal and Installation ........................................ 15 REMOVAL ........................................................... 36
REMOVAL ........................................................... 15 INSPECTION AFTER REMOVAL ....................... 36
INSTALLATION ................................................... 15 INSTALLATION ................................................... 37
AIR CLEANER AND AIR DUCT ............................... 16 FUEL INJECTOR AND FUEL TUBE ........................ 38
Removal and Installation ........................................ 16 Removal and Installation ........................................ 38
REMOVAL ........................................................... 16 REMOVAL ........................................................... 38
INSPECTION AFTER REMOVAL ....................... 17 INSTALLATION ................................................... 40
INSTALLATION ................................................... 17 INSPECTION AFTER INSTALLATION ................ 43
Changing Air Cleaner Filter .................................... 17 ROCKER COVER ..................................................... 44
REMOVAL ........................................................... 17 Removal and Installation ........................................ 44
INSTALLATION ................................................... 17 REMOVAL ........................................................... 44
INSTALLATION ................................................... 45
PRECAUTIONS PFP:00001
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
PIIB3706J
Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Precautions for Drain Engine Coolant and Engine Oil NBS00002
● Before starting work, make sure 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.
Precautions for Removal and Disassembly NBS00004
● When instructed to use special service tools, use specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.
● Exercise maximum care to avoid damage to mating or sliding surfaces.
● Cover openings of engine system with tape or equivalent, if necessary, to seal out foreign materials.
● Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
● When loosening bolts and nuts, 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.
Precautions for Inspection, Repair and Replacement NBS00005
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and Installation NBS00006
● After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage. A
Parts Requiring Angle Tightening NBS00007
● Use angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts: EM
– Cylinder head bolts
– Main bearing cap bolts
– Connecting rod cap bolts C
– Crankshaft pulley bolt
● Do not use a torque value for final tightening.
● The torque value for these parts are for a preliminary step. D
● Ensure thread and seat surfaces are clean and coated with engine oil.
Precautions for Liquid Gasket NBS00008 E
REMOVAL OF LIQUID GASKET SEALING
● After removing mounting bolts and nuts, separate the mating
surface using seal cutter (SST) and remove old liquid gasket F
sealing.
CAUTION:
Be careful not to damage the mating surfaces.
G
● 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 H
hammer to lightly tap the parts, to remove it.
CAUTION: PBIC0002E
If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces. I
PBIC0003E
M
3. Attach liquid gasket tube to tube presser [SST: WS39930000
( — )].
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions.
● If there is a groove for liquid gasket application, apply liquid
gasket to the groove.
EMA0622D
PREPARATION PFP:00002
A
Special Service Tools NBS00009
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number EM
(Kent-Moore No.) Description
Tool name
G
NT028
I
NT373
NT372
NT011
Tool number
(Kent-Moore No.) Description
Tool name
NT024
NT044
NT045
NT046
NT052
NT014
NT379
Tool number
(Kent-Moore No.) Description A
Tool name
NT636
NT822
F
— Removing fuel tube quick connectors in
(J-45488) engine room
Quick connector release
G
PBIC0198E
H
(Kent-Moore No.)
I
Description
Tool name
PBIC0190E
AMA126
PBIC1113E
(Kent-Moore No.)
Description
Tool name
ZZA1210D
NT047
NT048
NT030
NT015
NT016
(Kent-Moore No.)
Description A
Tool name
AEM489
F
PBIC3605E
Use the Chart Below to Help You Find the Cause of the Symptom. NBS0000C
A
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine. EM
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine C
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 D
Top of Ticking or Tappet
C A — A B — Valve clearance EM-111
engine clicking noise
Rocker
cover Camshaft Camshaft runout E
EM-102
Cylinder Rattle C A — A B C bearing Camshaft journal oil
EM-103
head noise clearance
WARNING:
Be sure to perform when engine is stopped.
1. Inspect belts for cracks, fraying, wear and oil. If necessary, replace.
2. Inspect drive belt deflection at a point on the belt midway
between pulleys.
● Inspection should be done only when engine is cold, or over
30 minutes after engine is stopped.
● Measure belt tension with tension gauge (BT3373-F or equiv-
alent) at points marked shown in the figure.
●When measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point.
● Adjust if belt deflection exceeds the limit or if belt tension is
not within specifications. KBIA1731J
CAUTION:
● When checking belt deflection or tension immediately after installation, first adjust it to the speci-
fied value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to
avoid variation in deflection between pulleys.
● Tighten idler pulley lock nut by hand and measure deflection or tension without looseness.
Belt deflection and tension
Deflection adjustment Unit: mm (in) Tension adjustment* Unit: N (kg, lb)
Used belt Used belt
New belt New belt
Limit After adjustment Limit After adjustment
Alternator and 730 - 818 838 - 926
4-5 3.5 - 4.5
power steering 7 (0.28) 294 (30, 66) (74.5 - 83.5, (85.5 - 94.5,
(0.16 - 0.20) (0.138 - 0.177)
oil pump belt 164 - 184) 188 - 208)
348 - 436 470 - 559
A/C compressor 9 - 10 8-9
12 (0.47) 196 (20, 44) (35.5 - 44.5, (48 - 57,
belt (0.35 - 0.39) (0.31 - 0.35)
78 - 98) 106 - 126)
Applied pushing
98 N (10 kg, 22 lb) —
force
*: If belt tension gauge cannot be installed at check points shown, check drive belt tension at different location on belt.
CAUTION:
● When belt is replaced with a new one, adjust it to value for “New belt” to accommodate for insuffi-
cient adaptability with pulley grooves.
● When deflection or tension of belt being used exceeds “Limit”, adjust it to value for “After adjust-
ment”.
● When checking belt deflection or tension immediately after installation, first adjust it to the speci-
fied value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to
avoid variation in deflection between pulleys.
● When installing belt, make sure that it is correctly engaged with pulley groove.
● Keep oil and water away from belt.
● Do not twist or bend belt excessively.
SBIA0532E H
A/C COMPRESSOR BELT
1. Remove undercover with power tool.
2. Loosen idler pulley lock nut (C) and adjust tension by turning adjusting bolt (D). I
● For specified belt tension, refer to EM-14, "Checking Drive Belts" .
● Check for engine oil and engine coolant are not adhered belt and each pulley groove.
PBIC2301E
REMOVAL
1. Remove clips, and slide air duct (inlet) frontward, disengage
clips and air cleaner case.
NOTE:
When removing air duct (inlet), remove front bumper and
bumper fascia stay radiator core support center. Refer to EI-14,
"FRONT BUMPER" and BL-19, "RADIATOR CORE SUPPORT"
.
KBIA1734E
PBIC1118E
INSTALLATION H
Installation is the reverse order of removal.
KBIA3590J
G
PBIC1093E
3. Drain engine coolant, or when water hose is disconnected, attach plug to prevent engine coolant leakage.
Refer to CO-10, "Changing Engine Coolant" . H
CAUTION:
● Perform this step when engine is cold.
KBIA0957E
6. Remove fuel sub-tube mounting bolt to disconnect from rear of intake manifold collector (lower). Refer to
EM-38, "FUEL INJECTOR AND FUEL TUBE" .
7. Disconnect vacuum hose and water hose from intake manifold collector (upper).
8. Remove EVAP canister purge volume control solenoid valve bracket mounting bolt from intake manifold
collector (upper).
PBIC1094E
10. Remove PCV hose [between intake manifold collector (lower) and rocker cover (right bank)].
11. Loosen mounting bolts with power tool in reverse order as
shown in the figure, and remove the intake manifold collector
cover, gasket, intake manifold collector (lower) and gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
PBIC0774E
PBIC0775E
INSTALLATION
Note the following, and install in the reverse order of removal. A
H
PBIC0776E
L
PBIC0774E
ure.
Water Hose
● Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.
Revision: 2006 November EM-21 2006 350Z
INTAKE MANIFOLD COLLECTOR
KBIA0957E
EM
G
PBIC2282E
REMOVAL H
1. Release fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" .
2. Remove intake manifold collectors (upper and lower). Refer to EM-18, "INTAKE MANIFOLD COLLEC-
TOR" . I
3. Remove fuel tube and fuel injector assembly. Refer to EM-38, "FUEL INJECTOR AND FUEL TUBE" .
4. Loosen mounting nuts and bolts with power tool in reverse order
as shown in the figure to remove intake manifold. J
PBIC0778E
M
5. Remove gaskets.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSPECTION AFTER REMOVAL
Surface Distortion
● Check the surface distortion of the intake manifold mating sur-
face 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, install them and tighten to the specified torque below.
1st step
: 4.9 - 9.8 N·m (0.5 - 1.0 kg-m, 4 - 7 ft-lb)
2nd step and after
: 26.5 - 31.4 N·m (2.7 - 3.2 kg-m, 20 - 23 ft-lb)
PBIC0778E
EM
PBIC3103E
K
1. Heated oxygen sensor 2 (bank 1) 2. Three way catalyst (right bank) 3. Gasket
4. Air fuel ratio sensor 1 (bank 1) 5. Exhaust manifold cover (right bank) 6. Exhaust manifold (right bank)
7. Exhaust manifold (left bank) 8. Exhaust manifold cover (left bank) 9. Three way catalyst (left bank) L
10. Air fuel ratio sensor 1 (bank 2) 11. Heated oxygen sensor 2 (bank 2)
REMOVAL
WARNING: M
Perform the work when the exhaust and cooling system have completely cooled down.
1. Remove tower bar. Refer to FSU-20, "TOWER BAR" .
2. Remove engine cover with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .
3. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant" .
CAUTION:
● Perform this step when engine is cold.
4. Remove air cleaner case and air duct. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .
5. Remove undercover with power tool.
7. Remove exhaust mounting bracket between three way catalysts (right and left bank) and transmission.
Refer to EX-3, "EXHAUST SYSTEM" .
8. Remove three way catalyst.
9. Disconnect harness connector and remove air fuel ratio sensor
1 on both banks using heated oxygen sensor wrench (SST).
● Put marks to identify installation positions of each air fuel ratio
sensor 1.
CAUTION:
● Be careful not to damage air fuel ratio sensor 1.
10. Remove water pipe and heater pipe on both right and left side. Refer to CO-31, "WATER OUTLET AND
WATER PIPING" .
11. Remove exhaust manifold cover.
12. Loosen mounting nuts with power tool in reverse order as shown
in the figure to remove exhaust manifold.
NOTE:
Disregard the numerical order No. 7 and 8 in removal.
PBIC2042E
D
PBIC1096E
INSTALLATION E
Note the following, and install in the reverse order of removal.
Exhaust Manifold Gasket
● Install in direction shown below. (Follow same procedure for F
both banks.)
● Locate thick side of port connecting part on right side from tech-
nician’s view. G
● Locate round press in thick side of port connecting part above
center level line of port.
H
I
KBIA1051E
Exhaust Manifold
● If stud bolts were removed, install them and tighten to the specified torque below. J
PBIC2042E
EM
PBIC4923E M
1. Oil pan gasket 2. Oil pan (upper) 3. O-ring
4. Oil pan gasket 5. O-ring 6. Connector bolt
7. Oil filter 8. Oil cooler 9. Relief valve
10. Oil pressure sensor 11. Bracket (A/T models) 12. Washer (M/T models)
13. Oil temperature sensor (M/T models) 14. Oil strainer 15. Drain plug
16. Drain plug washer 17. Oil pan (lower) 18. Baffle plate
19. Rear plate cover 20. Crankshaft position sensor (POS) 21. Rear cover plate
A. Oil pan side B. Refer to LU-10 C. To oil pump
● Do not disassemble.
PBIC0782E
b. Insert seal cutter (SST) between oil pan (upper) and oil pan
(lower). A
CAUTION:
● Be careful not to damage the mating surfaces.
SEM365E
D
21. Remove baffle plate.
22. Remove oil strainer.
23. Remove transmission joint bolts which pierce oil pan (upper). Refer to MT-18, "TRANSMISSION ASSEM- E
BLY" (M/T models) or AT-274, "TRANSMISSION ASSEMBLY" (A/T models).
24. Remove rear cover plate.
25. Loosen mounting bolts with power tool in reverse order as F
shown in the figure to remove oil pan (upper).
● Insert seal cutter [SST: KV10111100 (J37228)] between oil
pan (upper) and cylinder block. Slide seal cutter by tapping on G
the side of tool with hammer. Remove oil pan (upper).
CAUTION:
Be careful not to damage mating surface. H
PBIC0783E I
26. Remove O-rings from bottom of cylinder block and oil pump.
J
PBIC1144E
M
27. Remove oil pan gaskets.
PBIC1145E
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 cyl-
inder block.
● Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
MEM108A
PBIC2630E
PBIC1145E
c. Install new O-rings on the bottom of cylinder block and oil pump.
PBIC1144E
D
● Attaching should be done within 5 minutes after coating.
PBIC0783E
I
f. Tighten transmission joint bolts. Refer to MT-18, "TRANSMISSION ASSEMBLY" (M/T models) or AT-274,
"TRANSMISSION ASSEMBLY" (A/T models).
2. Install oil strainer to oil pump. J
3. Install baffle plate.
● Apply locking sealant to the thread of mounting bolts.
Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to GI-45, "RECOM- K
MENDED CHEMICAL PRODUCTS AND SEALANTS" .
4. Install oil pan (lower) as follows:
a. Use scraper to remove old liquid gasket from mating surfaces. L
● Also remove old liquid gasket from mating surface of oil pan
(upper).
● Remove old liquid gasket from the bolt holes and thread. M
CAUTION:
Do not scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
SEM958F
PBIC2657E
PBIC0782E
EM
G
PBIC4359E
PBIC4359E
REMOVAL
1. Remove engine cover with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .
2. Remove ignition coil. Refer to EM-35, "IGNITION COIL" .
3. Remove spark plug using spark plug wrench (commercial ser-
vice tool).
CAUTION:
Do not drop or shock it.
SEM294A
Make NGK
Standard type PLFR5A-11
Hot type PLFR4A-11
Cold type PLFR6A-11
CAUTION:
● Do not drop or shock spark plug. A
● Do not use wire brush for cleaning.
● If plug tip is covered with carbon, spark plug cleaner may
be used. EM
Cleaner air pressure:
Less than 588 kPa (6 kg/cm2 , 85 psi)
C
Cleaning time:
Less than 20 seconds
D
SMA773C
SMA806CA
H
INSTALLATION
Installation is the reverse order of removal.
I
SBIA0580E
CAUTION:
Do not remove or disassemble parts unless instructed as shown in the figure.
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.
● Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
● To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
1. Remove engine cover with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .
2. Release fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" .
3. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-10, "Changing Engine Coolant" and EM-18, "INTAKE MANIFOLD COLLECTOR" .
CAUTION:
Perform this step when engine is cold.
KBIA1293E
D
5. When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect
quick connector as follows:
a. Remove quick connector cap from quick connector connection E
on right member side.
b. Disconnect fuel feed hose (with damper) from bracket hose
clamp.
F
PBIC2083E H
ii. Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on K
that position.
CAUTION:
Inserting quick connector release hard will not disconnect L
quick connector. Hold quick connector release where it
contacts and goes no further.
iii. Draw and pull out quick connector straight from centralized
M
under-floor piping.
CAUTION:
● Pull quick connector holding “A” position as shown in PBIC1898E
the figure.
● Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
● Keep parts away from heat source. Especially, be careful when welding is performed around
them.
● Do not expose parts to battery electrolyte or other acids.
● Do not bend or twist connection between quick connector and fuel feed hose (with damper) dur-
ing installation/removal.
PBIC1899E
6. Remove intake manifold collectors (upper and lower). Refer to EM-18, "INTAKE MANIFOLD COLLEC-
TOR" .
7. Disconnect harness connector from fuel injector.
8. Loosen mounting bolts in reverse order as shown in the figure,
and remove fuel tube and fuel injector assembly.
CAUTION:
Do not tilt it, or remaining fuel in pipes may flow out from
pipes.
KBIA1296E
PBIC2470E
● 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, do not insert it EM
quickly into fuel tube.
● Insert O-ring straight into fuel tube. Do not decenter or twist it.
● Insert fuel damper and fuel sub-tube straight into fuel tube. C
● Tighten mounting bolts evenly in turn.
● After tightening mounting bolts, make sure that there is no gap between flange and fuel tube.
D
2. Install O-rings to fuel injector, paying attention to the following.
CAUTION:
● Upper and lower O-ring are different. Be careful not to confuse them.
E
Fuel tube side : Blue
Nozzle side : Brown
F
● Handle O-ring with bare hands. Do not wear gloves.
● 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, do not insert it H
quickly into fuel tube.
● Insert O-ring straight into fuel injector. Do not decenter or twist it.
PBIC2545E
KBIA1296E
● After tightening mounting bolts, make sure that there is no gap between flange and fuel sub-tube.
10. Connect quick connector between fuel feed hose (with damper) and centralized under-floor piping con-
nection as follows:
a. Make sure no foreign substances are deposited in and around centralized under-floor piping and quick
connector, and no damage on them.
b. Thinly apply new engine oil around centralized under-floor piping from tip end to spool end.
c. Align center to insert quick connector straightly into centralized under-floor piping.
● Insert quick connector to centralized under-floor piping until
top spool is completely inside quick connector, and 2nd level
spool exposes right below quick connector.
CAUTION:
● Hold “A” position as shown in the figure when inserting
centralized under-floor piping into quick connector.
● Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector.
● Insert until you hear a “click” sound and actually feel the
engagement.
PBIC2471E
● To avoid misidentification of engagement with a similar
sound, be sure to perform the next step.
d. Pull quick connector by hand holding “A” position. Make sure it is completely engaged (connected) so that
it does not come out from centralized under-floor piping.
e. Install quick connector cap to quick connector connection.
● Install quick connector cap with arrow on surface facing in
direction of quick connector (fuel feed hose side).
CAUTION:
If cap cannot be installed smoothly, quick connector may
have not been installed correctly. Check connection
again.
KBIA1298E
PBIC2303E
REMOVAL
1. Remove engine cover. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .
2. Release the fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" .
3. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-10, "Changing Engine Coolant" and EM-18, "INTAKE MANIFOLD COLLECTOR" .
CAUTION:
Perform this step when engine is cold.
4. Remove intake manifold collectors (upper and lower). Refer to EM-18, "INTAKE MANIFOLD COLLEC-
TOR" .
5. Separate engine harness removing their brackets from rocker covers.
6. Remove ignition coil. Refer to EM-35, "IGNITION COIL" .
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
G
KBIA0985E
PBIC2474E
KBIA0985E
● When installing, be careful not to twist or come in contact with other parts.
● Install PCV hose between right and left rocker covers with its identification paint facing upward (right
rocker cover side). Refer to component figure in EM-44, "Removal and Installation" .
8. Install in the reverse order of removal after this step.
NOTE:
● This section describes removal/installation procedure of front timing chain case and timing chain related EM
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 C
related parts, and rear timing chain case in this order, and install in the reverse order of removal. Refer to
EM-59, "TIMING CHAIN" .
● Refer to EM-59, "TIMING CHAIN" for component parts location.
D
REMOVAL
1. Remove engine cover with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .
2. Remove undercover with power tool. E
3. Release the fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" .
4. Disconnect the battery cable from the negative terminal.
5. Drain engine oil. Refer to LU-9, "Changing Engine Oil" . F
CAUTION:
● Perform this step when engine is cold.
SEM728G
15. Remove left and right valve timing control covers (including magnet retarder and cover) with the following
procedure. (M/T models)
PBIC3560E
● When carrying valve timing control cover, face the magnet retarder side up to prevent the cover
from falling from magnet retarder.
● Do not remove magnet retarder from valve timing control cover. (Disassembly prohibited parts)
16. Remove collared O-ring from front timing chain case (left and
right side). (A/T models)
PBIC2631E
17. Remove rocker covers (right and left banks). Refer to EM-44, "ROCKER COVER" .
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed.
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.
a. Rotate crankshaft pulley clockwise to align timing mark (grooved
line without color) with timing indicator.
KBIA1717J
b. Make sure that intake and exhaust cam noses on No. 1 cylinder
(engine front side of right bank) are located as shown in the fig- A
ure.
● If not, turn crankshaft one revolution (360 degrees) and align
as shown in the figure. EM
NOTE:
When only timing chain (primary) is removed, rocker cover does
not need to be removed. To make sure that No. 1 cylinder is at
C
its compression TDC, remove front timing chain case first. Then
check mating marks on camshaft sprockets. Refer to EM-68,
"INSTALLATION" (A/T models) or EM-88, "INSTALLATION" SEM418G
(M/T models). D
19. Remove crankshaft pulley as follows:
a. Remove starter motor and set ring gear stopper (SST) as shown
in the figure. Refer to SC-10, "STARTING SYSTEM" . E
PBIC1098E
H
b. Loosen crankshaft pulley bolt and locate bolt seating surface as
10 mm (0.39 in) from its original position.
CAUTION: I
Do not remove crankshaft pulley bolt as it will be used as a
supporting point for suitable puller.
J
K
PBIC1103E
EMQ0477D
20. Remove oil pan (lower). Refer to EM-29, "OIL PAN AND OIL STRAINER" .
21. Loosen two mounting bolts in front of oil pan (upper) in reverse
order as shown in the figure.
PBIC1116E
KBIA1303E
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 (J37228)] to cut liquid gas-
ket for removal.
CAUTION:
● Do not use screwdriver or something similar.
PBIC2548E
24. Remove oil pan gasket. Refer to EM-29, "OIL PAN AND OIL STRAINER" .
25. Remove water pump cover and chain tensioner cover from front timing chain case.
● Use seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for removal.
26. 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
EMQ0032D
D
27. Remove timing chain and related parts. Refer to EM-59, "TIMING CHAIN" .
28. Use 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
PBIC3492E
H
● Remove old liquid gasket from bolt hole and thread.
K
PBIC2084E
INSTALLATION
L
1. Install timing chain and related parts. Refer to EM-59, "TIMING CHAIN" .
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.
M
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.
SEM715A
PBIC0790E
4. Install water pump cover and chain tensioner cover to front timing chain case.
● Apply a continuous bead of liquid gasket with tube presser
[SST: WS39930000 ( — )] to front timing chain case as
shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
SEM744GA
G
PBIC2658E
K
PBIC2630E
● Align notch of front timing chain case with protrusion of oil pan
gasket. L
PBIC1114E
PBIC1099E
PBIC2548E
PBIC1100E
ii. Since front timing chain case is offset for difference of bolt holes,
tight 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.
PBIC1115E
PBIC1116E
H
7. Install oil pan (lower). Refer to EM-29, "OIL PAN AND OIL STRAINER" .
8. Install right and left intake valve timing control covers as follows. (A/T models)
a. Install new seal rings in shaft grooves. I
b. Apply a continuous bead of liquid gasket with tube presser [SST:
WS39930000 ( — )] to intake valve timing control covers as
shown in the figure. J
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" . K
SBIA0492E
c. Install new collared O-rings in front timing chain case oil hole M
(left and right sides).
PBIC2631E
d. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain
case with the holes to install intake valve timing control covers.
PBIC0918E
9. Install right and left valve timing control covers as follows. (M/T models)
a. Install new seal rings in shaft grooves.
PBIC3571E
b. Install magnet retarder aligning the dowel pins of the back with
the cover side dowel pin holes securely. Simultaneously insert
the harness into the installation groove securely.
NOTE:
Figure shows the structure of the parts. Therefore, magnet
retarder is being removed from the cover in this figure. But, if
magnet retarder is in the correct position, omit step “b” and per-
form step “c”.
PBIC3572E
c. To check the joint between dowel pins and dowel pin holes,
check the looseness in the axle direction by pushing the mating
surface of magnet retarder at several places and the circumfer-
ential looseness (between dowel pins and dowel pin holes) by
twisting in the circumferential direction.
CAUTION:
Always perform this procedure when removing because the
gap between dowel pins and dowel pin holes may not be
caused on purpose.
PBIC3573E
H
PBIC3560E
PBIC4627J
11. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns
smoothly.
12. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluid 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-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .
● 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 make sure there is no leakage of 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
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
EM
PBIC4926E
1. Timing chain tensioner (secondary) 2. Internal chain guide 3. Timing chain tensioner (secondary)
4. Camshaft sprocket (EXH) 5. Timing chain (secondary) 6. Timing chain (primary)
7. Camshaft sprocket (INT) 8. Camshaft sprocket (EXH) 9. Timing chain (secondary)
10. Camshaft sprocket (INT) 11. Slack guide 12. Crankshaft sprocket
13. Timing chain tensioner (primary) 14. Intake valve timing control cover 15. Collared O-ring
16. Seal ring 17. Chain tensioner cover 18. Intake valve timing control cover
19. Water hose clamp 20. Idler pulley bracket 21. Idler pulley
22. Idler pulley 23. Crankshaft pulley 24. Front oil seal
25. Idler pulley 26. A/C compressor bracket 27. Water pump cover
28. Bracket 29. Front timing chain case 30. Bracket
31. Rear timing chain case 32. O-ring 33. Tension guide
34. Water drain plug (front)
A. Refer to EM-68 B. Refer to ATC-128
8. Separate engine harnesses removing their brackets from front timing chain case.
9. Remove intake manifold collectors (upper and lower). Refer to EM-18, "INTAKE MANIFOLD COLLEC-
TOR" .
10. Remove radiator cooling fan assembly. Refer to CO-22, "COOLING FAN" .
11. Remove drive belts. Refer to EM-14, "DRIVE BELTS" .
12. Remove A/C compressor from bracket with piping connected, and temporarily secure it aside. Refer to
ATC-128, "Components" .
13. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
Refer to PS-29, "POWER STEERING OIL PUMP" .
14. Remove power steering oil pump bracket. Refer to PS-29, "POWER STEERING OIL PUMP" .
15. Remove alternator. Refer to SC-21, "CHARGING SYSTEM" .
16. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
17. Remove right and left intake valve timing control covers.
SEM728G
D
18. Remove collared O-ring from front timing chain case (left and
right side).
E
G
PBIC2631E
19. Remove rocker covers (right and left banks). Refer to EM-44, "ROCKER COVER" . H
20. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
a. Rotate crankshaft pulley clockwise to align timing mark (grooved
line without color) with timing indicator. I
KBIA1717J
L
b. Make sure 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
M
as shown in the figure.
SEM418G
a. Remove starter motor and set ring gear stopper (SST) as shown
in the figure. Refer to SC-10, "STARTING SYSTEM" .
PBIC1098E
PBIC1103E
EMQ0477D
22. Remove oil pans (upper and lower). Refer to EM-29, "OIL PAN AND OIL STRAINER" .
23. Remove front timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
KBIA1303E
b. Insert suitable tool into the notch at the top of the front timing
chain case as shown (1). A
c. Pry off case by moving the tool as shown (2).
● Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gas-
ket for removal. EM
CAUTION:
● Do not use screwdriver or something similar.
D
24. Remove O-rings from rear timing chain case.
G
PBIC2548E
25. Remove water pump cover and chain tensioner cover from front timing chain case. H
● Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
26. Remove front oil seal from front timing chain case using suitable
tool. I
● Use screwdriver for removal.
CAUTION:
Be careful not to damage front timing chain case. J
EMQ0032D
L
27. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt.
b. Loosen upper mounting bolt slowly, and then turn timing chain M
tensioner (primary) on the mounting bolt so that plunger is fully
expanded.
NOTE:
Even if plunger is fully expanded, it is not dropped from the body
of timing chain tensioner (primary).
c. Remove upper mounting bolt, and then remove timing chain ten-
sioner (primary).
PBIC3562E
28. Remove internal chain guide, tension guide and slack guide.
NOTE:
Tension guide can be removed after removing timing chain (pri-
mary).
PBIC2266E
PBIC2047E
KBIA1698J
G
PBIC2980E
SEM735G
L
CAUTION:
● Do not remove plate metal cover of oil passage.
KBIA1307E
SBIA0496E
PBIC0788E
35. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a. Remove camshaft brackets (No. 1). Refer to EM-101, "REMOVAL" .
b. Remove timing chain tensioners (secondary) with stopper pin attached.
36. Use scraper to remove all traces of old liquid gasket from front
and rear timing chain cases, and opposite mating surfaces.
SEM737G
PBIC2084E
37. Use scraper to remove all traces of liquid gasket from water
pump cover, chain tensioner cover and intake valve timing con- A
trol covers.
EM
SEM926E
D
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and any excessive wear at link plates and roller E
links of timing chain. Replace timing chain as necessary.
PBIC0282E H
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.
PBIC3493E
1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Refer to EM-105,
"INSTALLATION" .
a. Install timing chain tensioners (secondary) with stopper pin attached and new O-ring.
b. Install camshaft brackets (No. 1). Refer to EM-105, "INSTALLATION" .
2. Install rear timing chain case as follows:
a. Install new O-rings onto cylinder block.
PBIC0788E
EM
SBIA0496E
D
c. Apply liquid gasket with tube presser [SST: WS39930000 ( — )] to rear timing chain case back side as
shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-45, "RECOMMENDED CHEMICAL
E
PRODUCTS AND SEALANTS" .
CAUTION:
● For “A” in the figure, completely wipe out liquid gasket extended on a portion touching at
engine coolant. F
● Apply liquid gasket on installation position of water pump and cylinder head very completely.
PBIC2659E
d. Align rear timing chain case and water pump assembly with dowel pins (right and left) on cylinder block
and install rear timing chain case.
● Make sure O-rings stay in place during installation to cylinder block and cylinder head.
f. After all bolts are tightened, retighten them to the specified in numerical order shown in the figure.
● If liquid gasket protrudes, wipe it off immediately. A
g. After installing rear timing chain case, check the surface height
difference between following parts on oil pan (upper) mounting EM
surface.
Standard
Rear timing chain case to cylinder block: C
–0.24 to 0.14 mm (–0.0094 to 0.0055 in)
● If not within standard, repeat the installation procedure.
D
SEM943G
E
3. Install water pump with new O-rings. Refer to CO-24, "WATER PUMP" .
4. Make sure that dowel pin hole, dowel pin and crankshaft key are
located as shown in the figure. (No. 1 cylinder at compression
F
TDC)
● NOTE:
Though camshaft does not stop at the position as shown in
the figure, for the placement of cam nose, it is generally G
accepted camshaft is placed for the same direction of the fig-
ure.
H
Camshaft dowel pin hole (intake side)
: At cylinder head upper face side in each bank. KBIA1073E
CAUTION:
Hole on small dia. side must be used for intake side dowel pin hole. Do not misidentify (ignore big
K
dia. side).
5. Install timing chains (secondary) and camshaft sprockets as follows:
CAUTION: L
Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions
repeatedly during the installation process.
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with stopper pin. M
SEM430G
PBIC0891E
KBIA1698J
EM
PBIC2110E
D
6. Install tension guide.
7. Install timing chain (primary) as follows:
a. Install crankshaft sprocket. E
● Make sure the mating marks on crankshaft sprocket face the
front of engine.
F
SEM929E H
PBIC3494E
8. Install internal chain guide, slack guide and timing chain ten-
sioner (primary).
PBIC2109E
CAUTION:
Do not overtighten slack guide mounting bolts. It is normal
for a gap to exist under the bolt seats when mounting bolts
are tightened to specification.
PBIC2633E
9. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab up (or turn lever downward) so as to
remove plunger stopper tab from the ratchet of plunger.
NOTE:
Plunger stopper tab and lever are synchronized.
b. Push plunger into the inside of tensioner body.
c. Hold plunger in the fully compressed position by engaging
plunger stopper tab with the tip of ratchet.
d. To secure lever, insert stopper pin through hole of lever into ten-
sioner body hole.
● The lever parts and the tab are synchronized. Therefore, the PBIC3568E
plunger will be secured under this condition.
NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
PBIC3569E
D
10. Make sure again that the mating marks on sprockets and timing chain have not slipped out of alignment.
11. Install new O-rings on rear timing chain case.
E
PBIC2548E
H
12. Install new front oil seal on front timing chain case.
● Apply new engine oil to both oil seal lip and dust seal lip.
SEM715A L
● Using suitable drift, press-fit oil seal until it becomes flush with
front timing chain case end face.
M
● Make sure the garter spring is in position and seal lip is not
inverted.
PBIC0790E
13. Install water pump cover and chain tensioner cover to front timing chain case.
SEM744GA
PBIC2658E
b. Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
c. Tighten mounting bolts to the specified torque in numerical order
as shown in the figure.
● There are two types of mounting bolts. Refer to the following
for locating bolts.
M8 bolts : 1, 2
: 25.5 - 31.3 N·m (2.6 - 3.2 kg-m, 19 - 23 ft-lb)
M6 bolts : Except the above
: 11.7 - 13.7 N·m (1.2 - 1.4 kg-m, 9 - 10 ft-lb)
KBIA1303E
d. After all bolts are tightened, retighten them to the specified
torque in numerical order shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).
e. After installing front timing chain case, check the surface height
difference between the following parts on the oil pan (upper) A
mounting surface.
Standard
Front timing chain case to rear timing chain case: EM
–0.14 to 0.14 mm (–0.0055 to 0.0055 in)
● If not within standard, repeat the installation procedure. C
SEM943G
D
15. 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 [SST: E
WS39930000 ( — )] to intake valve timing control covers as
shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
F
GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
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
16. Install oil pans (upper and lower). Refer to EM-29, "OIL PAN AND OIL STRAINER" .
17. Install rocker covers (right and left banks). Refer to EM-44, "ROCKER COVER" .
18. Install crankshaft pulley as follows:
a. Fix crankshaft using ring gear stopper [SST: KV10117700 (J44716)].
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).
PBIC4627J
19. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns
smoothly.
20. Install in the reverse order of removal after this step.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in guide may gen-
erate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
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-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .
● 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
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 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 make sure 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
KBIA4372J
8. Separate engine harnesses removing their brackets from front timing chain case.
9. Remove intake manifold collectors (upper and lower). Refer to EM-18, "INTAKE MANIFOLD COLLEC-
TOR" .
10. Remove radiator cooling fan assembly. Refer to CO-22, "COOLING FAN" .
11. Remove drive belts. Refer to EM-14, "DRIVE BELTS" .
12. Remove A/C compressor from bracket with piping connected, and temporarily secure it aside. Refer to
ATC-128, "Components" .
13. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
Refer to PS-29, "POWER STEERING OIL PUMP" .
14. Remove power steering oil pump bracket. Refer to PS-29, "POWER STEERING OIL PUMP" .
15. Remove alternator. Refer to SC-21, "CHARGING SYSTEM" .
16. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
17. Remove left and right valve timing control covers (including magnet retarder and cover) with the following
procedure.
EM
PBIC3560E
D
b. Shaft is engaged with intake side camshaft sprocket center hole
on inside. Pull straight out so as not to tilt until the joint is disen-
gaged.
E
● The mating surface of magnet retarder may be fitted with the
exhaust side camshaft sprocket via the engine oil. Open valve
timing control cover carefully.
F
● If the mating surface of magnet retarder is fitted with the cam-
shaft sprocket, open the cover within the range that the load is
not applied to the harness. And then, remove it so as to pre-
vent magnet retarder from dropping. G
CAUTION: PBIC3561E
● When carrying valve timing control cover, face the magnet retarder side up to prevent the cover H
from falling from magnet retarder.
● Do not remove magnet retarder from valve timing control cover. (Disassembly prohibited parts)
18. Remove rocker covers (right and left banks). Refer to EM-44, "ROCKER COVER" . I
19. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
a. Rotate crankshaft pulley clockwise to align timing mark (grooved
line without color) with timing indicator. J
KBIA1717J
M
b. Make sure 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
as shown in the figure.
SEM418G
a. Remove starter motor and set ring gear stopper (SST) as shown
in the figure. Refer to SC-10, "STARTING SYSTEM" .
PBIC1098E
PBIC1103E
EMQ0477D
21. Remove oil pans (upper and lower). Refer to EM-29, "OIL PAN AND OIL STRAINER" .
22. Remove front timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
KBIA4375J
b. Insert suitable tool into the notch at the top of the front timing
chain case as shown (1). A
c. Pry off case by moving the tool as shown (2).
● Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gas-
ket for removal. EM
CAUTION:
● Do not use screwdriver or something similar.
D
23. Remove O-rings from rear timing chain case.
G
PBIC3570E
24. Remove water pump cover and chain tensioner cover from front timing chain case. H
● Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
25. Remove front oil seal from front timing chain case using suitable
tool. I
● Use screwdriver for removal.
CAUTION:
Be careful not to damage front timing chain case. J
EMQ0032D
L
26. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt.
b. Loosen upper mounting bolt slowly, and then turn timing chain M
tensioner (primary) on the mounting bolt so that plunger is fully
expanded.
NOTE:
Even if plunger is fully expanded, it is not dropped from the body
of timing chain tensioner (primary).
c. Remove upper mounting bolt, and then remove timing chain ten-
sioner (primary).
PBIC3562E
27. Remove internal chain guide, tension guide and slack guide.
NOTE:
Tension guide can be removed after removing timing chain (pri-
mary).
PBIC3563E
PBIC3564E
KBIA4379J
PBIC3565E
D
30. Remove water pump. Refer to CO-24, "WATER PUMP" .
31. Remove rear timing chain case as follows:
a. Loosen and remove mounting bolts in reverse order as shown in E
the figure.
b. Cut liquid gasket using seal cutter [SST: KV10111100 (J37228)]
and remove rear timing chain case. F
SEM735G H
CAUTION:
● Do not remove plate metal cover of oil passage. I
● After removal, handle rear timing chain case carefully so
it does not tilt, cant, or warp under a load.
J
KBIA1307E L
SBIA0496E
PBIC0788E
34. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a. Remove camshaft brackets (No. 1). Refer to EM-101, "REMOVAL" .
b. Remove timing chain tensioners (secondary) with stopper pin attached.
35. Use scraper to remove all traces of old liquid gasket from front
and rear timing chain cases, and opposite mating surfaces.
PBIC3492E
PBIC2084E
36. Use scraper to remove all traces of liquid gasket from water
pump cover, chain tensioner cover and valve timing control cov-
ers.
SEM926E
D
PBIC0282E
INSTALLATION
NOTE:
● The below figure shows the relationship between the mating mark on each timing chain and that on the
corresponding sprocket, with the components installed.
● In this figure, the drum of exhaust side camshaft sprocket has been omitted.
PBIC3590E
1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Refer to EM-105,
"INSTALLATION" .
a. Install timing chain tensioners (secondary) with stopper pin attached and new O-ring.
b. Install camshaft brackets (No. 1). Refer to EM-105, "INSTALLATION" .
2. Install rear timing chain case as follows:
a. Install new O-rings onto cylinder block.
PBIC0788E
EM
SBIA0496E
D
c. Apply liquid gasket with tube presser [SST: WS39930000 ( — )] to rear timing chain case back side as
shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-45, "RECOMMENDED CHEMICAL
E
PRODUCTS AND SEALANTS" .
CAUTION:
● For “A” in the figure, completely wipe out liquid gasket extended on a portion touching at
engine coolant. F
● Apply liquid gasket on installation position of water pump and cylinder head very completely.
PBIC2659E
d. Align rear timing chain case and water pump assembly with dowel pins (right and left) on cylinder block
and install rear timing chain case.
● Make sure O-rings stay in place during installation to cylinder block and cylinder head.
f. After all bolts are tightened, retighten them to the specified in numerical order shown in the figure.
● If liquid gasket protrudes, wipe it off immediately. A
g. After installing rear timing chain case, check the surface height
difference between following parts on oil pan (upper) mounting EM
surface.
Standard
Rear timing chain case to cylinder block: C
–0.24 to 0.14 mm (–0.0094 to 0.0055 in)
● If not within standard, repeat the installation procedure.
D
SEM943G
E
3. Install water pump with new O-rings. Refer to CO-24, "WATER PUMP" .
4. Make sure that dowel pin holes (small dia. side) and crankshaft
key are located as shown in the figure. (No. 1 cylinder at com-
F
pression TDC)
● NOTE:
Though camshaft does not stop at the position as shown in
the figure, for the placement of cam nose, it is generally G
accepted camshaft is placed for the same direction of the fig-
ure.
H
Camshaft dowel pin hole (intake side)
: At cylinder head upper face side in each bank. PBIC3498E
CAUTION:
The small dia. side of camshaft dowel pin holes should be used. (The large dia. side is not used.)
K
5. Install timing chains (secondary) and camshaft sprockets as follows:
CAUTION:
● When replacing camshaft sprocket (EXH), replace valve timing control cover (including magnet
L
retarder and cover).
● Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions
repeatedly during the installation process.
M
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with stopper pin.
SEM430G
PBIC3567E
KBIA4379J
EM
PBIC3564E
D
6. Install tension guide.
7. Install timing chain (primary) as follows:
a. Install crankshaft sprocket. E
● Make sure the mating marks on crankshaft sprocket face the
front of engine.
F
SEM929E H
PBIC3494E
8. Install internal chain guide, slack guide and timing chain ten-
sioner (primary).
PBIC3563E
CAUTION:
Do not overtighten slack guide mounting bolts. It is normal
for a gap to exist under the bolt seats when mounting bolts
are tightened to specification.
PBIC2633E
9. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab up (or turn lever downward) so as to
remove plunger stopper tab from the ratchet of plunger.
NOTE:
Plunger stopper tab and lever are synchronized.
b. Push plunger into the inside of tensioner body.
c. Hold plunger in the fully compressed position by engaging
plunger stopper tab with the tip of ratchet.
d. To secure lever, insert stopper pin through hole of lever into ten-
sioner body hole.
● The lever parts and the tab are synchronized. Therefore, the PBIC3568E
plunger will be secured under this condition.
NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
PBIC3569E
D
10. Make sure again that the mating marks on sprockets and timing chain have not slipped out of alignment.
11. Install new O-rings on rear timing chain case.
E
PBIC3570E
H
12. Install new front oil seal on front timing chain case.
● Apply new engine oil to both oil seal lip and dust seal lip.
L
SEM715A
● Using suitable drift, press-fit oil seal until it becomes flush with
front timing chain case end face. M
● Make sure the garter spring is in position and seal lip is not
inverted.
PBIC0790E
13. Install water pump cover and chain tensioner cover to front timing chain case.
SEM744GA
PBIC3495E
b. Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
c. Tighten mounting bolts to the specified torque in numerical order
as shown in the figure.
● There are two types of mounting bolts. Refer to the following
for locating bolts.
M8 bolts : 1, 2
: 25.5 - 31.3 N·m (2.6 - 3.2 kg-m, 19 - 23 ft-lb)
M6 bolts : Except the above
: 11.7 - 13.7 N·m (1.2 - 1.4 kg-m, 9 - 10 ft-lb)
KBIA4375J
d. After all bolts are tightened, retighten them to the specified
torque in numerical order shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).
e. After installing front timing chain case, check the surface height
difference between the following parts on the oil pan (upper) A
mounting surface.
Standard
Front timing chain case to rear timing chain case: EM
–0.14 to 0.14 mm (–0.0055 to 0.0055 in)
● If not within standard, repeat the installation procedure. C
SEM943G
D
15. Install right and left valve timing control covers as follows:
a. Install new seal rings in shaft grooves.
E
PBIC3571E
H
b. Install magnet retarder aligning the dowel pins of the back with
the cover side dowel pin holes securely. Simultaneously insert
the harness into the installation groove securely.
I
NOTE:
Figure shows the structure of the parts. Therefore, magnet
retarder is being removed from the cover in this figure. But, if
magnet retarder is in the correct position, omit step “b” and per- J
form step “c”.
K
PBIC3572E
c. To check the joint between dowel pins and dowel pin holes,
check the looseness in the axle direction by pushing the mating L
surface of magnet retarder at several places and the circumfer-
ential looseness (between dowel pins and dowel pin holes) by
twisting in the circumferential direction. M
CAUTION:
Always perform this procedure when removing because the
gap between dowel pins and dowel pin holes may not be
caused on purpose.
PBIC3573E
PBIC3560E
16. Install oil pans (upper and lower). Refer to EM-29, "OIL PAN AND OIL STRAINER" .
17. Install rocker covers (right and left banks). Refer to EM-44, "ROCKER COVER" .
18. Install crankshaft pulley as follows:
a. Fix crankshaft using ring gear stopper [SST: KV10117700 (J44716)].
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).
PBIC4627J
19. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns
smoothly.
20. Install in the reverse order of removal after this step.
CAMSHAFT PFP:13001
KBIA4393J
25. Camshaft (INT) 26. Camshaft (EXH) 27. Camshaft bracket (No. 2 to 4)
Exhaust valve timing control position Exhaust valve timing control position A
28. 29.
sensor (right bank) sensor (left bank)
A. Refer to EM-105 B. M/T models
EM
● Refer to GI-10, "Components" for symbol marks in the figure.
REMOVAL
1. Remove front timing chain case, camshaft sprocket, timing chain and rear timing chain case. Refer to EM- C
59, "TIMING CHAIN" .
2. Remove camshaft position sensor (PHASE) (right and left
banks) and exhaust valve timing control position sensor (right D
and left banks) (M/T models) from cylinder head back side.
CAUTION:
● Handle carefully to avoid dropping and shocks.
E
● Do not disassemble.
G
3. Remove intake valve timing control solenoid valves.
● Discard intake valve timing control solenoid valve gaskets and
use new gaskets for installation.
H
J
SEM443GA
PBIC2050E
5. Remove camshaft.
6. Remove valve lifter.
● Identify installation positions, and store them without mixing them up.
PBIC2111E
PBIC0040E
K
CAMSHAFT BRACKET INNER DIAMETER
● Tighten camshaft bracket bolt with the specified torque. Refer to EM-105, "INSTALLATION" for the tight-
ening procedure. L
● Measure the inner diameter “A” of camshaft bracket with a bore
gauge.
Standard: M
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
● If it exceeds the limit, replace either or both camshaft and cylinder head.
NOTE:
Camshaft brackets cannot be replaced as single parts, because there are machined together with cylinder
head. Replace whole cylinder head assembly.
Camshaft End Play
● Install a dial indicator in thrust direction on front end of camshaft.
Measure the end play of a dial indicator when camshaft is
moved forward/backward (in direction to axis).
Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in)
Limit : 0.24 mm (0.0094 in)
SEM864E
PBIC0930E
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
● If anything above is found, replace valve lifter. Refer to EM-170,
"Available Valve Lifter" .
KBIA0182E
H
SEM867E
Exhaust
Identification (stamped) mark “R” K
: 0.013 - 0.039 mm (0.0005 - 0.0015 in)
Identification (stamped) mark “V”
: 0.010 - 0.036 mm (0.0004 - 0.0014 in) L
● 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.
M
INSTALLATION
1. Install timing chain tensioners (secondary) on both sides of cyl-
inder head.
● Install timing chain tensioner with its stopper pin attached.
PBIC2111E
● Install camshaft with dowel pin attached to its front end face
on the exhaust side.
KBIA1071E
INT No Pink No RE
RH
EXH Yes No Orange RE
INT No Pink No LH
LH
EXH Yes No Orange LH KBIA1009E
● 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 direc-
tion).
● 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 PBIC2478E
figure.
PBIC3574E
INT Brown No RE
RH
EXH No Brown RE C
INT Brown No LH
LH
EXH No Brown LH PBIC3499E
D
● Install camshaft so that dowel pin hole (small dia. side) front
end face are positioned as shown in the figure. (No. 1 cylinder
TDC on its compression stroke) E
Intake : On cylinder head upper surface
Exhaust : On cylinder head lower surface
F
NOTE:
● Large and small dowel pin holes are located on the front
end of camshaft at 180 degree intervals. Only the small
dowel pin hole position is described in this text because the G
large dowel pin hole is not used for assembly of engine. PBIC3500E
PBIC2051E
PBIC2052E
PBIC2660E
EMQ0044D
D
8. Inspect and adjust the valve clearance. Refer to EM-111, "Valve Clearance" .
9. Install camshaft position sensor (PHASE) (right and left banks) and exhaust valve timing control position E
sensor (right and left banks) (M/T models) to the cylinder head back side.
● Install them in the position shown in the figure.
PBIC3518E
I
10. Install in the reverse order of removal after this step.
H
SEM713A
1. Remove rocker covers (right and left bank). Refer to EM-44, "ROCKER COVER" . I
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 J
(grooved line without color) with timing indicator.
KBIA1717J M
● Make sure that intake and exhaust cam nose on No. 1 cylin-
der (engine front side of right bank) are located as shown in
the figure.
● If not, turn crankshaft one revolution (360 degrees) and align
as shown in the figure.
SEM418G
SEM139D
Valve clearance:
Unit: mm (in)
Items 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)
PBIC2054E
c. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 3 cylinder at
TDC of its compression stroke.
NOTE:
● To align cylinder No. 3 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°counterclock-
wise from the compression top dead center using the hex
head of the crankshaft pulley bolt as a guide.
PBIC4628J
G
PBIC2055E
d. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 5 cylinder at
TDC of its compression stroke. H
NOTE:
● To align cylinder No. 5 with the compression top dead center,
place matching marks (A) on the crankshaft pulley (1) side I
and on the cylinder block side at a point 240°counterclock-
wise from the compression top dead center using the hex
head of the crankshaft pulley bolt as a guide.
J
PBIC4628J
PBIC2056E
3. If the measured values are out of the standard, perform adjustment. Refer to EM-114, "ADJUSTMENT" .
ADJUSTMENT
● Perform adjustment depending on selected head thickness of valve lifter.
1. Measure the valve clearance. Refer to EM-111, "INSPECTION" .
2. Remove camshaft. Refer to EM-101, "REMOVAL" .
3. Remove valve lifters at the locations that are out of the standard.
4. Measure the center thickness of removed valve lifters with a
micrometer.
KBIA0057E
5. Use the equation below to calculate valve lifter thickness for replacement.
Valve lifter thickness calculation: t = t1 + (C1 – C2 )
t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.30 mm (0.012 in)*
Exhaust : 0.33 mm (0.013 in)*
*: Approximately 20°C (68°F)
KBIA0119E
D
Stamp mark
Thickness
INT EXH
E
788U 788R 788V 7.88 mm
790U 790R 790V 7.90 mm
· · · · F
· · · ·
840U 840R 840V 8.40 mm
G
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-170, "Available Valve Lifter" .
CAUTION: H
● Install identification letters at each of proper positions.
REMOVAL
1. Remove camshaft relating to valve oil seal to be removed. Refer to EM-100, "CAMSHAFT" .
2. Remove valve lifters. Refer to EM-100, "CAMSHAFT" .
3. Turn crankshaft until the cylinder requiring new oil seals is at TDC. This will prevent valve from dropping
into cylinder.
4. Remove valve collet.
● Compress valve spring with valve spring compressor, attach-
ment, adapter (SST). Remove valve collet with magnet hand.
CAUTION:
When working, take care not to damage valve lifter holes.
PBIC1803E
5. Remove valve spring retainer, valve spring and valve spring seat.
6. Remove valve oil seal using valve oil seal puller (SST).
PBIC0884E
INSTALLATION
1. Apply engine oil on new valve oil seal joint and seal lip.
2. Using valve oil seal drift (SST), press fit valve oil seal to height
“H” shown in the figure.
NOTE:
Dimension “H”: Height measured before valve spring seat instal-
lation
Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
PBIC0802E
REMOVAL A
1. Remove the following parts:
● Undercover
SEM829E
INSTALLATION G
1. Apply 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
H
in the figure.
K
SEM715A
● Using suitable drift, press-fit until the height of front oil seal is
level with the mounting surface. L
– Suitable drift: outer diameter 60 mm (2.36 in), inner diameter
50 mm (1.97 in).
● Make sure the garter spring is in position and seal lips not M
inverted.
CAUTION:
● Be careful not to damage front timing chain case and
crankshaft.
● Press-fit straight and avoid causing burrs or tilting oil
SEM829E
seal.
REMOVAL
1. Remove oil pan (upper). Refer to EM-29, "OIL PAN AND OIL STRAINER" .
2. Remove transmission assembly. Refer to MT-18, "TRANSMISSION ASSEMBLY" (M/T models) or AT-
274, "TRANSMISSION ASSEMBLY" (A/T models).
3. Remove clutch cover and clutch disk (M/T models). Refer to CL-16, "CLUTCH DISC, CLUTCH COVER" .
4. Remove flywheel (M/T models) or drive plate (A/T models). Refer to EM-137, "CYLINDER BLOCK" .
5. Use seal cutter (SST) to cut away liquid gasket and remove rear
oil seal retainer.
CAUTION:
Be careful not to damage mating surfaces.
NOTE:
Regard both rear oil seal and retainer as an assembly.
SEM830E
INSTALLATION
1. Remove old liquid gasket on mating surface of cylinder block and oil pan (upper) using scraper.
2. Apply new engine oil to both oil seal lip and dust seal lip of new rear oil seal retainer.
3. Apply a continuous bead of liquid gasket with tube presser [SST:
WS39930000 ( — )] to rear oil seal retainer as shown in the
figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
● Assembly should be done within 5 minutes after coating.
PBIC2661E
4. Install rear oil seal retainer to cylinder block. Refer to EM-137, "CYLINDER BLOCK" .
● Make sure the garter spring is in position and seal lips not inverted.
PBIC2058E
F
4. Remove engine cover with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .
5. Remove ignition coil and spark plug from each cylinder. Refer to EM-35, "IGNITION COIL" and EM-36,
"SPARK PLUG (PLATINUM-TIPPED TYPE)" .
G
6. Connect engine tachometer (not required in use of CONSULT-ll).
7. Install compression tester with adapter onto spark plug hole.
H
PBIC0900E
K
● Use the adapter 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.
L
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.
If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine
●
speed again with normal battery gravity.
● 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 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.
– 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
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.
10. Start engine, and make sure that engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-83, "TROUBLE DIAGNOSIS" .
Removal and Installation NBS0000Z
SBIA0581E
1. Engine rear lower slinger 2. Cylinder head (left bank) 3. Cylinder head bolt
4. Cylinder head (right bank) 5. Cylinder head gasket (right bank) 6. Cylinder head gasket (left bank)
7. Oil level gauge guide
REMOVAL
1. Remove camshaft. Refer to EM-100, "CAMSHAFT" .
NOTE:
It is also possible to perform the following steps 2 and 3 just before removing the camshaft.
2. Temporarily fit front suspension member to support engine. Refer to FSU-19, "FRONT SUSPENSION
MEMBER" .
CAUTION:
Temporary fitting means the status that engine is adequately stable though the hoist is released A
from hanging.
NOTE:
At the time of the start of this procedure front suspension member is removed, and cylinder head is EM
hanged by the hoist with engine slinger installed.
3. Release the hoist from hanging, then remove the engine slinger.
4. Remove the following parts: C
● Fuel tube and fuel injector assembly: Refer to EM-38, "FUEL INJECTOR AND FUEL TUBE" .
● Exhaust manifold: Refer to EM-25, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . D
● Water inlet and thermostat assembly: Refer to CO-29, "WATER INLET AND THERMOSTAT ASSEM-
BLY" .
● Water outlet and water pipe: Refer to CO-31, "WATER OUTLET AND WATER PIPING" . E
5. Remove cylinder head bolts in reverse order as shown in the fig-
ure with cylinder head bolt wrench (commercial service tool).
F
PBIC2057E L
PBIC2480E
SEM861E
INSTALLATION
1. Install new cylinder head gaskets.
2. Turn crankshaft until No. 1 piston is set at TDC.
● Crankshaft key should line up with the right bank cylinder cen-
ter line as shown in the figure.
SEM532G
PBIC2057E
D
4. After installing cylinder head, measure distance between front
end faces of cylinder block and cylinder head (left and right
banks).
E
Standard : 14.1 - 14.9 mm (0.555 - 0.587 in)
● If the measured value is out of the standard, re-install cylinder
head. F
G
EMQ0662D
PBIC2637E
DISASSEMBLY
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.
PBIC1803E
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.
6. Remove valve oil seals using valve oil seal puller (SST).
A
EM
PBIC0884E
D
7. If valve seat must be replaced, refer to EM-129, "VALVE SEAT REPLACEMENT" .
8. If valve guide must be replaced, refer to EM-127, "VALVE GUIDE REPLACEMENT" .
9. Remove spark plug tube, as necessary. E
● Using pair of pliers, pull spark plug tube out of cylinder head.
CAUTION:
● Take care not to damage cylinder head. F
● Once removed, spark plug tube will be deformed and cannot be reused. Do not remove it unless
absolutely necessary.
ASSEMBLY G
1. When valve guide is removed, install it. Refer to EM-127, "VALVE GUIDE REPLACEMENT" .
2. When valve seat is removed, install it. Refer to EM-129, "VALVE SEAT REPLACEMENT" .
H
3. Install valve oil seals.
● Install with valve oil seal drift (SST) to match dimension in the
figure.
I
Height “H” (Without valve spring seat installed)
Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
J
K
PBIC0802E
SEM085D
PBIC1803E
tool).
Inspection After Disassembly NBS00011
VALVE DIMENSIONS
● Check dimensions of each valve. For dimensions, refer to EM-
171, "Valve Dimensions" .
● If dimensions are out of the standard, replace valve and check
valve seat contact. Refer to EM-129, "VALVE SEAT CONTACT"
.
SEM188A
D
SEM938C
SEM008A
SEM931C
SEM932C
SEM008A
SEM950E
SEM932C
SEM795A
J
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
K
M
SEM008A
4. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head.
WARNING:
● Avoid directly touching cold valve seats.
● Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
SEM934C
PBIC0080E
SEM113
Standard:
Items A/T models M/T models
Free height 47.07 mm (1.8531 in) 45.43 mm (1.7886 in)
Installation height 37.00 mm (1.4567 in) 37.00 mm (1.4567 in)
Installation load 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb) 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)
Height during valve open 27.20 mm (1.071 in) 26.80 mm (1.055 in)
Load with valve open 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb) 434 - 490 N (44.3 - 50.0 kg, 97.6 - 110.2 lb)
Identification color Blue Purple
● If the installation load or load with valve open is out of the standard, replace valve spring.
EM
PBIC2309E
K
1. Engine mounting bracket (RH) 2. Heat insulator (RH) 3. Engine mounting Insulator (RH)
4. Engine mounting insulator (LH) 5. Heat insulator (LH) 6. Engine mounting bracket (LH)
7. Harness bracket 8. Rear engine mounting member 9. Mass damper L
10. Engine mounting insulator (rear) 11. Dynamic damper
WARNING:
● Situate vehicle on a flat and solid surface. M
● Place chocks at 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, avoid forceful or uninstructed operations.
● Do not 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.
● 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
unavoidable reasons, 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-39, "Garage Jack and
Safety Stand" .
REMOVAL
Outline
At first, remove engine and transmission assembly with front suspension member from vehicle downward.
Then separate engine from transmission.
Preparation
1. Release fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" .
2. Drain engine coolant from radiator. Refer to CO-10, "Changing Engine Coolant" .
CAUTION:
● Perform this step when engine is cold.
● Front wiper arm and cowl top cover: Refer to EI-20, "COWL TOP" .
● Undercover
5. Remove air cleaner case and air duct. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .
6. Discharge refrigerant from A/C circuit. Refer to ATC-126, "REFRIGERANT LINES" .
7. Remove radiator cooling fan assembly, reservoir tank and hoses. Refer to CO-22, "COOLING FAN" and
CO-13, "RADIATOR" .
Engine Room
1. Disconnect heater hose at engine-side, and fit a plug onto hose end to prevent engine coolant leak.
2. Disconnect ground cable (between vehicle to left cylinder head).
3. Disconnect battery positive cable harness at vehicle side and temporarily fasten it on engine.
4. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope.
5. Remove engine room harness connectors as shown in the fig-
ure.
PBIC1105E
1. Remove passenger-side kicking plate inner, dash side finisher, and instrument passenger panel lower.
Refer to EI-35, "BODY SIDE TRIM" and IP-10, "INSTRUMENT PANEL ASSEMBLY" . A
2. Disconnect engine room harness connectors at unit sides TCM
(A/T models), ECM and other.
EM
D
PBIC0883E
3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily E
secure them on engine.
CAUTION:
● When pulling out harnesses, take care not to damage harnesses and connectors.
F
● After temporarily securing, cover connectors with vinyl or similar material to protect against for-
eign material adhesion.
Vehicle Underbody G
1. Remove exhaust front tube. Refer to EX-3, "EXHAUST SYSTEM" .
2. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.
Refer to PS-11, "STEERING COLUMN" . H
3. Remove propeller shaft. Refer to PR-5, "REAR PROPELLER SHAFT" .
CAUTION:
Do not impact or damage propeller shaft tube. I
4. Disengage shift lever and clutch operating cylinder (M/T models). Refer to MT-18, "TRANSMISSION
ASSEMBLY" and CL-11, "OPERATING CYLINDER" .
5. Disengage A/T control rod at control device assembly side. Then, temporarily secure it on transmission, J
so that it does not sag (A/T models). Refer to AT-236, "SHIFT CONTROL SYSTEM" .
6. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter
(A/T models). Refer to EM-29, "OIL PAN AND OIL STRAINER" and AT-274, "TRANSMISSION ASSEM- K
BLY" .
7. Remove bolts fixing transmission to lower rear side of oil pan (upper). Refer to MT-18, "TRANSMISSION
ASSEMBLY" (M/T models) or AT-274, "TRANSMISSION ASSEMBLY" (A/T models). L
8. Remove front stabilizer. Refer to FSU-18, "STABILIZER BAR" .
9. Separate steering outer sockets from steering knuckle. Refer to PS-18, "POWER STEERING GEAR AND
LINKAGE" . M
10. Separate transverse links from suspension member and vehicle body. Refer to FSU-13, "TRANSVERSE
LINK" .
Removal Work
1. Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as transmission jack. Securely support
bottom of suspension member and transmission.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
PBIC0804E
3. Remove front suspension member mounting nuts. Refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" .
4. Carefully lower jack, or raise lift to remove the engine, transmission and front suspension member assem-
bly. When performing work, observe the following caution:
CAUTION:
● Confirm there is no interference with the vehicle.
● Keep in mind the center of the vehicle gravity changes. If necessary, use jack(s) to support the
vehicle at rear jacking point(s) to prevent it from falling it off the lift.
Separation Work
1. Install engine slingers into front of cylinder head (right bank) and
rear of cylinder head (left bank).
Slinger bolts:
: 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)
PBIC2061E
KBIA1017E
2. Remove power steering oil pump from engine side. Refer to PS-29, "POWER STEERING OIL PUMP" .
3. Remove engine mounting insulators (RH and LH) under side nut.
4. Lift with hoist and separate engine and transmission assembly from front suspension member.
CAUTION:
● Before and during this lifting, always make sure that any harnesses are left connected.
● Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
EM
PBIC2062E
D
● Make sure all engine mounting insulators are seated properly, then tighten mounting nuts.
● Tighten rear engine mounting member bolts in numerical order
as shown in the figure. E
PBIC2289E
K
PBIC2290E
EM
PBIC3496E
PBIC2614E
DISASSEMBLY
1. Remove engine assembly from vehicle, and separate front suspension member and transmission from
engine. Refer to EM-131, "ENGINE ASSEMBLY" .
2. Remove engine mounting brackets (RH and LH). Refer to EM-131, "ENGINE ASSEMBLY" .
3. Remove exhaust manifold (right bank). Refer to EM-25, "EXHAUST MANIFOLD AND THREE WAY CAT-
ALYST" .
EM
PBIC0920E
D
5. Lift engine, and mount it onto engine stand (SST).
PBIC0805E
K
● A widely use engine stand can be used.
CAUTION:
L
Use engine stand that has a load capacity [approximately
220 kg (441 lb) or more] large enough for supporting the
engine weight.
NOTE: M
This example is engine stand for holding at transmission
mounting side with flywheel (M/T models) or drive plate (A/T
models) removed.
PBIC0085E
PBIC2610E
8. Remove clutch cover and clutch disc (M/T models). Refer to CL-16, "CLUTCH DISC, CLUTCH COVER" .
9. Remove flywheel (M/T models) or drive plate (A/T models). Fix
crankshaft with ring gear stopper (SST), and remove mounting
bolts.
● Loosen mounting bolts in diagonal order.
PBIC1109E
CAUTION:
● Do not disassemble flywheel (M/T models) and drive
plate (A/T models).
● Do not place drive plate (A/T models) 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
becoming magnetized.
SEM760G
12. Remove pilot bushing (M/T models) or pilot converter (A/T mod-
els) using pilot bushing puller (SST) or suitable tool as neces- A
sary.
EM
SEM005G
D
13. Remove rear oil seal retainer.
● Remove by inserting screwdriver between main bearing cap and rear oil seal retainer.
CAUTION: E
If rear oil seal retainer is removed, replace it with new one.
NOTE:
Regard both rear oil seal and retainer as an assembly. F
14. Remove baffle plate from main bearing beam.
15. Remove piston and connecting rod assembly as follows:
● Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer G
to EM-156, "CONNECTING ROD SIDE CLEARANCE" .
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod bearing cap. H
c. Using hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side.
CAUTION: I
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end. J
K
EMQ0191D
16. Remove connecting rod bearings from connecting rod and connecting rod bearing cap. L
CAUTION:
Identify installation position, and store them without mixing them up.
17. Remove piston rings form piston. M
● Before removing piston rings, check the piston ring side clearance. Refer to EM-157, "PISTON RING
SIDE CLEARANCE" .
● Use piston ring expander (commercial service tool).
CAUTION:
● When removing piston rings, be careful not to damage
piston.
● Be careful not to damage piston rings by expanding them
excessively.
PBIC0087E
PBIC1638E
PBIC1639E
PBIC0262E
PBIC1800E
EM
PBIC0881E
D
21. Remove main bearing caps.
● Using main bearing cap bolts, remove main bearing cap while
shaking it back-and-forth. E
EMQ0195D
H
22. Remove crankshaft.
23. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION: I
Identify installation positions, and store them without mixing them up.
24. Remove oil jet.
ASSEMBLY J
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION: K
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”, “B” and
L
“C”.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND M
SEALANTS" .
● Apply sealant to the thread of plugs “D” and “E”.
Use Genuine High Strength Thread Locking Sealant or
equivalent. Refer to GI-45, "RECOMMENDED CHEMICAL
PRODUCTS AND SEALANTS" .
● Apply sealant to the thread of plug “F”.
Use Anaerobic Liquid Gasket or equivalent. Refer to GI-
45, "RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS" .
● Replace washers with new one.
PBIC2610E
PBIC0898E
PBIC0807E
SEM456G
D
7. Install main bearing beam.
● Install main bearing beam with front mark facing downward (oil pan side).
PBIC0881E H
8. Inspect the outer diameter of main bearing cap bolt. Refer to EM-165, "MAIN BEARING CAP BOLT
OUTER DIAMETER" . I
9. Tighten main bearing cap bolts in numerical order as shown in
the figure as follows:
a. Apply new engine oil to threads and seat surfaces of main bear- J
ing cap bolts.
b. Tighten main bearing cap bolts in several different steps.
: 32.3 - 38.3 N·m (3.3 - 3.9 kg-m, 24 - 28 ft-lb) K
L
PBIC1800E
● 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
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
the figure.
NOTE:
Figure shows the piston of A/T models. The front marks of M/T
models are 2 punched.
c. Install new snap ring to the groove of the piston front side.
● Insert it fully into groove to install.
11. Using piston ring expander (commercial service tool), install pis-
ton rings.
CAUTION:
● When installing piston rings, be careful not to damage
piston.
● Be careful not to damage piston rings by expending them
excessively.
PBIC0087E
PBIC0808E
●Check the piston ring side clearance. Refer to EM-157, "PISTON RING SIDE CLEARANCE" .
12. 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.
PBIC2067E
D
13. 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. E
● Match the cylinder position with the cylinder number on connecting rod to install.
I
SEM620
PBIC0809E
M
15. Inspect the outer diameter of connecting rod bolt. (A/T models) Refer to EM-165, "CONNECTING ROD
BOLT OUTER DIAMETER (A/T MODELS)" .
CAUTION:
Do not reuse connecting rod bolt for M/T models. Replace it with a new one.
16. 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. Install pilot bushing (M/T models) or pilot converter (A/T mod-
els).
● With drift of the following outer diameter, press-fit as far as it
will go.
Pilot bushing : Approx. 17 mm (0.67 in)
Pilot converter : Approx. 33 mm (1.30 in)
PBIC0899E
PBIC2068E
EM
SEM537E
D
20. Install knock sensor.
● Install knock sensor so that connector faces front of engine.
PBIC1110E L
PBIC1112E
● Holding ring gear with ring gear stopper (SST), tighten secur-
ing bolts with TORX socket (size: T55, commercial service
tool).
● Tighten the mounting bolts crosswise over several times.
PBIC1109E
PBIC0910E
DESCRIPTION A
Selection points Selection parts Selection items Selection methods
Determined by match of cylin-
der block bearing housing
EM
Between cylinder block to Main bearing grade grade (inner diameter of hous-
Main bearing
crankshaft (bearing thickness) ing) and crankshaft journal
grade (outer diameter of jour-
C
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft to connect- Connecting rod bearing grade D
Connecting rod bearing ter and crankshaft pin outer
ing rod (bearing thickness)
diameter determine connecting
rod bearing selection.
Piston and piston pin assembly E
Between cylinder block to pis- Piston grade Piston grade = cylinder bore
(Piston is available together
ton (piston skirt diameter) grade (inner diameter of bore)
with piston pin as assembly.)
Between piston to connecting F
— — —
rod*
*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is available.) The
information at the shipment from the plant is described as a reference.
G
● The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
● For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the H
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. I
HOW TO SELECT PISTON
When New Cylinder Block is Used
Check the cylinder bore grade (“1”, “2” or “3”) on rear side of cylinder J
block, and select piston of the same grade.
NOTE:
Piston is available with piston pin as a set for the service part. (Only K
“0” grade piston pin is available.)
SEM756G
M
PBIC0812E
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
piston 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 diameter 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.
SEM452G
Unit: mm (in)
Crankshaft Connecting rod bearing
Crankshaft pin journal diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
51.968 - 51.974 (2.0460 - 2.0462) 0 1.500 - 1.503 (0.0591 - 0.0592) STD 0 Black
51.962 - 51.968 (2.0457 - 2.0460) 1 1.503 - 1.506 (0.0592 - 0.0593) STD 1 Brown
51.956 - 51.962 (2.0455 - 2.0457) 2 1.506 - 1.509 (0.0593 - 0.0594) STD 2 Green
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep A
the fillet R [1.5 mm (0.059 in)].
EM
PBIC1908E D
Bearing undersize table
Unit: mm (in)
E
Size Thickness
US 0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643)
SEM756G
J
2. “Main Bearing Selection Table” columns correspond to journal
diameter grade on front side of crankshaft.
K
M
SEM452G
3. Select main bearing grade at the point where selected row and column meet in “Main Bearing Selection
Table”.
When Cylinder Block and Crankshaft are Reused
1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer
to EM-160, "MAIN BEARING HOUSING INNER DIAMETER" and EM-162, "CRANKSHAFT MAIN
JOURNAL DIAMETER" .
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
Selection Table”.
4. Select main bearing grade at the point where selected row and column meet in following selection table.
PBIC1981E
PBIC1908E
EMQ0196D
PBIC0815E
PBIC0116E
PBIC0117E
● When replacing piston and piston pin assembly, refer to EM-151, "HOW TO SELECT PISTON" .
NOTE: A
● 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 piston pin grades can be selected. (Only “0” grade is available.) EM
PISTON RING SIDE CLEARANCE
● Measure the side clearance of piston ring and piston ring groove
with feeler gauge. C
Standard:
A/T models D
Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in)
E
Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in)
M/T models
Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in) SEM024AA
F
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Limit: G
A/T models
Top ring : 0.11 mm (0.0043 in) H
2nd ring : 0.10 mm (0.004 in)
Oil ring : —
M/T models I
Top ring : 0.11 mm (0.0043 in)
2nd ring : 0.10 mm (0.004 in)
J
Oil ring : 0.17 mm (0.0067 in)
● If the measured value exceeds the limit (or exceeding the standard in the case of oil ring of A/T models),
replace piston ring, and measure again. If it still exceeds the limit (or exceeding the standard in the case of K
oil ring of A/T models), replace piston also.
PBIC2077E
PBIC1641E
D
H
PBIC0120E
L
PBIC0117E
NOTE:
Figure shows the piston of A/T models. The front marks of M/T
models are 2 punched.
PBIC0812E
SEM123C
PBIC0125E
M
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).
Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit : 0.08 mm (0.0031 in)
● If calculated value exceeds the limit, replace piston and piston pin assembly. Refer to EM-151, "HOW TO
SELECT PISTON" .
Re-boring Cylinder Bore
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
where,
D: Bored diameter
A: Piston skirt diameter as measured
● 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.
5. Measure finished cylinder bore for the out-of-round and taper.
NOTE:
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER
● Measure the outer diameter of crankshaft main journals with micrometer.
Standard : 59.951 - 59.975 mm (2.3603 - 2.3612 in) dia.
● If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to EM-
164, "MAIN BEARING OIL CLEARANCE" .
CRANKSHAFT PIN JOURNAL DIAMETER
● Measure the outer diameter of crankshaft pin journal with
micrometer.
Standard : 51.956 - 51.974 mm (2.0455 - 2.0462 in) dia.
● If out of the standard, measure the connecting rod bearing oil
clearance. Then use undersize bearing. Refer to EM-163,
"CONNECTING ROD BEARING OIL CLEARANCE" .
PBIC0127E
CRANKSHAFT RUNOUT
● Place V-block on precise flat table, and support the journals on A
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 EM
dial indicator. (Total indicator reading)
Standard : Less than 0.05 mm (0.0020 in)
C
Limit : 0.10 mm (0.004 in)
● If it exceeds the limit, replace crankshaft.
SEM346D
D
● 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 I
to EM-152, "HOW TO SELECT CONNECTING ROD BEARING" .
Method of Using Plastigage
J
● Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
● Cut plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
K
● Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the speci-
fied torque. Refer to EM-143, "ASSEMBLY" for the tightening procedure.
CAUTION:
Do not rotate crankshaft. L
● Remove connecting rod bearing cap and bearing, and using
scale on plastigage bag, measure the plastigage width.
NOTE: M
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
PBIC1149E
● If the clearance exceeds the limit, select proper main bearing according to main bearing inner diameter
and crankshaft main journal diameter to obtain the specified bearing oil clearance. Refer to EM-153,
"HOW TO SELECT MAIN BEARING" .
Method of Using Plastigage
● Remove oil and dust on crankshaft main journal and the surfaces of each bearing completely.
● 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 main bearing caps, and tighten main bearing bolts with main
bearing beam to the specified torque. Refer to EM-143, "ASSEMBLY" for the tightening procedure.
CAUTION:
Do not rotate crankshaft.
● Remove main bearing caps and bearings, and using scale on
plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
PBIC1149E
SEM502G
PBIC1646E
D
PBIC0911E H
CONNECTING ROD BOLT OUTER DIAMETER (A/T MODELS)
CAUTION:
Do not reuse connecting rod bolt for M/T models. Replace it with a new one. I
● 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”. J
PBIC2168E
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
● Using clean plastic stick, press check valve in oil jet relief valve.
Make sure that valve moves smoothly with proper reaction
force.
● If it is not satisfied, replace oil jet relief valve.
EMU0468D
GENERAL SPECIFICATIONS
Cylinder arrangement V-6 EM
Displacement cm3 (cu in) 3,498 (213.45)
Bore and stroke mm (in) 95.5 x 81.4 (3.76 x 3.205)
C
Valve arrangement DOHC
Firing order 1-2-3-4-5-6
Compression 2 D
Number of piston rings
Oil 1
Number of main bearings 4
Compression ratio 10.3
E
H
Cylinder number
SEM713A
J
Valve timing
(Intake valve timing control - “OFF”) L
M
PBIC0187E
Unit: degree
a b c d e f
A/T models 240 238 −6 64 8 52
M/T models 248 248 −2 70 −2 70
DRIVE BELT
Deflection adjustment Unit: mm (in) Tension adjustment* Unit: N (kg, lb)
Used belt Used belt
New belt New belt
Limit After adjustment Limit After adjustment
Alternator and 730 - 818 838 - 926
4-5 3.5 - 4.5
power steering 7 (0.28) 294 (30, 66) (74.5 - 83.5, (85.5 - 94.5,
(0.16 - 0.20) (0.138 - 0.177)
oil pump belt 164 - 184) 188 - 208)
348 - 436 470 - 559
A/C compressor 9 - 10 8-9
12 (0.47) 196 (20, 44) (35.5 - 44.5, (48 - 57,
belt (0.35 - 0.39) (0.31 - 0.35)
78 - 98) 106 - 126)
Applied pushing
98 N (10 kg, 22 lb) —
force
KBIA1731J
*: If belt tension gauge cannot be installed at check points shown, check drive belt tension at different location on the belt.
SPARK PLUG
Make NGK
Standard type PLFR5A-11
Hot type PLFR4A-11
Cold type PLFR6A-11
Gap (Nominal) 1.1 mm (0.043 in)
SEM671 J
Valve Clearance
Unit: mm (in)
Items 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)
SEM758G
CYLINDER HEAD
Unit: mm (in) A
Items Standard Limit
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
EM
Normal cylinder head height “H” 126.3 - 126.5 (4.972 - 4.980) —
PBIC0924E
F
Valve Dimensions
Unit: mm (in)
SEM188
J
Intake 37.0 - 37.3 (1.457 - 1.469)
Valve head diameter “D”
Exhaust 31.2 - 31.5 (1.228 - 1.240)
K
Intake 96.37 (3.794)
Valve length “L”
Exhaust 93.99 (3.700)
Intake 5.965 - 5.980 (0.2348 - 0.2354) L
Valve stem diameter “d”
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Intake
Valve seat angle “α” 45°15′ - 45°45′ M
Exhaust
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 1.3 (0.051)
Valve margin “T” limit 0.5 (0.020)
Valve stem end surface grinding limit 0.2 (0.008)
Valve Guide
Unit: mm (in)
SEM950E
Valve Seat
Unit: mm (in) A
EM
D
PBIC2745E
Valve Spring
Items A/T models M/T models
Free height 47.07 mm (1.8531 in) 45.43 mm (1.7886 in)
Installation height 37.00 mm (1.4567 in) 37.00 mm (1.4567 in)
Installation load 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb) 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)
Height during valve open 27.20 mm (1.071 in) 26.80 mm (1.055 in)
Load with valve open 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb) 434 - 490 N (44.3 - 50.0 kg, 97.6 - 110.2 lb)
squareness 2.1 mm (0.083 in) 2.0 mm (0.079 in)
CYLINDER BLOCK
Unit: mm (in)
PBIC0923E
EM
SEM882E E
Items Standard Oversize (Service) [0.20 (0.008)]
“a” dimension 41.0 (1.614)
F
Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) —
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) — G
Service — 95.680 - 95.710 (3.7669 - 3.7681)
Items Standard Limit
H
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) I
Piston Ring
Unit: mm (in)
Standard Limit J
Items
A/T models M/T models A/T models M/T models
0.045 - 0.080
Top
(0.0018 - 0.0031)
0.11 (0.0043) 0.11 (0.0043) K
0.030 - 0.070
Side clearance 2nd 0.10 (0.004) 0.10 (0.004)
(0.0012 - 0.0028)
L
0.065 - 0.135
Oil ring — 0.17 (0.0067)
(0.0026 - 0.0053)
0.23 - 0.33 0.23 - 0.33
Top 0.54 (0.0213) 0.54 (0.0213) M
(0.0091 - 0.0130) (0.0091 - 0.0130)
0.33 - 0.48 0.23 - 0.33
End gap 2nd 0.80 (0.0315) 0.53 (0.0209)
(0.0130 - 0.0189) (0.0091 - 0.0130)
0.20 - 0.50 0.20 - 0.50
Oil (rail ring) 0.95 (0.0374) 0.85 (0.0335)
(0.008 - 0.020) (0.008 - 0.020)
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 144.15 - 144.25 (5.6752 - 5.6791) —
Bend [per 100 (3.94)] — 0.15 (0.0059)
Torsion [per 100 (3.94)] — 0.30 (0.0120)
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) 55.000 - 55.013 (2.1654 - 2.1659) —
Side clearance 0.20 - 0.35 (0.0080 - 0.0138) 0.40 (0.0160)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in) A
EM
D
SEM645 SBIA0535E
MAIN BEARING
PBIC2619E
Grade number UPR/LWR Thickness mm (in) Width mm (in) Identification color Remarks
0 — 2.000 - 2.003 (0.0787 - 0.0789) Black
1 — 2.003 - 2.006 (0.0789 - 0.0790) Brown
2 — 2.006 - 2.009 (0.0790 - 0.0791) Green
3 — 2.009 - 2.012 (0.0791 - 0.0792) Yellow Grade is the same
for upper and lower
4 — 2.012 - 2.015 (0.0792 - 0.0793) Blue bearings.
5 — 2.015 - 2.018 (0.0793 - 0.0794) Pink
6 — 2.018 - 2.021 (0.0794 - 0.0796) Purple
7 — 2.021 - 2.024 (0.0796 - 0.0797) White
UPR 2.003 - 2.006 (0.0789 - 0.0790) Brown
01
LWR 2.000 - 2.003 (0.0787 - 0.0789) Black
UPR 2.006 - 2.009 (0.0790 - 0.0791) 19.9 - 20.1 Green
12
LWR 2.003 - 2.006 (0.0789 - 0.0790) (0.783 - 0.791) Brown
UPR 2.009 - 2.012 (0.0791 - 0.0792) Yellow
23
LWR 2.006 - 2.009 (0.0790 - 0.0791) Green
UPR 2.012 - 2.015 (0.0792 - 0.0793) Blue Grade is different
34 for upper and lower
LWR 2.009 - 2.012 (0.0791 - 0.0792) Yellow bearings.
UPR 2.015 - 2.018 (0.0793 - 0.0794) Pink
45
LWR 2.012 - 2.015 (0.0792 - 0.0793) Blue
UPR 2.018 - 2.021 (0.0794 - 0.0796) Purple
56
LWR 2.015 - 2.018 (0.0793 - 0.0794) Pink
UPR 2.021 - 2.024 (0.0796 - 0.0797) White
67
LWR 2.018 - 2.021 (0.0794 - 0.0796) Purple
Undersize
Unit: mm (in)
Items Thickness Main journal diameter
0.25 (0.0098) 2.132 - 2.140 (0.0839 - 0.0843) Grind so that bearing clearance is the specified value.
Undersize C
Unit: mm (in)
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)
E
Items Standard Limit
Connecting rod bearing oil clearance 0.034 - 0.059 (0.0013 - 0.0023)* 0.070 (0.0028)
*: Actual clearance F