Engine Mechanical: Section

ENGINE
SECTION
ENGINE MECHANICAL
EM EM
E
CONTENTS
QR25DE AIR CLEANER FILTER ..................................... 16 F
Removal and Installation .........................................16
PRECAUTION ............................................... 4
SPARK PLUG ................................................... 17 G
PRECAUTIONS ................................................... 4 Exploded View .........................................................17
Precaution for Supplemental Restraint System Removal and Installation .........................................17
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 4 CAMSHAFT VALVE CLEARANCE .................. 19 H
Precaution for Drain Engine Coolant and Engine Valve Clearance ......................................................19
Oil .............................................................................. 4
Precaution for Disconnecting Fuel Piping ................. 4
COMPRESSION PRESSURE ........................... 22
I
Compression Pressure ............................................22
Precaution for Removal and Disassembly ................ 4
Precaution for Inspection, Repair and Replace- ON-VEHICLE REPAIR ................................. 24
ment .......................................................................... 4 J
Precaution for Assembly and Installation .................. 4 AIR CLEANER AND AIR DUCT ....................... 24
Parts Requiring Angle Tightening ............................. 5 Exploded View .........................................................24
Precaution for Liquid Gasket ..................................... 5 Removal and Installation .........................................24
K
PREPARATION ............................................ 7 INTAKE MANIFOLD ......................................... 25
Exploded View .........................................................25
PREPARATION ................................................... 7 Removal and Installation .........................................25 L
Special Service Tool ................................................. 7
Commercial Service Tool .......................................... 9 EXHAUST MANIFOLD AND THREE WAY
CATALYST ........................................................ 28
FUNCTION DIAGNOSIS .............................. 12 Exploded View .........................................................28
M
NOISE, VIBRATION AND HARSHNESS Removal and Installation .........................................28

(NVH) TROUBLESHOOTING ............................12 OIL PAN ............................................................ 31 N
NVH Troubleshooting - Engine Noise ..................... 12 Exploded View .........................................................31
Use the Chart Below to Help You Find the Cause Removal and Installation .........................................31
of the Symptom ....................................................... 13
IGNITION COIL ................................................. 34 O
ON-VEHICLE MAINTENANCE .................... 14 Exploded View .........................................................34
DRIVE BELTS ....................................................14
P
Exploded View ........................................................ 14 ROCKER COVER ............................................. 35
Checking Drive Belt ................................................. 14 Exploded View .........................................................35
Tension Adjustment ................................................ 14 Removal and Installation .........................................35
Removal and Installation ......................................... 14
Removal and Installation of Drive Belt Auto Ten- FUEL INJECTOR AND FUEL TUBE ................ 37
sioner ...................................................................... 15 Exploded View .........................................................37
Revision: August 2007 EM-1 2008 Frontier

TIMING CHAIN .................................................. 42 PREPARATION ................................................ 117
Exploded View ........................................................ 42 Special Service Tool ............................................. 117
Removal and Installation ........................................ 43 Commercial Service Tool ...................................... 119
CAMSHAFT ....................................................... 51 FUNCTION DIAGNOSIS ........................... 121

Exploded View ........................................................ 51
Removal and Installation ........................................ 51 NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ........................... 121
OIL SEAL ........................................................... 60 NVH Troubleshooting - Engine Noise ................... 121
Removal and Installation of Valve Oil Seal ............. 60 Use the Chart Below to Help You Find the Cause
Removal and Installation of Front Oil Seal ............. 60 of the Symptom ..................................................... 121
Removal and Installation of Rear Oil Seal .............. 61
ON-VEHICLE MAINTENANCE ................. 123
CYLINDER HEAD .............................................. 63
Exploded View ........................................................ 63 DRIVE BELTS .................................................. 123
Removal and Installation ........................................ 63 Exploded View ...................................................... 123
Exploded View ........................................................ 66 Checking Drive Belts ............................................. 123
Disassembly and Assembly .................................... 66 Adjustment ............................................................ 123
Inspection After Disassembly ................................. 68 Removal and Installation ....................................... 123
Drive Belt Auto Tensioner and Idler Pulley ........... 124
REMOVAL AND INSTALLATION ............... 73
AIR CLEANER FILTER .................................... 125
ENGINE ASSEMBLY ......................................... 73 Exploded View ...................................................... 125
Exploded View ........................................................ 73 Removal and Installation ....................................... 125
Removal and Installation ........................................ 73
SPARK PLUG ................................................... 126
DISASSEMBLY AND ASSEMBLY ............. 76 Exploded View ...................................................... 126
Removal and Installation ....................................... 126
ENGINE UNIT .................................................... 76
Exploded View ........................................................ 76 CAMSHAFT VALVE CLEARANCE ................. 128
Disassembly and Assembly .................................... 77 Valve Clearance .................................................... 128
Inspection After Disassembly ................................. 86
COMPRESSION PRESSURE .......................... 132
HOW TO SELECT PISTON AND BEARING ..... 96 Compression Pressure ......................................... 132
How to Select Piston and Bearing .......................... 96
ON-VEHICLE REPAIR .............................. 134
SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 103 ENGINE ROOM COVER .................................. 134
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................ 103 AIR CLEANER AND AIR DUCT ....................... 135
Exploded View ...................................................... 135
Standard and Limit ................................................103
VQ40DE
INTAKE MANIFOLD COLLECTOR ................. 136
PRECAUTION ............................................ 114 Exploded View ...................................................... 136
PRECAUTIONS ............................................... 114 Removal and Installation ....................................... 136
Precaution for Supplemental Restraint System INTAKE MANIFOLD ......................................... 139
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Exploded View ...................................................... 139
SIONER" ................................................................114 Removal and Installation ....................................... 139
Precaution for Drain Engine Coolant .....................114
Precaution for Disconnecting Fuel Piping ..............114 EXHAUST MANIFOLD AND THREE WAY
Precaution for Removal and Disassembly .............114 CATALYST ....................................................... 141
Precaution for Inspection, Repair and Replace- Exploded View ...................................................... 141
ment .......................................................................114 Removal and Installation ....................................... 141
Precaution for Assembly and Installation ..............114
Parts Requiring Angle Tightening ..........................115 OIL PAN AND OIL STRAINER ........................ 146
Precaution for Liquid Gasket .................................115 Exploded View ...................................................... 146
PREPARATION .......................................... 117
IGNITION COIL ................................................. 151

Exploded View ...................................................... 151 Exploded View ....................................................... 204
Removal and Installation ....................................... 151 Removal and Installation ....................................... 204 A
Exploded View ....................................................... 207
ROCKER COVER ............................................. 152 Disassembly and Assembly ................................... 208
Exploded View ...................................................... 152 Inspection After Disassembly ................................ 210
Removal and Installation ....................................... 152 EM
REMOVAL AND INSTALLATION ............. 214
FUEL INJECTOR AND FUEL TUBE ............... 157
Exploded View ...................................................... 157 ENGINE ASSEMBLY ...................................... 214 C
Removal and Installation ....................................... 157 Exploded View ....................................................... 214
FRONT TIMING CHAIN CASE ......................... 162
Exploded View ...................................................... 162 DISASSEMBLY AND ASSEMBLY ............ 218 D
ENGINE UNIT .................................................. 218
TIMING CHAIN ................................................. 172 Exploded View ....................................................... 218 E
Exploded View ...................................................... 172 Disassembly and Assembly ................................... 219
Removal and Installation ....................................... 173 Inspection After Disassembly ................................ 229
CAMSHAFT ...................................................... 192 HOW TO SELECT PISTON AND BEARING .. 240 F
Exploded View ...................................................... 192 How to Select Piston and Bearing ......................... 240
SERVICE DATA AND SPECIFICATIONS G
OIL SEAL ......................................................... 201 (SDS) .......................................................... 245
Removal and Installation of Valve Oil Seal ........... 201
Removal and Installation of Front Oil Seal ............ 201 SERVICE DATA AND SPECIFICATIONS
Removal and Installation of Rear Oil Seal ............ 202 H
(SDS) ............................................................... 245
Standard and Limit ................................................ 245
CYLINDER HEAD ............................................ 204
I

PRECAUTIONS
< PRECAUTION > [QR25DE]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000003288920
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
Precaution for Drain Engine Coolant and Engine Oil INFOID:0000000003261094
Drain engine coolant and engine oil when the engine is cooled.
Precaution for Disconnecting Fuel Piping INFOID:0000000003261095
• Before starting work, make sure no fire or spark producing items are in the work area.
• Release fuel pressure before disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.
Precaution for Removal and Disassembly INFOID:0000000003261096
• When instructed to use special service tools, use the 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 a tape or the equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
where noted in the step.
Precaution for Inspection, Repair and Replacement INFOID:0000000003261097
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and Installation INFOID:0000000003261098
• Use torque wrench to tighten bolts or nuts to specification.

• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
make sure that dowel pins are installed in the original position.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.

PRECAUTIONS
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well. A
• Release air within route when refilling after draining engine coolant.
• Before starting the engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with the engine
stopped). Then make sure there are no leaks at fuel line connections.
EM
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Parts Requiring Angle Tightening INFOID:0000000003261099
C
• For the final tightening of the following engine parts use Tool:
Tool number : KV10112100 (BT-8653-A) D
- Cylinder head bolts

- Lower cylinder block bolts
E
- Connecting rod cap bolts
- Crankshaft pulley bolt (No angle wrench is required as bolt flange is provided with notches for angle tighten-
ing)
• Do not use a torque value for final tightening. F
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000003261100 G
REMOVAL OF LIQUID GASKET SEALING

• After removing nuts and bolts, separate the mating surface and H
remove old liquid gasket sealing using Tool.
Tool number : KV10111100 (J-37228) I

CAUTION:
Be careful not to damage the mating surfaces.
• Tap seal cutter to insert it, and then slide it by tapping on the side J
as shown.
• In areas where Tool is difficult to use, use plastic hammer to lightly
tap the parts, to remove it.
K
CAUTION: WBIA0566E
If for some unavoidable reason tool such as screwdriver is

used, be careful not to damage the mating surfaces.
L
LIQUID GASKET APPLICATION PROCEDURE
1. Using scraper, remove old liquid gasket adhering to the gasket
application surface and the mating surface.
M
• Remove liquid gasket completely from the groove of the gas-
ket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign materials. N
PBIC0003E

PRECAUTIONS
3. Attach liquid gasket tube to Tool.
Tool number : WS39930000 ( — )

Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-26, "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.
WBIA0567E
• As for bolt holes, normally apply liquid gasket inside the holes.
Occasionally, it should be applied outside the holes. Make
sure to read the text of this manual.
• Within five minutes of liquid gasket application, install the mat-
ing component.
• If liquid gasket protrudes, wipe it off immediately.
• Do not retighten nuts or bolts after the installation.
• After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe
SEM159F
them.

PREPARATION
< PREPARATION > [QR25DE]
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000003261101
EM
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.) C
Tool name
KV10111100 Removing oil pan and front cover, etc.
(J-37228) D
Seal cutter
S-NT046
KV10116200 Disassembling valve mechanism F

(J-26336-A) Part (1) is a component of KV10116200 (J-
Valve spring compressor 26336-A), but Part (2) is not so.
1. KV10115900
G
(J-26336-20)
Attachment
2. KV10109220
( — ) H
Adapter PBIC1650E
KV10112100 Tightening bolts for connecting rod bearing

(BT-8653-A) cap, cylinder head, etc. in angle
I
Angle wrench
NT014
KV10117100 Loosening or tightening air fuel ratio sensor 1 K

(J-36471-A) For 22 mm (0.87 in) width hexagon nut
Heated oxygen sensor wrench
NT379 M
KV10107902 Replacing valve oil seal
(J-38959)
Valve oil seal puller N
O
NT011
KV10115600 Installing valve oil seal

(J-38958) P
Valve oil seal drift
NT024

PREPARATION
(Kent-Moore No.)
Tool name
EM03470000 Installing piston assembly into cylinder bore
(J-8037)
Piston ring compressor
NT044
ST16610001 Removing pilot bushing (M/T models) or pilot

(J-23907) converter (A/T models)
Pilot bushing puller
NT045
WS39930000 Pressing the tube of liquid gasket

( — )
Tube presser
NT052
— Removing fuel tube quick connectors in en-

(J-45488) gine room
Quick connector release (Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)
PBIC0198E
— Releasing drive belt tension

(J-46535)
Drive belt tension releaser
WBIA0536E
— Loosening or tightening air fuel ratio A/F sen-

(J-44626) sor
Air fuel sensor Socket a: 22 mm (0.87 in)
LBIA0444E
KV10114400 Loosening or tightening heated oxygen sen-

(J-38365) sor 1
Heated oxygen sensor wrench a: 22 mm (0.87 in)
NT636

PREPARATION
Commercial Service Tool INFOID:0000000003261102
(Kent-Moore No.) Description

Tool name
EM
Power tool Loosening nuts and bolts
D
PBIC0190E
( — ) Removing and installing spark plug

Spark plug wrench E
PBIC2982E
( — ) Removing and installing crankshaft pulley G

Pulley holder
ZZA1010D I
( — ) Removing crankshaft pulley
Pulley puller
J
K
NT676
( — ) Checking compression pressure

1. Compression tester L
2. Adapter
ZZA0008D
N
(J-24239-01) Loosening and tightening cylinder head bolt,
Cylinder head bolt wrench and used with the angle wrench [SST:
KV10112100 (BT8653-A)]
a: 13 (0.51) dia. O
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
P
NT583

PREPARATION
Tool name
( — ) Finishing valve seat dimensions
Valve seat cutter set
S-NT048
TORX socket Removing and installing flywheel

Size: T55
PBIC1113E
Deep socket Removing and installing oil pressure switch

a: 27 mm (1.06 in)
PBIC2072E
( — ) Removing and installing piston ring

Piston ring expander
S-NT030
( — ) Removing and installing valve guide

Valve guide drift Intake and Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
S-NT015
( — ) 1: Reaming valve guide inner hole

Valve guide reamer 2: Reaming hole for oversize valve guide
Intake and Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia.
S-NT016

PREPARATION
Tool name A
a: (J-43897-18) Reconditioning the exhaust system threads
b: (J-43897-12) before installing a new heated oxygen sensor
Oxygen sensor thread cleaner (Use with anti-seize lubricant shown below.) EM
a = 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor
b = 12 mm (0.47 in) dia. for titania heated
oxygen sensor C
AEM488
( — ) Lubricating oxygen sensor thread cleaning

Anti-seize lubricant i.e.: (PermatexTM tool when reconditioning exhaust system D
133AR or equivalent meeting MIL threads
specification MIL-A-907)
E
AEM489
F

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< FUNCTION DIAGNOSIS > [QR25DE]
FUNCTION DIAGNOSIS
NVH Troubleshooting - Engine Noise INFOID:0000000003261103
PBIC2983E

< FUNCTION DIAGNOSIS > [QR25DE]
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000003261104
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.
C
Operating condition of engine
Location Type of Before After When Source of Refer-
When When While Check item D
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-103 E
gine clicking noise
Rocker
cover Camshaft Camshaft journal oil
EM-51
Cylinder Rattle C A — A B C bearing clearance
EM-51
head noise Camshaft runout F
Piston to piston pin oil
Slap or Piston pin clearance EM-86
— A — B B —
knock noise Connecting rod bushing EM-86 G
oil clearance
Piston to cylinder bore
Crank- clearance H
EM-86
shaft pul- Piston ring side clear-
Slap or Piston EM-86
ley A — — B B A ance
rap slap noise EM-86
Cylinder Piston ring end gap
EM-86
block Connecting rod bend I
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-86
Knock A B C B B B J
bearing Connecting rod bearing EM-86
noise oil clearance
Main bearing oil clear-
Main bear- EM-86 K
Knock A B — A B C ance
ing noise EM-86
Crankshaft runout
Timing
Front of Timing chain cracks
chain and L
engine Tapping or and wear EM-43
A A — B B B chain ten-
Front cov- ticking Timing chain tensioner EM-43
sioner
er operation
noise
M
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — B Drive belt deflection
or slip-
ing EM-14
ping) N
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Squall
Water O
A B — B A B pump Water pump operation CO-20
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related P

DRIVE BELTS
< ON-VEHICLE MAINTENANCE > [QR25DE]
ON-VEHICLE MAINTENANCE
DRIVE BELTS
Exploded View INFOID:0000000003288901
LBIA0438E
1. Drive belt 2. Power steering oil pump pulley 3. Generator pulley

4. Crankshaft pulley 5. A/C compressor (if equipped) or idler 6. Idler pulley
pulley
7. Water pump 8. Idler pulley 9. Drive belt auto- tensioner
Checking Drive Belt INFOID:0000000003261105
WARNING:
• Be sure to perform this step when the engine is stopped.
• Make sure that the indicator (fixed side) of the drive belt auto-tensioner is within the possible use
range (moving side) as shown.
NOTE:
• On vehicles not equipped with A/C, there is an idler pulley in the A/C compressor position for the drive belt
routing.
• Check the drive belt auto-tensioner indication when the engine is cold.
• Visually check entire drive belt for wear, damage or cracks.
• When new drive belt is installed, the indicator (fixed side) should be within the range "A". If the indicator
(fixed side) is out of the possible use range or drive belt is damaged, replace drive belt.
Tension Adjustment INFOID:0000000003261106
Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Removal and Installation INFOID:0000000003261107
REMOVAL

DRIVE BELTS
1. Install Tool on auto tensioner pulley bolt, move in the direction of
arrow (loosening direction of tensioner) using Tool. A
Tool number : — (J-46535)

CAUTION: EM
• Avoid placing hand in a location where pinching may
occur if the holding tool accidentally comes off.
• Do not loosen the auto-tensioner pulley bolt. (Do not turn C
it counterclockwise.) If turned counterclockwise, the com-
plete auto-tensioner must be replaced as a unit, including
pulley. LBIA0439E
D
2. Remove drive belt.
INSTALLATION
Installation is in the reverse order of removal. E
CAUTION:
• Do not loosen the auto-tensioner pulley bolt. (Do not turn it counterclockwise.) If turned counter-
clockwise, the complete auto-tensioner must be replaced as a unit, including pulley.
• Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes F
off.
• Confirm belts are completely set on the pulleys.
• Check that there are no engine working fluids on the drive belt or pulley grooves. G
NOTE:
• Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
• Confirm tension of drive belt indicator (fixed side) is within the possible use range.
H
Removal and Installation of Drive Belt Auto Tensioner INFOID:0000000003261108
N
LBIA0440E
REMOVAL O
1. Remove air cleaner and air duct. Refer to EM-24, "Removal and Installation".
2. Remove drive belt. Refer to EM-14, "Removal and Installation".
3. Remove the power steering oil pump and position aside. Refer to ST-18, "Removal and Installation". P
4. Remove generator. Refer to CHG-21, "Removal and Installation - QR25DE Models".
5. Remove drive belt auto-tensioner.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
If there is damage greater than peeled paint, replace drive belt auto-tensioner.

AIR CLEANER FILTER
AIR CLEANER FILTER
REMOVAL
1. Unfasten clips and lift up air cleaner case upper.
2. Remove air cleaner filter.
LBIA0442E
INSTALLATION

SPARK PLUG
SPARK PLUG
A
EM
G
PBIC2995E
1. Ignition coil 2. Spark plug 3. Rocker cover

H
REMOVAL I
1. Remove the intake manifold (except for spark plug No.1). Refer to EM-25.
2. Remove the ignition coil. Refer to EM-34.
3. Remove the spark plug using a suitable tool. J
M
PBIC2996E
INSPECTION AFTER REMOVAL

• Do not use a wire brush to clean the spark plug. N
SMA773C
• If plug tip is covered with carbon, spark plug cleaner may be used.

SPARK PLUG
Cleaner air pressure : Less than 588 kPa (5.9 bar, 6 kg/cm2, 85 psi)
Cleaning time : Less than 20 seconds
• Checking and adjusting plug gap is not required between change
intervals.
SMA806CA
CAUTION:
Do not drop or shock the spark plug.
INSTALLATION
Spark Plug Types
Make NGK
Standard type PLZKAR6A-11
Gap (nominal) 1.1 mm (0.043 in)
CAUTION:

CAMSHAFT VALVE CLEARANCE
A
Valve Clearance INFOID:0000000003261119
INSPECTION EM
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
1. Remove rocker cover. Refer to EM-35, "Removal and Installation". C
2. Remove undercover.
3. Remove radiator shroud (lower). Refer to CO-16, "Exploded View".
4. Measure the valve clearance with the following procedure: D
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley clockwise and align TDC mark to tim-
ing indicator on front cover. E
PBIC3015E
H
• At the same time, make sure that both intake and exhaust cam
noses of No. 1 cylinder face outside as shown.
• If they do not face outside, rotate crankshaft pulley once more I
(360° degrees) and align as shown.
K
KBIA0400J
b. Use a feeler gauge, measure the clearance between valve lifter L

and camshaft.
SEM139D O
Valve clearance:
Unit: mm (in)
Cold Hot * (reference data) P

Intake 0.24 - 0.32 (0.009 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*:Approximately 80°C (176°F)

• By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below (locations
indicated with black arrow shown) with a feeler gauge.
• No. 1 cylinder compression TDC
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
No. 1 cylinder at INT × ×

compression TDC EXH × ×
PBIC3017E
c. Rotate crankshaft pulley one revolution (360° degrees) and align

TDC mark to timing indicator on front cover.
PBIC3015E
• By referring to the figure, measure the valve clearance at loca-

tions marked “×” as shown in the table below (locations indi-
cated with black arrow shown) with a feeler gauge.
• No. 4 cylinder compression TDC
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
No. 4 cylinder at INT × ×

compression TDC EXH × ×
PBIC3026E
5. If out of standard, perform adjustment.

ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
1. Remove camshaft. Refer to EM-51, "Removal and Installation".
2. Remove valve lifters at the locations that are out of the standard.
3. Measure the center thickness of the removed valve lifters with a
micrometer.
KBIA0057E
4. 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
A
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.28 mm (0.011 in) EM
Exhaust : 0.30 mm (0.012 in)
• Thickness of new valve lifter can be identified by stamp mark
on the reverse side (inside the cylinder). C
Stamp mark “696” indicates 6.96 mm (0.2740 in) in thickness.
KBIA0119E
F
NOTE:
Available thickness of valve lifter: 26 sizes range 6.96 to 7.46 mm (0.2740 to 0.2937 in) in steps of 0.02
mm (0.0008 in) (when manufactured at factory). Refer to EM-103, "Standard and Limit". G
5. Install the selected valve lifter.
6. Install camshaft. Refer to EM-51, "Removal and Installation".
H
7. Manually rotate crankshaft pulley a few rotations.
8. Make sure that valve clearances for cold engine are within specifications by referring to the specified val-
ues.
I
9. Installation of the remaining components is in reverse order of removal.
10. Warm up the engine, and check for unusual noise and vibration.
J

COMPRESSION PRESSURE
Compression Pressure INFOID:0000000003288898
CHECKING COMPRESSION PRESSURE

1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure. Refer to EC-444, "Fuel Pressure Check".
3. Disconnect fuel pump fuse to avoid fuel injection during mea-
surement.
BBIA0534E
4. Remove spark plug from each cylinder. Refer to EM-17, "Removal and Installation".
5. Connect an engine tachometer (not required in use of CONSULT-III).
6. Install a compression tester with an adapter (commercial service
tool) onto spark plug hole.
LBIA0448E
• 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.
SBIA0533E
7. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each
cylinder.
Compression pressure:
Unit: kPa (kg/cm2, psi) /rpm
Standard Minimum Differential limit between cylinders

1,304 (13.3, 189) / 250 1,108 (11.3, 161) / 250 100 (1.0, 14) / 250
CAUTION:
Always use fully a changed battery to obtain the specified engine speed.
• If the engine speed is out of the 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 A
gasket). After the checking, measure the compression pressure again.
• If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole
of the cylinder to re-check it for compression.
EM
• If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-
ton rings and replace if necessary.
• If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly. C
• If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gasket is leaking. In such a case, replace cylinder
head gasket. D
8. After inspection is completed, install removed parts.
9. Start the engine, and confirm that the engine runs smoothly.
10. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-75, "Inspection Procedure". E

AIR CLEANER AND AIR DUCT
< ON-VEHICLE REPAIR > [QR25DE]
ON-VEHICLE REPAIR
LBIA0441E
1. Air cleaner case 2. Air duct and resonator assembly 3. Air duct
4. Intake manifold 5. Air cleaner filter
REMOVAL
1. Remove two bolts and remove air duct.
• Add mating marks as necessary for easier installation.
2. Remove resonator in fender lifting left fender protector, as necessary.
Inspect air duct assembly for cracks or tear.
• Replace air duct assembly, if necessary.
INSTALLATION
• Align marks. Attach each joint. Screw clamps firmly.
• Install duct to intake manifold by aligning "LOCK-UNLOCK" upward.

INTAKE MANIFOLD
INTAKE MANIFOLD
A
EM
J
WBIA0733E
1. Vacuum hose 2. Vacuum hose adapter 3. O–ring K

EVAP canister purge volume control
4. Vacuum hose 5. 6. Vacuum hose
solenoid valve
7. Service port 8. Collar 9. Grommet L
10. Intake manifold support 11. Vacuum hose 12. Gasket
13. Intake manifold 14. Fuel tube protector 15. Air cleaner
16. Air cleaner case 17. PCV hose 18. Gasket M
19. PCV hose 20. Water hose 21. Water hose
22. Air duct 23. Electric throttle control actuator 24. Mass air flow sensor
A. To vacuum pipe (EVAP canister) B. To brake booster C. To PCV valve N
D. To heater outlet E. To heater pipe F. To rocker cover
→ Engine front
O
CAUTION:
Do not remove or disassemble parts unless instructed as shown.
Removal and Installation INFOID:0000000003261111 P
REMOVAL
2. Remove air cleaner case, air cleaner and air duct.
3. Disconnect water hoses from electric throttle control actuator, and pinch water hoses near electric throttle
control actuator to prevent engine coolant spilling.

INTAKE MANIFOLD
CAUTION:
• Perform this step when engine is cold.
• Do not spill engine coolant on drive belt.
4. Remove mass air flow sensor from intake manifold.

CAUTION:
Handle the mass air flow sensor with care:
• Do not shock it.
• Do not disassemble it.
• Do not touch the internal sensor.
5. Remove quick connector cap, and disconnect quick connector
at the engine side. Refer to EM-37.
LBIA0450E
6. Remove electric throttle control actuator with the following procedure:

a. Disconnect harness connector.
b. Loosen bolts in reverse order as shown, and remove electric
throttle control actuator and gasket.
CAUTION:
• Handle carefully to avoid any shock to electric throttle
control actuator.
• Do not disassemble.
PBIC2987E
7. Disconnect harness, vacuum hoses and PCV hoses from intake manifold, and move them aside.
8. Remove intake manifold support.
9. Loosen nuts and bolts in reverse order as shown, and remove
intake manifold, fuel tube protector and gasket.
CAUTION:
• Cover engine openings to avoid entry of foreign materi-
als.
• Do not disassemble intake manifold.
NOTE:
Disregard No. 6 when loosening.
PBIC2988E
10. Remove EVAP canister purge volume control solenoid valve and vacuum hose adapter from intake mani-
fold, if necessary.
11. Disconnect sub-harness from fuel injector. Refer to EM-37.
12. Remove fuel tube and fuel injector assembly from intake manifold. Refer to EM-37.
INSTALLATION
Installation in the reverse order of removal.

INTAKE MANIFOLD
Intake Manifold and Fuel Tube Protector
• If stud bolts were removed, install them and tighten to the specified torque below. A
Intake manifold bolts : 9.4 N·m (0.96 kg-m, 83in-lb)

• Tighten in numerical order as shown. EM
NOTE:
No. 6 means double tightening of bolt No. 1.
C
Use the following for locating bolts and nuts.
M8 x 38 mm (1.50 in) (Color green) : No. 1, 6
M8 x 35 mm (1.38 in) : No. 2, 3 D
Nut : No. 4, 5
PBIC2988E
E
Electric Throttle Control Actuator

• Tighten bolts equally and diagonally in several steps and in numer-
ical order as shown. F
• Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is disconnected.
Refer to EC-24, "Throttle Valve Closed Position Learning". G
• Perform the “Idle Air Volume Learning” and “Throttle Valve Closed
Position Learning” when electric throttle control actuator is
replaced. Refer to EC-24, "Idle Air Volume Learning". H
PBIC2987E
I
INSPECTION AFTER INSTALLATION
Make sure there are no fuel leaks at connections with the following procedure:
1. Apply fuel pressure to fuel lines with turning ignition switch “ON” (with the engine stopped). Then make J
sure there are no fuel leaks at connections.
NOTE:
Use mirrors for checking on invisible points.
K
2. Start the engine. With engine speed increased, make sure again there are no fuel leaks at connections.
CAUTION:
Do not touch the engine immediately after stopped as the engine becomes extremely hot.
L

EXHAUST MANIFOLD AND THREE WAY CATALYST
WBIA0647E
1. Air fuel ratio sensor 1 2. Exhaust manifold and three way catalyst assembly 3. Gasket
4. Bracket 5. Exhaust manifold cover
REMOVAL
2. Remove quick connector cap, and disconnect quick connector
at the engine side. Refer to EM-24.
LBIA0450E
3. Remove air duct, PCV hose (between air duct and rocker cover) and electric throttle control actuator.
Refer to EM-25.
4. Disconnect harness connector of air fuel ratio sensor 1, and harness from bracket and middle clamp.
5. Remove air fuel ratio sensor 1 using Tool.

CAUTION:
• Be careful not to damage air fuel ratio sensor 1.

• Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0.5 m
(19.7 in) onto a hard surface such as a concrete floor; replace with a new one. A
6. Remove exhaust front tube. Refer to EX-5, "Exploded View".

7. Remove exhaust manifold cover. EM
8. Remove bracket between exhaust manifold–three way catalyst assembly and transmission assembly.
9. Loosen nuts in reverse order as shown to remove exhaust man-
ifold and three way catalyst assembly. C
PBIC2990E
F
10. Remove gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
G
Surface Distortion
• Using a straightedge and a feeler gauge, check the surface distor- H
tion of exhaust manifold and three way catalyst assembly mating
surface.
I
Limit : 0.3 mm (0.012 in)
• If it exceeds the limit, replace exhaust manifold and three way cat-
alyst assembly. J
PBIC2991E
K
INSTALLATION
installation is in the reverse order of removal.
L
Exhaust Manifold
1. If stud bolts were removed, install them and tighten to the specified torque below.
M
Exhaust manifold stud bolt : 14.7 N·m (1.5 kg-m, 11 ft-lb)
2. Tighten nuts in numerical order as shown.
N
3. Tighten nuts in numerical order as shown again.
PBIC2990E
Air Fuel Ratio Sensor 1

CAUTION:

• Before installing new air fuel ratio sensor 1, clean exhaust system threads using a heated oxygen
sensor thread cleaner (commercial service tool: J-43897-18 or J-43897-12) and apply anti-seize lubri-
cant (commercial service tool).
• Do not over torque air fuel ratio sensor 1. Doing so may cause damage to air fuel ratio sensor 1,
resulting in the “MIL” coming on.

OIL PAN
OIL PAN
A
EM
G
PBIC2992E
1. Oil pan 2. A/T fluid cooler tube bracket (A/T models) 3. Drain plug
4. Drain plug washer
H
I
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain the engine oil when the engine is hot. J
1. Remove engine undercover.
2. Drain engine oil. Refer to LU-9, "Changing Engine Oil".
CAUTION: K
• Perform this step when the engine is cold.
• Do not spill engine oil on drive belt.
3. Remove oil pan with the following procedure: L
a. Remove A/T fluid cooler tube (A/T models). Refer to TM-382, "Removal and Installation for QR25DE" .
b. Loosen bolts in reverse order as shown with power tool.
Remove A/T fluid cooler tube bracket (A/T models). M
PBIC2993E
P
c. Insert the seal cutter [SST] between oil pan and cylinder block, and slide it by tapping on the side of the
tool with a hammer. Remove oil pan.

OIL PAN
Tool number : KV10111100 (J-37228)

CAUTION:
• Be careful not to damage the mating surfaces.
• Do not insert a screwdriver, this will damage the mating
surfaces.
WBIA0566E
INSTALLATION
1. Install oil pan with the following procedure:
a. Use a scraper to remove old liquid gasket from mating surfaces.
• Also remove the old liquid gasket from mating surface of cylin-
der 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.
PBIC2994E
b. Apply a continuous bead of liquid gasket using Tool as shown.

CAUTION:
Attaching should be done within 5 minutes after coating.
PBIC2984E
c. Tighten bolts in numerical order as shown.

• Install A/T fluid cooler tube bracket with bolts No.1 and 9 as
shown (A/T models).
PBIC2993E
2. Install oil pan drain plug. Refer to LU-9, "Changing Engine Oil".
3. Install in the reverse order of removal after this step.
NOTE:
Pour engine oil at least 30 minutes after oil pan is installed.
1. Check the engine oil level, and adjust the level. Refer to LU-8, "Inspection".

OIL PAN
2. Start the engine, and make sure there is no leaks of engine oil.
3. Stop the engine and wait for 10 minutes. A
4. Check the engine oil level again. Refer to LU-8, "Inspection".
EM

IGNITION COIL
IGNITION COIL
WBIA0648E
1. Ignition coil 2. Spark plug 3. Rocker cover
REMOVAL
1. Remove intake manifold (except for ignition coil No.1). Refer to EM-25.
2. Disconnect harness connector from ignition coil.
3. Remove ignition coil.
CAUTION:
Do not drop or shock it.
INSTALLATION

ROCKER COVER
ROCKER COVER
A
EM
G
WBIA0650E
1. PCV hose 2. PCV valve 3. O-ring

4. Oil filler cap 5. Rocker cover 6. Rocker cover gasket
H
7. PCV hose
Removal and Installation INFOID:0000000003261117 I
REMOVAL
1. Remove intake manifold. Refer to EM-25. J
2. Disconnect PCV hose from rocker cover.
3. Remove ignition coil. Refer to EM-34.
K
4. Remove PCV valve and O-ring from rocker cover, if necessary.
5. Remove oil filler cap from rocker cover, if necessary.
6. Loosen bolts in reverse order shown. L
PBIC3003E
O
7. Remove rocker cover gasket from rocker cover.
8. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 1).
CAUTION: P
Do not scratch or damage the mating surface when cleaning off old liquid gasket.
INSTALLATION

ROCKER COVER
1. Apply liquid gasket to the position shown with the following pro-
cedure:
a. Follow figure “a” to apply liquid gasket to joint part of camshaft
bracket (No. 1) and cylinder head.
b. Follow figure “b” to apply liquid gasket in 90° to figure “a”.
PBIC2635E
2. Install new rocker cover gasket to rocker cover.

3. Install rocker cover.
• Check if rocker cover gasket is not dropped from the installation groove of rocker cover.
4. Tighten bolts in two steps separately in numerical order as shown.
Rocker cover bolts

1st step : 2.0 N·m (0.2 kg-m, 18 in-lb)
2nd step : 8.3 N·m (0.85 kg-m, 73 in-lb)
5. Installation of the remaining components is in the reverse order of removal.

FUEL INJECTOR AND FUEL TUBE
A
EM
G
WBIA0649E
1. Fuel feed hose 2. Quick connector cap (engine side) 3. Sub-harness

4. Fuel tube 5. O-ring (black) 6. Clip
H
7. Fuel injector 8. O-ring (green)
CAUTION:
I
Do not remove or disassemble parts unless instructed as shown.
J
REMOVAL
WARNING:
• Put a “CAUTION: INFLAMMABLE” sign in the workshop. K
• 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.
1. Release fuel pressure. Refer to EC-444, "Fuel Pressure Check". L
LBIA0450E

2. Remove quick connector cap (engine side).
KBIA0701E
3. With the sleeve side of quick connector release facing quick connector, install quick connector release
onto fuel tube.
4. Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick
connector release on that position.

CAUTION:
Disconnect quick connector by using tool, not by picking
out retainer tabs.
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
5. Draw and pull out quick connector straight from fuel tube.
CAUTION:
• Pull quick connector holding “A” position as shown.
• Do not pull with lateral force applied. O-ring inside quick
connector may be damaged. KBIA0702E
• Prepare container and cloth beforehand as fuel will leak
out.
• Avoid fire and sparks.
• 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 during installation/
removal.
• To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar.
PBIC2205E
6. Remove intake manifold. Refer to EM-25, "Removal and Installation".

7. Disconnect sub-harness for fuel injector.

8. Loosen bolts in reverse order as shown.
9. Remove fuel tube and fuel injector assembly. A
CAUTION:
• When removing, be careful to avoid any interference with
fuel injector. EM
• Use a shop cloth to absorb any fuel leaks from fuel tube.
PBIC2998E
D
10. Remove fuel injector from fuel tube with the following procedure:
a. Open and remove clip.
b. Remove fuel injector from fuel tube by pulling straight. E
CAUTION:
• Be careful with remaining fuel that may go out from fuel
tube.
F
• Be careful not to damage fuel injector nozzle during
removal.
• Do not bump or drop fuel injector.
• Do not disassemble fuel injector. G
PBIC2999E
K
INSTALLATION
1. Note the following, and install O-rings to fuel injector.
L
CAUTION:
• Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side : Black M

Nozzle side : Green
• Handle O-ring with bare hands. Do not wear gloves. N
• Lubricate O-ring with new engine oil.
• Do not clean O-ring with solvent.
• Make sure that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to O
twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it
quickly into fuel tube.
P

• Insert O-ring straight into fuel tube. Do not decenter or
twist it.
2. Insert clip into clip attachment groove on fuel injector.
CAUTION:
• Do not reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
3. Insert fuel injector into fuel tube with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion of fuel tube matches cut-
out of clip.
• Make sure that fuel tube flange is securely fixed in flange fixing
groove on clip.
4. Make sure that installation is complete by checking that fuel
injector does not rotate or come off.
PBIC3000E
5. Install fuel tube and fuel injector assembly with the following procedure:
CAUTION:
When installing, be careful to avoid any interference with fuel injector.
a. Insert the tip of each fuel injector into intake manifold.
b. Tighten bolts evenly in two steps in numerical order as shown.
Fuel tube bolts

1st step : 12.8 N·m (1.3 kg-m, 9 ft-lb)
2nd step : 28.0 N·m (2.9 kg-m, 21 ft-lb)
PBIC2998E
6. Connect sub-harness for fuel injector.

7. Install intake manifold. Refer to EM-25, "Removal and Installation".
8. Note the following, and connect quick connector at the engine side to install fuel feed hose.
a. Check the connection for foreign material and damage.
b. Align center to insert quick connector straightly into fuel tube.
NOTE:
The figure shows the engine side as an example.
• Insert quick connector to fuel tube until the top spool on fuel
tube is inserted completely and the second level spool is posi-
tioned slightly below quick connector bottom end.
CAUTION:
• Hold “A” position as shown when inserting fuel tube
into quick connector.
• Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector.
KBIA0272E
• Insert until you hear a “click” sound and actually feel
the engagement.
• To avoid misidentification of engagement with a similar sound, be sure to perform the next
step.

c. Before clamping fuel feed hose with hose clamps, pull quick connector hard by hand holding “A” position.
Make sure it is completely engaged (connected) so that it does not come out from fuel feed tube. A
d. Install quick connector cap to quick connector connection.
(engine side)
• Install so that the arrow mark on the side faces up. EM
CAUTION:
• Make sure that quick connector and fuel tube are securely
fit into quick connector cap installation groove.
• If quick connector cap cannot be installed smoothly, C
quick connector may have not been installed correctly.
Check the connection again.
9. Install fuel feed hose to hose clamp. D
10. Installation is in the reverse order of removal after this step. PBIC2348E

E
Check on Fuel Leaks
1. Apply fuel pressure to fuel lines with turning ignition switch “ON” (with the engine stopped). Then make
sure there are no fuel leaks at connections. F
NOTE:
Use mirrors for checking on invisible points.
2. Start the engine. With engine speed increased, make sure again there are no fuel leaks at connections. G
CAUTION:
Do not touch the engine immediately after stopped as the engine becomes extremely hot.
H

TIMING CHAIN
TIMING CHAIN
WBIA0834E
1. O-ring 2. Camshaft sprocket (INT) 3. Camshaft sprocket (EXH)

4. Chain tensioner 5. Spring 6. Chain tensioner plunger
7. Timing chain slack guide 8. Timing chain 9. Front cover
Intake valve timing control solenoid
10. Chain guide 11. 12. Intake valve timing control cover
valve
13. Oil ring 14. Front oil seal 15. Crankshaft pulley
16. Crankshaft pulley bolt 17. Crankshaft sprocket 18. Spacer
19. Balancer unit timing chain tensioner 20. Timing chain tension guide 21. Balancer unit
22. Balancer unit sprocket 23. Balancer unit timing chain A. Refer to EM-43, "Removal and Instal-
lation"
B. Refer to EM-43, "Removal and Instal-
lation"

TIMING CHAIN
REMOVAL
1. Release the fuel pressure. Refer to EC-444, "Fuel Pressure Check". EM
2. Remove the air cleaner and air duct assembly. Refer to EM-24, "Removal and Installation".
3. Remove the spark plugs. Refer to EM-17, "Removal and Installation".
C
4. Remove the rocker cover. Refer toEM-35, "Removal and Installation".
5. Remove the coolant overflow reservoir tank.
6. Remove the auxiliary drive belt auto-tensioner. Refer to EM-15, "Removal and Installation of Drive Belt D
Auto Tensioner".
7. Remove the generator. Refer to CHG-21, "Removal and Installation - QR25DE Models".
8. Remove the strut tower brace. Refer to FSU-12, "Component". E
9. Dismount and position aside the A/C compressor with the piping attached.
10. Dismount and position aside the power steering pump and reservoir tank with the piping attached.
11. Remove the upper and lower oil pan, and oil strainer. Refer to EM-31, "Removal and Installation". F
12. Remove IVT control cover bolts in the order as shown.
13. Remove the IVT control cover by cutting the sealant using Tool.
G
Tool number : KV10111100 (J-37228)
14. Pull chain guide between camshaft sprockets out through front
H
cover.
I
KBIA0085E
15. Set the No.1 cylinder at TDC on the compression stroke with the J
following procedure:
a. Rotate the crankshaft pulley clockwise and align the mating
marks to the timing indicator on the front cover. K
KBIA0190E
M
b. At the same time, make sure that the mating marks on the cam-
shaft sprockets are lined up as shown. N
• If not lined up, rotate the crankshaft pulley one more turn to line up
the mating marks to the positions as shown.
O
KBIA0115E

TIMING CHAIN
16. Remove crankshaft pulley with the following procedure:
a. Hold the crankshaft pulley with a suitable tool, then loosen the
crankshaft pulley bolt, and pull the pulley out about 10 mm (0.39
in). Remove the crankshaft pulley bolt.
KBIA0077E
b. Attach a pulley puller in the M6 (0.24 in diameter) thread hole on

crankshaft pulley, and remove crankshaft pulley.
KBIA0078E
17. Remove the front cover with the following procedure:

a. Loosen the front cover bolts in the order as shown, and remove
them.
b. Remove the front cover.
CAUTION:
• Be careful not to damage the mating surface.
WBIA0032E
18. If the front oil seal needs to be replaced, remove it using a suit-
able tool.
SEM829E

TIMING CHAIN
19. Remove timing chain with the following procedure:
a. Push in chain tensioner plunger. Insert a stopper pin into hole on chain tensioner body to secure chain A
tensioner plunger and remove chain tensioner.
NOTE:
Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a EM
stopper pin.
KBIA0048E E
b. Remove timing chain.

CAUTION:
F
Do not rotate crankshaft or camshaft while timing chain is removed. It causes interference
between valve and piston.
20. Remove camshaft sprockets. Refer to EM-51.
G
21. Remove timing chain slack guide, timing chain tension guide and spacer.
22. Remove balancer unit timing chain tensioner with the following procedure:
a. Lift lever up, and release ratchet claw for return proof. H
b. Push tensioner sleeve in, and hold it.
c. Matching the hole on lever with the one on body, insert a stopper
I
pin to secure tensioner sleeve.
NOTE:
Use approximately 1 mm (0.04 in) dia. hard metal pin as a stop-
per pin. J
d. Remove balancer unit timing chain tensioner.
K
PBIC3027E
23. Secure the hexagonal portion of the balancer shaft using a suitable tool. Loosen the balancer unit
sprocket bolt. L
24. Remove balancer unit timing chain, balancer unit sprocket and crankshaft sprocket.
NOTE:
When removing balancer unit timing chain, remove crankshaft sprocket and balancer unit sprocket at the M
same time.
25. Loosen mounting bolts in reverse order as shown, and remove
balancer unit. N
CAUTION:
Do not disassemble balancer unit.
NOTE:
Use TORX socket (size E14) for bolts No.1 to 4. O
PBIC3028E

Timing Chain

TIMING CHAIN
Check timing chain for cracks and any excessive wear at the roller
links of timing chain. Replace timing chain if necessary.
PBIC0282E
Balancer Unit Bolt Outer Diameter

• Measure outer diameters (“d1”, “d2”) at two positions as shown.
• If reduction appears in “A” range, regard it as “d2”.
Limit (“d1” – “d2”) : 0.15 mm (0.0059 in)

• If it exceeds the limit (large difference in dimensions), replace bal-
ancer unit bolt with a new one.
PBIC1137E
Balancer Unit Bolt Length

Measure balancer unit bolt length. If it exceeds the limit, replace balancer unit bolt with a new one.
Limit : 172 mm (6.77 in)
INSTALLATION
NOTE:
The figure shows the relationship between the mating mark on each
timing chain and that on the corresponding sprocket, with the com-
ponents installed.
1. Make sure that crankshaft key points straight up.
PBIC3029E
2. Install O-ring to balancer unit.

TIMING CHAIN
3. Tighten bolts in numerical order as shown with the following pro-
cedure to install balancer unit, using Tool. A
Tool number : KV10112100 (BT8653-A)

CAUTION: EM
If bolts are re-used, check their outer diameter before instal-
lation. Follow the "Balancer Unit Bolt Outer Diameter" pro-
cedure. C
CAUTION:
• Check tightening angle using Tool or a protractor. Do not
make judgment by visual check alone. PBIC3028E
• In step 3, loosen bolts in reverse order as shown. D

NOTE:
Apply new engine oil to threads and seat surfaces of bolts.
E
Balancer bolt torque
Step 1 bolts 1 - 4 : 48.1 N·m (4.9 kg-m, 35 ft-lb)
Step 2 bolts 1 - 4 : 100° clockwise F
Step 3 bolts 1 - 4 : 0 N·m (0 kg-m, 0 ft-lb)
G
Step 5 bolts 1 - 4 : 100° clockwise
PBIC3030E H
4. Install crankshaft sprocket, balancer unit sprocket and balancer
unit timing chain.
• Make sure that crankshaft sprocket is positioned with mating I
marks on cylinder block and crankshaft sprocket meeting at
the top.
• Install it by aligning mating marks on each sprocket and bal- J
ancer unit timing chain.
• Secure the hexagonal portion of the balancer shaft using a
suitable tool. Tighten the balancer unit sprocket bolt to the
specified torque. K
NOTE:
PBIC2183E
Install crankshaft sprocket, balancer unit sprocket and balancer
unit timing chain at the same time. L
5. Install balancer unit timing chain tensioner.

• After installation, make sure the mating marks have not
slipped, then remove stopper pin and release tensioner M
sleeve.
PBIC3032E

TIMING CHAIN
6. Install timing chain and related parts.
• Install by aligning mating marks on each sprocket and timing
chain.
• Before and after installing chain tensioner, check again to
make sure that mating marks have not slipped.
• After installing chain tensioner, remove stopper pin, and make
sure that tensioner moves freely.
CAUTION:
• For the following note, after the mating marks are
aligned, keep them aligned by holding them with a hand.
• To avoid skipped teeth, do not rotate crankshaft and
camshaft until front cover is installed.
NOTE:
Before installing chain tensioner, it is possible to change the
position of mating mark on timing chain for that on each
sprocket for alignment.
PBIC3029E
7. Install front oil seal to front cover. Refer to EM-60, "Removal and Installation of Front Oil Seal".
8. Install O-rings to cylinder head and cylinder block.
9. Apply a continuous bead of liquid gasket with the tube presser
to front cover as shown, using Tool.

NOTE:
Application instruction differs depending on the position.
Detail of A : Cross over the start of the applica-

tion and the end.
Detail of B : Apply liquid gasket outside of bolt
holes. (For all bolt holes other than B,
apply to the inside.)
Detail of C : Between here only, apply 4.5 - 5.5
mm (0.177 - 0.217 in) dia.
PBIC3031E
10. Make sure that mating marks of timing chain and each sprocket are still aligned. Then install front cover.
CAUTION:
Be careful not to damage front oil seal by interference with front end of crankshaft.

TIMING CHAIN
11. Tighten bolts in numerical order as shown.
• Use the following for locating M6 bolts. A
Bolt position
: 45 mm (1.77 in) : 5, 10, 14, 17 EM
: 20 mm (0.79 in) : Except the above (Except 1 to 4)
• Tighten bolts to the specified torque.
C
M6 bolts 12.8 N·m (1.3 kg-m, 9 ft-lb)
M10 bolts 49.0 N·m (5.0 kg-m, 36 ft-lb) D
12. After all bolts are tightened, retighten them to the specified
torque in numerical order as shown.
CAUTION: E
Be sure to wipe off any excessive liquid gasket leaking to
surface for fitting oil pan.
F
G
KBIA0083E
13. Install chain guide between camshaft sprockets.

H
14. Install oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control
cover.
15. Install O-ring to front cover.
I
16. Apply a continuous bead of liquid gasket using Tool to intake
valve timing control cover as shown.
Tool number : WS39930000 ( — ) J

K
L
SBIA0260E

M
KBIA0085E
P
18. Install intake valve timing control solenoid valve to intake valve timing control cover if removed.
19. Connect ground cables, and install harness clip.
20. Insert crankshaft pulley by aligning with crankshaft key.
• When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Install protecting front oil seal lip section from any damage.

TIMING CHAIN
21. Tighten crankshaft pulley bolt using Tool.
Tool number : KV10112100 (BT-8653-A)

• Secure crankshaft pulley using suitable tool, and tighten crankshaft pulley bolt.
a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
b. Tighten crankshaft pulley bolt.
: 42.1 N·m (4.3 kg-m, 31 ft-lb)

c. Put a paint mark on crankshaft pulley, mating with any one of six
easy to recognize angle marks on bolt flange.
d. Turn another 60° degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark.
SEM751G
22. Install all removed parts in the reverse order of removal.

Inspection for Leaks
The following are procedures for checking fluid leaks, lubricates leak and exhaust gases leak.
• Before starting the engine, check oil fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to LU-8, "Inspection" and CO-11, "System Inspection".
• Use procedures below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start the engine. With the engine speed increased, check again for fuel leakage at connection points.
• Run the 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 the engine start. However, this is normal. Noise will stop
after hydraulic pressure rises.
• Warm up the 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 the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to
the specified level, if necessary.
Summary of the inspection items:
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
* Transmission/transaxle/AT fluid, power steering fluid, brake fluid, etc.

CAMSHAFT
CAMSHAFT
A
EM
J
WBIA0833E
1. Camshaft bracket (No. 2 to 5) 2. Seal washer 3. Camshaft bracket (No. 1) K

4. Front cover 5. Chain guide 6. Chain tensioner
7. Spring 8. Chain tensioner plunger 9. O-ring
Intake valve timing control solenoid L
10. Oil ring 11. O-ring 12.
valve
13. Intake valve timing control cover 14. Camshaft sprocket (INT) 15. Camshaft sprocket (EXH)
16. O-ring 17. Valve lifter 18. Camshaft (INT) M
19. Camshaft (EXH) 20. O-ring 21. Camshaft position sensor (PHASE)
A. Refer to EM-51, "Removal and Installation"
N
NOTE:
This section describes removal/installation procedure of camshaft without removing front cover. If front cover O
is removed or installed, refer to EM-43.
REMOVAL
P
1. Remove the rocker cover. Refer to EM-35, "Removal and Installation".
2. Remove the drive belt. Refer to EM-14, "Removal and Installation".
3. Disconnect and remove the camshaft position sensor (PHASE).
4. Disconnect the IVT control solenoid electrical connector.
5. Disconnect the ground electrical connections from the front cover.

CAMSHAFT
6. Remove IVT control cover bolts in the order as shown.
7. Remove the IVT control cover by cutting the sealant using Tool.
Tool number : KV10111100 (J-37228)
KBIA0085E
8. Set the No.1 cylinder at TDC on its compression stroke with the
following procedure:
9. Rotate crankshaft pulley clockwise, and align mating marks for
TDC with timing indicator on front cover, as shown.
KBIA0190E
10. At the same time, make sure that the mating marks on camshaft
sprockets are lined up with the yellow links in the timing chain,
as shown.
• If not, rotate crankshaft pulley one more turn to line up the
mating marks to the yellow links, as shown.
KBIA0115E
11. Pull the timing chain guide out between the camshaft sprockets through front cover.
12. Line up the mating marks on camshaft sprockets with the yellow links in the timing chain, and paint an
indelible mating mark on the sprocket and timing chain link plate.
CAUTION:
Do not rotate the crankshaft or camshaft while the timing chain is removed. It causes interference
between valve and piston.
NOTE:
Chain tension holding work is not necessary. Crankshaft sprocket and timing chain do not disconnect
structurally while front cover is attached.
13. Push in the tensioner plunger and hold. Insert a stopper pin into
the hole on tensioner body to hold the chain tensioner. Remove
the timing chain tensioner.
• Use a wire with 0.5 mm (0.02 in) diameter for a stopper pin.
KBIA0048E

CAMSHAFT
14. Secure the hexagonal part of camshaft with a suitable tool.
Loosen the camshaft sprocket bolts and remove the camshaft A
sprockets.
EM
KBIA0049E
D
15. Loosen the camshaft bracket bolts in the order as shown, and
remove the camshaft brackets and camshafts.
• Remove No.1 camshaft bracket by slightly tapping it with a E
rubber mallet.
• Note positions, and set them aside in the order removed.
16. Remove the valve lifters. F
• Note positions, and set them aside in the order removed.
G
WBIA0028E
INSPECTION AFTER REMOVAL H

Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 jour-
nals of camshaft. I
CAUTION:
Do not support No. 1 journal (on the side of camshaft
sprocket) because it has a different diameter from the other J
four locations.
2. Set a dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the K
camshaft runout on the dial indicator. (Total indicator reading)
PBIC2499E
Standard: Less than 0.02 mm (0.0008 in). L
4. If out of the standard, replace camshaft.
Camshaft Cam Height
M
1. Measure the camshaft cam height with a micrometer.
Standard:
N
Intake : 45.015 - 45.205 mm (1.7722 - 1.7797 in)
Exhaust : 43.975 - 44.165 mm (1.7313 - 1.7388 in)
Cam wear limit O
: 0.2 mm (0.008 in)
2. If wear is beyond the limit, replace camshaft.
P
PBIC0039E
Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL DIAMETER

CAMSHAFT
Measure the outer diameter of camshaft journal with a micrometer.
Standard:
No. 1 : 27.935 - 27.955 mm (1.0998 - 1.1006 in)
No. 2, 3, 4, 5 : 23.435 - 23.455 mm (0.9226 - 0.9234 in)
PBIC0040E
CAMSHAFT BRACKET INNER DIAMETER

• Tighten camshaft bracket bolts with the specified torque. Refer to EM-51, "Removal and Installation".
• Measure inner diameter “A” of camshaft bracket with a bore gauge.
Standard:
No. 1 : 28.000 - 28.021 mm (1.1024 - 1.1032 in)
No. 2, 3, 4, 5 : 23.500 - 23.521 mm (0.9252 - 0.9260 in)
PBIC1645E
CAMSHAFT JOURNAL OIL CLEARANCE

• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)
Standard : 0.045 - 0.086 mm (0.0018 - 0.0034 in)

• If out of the standard, replace either or both camshaft and cylinder head.
NOTE:
Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinder
head. Replace whole cylinder head assembly.
Camshaft End Play
1. Install camshaft in cylinder head. Refer to EM-51, "Removal and Installation".
2. Install a dial indicator in thrust direction on front end of camshaft.
Measure the camshaft end play on the dial indicator when cam-
shaft is moved forward/backward (in direction to axis).
Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in)
PBIC2446E

CAMSHAFT
• Measure the following parts if out of the standard.
- Dimension “A” for camshaft No. 1 journal A
Standard : 25.800 - 25.848 mm (1.0157 - 1.0176 in)

- Dimension “B” for cylinder head No. 1 journal bearing EM
Standard : 25.660 - 25.685 mm (1.0102 - 1.0112 in)

• Use the standards above, and then replace camshaft and/or C
cylinder head.
KBIA2426J
D
Camshaft Sprocket Runout
1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter E
from the other four locations.
2. Measure the camshaft sprocket runout with a dial indicator.
(Total indicator reading) F
Limit : 0.15 mm (0.0059 in)

G
• If it exceeds the limit, replace camshaft sprocket.
PBIC0930E
I
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-103,
"Standard and Limit". J
KBIA0182E
Valve Lifter Clearance M

VALVE LIFTER OUTER DIAMETER
• Measure the outer diameter of valve lifter with a micrometer.
N
Standard : 33.965 - 33.980 mm (1.3372 - 1.3378 in)
JEM798G
VALVE LIFTER HOLE DIAMETER

CAMSHAFT
Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer.
Standard : 34.000 - 34.021 mm (1.3386 - 1.3394 in)
PBIC0043E
VALVE LIFTER CLEARANCE

• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
Standard : 0.020 - 0.056 mm (0.0008 - 0.0022 in)

• If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diame-
ter, replace either or both valve lifter and cylinder head.
INSTALLATION
1. Install valve lifters.
• Install them in the original positions.
2. Install camshafts.
• Distinction between intake and exhaust camshafts is per-
formed with the different shapes of rear end.
Intake : Signal plate shape for camshaft posi-

tion sensor (PHASE)
Exhaust : Cone end shape
KBIA0246E
• Install camshafts so that camshaft dowel pins on the front side

are positioned as shown.
KBIA0051E
3. Install camshaft brackets with the following procedure:

a. Remove foreign material completely from camshaft bracket backside and from cylinder head installation
face.

CAMSHAFT
b. Install camshaft brackets (No. 2 to 5) aligning the identification
marks on upper surface as shown. A
NOTE:
Install so that identification mark can be correctly read when
viewed from the exhaust side.
EM
SBIA0256E
D
c. Install camshaft bracket (No. 1) with the following procedure:
i. Apply liquid gasket to camshaft bracket (No. 1) as shown.
Use Genuine RTV Silicone Sealant or equivalent. Refer to E
CAUTION:
After installation, be sure to wipe off any excessive liquid
gasket leaking from part “A”. F
PBIC2579E
H
ii. Apply liquid gasket to camshaft bracket (No. 1) contact surface
on the front cover backside.
GI-26, "Recommended Chemical Products and Sealants". I
• Apply liquid gasket to the outside of bolt hole on front cover.
K
SBIA0258E
iii. Locate camshaft bracket (No. 1) near installation position, and

install it without disturbing the liquid gasket applied to the sur- L
faces.
PBIC2746E
O
4. Tighten bolts of camshaft brackets in the following steps, in numerical order as shown.

CAMSHAFT
Step 1 (bolts 9 - 11) : 2.0 N·m (0.2 kg-m, 17 in-lb)

CAUTION:
After tightening bolts of camshaft brackets, be sure to wipe off
excessive liquid gasket from the parts.
5. Install camshaft position sensor (PHASE).
SBIA0255E
6. Install camshaft sprockets.
• Install them by aligning the mating marks on each camshaft
sprocket with the paint marks on the timing chain link plates
during removal.
CAUTION:
• Aligned mating marks could slip. Therefore, after match-
ing them, hold the timing chain in place by hand.
• Before and after installing chain tensioner, make sure
again that mating marks have not slipped.
NOTE:
Before installation of chain tensioner, it is possible to re-match
the marks on timing chain with the ones on each sprocket.
PBIC2351E
7. Install chain tensioner.
CAUTION:
After installation, pull the stopper pin off completely, and make sure that chain tensioner plunger
is released.
8. Install chain guide.
9. Install oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control
cover.
10. Install O-ring to front cover.
11. Apply liquid gasket using Tool to intake valve timing control
cover as shown.

SBIA0260E
KBIA0085E
13. Install intake valve timing control solenoid valve to intake valve timing control cover if removed.
14. Connect ground cables, and install harness clip.
15. Check and adjust valve clearance. Refer toEM-103, "Standard and Limit".

CAMSHAFT
16. Installation is in the reverse order of removal after this step.
NOTE: A
EM
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION: C
• Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III
and it is directed according to inspection procedure of EC section. Refer to EC-92, "Component
Inspection". D
• Check when the engine is cold so as to prevent burns from any splashing engine oil.
1. Check the engine oil level. Refer to LU-8, "Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while E
checking.
a. Release fuel pressure. Refer to EC-444, "Fuel Pressure Check".
b. Disconnect ignition coil and injector harness connectors. F
c. Remove drive belt. Refer to EM-14.
3. Remove intake valve timing control solenoid valve. Refer to EM-42, "Exploded View".
4. Crank the engine, and then make sure that engine oil comes out G
from intake valve timing control cover oil hole. End crank after
checking.
WARNING: H
Be careful not to touch rotating parts (drive belt, idler pul-
ley, and crankshaft pulley, etc.).
CAUTION: I
Engine oil may squirt from intake valve timing control sole-
noid valve installation hole during cranking. Use a shop
cloth to prevent the engine components and the vehicle. Do
not allow engine oil to get on rubber components such as J
PBIC2723E
drive belt or engine mount insulators. Immediately wipe off
any splashed engine oil.
• Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not K
come out from intake valve timing control cover oil hole. Refer to LU-6, "Lubrication Circuit".
5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging. L
• Clean oil groove if necessary. Refer to LU-6, "Lubrication Circuit".
6. After inspection, install removed parts.
M

OIL SEAL
OIL SEAL
Removal and Installation of Valve Oil Seal INFOID:0000000003261121
REMOVAL
1. Remove fan shroud (lower). Refer to CO-16, "Exploded View".
2. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
3. Remove camshafts. Refer to EM-51.
4. Remove valve lifters. Refer to EM-51.
5. Remove valve collet, valve spring retainer and valve spring
using Tool.
Tool numbers : KV10116200 (J-26336-B)

: KV10115900 (J-26336-20)
CAUTION:
When working, be careful not to damage valve lifter holes.
WBIA0477E
6. Remove valve spring retainer and valve spring.

CAUTION:
Do not remove valve spring seat from valve spring.
7. Remove valve oil seal using Tool.
Tool numbers : KV10107902 (J-38959)
WBIA0478E
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the height “H” as shown using Tool.
WBIA0653E

Removal and Installation of Front Oil Seal INFOID:0000000003261122
REMOVAL
1. Remove engine undercover.

OIL SEAL
2. Remove fan shroud (lower); Refer to CO-16, "Exploded View"
3. Remove cooing fan; Refer to CO-19, "Removal and Installation (Crankshaft driven type)". A
4. Remove drive belt; Refer to EM-14.
5. Remove crankshaft pulley; Refer to EM-43.
EM
6. Remove front oil seal using a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft.
C
E
SEM829E
INSTALLATION
F
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown.
G
SEM715A
J
• Press-fit front oil seal until it is flush with front end surface of
front cover using suitable tool.
CAUTION: K
• Be careful not to damage front cover and crankshaft.
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
L
M
PBIC3033E
3. Installation of the remaining components is in the reverse order of removal. N

Removal and Installation of Rear Oil Seal INFOID:0000000003261123
REMOVAL O
1. Remove transmission assembly. Refer to TM-19, "Removal and Installation from Vehicle" (M/T models),
TM-382, "Removal and Installation for QR25DE" (A/T models).
2. Remove clutch cover and clutch disk (M/T models). Refer to CL-20, "5M/T : Removal and Installation". P
3. Remove drive plate (A/T models) or flywheel (M/T models) with power tool. Refer to EM-76, "Exploded
View".
4. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION

OIL SEAL
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown.
SEM715A
• Press in rear oil seal to the position as shown.
WBIA0654E
• Press-fit rear oil seal using a suitable drift [outside diameter

102 mm (4.02 in), inside diameter 86 mm (3.39 in)].
CAUTION:
• Be careful not to damage crankshaft and cylinder block.
ing.
• Do not touch grease applied onto oil seal lip.
SBIA0280E

CYLINDER HEAD
CYLINDER HEAD
A
EM
G
WBIA0835E
1. Cylinder head assembly 2. Cylinder head gasket 3. Cylinder head bolt

A. Refer to EM-63, "Removal and Installation"
H
I
REMOVAL
2. Drain engine coolant. Refer to CO-12, "Changing Engine Coolant". J
CAUTION:
• Perform this step when the engine is cold.
• Do not spill engine coolant on drive belt. K
3. Drain engine oil; Refer to LU-9, "Changing Engine Oil".
CAUTION:
• Perform this step when the engine is cold. L
• Do not spill engine oil on drive belt.
4. Intake manifold and fuel tube assembly; Refer to EM-25.
5. Remove fuel injector and fuel tube assembly; Refer to EM-37. M
6. Exhaust manifold and three way catalyst assembly; Refer to EM-28.
7. Remove water outlet; Refer to CO-27, "Removal and Installation".
8. Remove heater outlet; Refer to CO-27, "Exploded View". N
NOTE:
Can be removed and installed even when assembled with cylinder head.
9. Remove front cover and timing chain. Refer to EM-43. O
10. Remove camshafts. Refer to EM-51.

CYLINDER HEAD
11. Remove cylinder head loosening bolts in reverse order as
shown using power tool.
• Using the cylinder head bolt wrench (commercial service tool:
J-24239-01), loosen cylinder head bolts.
KBIA0058E
12. Remove cylinder head gasket.

Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace them with a new one.
Limit (“d1” – “d2”): 0.23 mm (0.0091 in)

• If reduction of outer diameter appears in a position other than “d2”,
use it as “d2” point.
WBIA0836E
Cylinder Head Distortion

NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-86, "Inspec-
tion After Disassembly".
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for engine oil or engine coolant.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions.
Limit : 0.1 mm (0.004 in)

• If it exceeds the limit, replace cylinder head.
PBIC0075E
INSTALLATION
1. Install new cylinder head gasket.

CYLINDER HEAD
2. Install cylinder head follow the steps below to tighten cylinder
head bolts in numerical order as shown. A
CAUTION:
If cylinder head bolts re-used, check their outer diameters
before installation. Follow the "Cylinder Head Bolts Outer
EM
Diameter" procedure.
NOTE:
Apply new engine oil to threads and seating surfaces of mount-
ing bolts. C
Tool number : KV10112100 (BT8653-A) KBIA0058E
Step a : 50 N·m (5.1 kg-m, 37 ft-lb)

Step b : 60° clockwise E
Step c : Loosen to 0 N·m in the reverse order of tight-
ening.
Step d : 39.2 N·m (4.0 kg-m, 29 ft-lb) F
Step e : 75° clockwise
Step f : 75° clockwise
G
WBIA0617E
3. Installation of the remaining components is in reverse order of removal.

H

Inspection for Leaks I
quantity, fill to the specified level. Refer to LU-8, "Inspection" and CO-11, "System Inspection". J
- Start the engine. With the engine speed increased, check again for fuel leakage at connection points. K
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may L
including engine oil and engine coolant. M
the specified level, if necessary. N
Engine coolant Level Leakage Level O
P
* Transmission/transaxle/AT fluid, power steering fluid, brake fluid, etc.

CYLINDER HEAD
PBIC3024E
1. Valve collet 2. Valve spring retainer 3. Valve spring (with valve spring seat)
4. Valve oil seal 5. Valve guide 6. Cylinder head
7. Valve seat 8. Valve (INT) 9. Valve (EXH)
10. Spark plug tube 11. Spark plug
Disassembly and Assembly INFOID:0000000003261126
DISASSEMBLY
1. Remove spark plug using suitable tool.
2. Remove valve lifter.
• Identify installation positions, and store them without mixing them up.
using Tool.

: KV10115900 (J-26336-20)
CAUTION:
WBIA0477E
CAUTION:
4. Push valve stem to combustion chamber side, and remove valve.

CYLINDER HEAD
A
EM
WBIA0478E
D
6. When valve seat must be replaced, refer to EM-68, "Inspection After Disassembly".
7. When valve guide must be replaced, refer to EM-68, "Inspection After Disassembly".
8. Remove spark plug tube, if necessary. E
• Remove it from cylinder head using suitable tool.
CAUTION:
• Be careful not to damage cylinder head.
• Do not remove spark plug tube if not necessary. Once removed, spark plug tube cannot be F
reused because of deformation.
ASSEMBLY
G
1. Install valve guide if removed. Refer to EM-68, "Inspection After Disassembly".
2. Install valve seat if removed. Refer to EM-68, "Inspection After Disassembly".
3. Install valve oil seal using Tool. H

NOTE: I
Install with the valve oil seal to match dimension as shown.
Height “H” : 11.8 - 12.4 mm (0.465 - 0.488 in) J
WBIA0653E K
4. Install valve.
NOTE:
Install larger diameter to intake side. L
5. Install valve spring (with valve spring seat).
NOTE:
• Install smaller pitch (valve spring seat side) to cylinder head M
side.
• Confirm identification color of valve spring.
N
Intake : Pink
Exhaust : Green
O
PBIC0525E
6. Install valve spring retainer. P

7. Install valve collet using Tool.

: KV10115900 (J-26336-20)

CYLINDER HEAD
• Install valve collet with a magnet hand.
CAUTION:
• Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition.
WBIA0578E
8. Install valve lifter.

9. Install spark plug tube if removed.
• Press-fit it into cylinder head with the following procedure:
a. Remove old sealant from cylinder head side installation hole.
b. Apply sealant all round on spark plug tube within approximately
12 mm (0.47 in) width from edge of spark plug tube on the
press-fit side.
Use Genuine High Strength Locking Sealant or equivalent.
Refer to GI-26, "Recommended Chemical Products and
Sealants".
c. Press-fit spark plug tube so that height is as same as “H” as
shown using suitable tool. PBIC2713E
Standard press-fit height “H”:

41.2 - 42.2 mm (1.622 - 1.661 in)
CAUTION:
• When press-fitting, be careful not to deform spark plug tube.
• After press-fitting, wipe off any protruding sealant on top surface of cylinder head.
10. Install spark plug.
Inspection After Disassembly INFOID:0000000003261127
VALVE DIMENSIONS
• Check dimensions of each valve. For dimensions, refer to EM-103,
"Standard and Limit".
• If dimensions are out of the standard, replace valve.
SEM188A
VALVE GUIDE CLEARANCE

Valve Stem Diameter

CYLINDER HEAD
Measure the diameter of valve stem with a micrometer.
A
Standard
Intake : 5.965 - 5.980 mm (0.2348 - 0.2354 in)
Exhaust : 5.955 - 5.970 mm (0.2344 - 0.2350 in) EM
SEM938C
D
Valve Guide Inner Diameter
Measure the inner diameter of valve guide with a bore gauge.
Standard E
Intake and Exhaust
: 6.000 - 6.018 mm (0.2362 - 0.2369 in)
F
Valve Guide Clearance
(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
G
Valve guide clearance:
Standard
Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in) H
Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in)
Limit
I
Intake : 0.08 mm (0.003 in)
Exhaust : 0.09 mm (0.004 in)
• If it exceeds the limit, replace valve guide and/or valve. When valve guide must be replaced, follow the J
"VALVE GUIDE REPLACEMENT" procedure.
VALVE GUIDE REPLACEMENT
K
When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.
1. To remove valve guide, heat cylinder head to 110° to 130°C
(230° to 266°F) by soaking in heated oil.
L
SEM008A
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US O

ton, 2.0 lmp ton) force] or suitable tool.
CAUTION:
Cylinder head contains heat, when working, wear protective P
equipment to avoid getting burned.
SEM931C

CYLINDER HEAD
3. Ream cylinder head valve guide hole using suitable reamer.
Valve guide hole diameter (for service parts):

Intake and exhaust
: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
4. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking

in heated oil.
SEM008A
5. Press valve guide from camshaft side to dimensions as shown

using suitable tool.
Projection “H”:
Intake : 10.1 - 10.3 mm (0.398 - 0.406 in)
Exhaust : 10.0 - 10.4 mm (0.394 - 0.409 in)
CAUTION:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
PBIC2187E
6. Apply reamer finish to valve guide using suitable reamer.
Standard
Intake and exhaust:
6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM932C
VALVE SEAT CONTACT

CYLINDER HEAD
• After confirming that the dimensions of valve guides and valves are
within specifications, perform this procedure. A
• Apply prussian blue (or white lead) onto contacting surface of valve
seat to check the condition of the valve contact on the surface.
• Check if the contact area band is continuous all around the circum-
EM
ference.
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has NG conditions even after the re-check, replace
valve seat. Follow the "VALVE SEAT REPLACEMENT" procedure. C
SBIA0322E
D
VALVE SEAT REPLACEMENT
When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
E
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-103, "Standard and Limit".
CAUTION:
Prevent to scratch cylinder head by excessive boring.
2. Ream cylinder head recess diameter for service valve seat. F
Oversize [0.5 mm (0.020 in)]

Intake : 37.000 - 37.016 mm (1.4567 - 1.4573 in) G
Exhaust : 32.000 - 32.016 mm (1.2598 - 1.2605 in)
• Be sure to ream in circles concentric to the valve guide center. H
This will enable valve seat to fit correctly.
SEM795A
I

in heated oil. J
SEM008A
M
4. Provide valve seats cooled well with a dry ice. Press-fit valve seats into cylinder head.
CAUTION:
• Avoid directly to touching cold valve seats.
N
• Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
5. Finish valve seat to the specified dimensions. For dimensions,

refer to EM-103, "Standard and Limit" using suitable tool. O
CAUTION:
When using a valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
P
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.
SEM934C

CYLINDER HEAD
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact. Follow the "VALVE SEAT CONTACT" procedure.
VALVE SPRING SQUARENESS
• Set a try square along the side of valve spring and rotate valve
spring. Measure the maximum clearance between the top of valve
spring and try square.
CAUTION:
Limit
Intake : 1.8 mm (0.071 in)
Exhaust : 1.9 mm (0.075 in)
• If it exceeds the limit, replace valve spring (with valve spring seat). PBIC0080E
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

• Check valve spring pressure with valve spring seat installed at the
specified spring height.
CAUTION:
SEM113
Standard:
Items Intake Exhaust
Free height 43.72 - 43.92 mm (1.7213 - 1.7291 in) 45.29 - 45.49 mm (1.7831 - 1.7909 in)
Installation height 35.30 mm (1.390 in) 35.30 mm (1.390 in)
Installation load 151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb) 151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb)
Height during valve open 25.3 mm (0.996 in) 26.76 mm (1.0535 in)
Load with valve open 351 - 394 N (35.8 - 40.2 kg, 79 - 89 lb) 318 - 362 N (32.4 - 36.9 kg, 71 - 81 lb)
Identification color Pink Green
• If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring
seat).

ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
REMOVAL AND INSTALLATION A

ENGINE ASSEMBLY
EM
LBIA0443E K
1. RH engine mounting bracket (upper) 2. RH engine mounting insulator 3. RH engine mounting bracket (lower)
4. LH engine mounting bracket (upper) 5. LH engine mounting insulator 6. LH engine mounting bracket (lower) L
7. Rear engine mounting insulator

M
WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels. N
• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations. O
• Do not start working until exhaust system and coolant are cool enough.
• If items or work required are not covered by the engine section, follow the applicable procedures.
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid- P
able reasons, support at the rear axle jacking point with a 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-43, "Garage Jack and
Safety Stand".
REMOVAL
1. Drain engine coolant. Refer to CO-12, "Changing Engine Coolant".

ENGINE ASSEMBLY
2. Partially drain A/T fluid. Refer to TM-341, "Changing the A/T Fluid (ATF)".
4. Remove the engine hood. Refer to DLK-113, "Removal and Installation of Hood Assembly".
5. Remove the air duct and air cleaner case assembly. Refer to EM-24, "Removal and Installation".
6. Disconnect vacuum hose between vehicle and engine and set it aside.
7. Remove the radiator assembly and hoses. Refer to CO-16, "Removal and Installation".
8. Remove the drive belts. Refer to EM-14, "Removal and Installation".
9. Remove the engine cooling fan. Refer to CO-19, "Removal and Installation (Crankshaft driven type)".
10. Disconnect the engine room harness from the engine side and set it aside for easier work.
11. Disconnect the engine harness grounds.
12. Disconnect the reservoir tank for power steering from engine and move it aside for easier work.
13. Disconnect power steering oil pump from engine and position out of the way for easier work. Refer to ST-
18, "Removal and Installation".
14. Remove the A/C compressor bolts and set aside. Refer to HA-33, "Removal and Installation for Compres-
sor".
15. Disconnect brake booster vacuum line.
16. Disconnect EVAP line.
17. Disconnect the fuel hose at the engine side connection. Refer to EM-37, "Removal and Installation".
18. Disconnect the heater hoses at cowl, and install plugs to avoid leakage of engine coolant.
19. Remove the A/T oil level indicator and indicator tube.
20. Remove three way catalyst. Refer to EM-28, "Removal and Installation".
21. Install engine slingers into left bank and right bank.
Engine slinger torque

Front engine slinger : 48.1 N·m (4.9 kg-m, 35 ft-lb)
Rear engine slinger : 22.0 N·m (2.2 kg-m, 16 ft-lb)
22. Remove transmission. Refer to TM-19, "Removal and Installa-
tion from Vehicle" (M/T models), TM-382, "Removal and Installa-
tion for QR25DE" (A/T models).
23. Lift with hoist and secure the engine in position.
LBIA0449E
24. Remove engine assembly from vehicle, avoiding interference
with vehicle body.
CAUTION:
• Before and during this lifting, always check if any harnesses are left connected.
25. Remove the parts that may restrict installation of engine to engine stand.
NOTE:
The procedure is described assuming that you use a engine holding the surface, to which transmission is
installed.
a. Remove drive plate.
• Holding crankshaft pulley bolts, lock crankshaft to remove drive plate bolts.
• Loosen bolts diagonally.
CAUTION:
• Be careful not to damage drive plate. Especially avoid
deforming and damaging of signal plate teeth (circum-
ference position).
• Place the drive plate with signal plate surface facing
other than downward.
• Keep magnetic materials away from signal plate.
KBIA2491E

ENGINE ASSEMBLY
CAUTION: A
Use an engine stand that has a load capacity [approximately 240kg (529 lb) or more] large enough
for supporting the engine weight.
• If the load capacity of the stand is not adequate, remove the following parts beforehand to
reduce the potential risk of overturning the stand. EM
- Remove fuel tube and fuel injector assembly. Refer to EM-37, "Removal and Installation".
- Remove intake manifold. Refer to EM-25, "Removal and Installation".
- Remove rocker cover. Refer to EM-35, "Removal and Installation". C
- Other removable brackets.
CAUTION:
Before removing the hanging chains, make sure the engine stand is stable and there is no risk of
overturning. D
26. Remove generator. Refer to CHG-21, "Removal and Installation - QR25DE Models".
27. Remove engine mounting insulator bracket (upper) with power tool.
E
INSTALLATION
Note the following, and installation is in the reverse order of removal.
• Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting insu-
F
lator.
• When installation directions are specified, install parts according to the direction marks on them referring to
the figure of components.
• Make sure that each mounting insulator is seated properly, and tighten nuts and bolts. G
Inspection for Leaks H
quantity, fill to the specified level. Refer to LU-8, "Inspection" and CO-11, "System Inspection".
I
• Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
• Start the engine. With the engine speed increased, check again for fuel leakage at connection points. J
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may K
including engine oil and engine coolant. L
the specified level, if necessary. M
Engine coolant Level Leakage Level N
O
* Transmission/transaxle/AT fluid, power steering fluid, brake fluid, etc. P

ENGINE UNIT
< DISASSEMBLY AND ASSEMBLY > [QR25DE]
DISASSEMBLY AND ASSEMBLY

ENGINE UNIT
WBIA0837E

ENGINE UNIT
1. Cylinder block 2. O-ring 3. Crankshaft position sensor (POS) A

4. Knock sensor 5. Oil pressure switch 6. Water drain plug
7. Oil level gauge 8. Oil level gauge guide 9. O–ring
10. Lower cylinder block 11. Lower cylinder block mounting bolt 12. Snap ring EM
13. Connecting rod 14. Connecting rod bearing 15. Connecting rod bearing cap
16. Connecting rod bolt 17. Piston 18. Oil ring
19. Second ring 20. Top ring 21. Piston pin C
22. Thrust bearing 23. Main bearing upper 24. Crankshaft
25. Crankshaft key 26. Main bearing lower 27. Rear oil seal
28. Pilot convertor (A/T models) 29. Pilot bushing (M/T models) 30. D
31. Signal plate (type 2) 32. Drive plate (A/T models) 33. Reinforce plate (A/T models)
34. Flywheel (M/T models) A. Refer to EM-77, "Disassembly and B. Refer to EM-77, "Disassembly and
Assembly" Assembly" E
C. Refer to EM-77, "Disassembly and D. Refer to EM-77, "Disassembly and
Assembly" Assembly"
M
PBIC3021E
1. Cylinder block 2. Gasket 3. Cylinder block heater N

4. Connector protector cap
Disassembly and Assembly INFOID:0000000003261129 O
DISASSEMBLY
NOTE: P
Explained here is how to disassemble with an engine stand supporting mating surface of transmission. When
using different type of engine stand, note with difference in steps and etc.
1. Remove the engine and the transmission assembly from the vehicle, and separate the transmission
assembly from the engine. Refer to EM-73.
2. Remove clutch cover and clutch disc (M/T models). Refer to CL-20, "5M/T : Removal and Installation".

ENGINE UNIT
3. Remove flywheel (M/T models) or drive plate (A/T models) with
power tool.
• Secure crankshaft with a stopper plate, and remove bolts.
• Loosen bolts using suitable tool.
Flywheel (M/T models)

: size T55 (commercial service tool)
Drive plate (A/T models)
: size E20
CAUTION: PBIC2352E
Be careful not to damage or scratch drive plate (A/T mod-

els) and contact surface for clutch disc of flywheel (M/T models).
NOTE:
The flywheel, two block construction, allows movement in response to transmission side pressure, or
when twisted in its rotational direction. Therefore, some amount of noise is normal.
4. Lift the engine with a hoist to install it onto widely use engine
stand.
CAUTION:
• Use the engine stand that has a load capacity [approxi-
mately 240kg (529 lb) or more] large enough for support-
ing the engine weight.
• Before removing the hanging chains, make sure the
engine stand is stable and there is no risk of overturning.
NOTE:
The figure shows an example of widely use engine stand that
can support mating surface of transmission with flywheel (M/T
PBIC0085E
models) or drive plate (A/T models) removed.
6. Drain engine coolant by removing water drain plug from inside of
the engine.
PBIC2716E
7. Remove cylinder head with power tool. Refer to EM-63, "Removal and Installation".
8. Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks.
9. Remove crankshaft position sensor (POS).
CAUTION:
• Avoid impacts such as a dropping.
• Keep it away from metal particles.
• Do not place the sensor in a location where it is exposed
to magnetism.
PBIC2191E
10. Remove oil pressure sensor using a suitable tool.

ENGINE UNIT
CAUTION:
Do not drop or shock oil pressure sensor. A
11. Remove pilot converter (A/T models) or pilot bushing (M/T mod-
els) using Tool.
EM
Tool number : ST16610001 (J-23907)
WBIA0618E
12. Remove piston and connecting rod assembly with the following procedure: E
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-86, "Inspection After Disassembly".
13. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. F
14. Remove connecting rod cap.
15. Push piston and connecting rod assembly out to the cylinder
head side using suitable tool. G
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big H
end.
PBIC0259E
J
16. Remove connecting rod bearings.
CAUTION:
Identify installation positions, and store them without mixing them up. K
17. Remove piston rings form piston; using piston ring expander or suitable tool.
• Before removing piston rings, check the piston ring side clear-
ance. Refer to EM-86, "Inspection After Disassembly".
L
CAUTION:
• When removing piston rings, be careful not to damage
the piston.
• Be careful not to damage piston rings by expanding M
them excessively.
PBIC0087E
18. Remove piston from connecting rod with the following procedure:

ENGINE UNIT
a. Remove snap rings; using suitable snap ring pliers.
PBIC1638E
b. Heat piston to 60° to 70°C (140° to 158°F) with an industrial use

drier or equivalent.
PBIC1639E
c. Push out piston pin with a stick of outer diameter approximately

19 mm (0.75 in).
PBIC0262E
19. Remove lower cylinder block bolts.

• Before loosening lower cylinder block bolts, measure crankshaft end play. Refer to EM-86, "Inspection
After Disassembly".
• Loosen them in reverse order as shown, and remove them.
NOTE:
Use TORX socket (size E14) for bolts No. 1 to 10.
PBIC2718E
20. Remove lower cylinder block.

• Cut liquid gasket for removal; using Tool
Tool number : KV10111100 (J-37228)

CAUTION:
Be careful not to damage the mounting surface.
21. Remove crankshaft.
CAUTION:

ENGINE UNIT
• Be careful not damage or deform signal plate mounted on
crankshaft. A
• When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate
and the floor surface.
EM
• Do not remove signal plate unless it is necessary to do
so.
NOTE:
When removing or installing signal plate, use TORX socket (size C
T30).
22. Pull rear oil seal out from rear end of crankshaft. SBIA0275E
NOTE: D
When replacing rear oil seal without removing lower cylinder block, use a suitable tool to remove the oil
seal installed between crankshaft and cylinder block out.
CAUTION:
Be careful not to damage crankshaft and cylinder block. E
23. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
Identify installation positions, and store them without mixing them up. F
ASSEMBLY
1. Using compressed air, clean out the coolant and oil passages in the cylinder block, the cylinder bore and G
the crankcase to remove any foreign material.
CAUTION:
Use approved safety glasses to protect your eyes.
H
2. Apply Silicone RTV Sealant to the drain plugs. Install the drain
plugs on the cylinder block.
• Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-
26, "Recommended Chemical Products and Sealants". I
• Replace the copper washers with new ones.
K
WBIA0159E
3. Install the main bearings and the thrust bearings.

a. Remove dust, dirt, and oil from the bearing mating surfaces of L
the cylinder block and lower cylinder block.
b. Install the thrust bearings to both sides of the No. 3 main bearing
journal on the cylinder block. M
• Install the thrust bearings with the oil groove facing the crank-
shaft arm (outside).
N
PBIC0264E
O

ENGINE UNIT
c. Install the main bearings paying attention to their position and
direction.
• The main bearing with an oil hole and groove goes on the cyl-
inder block. The one without them goes on the lower cylinder
block.
• Only the main bearing (on the cylinder block) for No. 3 journal
has different specifications.
• Before installing the bearings, apply engine oil to the bearing
friction surface (inside). Do not apply oil to the back surface,
but thoroughly clean it.
• When installing, align the bearing stopper to the notch.
SBIA0277E
• Make sure that the oil holes on the cylinder block and those on
the corresponding bearing are aligned.
4. Install the signal plate to the crankshaft.

a. Position the crankshaft and signal plate using a positioning
dowel pin, and tighten the signal plate bolts to specification.
Signal plate bolts

Type 1 : 18.5 N·m (1.9 kg-m, 14 ft-lb)
Type 2 : 22.0 N·m (2.2 kg-m, 16 ft-lb)
b. Remove the dowel pin.
CAUTION:
SBIA0278E
Be sure to remove dowel pin before installing the crank-
shaft.
NOTE:
Dowel pins for the crankshaft and signal plate are supplied as a set for each.
5. Install the crankshaft onto the cylinder block.
• While turning the crankshaft by hand, check that it turns smoothly.
CAUTION:
Do not install rear oil seal at this time.
6. Apply Silicone RTV Sealant to positions shown and install the
lower cylinder block.
• Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-
26, "Recommended Chemical Products and Sealants".
NOTE:
Cylinder block and lower cylinder block are machined together.
Neither of them can be replaced separately.
CAUTION:
After the Silicone RTV Sealant is applied, the lower cylinder
block installation must be finished within 5 minutes.
WBIA0160E
7. Tighten lower cylinder block bolts in three steps in the order as

shown; Using Tool.
CAUTION:
There are more processes to complete the tightening of
lower cylinder bolts. However stop procedure after step 1
and install rear oil seal.
Lower cylinder block bolts

Step 1 (bolts 11 - 22) : 25.1 N·m (2.6 kg-m, 19 ft-lb)
Step 2 (bolts 1 - 10) : 39.2 N·m (4.0 kg-m, 29 ft-lb)
KBIA0063E
Step 3 (bolts 1 - 10) : 60° - 65° (target: 60°)

ENGINE UNIT
Install rear oil seal using a suitable drift.
CAUTION: A
• Be careful not to damage crankshaft and/or cylinder
block.
EM
• Press fit oil seal straight to avoid causing burrs or tilting.
SBIA0280E
G
SBIA0281E
NOTE:
• Apply new engine oil to threads and seat surfaces of the bolts. H
CAUTION:
Check tightening angle using Tool. Do not tighten by visual
inspection.
I
• Wipe off completely any protruding Silicone RTV Sealant on
J
the exterior of engine.
• Check crankshaft side clearance. Refer to EM-103, "Standard
and Limit".
• After installing the bolts, make sure that the crankshaft can be K
rotated smoothly by hand.
WBIA0619E
8. Apply new engine oil to new oil seal and install it using a suitable L
tool.
• Install new oil seal in the direction shown.
M
SEM715A
O
9. Install the piston to the connecting rod. Assemble the components in their original positions. P
a. Using a snap ring pliers, install the snap ring into the grooves of the piston's rear side.
• Insert the piston pin snap ring fully into groove.
b. Install the piston to the connecting rod.
• Using a heat gun, heat the piston [approximately 60° - 70° C (140° - 158° F)] until the piston pin can be
pushed in by hand without excessive force. From the front to the rear, insert the piston pin into the piston
and the connecting rod.

ENGINE UNIT
• Assemble so that the front mark on the piston crown and the
oil holes and the cylinder No. on the connecting rod are posi-
tioned as shown.
c. Install the piston pin snap ring into the front of the piston.
• Check that the connecting rod moves smoothly.
PBIC0099E
10. Using a piston ring expander, install the piston rings. Assemble
the components in their original positions.
CAUTION:
Be careful not to damage the piston.
• Position each ring with the gap as shown, referencing the pis-
ton front mark as the starting point.
• Install the top ring and the second ring with the stamped sur-
face facing upward.
Stamped mark : 2ND (second ring)

PBIC0100E
11. Install the connecting rod bearings to the connecting rod and the
connecting rod cap. Assemble the components in their original
positions.
• When installing the connecting rod bearings, apply engine oil
to the bearing friction surface (inside). Do not apply oil to the
back surface, but thoroughly clean the back.
• When installing, align the connecting rod bearing stopper pro-
trusion with the notch of the connecting rod to install.
• Check the oil holes on the connecting rod and those on the
corresponding bearing are aligned.
PBIC0266E
12. Install the piston and connecting rod assembly to the crankshaft.
Assemble the components in their original positions.
• Rotate the crankshaft so the pin corresponding to the connect-
ing rod to be installed is at the bottom dead center position.
• Apply engine oil sufficiently to the cylinder bore, piston, and
crankshaft pin.
• Match the cylinder position number with the cylinder No. on
the connecting rod for installation.
• Install the piston with the front mark on the piston crown facing
the front of the engine using Tool.
CAUTION:
WBIA0620E
Be careful not to damage the crankshaft pin, resulting from
an interference of the connecting rod big end.

ENGINE UNIT
13. Install the connecting rod caps. Assemble the components in
their original positions. A
• Match the stamped cylinder number marks on the connecting
rod with those on the cap to install.
EM
SBIA0282E
D
14. Tighten the connecting rod bolts using Tool in four steps as fol-
lows:
• Apply engine oil to the threads and seats of the connecting rod E
bolts.
CAUTION:
Always use either an angle wrench or protractor. Avoid
tightening based on visual check alone. F
Step 1 : 27.4 N·m (2.8 kg-m, 20 lb-ft)

G
Step 2 : 0 N·m (0 kg-m, 0 lb-ft
Step 3 : 19.6 N·m (2.0 kg-m, 14 ft-lb) WBIA0621E
Step 4 : 85° - 95° (target 90° degrees) H

• Check the connecting rod side clearance. Refer to EM-86, "Inspection After Disassembly".
• After tightening the bolts, make sure that the crankshaft rotates smoothly.
15. Install flywheel (M/T Models), or drive plate (A/T Models). I
• Install drive plate, reinforcement plate and pilot converter as
shown.
• Using a drift with 33 mm (1.30 in) diameter, push pilot con- J
verter into the end of the crankshaft.
• Press fit pilot bushing into the crankshaft as shown; using a
suitable drift of 19 mm (0.75 in)
K
KBIA0075E
L
16. Install the cylinder block heater.

M
Cylinder block heater : 73.5 N·m (7.5 kg-m, 54 ft-lb)
17. Install the knock sensor.
N
• Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of the knock sen-
sor.
• Install the knock sensor with the connector facing lower left by O
45° as shown.
• Do not tighten the knock sensor bolt while holding the connec-
tor. P
• Make sure that the knock sensor does not interfere with other
components.
PBIC3020E
Knock sensor bolt : 21.1 N·m (2.2 kg-m, 16 ft-lb)
CAUTION:
If the knock sensor is dropped, replace it with new one.
18. Install the crankshaft position sensor (POS).

ENGINE UNIT
Crankshaft position : 7.0 N·m (0.71 kg-m, 62 in-lb)

sensor bolt
19. Installation of remaining components is in reverse order of removal.
CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator.
Standard : 0.10 - 0.26 mm (0.0039 - 0.0102 in)

Limit : 0.30 mm (0.0118 in)
• If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft
also.
PBIC2377E
CONNECTING ROD SIDE CLEARANCE

• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge.
Standard : 0.20 - 0.25 mm (0.0079 - 0.098 in)

Limit : 0.50 mm (0.0197 in)
• If the measured value exceeds the limit, replace connecting rod,
also.
KBIA0071E
PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer.
Standard: 19.993 - 20.005 mm (0.7871 - 0.7876 in)
PBIC0116E
Piston Pin Outer Diameter

Measure the outer diameter of piston pin with a micrometer.
Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 in)
PBIC0117E

ENGINE UNIT
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter) A
Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 in)

• If oil clearance is out of the standard, replace piston and piston pin assembly. EM
• When replacing piston and piston pin assembly, refer to EM-103, "Standard and Limit".
NOTE:
• Piston is available together with piston pin as assembly. C
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
grades can be selected. (Only grade “0” is available.)
PISTON RING SIDE CLEARANCE D
• Measure the side clearance of piston ring and piston ring groove
with a feeler gauge.
E
Standard:
Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in) F
Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Limit: G
SEM024AA
Top ring : 0.11 mm (0.0043 in)
2nd ring : 0.10 mm (0.0039 in)
H
• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
replace piston also.
PISTON RING END GAP I
• Make sure that cylinder bore inner diameter is within the specifica-
tion. Refer to EM-103, "Standard and Limit".
• Lubricate with new engine oil to piston and piston ring, and then J
insert piston ring until middle of cylinder with piston, and measure
piston ring end gap with a feeler gauge.
K
Standard:
Top ring : 0.21 - 0.31 mm (0.0083 - 0.0122 in)
2nd ring : 0.32 - 0.47 mm (0.0126 - 0.0185 in) L
Oil ring (rail ring) : 0.20 - 0.60 mm (0.0079 - 0.0236 in) SEM822B
Limit: M
Top ring : 0.54 mm (0.0213 in)
2nd ring : 0.65 mm (0.0256 in)
N
Oil ring (rail ring) : 0.95 mm (0.0374 in)
re-bore cylinder inner wall and use oversized piston and piston rings. O
CONNECTING ROD BEND AND TORSION

ENGINE UNIT
• Check with a connecting rod aligner.
Bend:
Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion:
• If it exceeds the limit, replace connecting rod assembly.
PBIC2077E
CONNECTING ROD BIG END DIAMETER

• Install connecting rod cap without connecting rod bearing installed, and tightening connecting rod bolts to
the specified torque. Refer to EM-77, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of connecting rod big end with an
inside micrometer.
Standard: 48.000 - 48.013 mm (1.8898 - 1.8903 in)

• If out of the standard, replace connecting rod assembly.
PBIC1641E
CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer.
Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)
PBIC0120E

ENGINE UNIT
Measure the outer diameter of piston pin with a micrometer.
A
Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 in)
EM
PBIC0117E
D
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
E
Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly. F
• If replacing piston and piston pin assembly, refer to EM-103, "Standard and Limit".
• If replacing connecting rod assembly, refer to EM-103, "Standard
and Limit" to select connecting rod bearing. G
PBIC2196E
J
Factory installed parts grading:
• Service parts apply only to grade “0”.
Unit: mm (in) K
Grade 0 1
Connecting rod bushing 20.000 - 20.006 20.006 - 20.012
inner diameter* (0.7874 - 0.7876) (0.7876 - 0.7879) L
19.993 - 19.999 19.999 - 20. 005
Piston pin hole diameter
(0.7871 - 0.7874) (0.7874 - 0.7876)
19.989 - 19.995 19.995 - 20.001 M
Piston pin outer diameter
(0.7870 - 0.7872) (0.7872 - 0.7874)
PBIC3019E
*: After installing in connecting rod.
N
CYLINDER BLOCK DISTORTION
• Remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or other contami-
nation; using suitable tool. O
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.

ENGINE UNIT
• Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge and a feeler
gauge.
Limit: 0.1 mm (0.004 in)

• If it exceeds the limit, replace cylinder block and lower cylinder
block assembly.
NOTE:
Cylinder block cannot be replaced as a single, because it is
machined together with lower cylinder block.
PBIC0121E
MAIN BEARING HOUSING INNER DIAMETER

• Install lower cylinder block without main bearings installed, and
tighten lower cylinder block bolts to the specified torque. Refer to
EM-77, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of main bearing housing with a bore
gauge.
Standard: 58.944 - 58.968 mm (2.3206 - 2.3216 in)

• If out of the standard, replace cylinder block and lower cylinder
block assembly.
NOTE:
Cylinder block cannot be replaced as a single, because it is PBIC2012E

PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
• Using a bore gauge, measure the cylinder bore for wear, out-of-
round and taper at six different points on each cylinder. (“X” and
“Y” directions at “A”, “B” and “C”) (“Y” is in longitudinal direction of
the engine)
NOTE:
When determining cylinder bore grade, measure cylinder bore at
“B” position.
Standard inner diameter:

89.010 - 89.030 mm (3.5043 - 3.5051 in)
Wear limit: SBIA0284E
0.2 mm (0.008 in)

Out-of-round (Difference between “X” and “Y”):
0.015 mm (0.0006 in)
Taper limit (Difference between “A” and “C”):
0.01 mm (0.0004 in)
• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or re-bore the cylinder inner wall.
• Oversize piston is provided. When using oversize piston, re-bore the cylinder so that the clearance of the
piston to cylinder bore satisfies the standard.
CAUTION:
When using an oversize piston, use oversize pistons for all cylinders with oversize piston rings.
Oversize (OS): 0.2 mm (0.008 in)

Piston Skirt Diameter

ENGINE UNIT
Measure the outer diameter of piston skirt with a micrometer.
A
Measure point
: Distance from the top 42.98 mm (1.692 in)
Standard EM
: 88.990 - 89.010 mm (3.5035 - 3.5043 in)
PBIC0125E
Piston to Cylinder Bore Clearance D

Calculate by piston skirt diameter and cylinder bore inner diameter (direction “X”, position “B”).
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter)
E
Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit : 0.08 mm (0.0031 in)
F
• If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-96, "How to Select Piston and
Bearing".
Re-boring Cylinder Bore
G
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
Re-bored size calculation: D = A + B - C H

where,
D: Bored diameter
I
A: Piston diameter as measured
B: Piston - to - cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in) J
2. Install lower cylinder block, and tighten bolts to the specified torque. Otherwise, cylinder bores may be dis-
torted in final assembly. Refer to EM-77, "Disassembly and Assembly" for the tightening procedure.
3. Cut cylinder bores. K
NOTE:
• When any cylinder needs boring, all other cylinders must also be bored.
• Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a L
time.
4. Hone cylinders to obtain the specified piston to cylinder bore clearance.
5. Measure the finished cylinder bore for out-of-round and taper. M
NOTE:
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER N
• Measure the outer diameter of crankshaft main journals with a
micrometer.
O
Standard: 54.955 - 54.979 mm (2.1636 - 2.1645 in) dia.
• If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to EM-103, "Standard and P
Limit".
PBIC0270E
CRANKSHAFT PIN JOURNAL DIAMETER

ENGINE UNIT
• Measure the outer diameter of crankshaft pin journal with a micrometer.
Standard: 44.956 - 44.974 mm (1.7699-1.7706 in) dia.

• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer
to EM-103, "Standard and Limit".
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
• Measure the dimensions at four different points as shown on each
main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in dimensions between
“X” and “Y” at “A” and “B”.
• Taper is indicated by the difference in dimension between “A” and
“B” at “X” and “Y”.
Limit:
Out-of-round (Difference between “X” and “Y”)
: 0.0025 mm (0.0001 in)
PBIC2203E
Taper (Difference between “A” and “B”)
: 0.002 mm (0.0001 in)
• If the measured value exceeds the limit, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
main bearing and/or connecting rod bearing. Refer to EM-103, "Standard and Limit".
CRANKSHAFT RUNOUT
• Place a V-block on a precise flat table to support the journals on
the both end of crankshaft.
• Place a dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on the
dial indicator. (Total indicator reading)
Limit : 0.05 mm (0.0020 in)

• If it exceeds the limit, replace crankshaft.
PBIC2541E
CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-77, "Disassembly and Assembly" for tightening procedure.
• Measure the inner diameter of connecting rod bearing with an
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter)
Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 in)

• If the clearance exceeds the limit, select proper connecting rod
bearing according to connecting rod big end diameter and crank-
shaft pin journal diameter to obtain the specified bearing oil clear-
ance. Refer to EM-96, "How to Select Piston and Bearing".
PBIC1642E
Method of Using Plastigage

• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
torque. Refer to EM-77, "Disassembly and Assembly" for the tightening procedure.

ENGINE UNIT
CAUTION:
Do not rotate crankshaft. A
• Remove connecting rod cap and bearing, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
EM
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
D
PBIC1149E
MAIN BEARING OIL CLEARANCE

E
• Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block bolts to the
specified torque. Refer to EM-77, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of main bearing with a bore gauge. F
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
G
Standard:
No. 1, 3 and 5 journals
: 0.028 - 0.042 mm (0.0011 - 0.0017 in) H
No. 2 and 4 journals
: 0.041 - 0.056 mm (0.0016 - 0.0022 in)
I
PBIC2204E
Limit : 0.1 mm (0.004 in)
• 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-96, "How to J
Select Piston and Bearing".
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely. K
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block bolts to the L
CAUTION:
Do not rotate crankshaft.
• Remove lower cylinder block and bearings, and using the scale on M
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is N
PBIC1149E P
MAIN BEARING CRUSH HEIGHT

ENGINE UNIT
• When lower cylinder block is removed after being tightened to the
specified torque with main bearings installed, the tip end of bearing
must protrude. Refer to EM-77, "Disassembly and Assembly" for
the tightening procedure.
Standard: There must be crush height.

• If the standard is not met, replace main bearings.
SEM502G
CONNECTING ROD BEARING CRUSH HEIGHT

• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings installed, the
tip end of bearing must protrude. Refer to EM-77, "Disassembly
and Assembly" for the tightening procedure.
Standard: There must be crush height.

• If the standard is not met, replace connecting rod bearings.
PBIC1646E
LOWER CYLINDER BLOCK MOUNTING BOLT OUTER DIAMETER

• Perform only with M10 bolts.
• Measure the outer diameters (“d1”, “d2”) at two positions as shown.
Limit (“d1 ” – “d2 ”): 0.13 mm (0.0051 in)

• If it exceeds the limit (a large difference in dimensions), replace
lower cylinder block bolt with a new one.
PBIC0911E
CONNECTING ROD BOLT OUTER DIAMETER

• Measure the outer diameter “d” at position as shown.
• If reduction appears in a position other than “d”, regard it as “d”.
Limit: 7.75 mm (0.3051 in)

• When “d ” falls below the limit (when it becomes thinner), replace
connecting rod bolt with a new one.
PBIC0912E
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)

CAUTION:
Do not disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
• Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added
at the portion of 125 mm (4.92 in) radius from the center of flywheel.
Standard : 1.3 mm (0.051 in) or less

ENGINE UNIT
• If measured value is out of the standard, replace flywheel.
Movement Amount in Radial (Rotation) Direction A
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line. EM
• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard C
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transmis- D
sion side.
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of flywheel on the transmission side. E
Standard: 44.3 mm (1.744 in) or less.

PBIC1263E
• If measured value is out of the standard, replace flywheel. F

HOW TO SELECT PISTON AND BEARING
How to Select Piston and Bearing INFOID:0000000003261130
DESCRIPTION
Selection points Selection parts Selection items Selection methods

Determined by match of cylin-
der block bearing housing
Between cylinder block and Main bearing grade (bearing grade (inner diameter of hous-
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block and pis- Piston grade (piston skirt diam- Piston grade = cylinder bore
(piston is available together with
ton eter) grade (inner diameter of bore)
piston pin as an assembly.)
Between piston and connecting
— — —
rod*
*For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only grade “0” is available.) The
information at the shipment from the plant is described as a reference.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, follow the applicable procedures.
HOW TO SELECT PISTON
When New Cylinder Block Is Used
• Check the cylinder bore grade on rear-left side of cylinder block,
and select piston of the same grade.
• If there is a corrected stamp mark on cylinder block, use it as a cor-
rect reference.
SBIA0283E
PBIC3019E
When Cylinder Block Is Reused

1. Measure the cylinder bore inner diameter. Refer to EM-86, "Inspection After Disassembly".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner A
diameter of the “Piston Selection Table”.
3. Select piston of the same grade.
EM
Piston Selection Table
Unit: mm (in)
Grade number (Mark) 2 (or no mark) 3
C
Cylinder bore Inner diameter 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
Piston skirt diameter 88.990 - 89.000 (3.5035 - 3.5039) 89.000 - 89.010 (3.5039 - 3.5043)
NOTE: D
• There is no piston grade “1”.
• Piston is available together with piston pin as an assembly.
• The piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no E
grades can be selected. (Only grade “0” is available.)
HOW TO SELECT CONNECTING ROD BEARING F

When New Connecting Rod and Crankshaft Are Used
1. Apply connecting rod big end diameter grade stamped on con-
necting rod side face to the row in the “Connecting Rod Bearing G
Selection Table”.
PBIC2196E
J
2. Apply crankshaft pin journal diameter grade stamped on crank-
shaft front side to the column in the “Connecting Rod Bearing
Selection Table”. K
M
PBIC2198E
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection N
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
When Crankshaft and Connecting Rod Are Reused O
1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-86, "Inspection After Disassembly" and EM-86, "Inspection After Disassembly".
2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”. P
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.

Connecting Rod Bearing Selection Table
WBIA0838E
Connecting Rod Bearing Grade Table

Unit: mm (in)
Grade number 0 1 2 3 4
1.493 - 1.496 1.496 - 1.499 1.499 - 1.502 1.502 - 1.505 1.505 - 1.508
Thickness
(0.0588 - 0.0589) (0.0589 - 0.0590) (0.0590 - 0.0591) (0.0591 - 0.0593) (0.0593 - 0.0594)
Identification col-
Black Brown Green Yellow Blue
or
Undersize Bearings Usage Guide

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

In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)]. A
EM
PBIC2200E
D
Bearing undersize table
Unit: mm (in)
Size Thickness E
US 0.25 (0.0098) 1.622 - 1.630 (0.0639 - 0.0642)
HOW TO SELECT MAIN BEARING F

When New Cylinder Block and Crankshaft Are Used
1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on rear-left side of cylinder block. G
• If there is a corrected stamp mark on cylinder block, use it as a
correct reference.
H
SBIA0283E
J
2. Apply main journal diameter grade stamped on crankshaft front
side to column in the “Main Bearing Selection Table”.
K
M
PBIC2198E
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”. N
CAUTION:
There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and
the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table.
This is due to differences in the specified clearances. O
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower. P
When Cylinder Block and Crankshaft Are Reused
1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-86, "Inspection After Disassembly" and EM-86, "Inspection After
Disassembly".
2. Apply the measured dimension to the “Main Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.

CAUTION:
There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and
the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table.
This is due to differences in the specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
Main Bearing Selection Table (No. 1, 3 and 5 journals)
PBIC2201E

Main Bearing Selection Table (No. 2 and 4 journals)
A
EM
PBIC2202E
K
Main Bearing Grade Table (All Journals)

Unit: mm (in)
L
Grade number Thickness Identification color Remarks
0 1.973 - 1.976 (0.0777 - 0.0778) Black
1 1.976 - 1.979 (0.0778 - 0.0779) Brown M
2 1.979 - 1.982 (0.0779- 0.0780) Green
3 1.982 - 1.985 (0.0780 - 0.0781) Yellow Grade and color are the same
N
4 1.985 - 1.988 (0.0781 - 0.0783) Blue for upper and lower bearings.
5 1.988 - 1.991 (0.0783 - 0.0784) Pink

6 1.991 - 1.994 (0.0784 - 0.0785) Purple O
7 1.994 - 1.997 (0.0785 - 0.0786) White

UPR 1.973 - 1.976 (0.0777 - 0.0778) Black
01
LWR 1.976 - 1.979 (0.0778 - 0.0779) Brown
UPR 1.976 - 1.979 (0.0778 - 0.0779) Brown
12
LWR 1.979 - 1.982 (0.0779 - 0.0780) Green
UPR 1.979 - 1.982 (0.0779- 0.0780) Green
23
LWR 1.982 - 1.985 (0.0780 - 0.0781) Yellow
Grade and color are different
UPR 1.982 - 1.985 (0.0780 - 0.0781) Yellow for upper and lower bearings.
34
LWR 1.985 - 1.988 (0.0781 - 0.0783) Blue
UPR 1.985 - 1.988 (0.0781 - 0.0783) Blue
45
LWR 1.988 - 1.991 (0.0783 - 0.0784) Pink
UPR 1.988 - 1.991 (0.0783 - 0.0784) Pink
56
LWR 1.991 - 1.994 (0.0784 - 0.0785) Purple
UPR 1.991 - 1.994 (0.0784 - 0.0785) Purple
67
LWR 1.994 - 1.997 (0.0785 - 0.0786) White
Use Undersize Bearing Usage Guide

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-
size (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
PBIC2200E

Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 2.106 - 2.114 (0.0829 - 0.0832)

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE]
SERVICE DATA AND SPECIFICATIONS (SDS) A

Standard and Limit INFOID:0000000003261132
EM
GENERAL SPECIFICATIONS
C
Cylinder arrangement In-line 4
Displacement cm3 (cu in) 2,488 (151.82)
Bore and stroke mm (in) 89.0 x 100.0 (3.504 x 3.937) D
Valve arrangement DOHC
Firing order 1-3-4-2
E
Compression 2
Number of piston rings
Oil 1
Compression ratio 9.5 F
Standard 1,304 (13.3, 189)
Compression pressure
Minimum 1,108 (11.3, 161)
kPa (kg/cm2, psi) / 250 rpm G
Differential limit between cylinders 100 (1.0, 14)
DRIVE BELT
H
Tension of drive belt Auto adjustment by auto-tensioner
EXHAUST MANIFOLD AND THREE WAY CATALYST ASSEMBLY

I
Unit: mm (in)
Item Limit
Surface distortion 0.3 (0.012) J
SPARK PLUG
Make NGK K
Standard type PLZKAR6A–11
L
CYLINDER HEAD
Unit: mm (in)
Items Limit M
Head surface distortion 0.1 (0.004)
PBIC0283E
VALVE
Valve Timing

Valve timing
PBIC0187E
Unit: degree
a b c d e f
236 224 -4 60 32 37
Valve Dimensions
Unit: mm (in)
SEM188A
Intake 35.5 - 35.8 (1.398 - 1.409)

Valve head diameter “D”
Exhaust 30.5 - 30.8 (1.201 - 1.213)
Intake 97.16 (3.8252)
Valve length “L”
Exhaust 98.82 (3.8905)
Intake 5.965 - 5.980 (0.2348 - 0.2354)
Valve stem diameter “d”
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Intake
Valve seat angle “α” 45°15′ - 45°45′
Exhaust
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 1.3 (0.051)
Valve Clearance
Unit: mm (in)
Items Cold Hot* (reference data)

Intake 0.24 - 0.32 (0.009 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)
Available Valve Lifter

Thickness mm (in) Identification mark A
EM
KBIA0119E
6.96 (0.2740) 696 E

6.98 (0.2748) 698
7.00 (0.2756) 700
F
7.02 (0.2764) 702
7.04 (0.2772) 704
7.06 (0.2780) 706 G
7.08 (0.2787) 708
7.10 (0.2795) 710
H
7.12 (0.2803) 712
7.14 (0.2811) 714
7.16 (0.2819) 716 I
7.18 (0.2827) 718
7.20 (0.2835) 720
7.22 (0.2843) 722 J
7.24 (0.2850) 724
7.26 (0.2858) 726
K
7.28 (0.2866) 728
7.30 (0.2874) 730
7.32 (0.2882) 732 L
7.34 (0.2890) 734
7.36 (0.2898) 736
M
7.38 (0.2906) 738
7.40 (0.2913) 740
7.42 (0.2921) 742 N
7.44 (0.2929) 744
7.46 (0.2937) 746
O
Valve Spring
Items Intake Exhaust

P
Free height 43.72 - 43.92 mm (1.7213 - 1.7291 in) 45.29 - 45.49 mm (1.7831 - 1.7909 in)
Installation height 35.30 mm (1.390 in) 35.30 mm (1.390 in)
Installation load 151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb) 151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb)
Height during valve open 25.3 mm (0.996 in) 26.76 mm (1.0535 in)
Load with valve open 351 - 394 N (35.8 - 40.2 kg, 79 - 89 lb) 318 - 362 N (32.4 - 36.9 kg, 71 - 81 lb)
Identification color Pink Green

Valve Lifter
Unit: mm (in)
Items Standard
Valve lifter outer diameter 33.965 - 33.980 (1.3372 - 1.3378)
Valve lifter hole diameter 34.000 - 34.021 (1.3386 - 1.3394)
Valve lifter clearance 0.020 - 0.056 (0.0008 - 0.0022)
Valve Guide
Unit: mm (in)
PBIC0184E
Items Standard part Service part

Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Items Standard Limit
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.003)
Valve guide clearance
Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.09 (0.004)
Intake 10.1 - 10.3 (0.398 - 0.406)
Projection length “L”
Exhaust 10.0 - 10.4 (0.394 - 0.409)
Valve Seat
Unit: mm (in)
PBIC2745E
Items Standard Oversize [0.5 (0.02)] (Service)

Intake 36.500 - 36.516 (1.4370 - 1.4376) 37.000 - 37.016 (1.4567 - 1.4573)
Cylinder head seat recess diameter “D”
Exhaust 31.500 - 31.516 (1.2402 - 1.2408) 32.000 - 32.016(1.2598 - 1.2605)
Intake 36.597 - 36.613 (1.4408 - 1.4415) 37.097 - 37.113 (1.4605 - 1.4611)
Valve seat outer diameter “d”
Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)
Intake 0.081 - 0.113 (0.0032 - 0.0044)
Valve seat interference fit
Exhaust 0.084 - 0.116 (0.0033 - 0.0046)

Intake 33.5 (1.319)
Diameter “d1”*1 A
Exhaust 28.0 (1.102)
Intake 35.1 - 35.3 (1.382 - 1.390)
Diameter “d2”*2
Exhaust 29.9 - 30.1 (1.177 - 1.185) EM
Intake 60°
Angle “α1”
Exhaust 60°
Intake 88°45′ - 90°15′ C
Angle “α2”
Exhaust 88°45′ - 90°15′
Intake 120°
Angle “α3” D
Exhaust 120°
Intake 1.05 - 1.35 (0.0413 - 0.0531)
Contacting width “W”*3
Exhaust 1.25 - 1.55 (0.0492 - 0.0610) E
Intake 5.9 - 6.0 (0.232 - 0.236) 5.0 - 5.1 (0.197 - 0.201)
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.91 - 5.01 (0.1933 - 0.1972)
F
Depth “H” 6.0 (0.236)
*1: Diameter made by intersection point of conic angles α1 and α2

*2: Diameter made by intersection point of conic angles α2 and α3 G
*3: Machining data
CAMSHAFT AND CAMSHAFT BEARING H

Unit: mm (in)

Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034) — I
No. 1 28.000 - 28.021 (1.1024 - 1.1032) —
Camshaft bracket inner diameter
No. 2, 3, 4, 5 23.500 - 23.521 (0.9252 - 0.9260) —
J
No. 1 27.935 - 27.955 (1.0998 - 1.1006) —
Camshaft journal outer diameter
No. 2, 3, 4, 5 23.435 - 23.455 (0.9226 - 0.9234) —
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) — K
Intake 45.015 - 45.205 (1.7722 - 1.7797)
Camshaft cam height “A” 0.2 (0.008)*1
Exhaust 43.975 - 44.165 (1.7313 - 1.7388)
L
Camshaft runout [TIR*2] Less than 0.02 (0.0008) —
Camshaft sprocket runout [TIR*2] — 0.15 (0.0059)

M
P
SEM671
*1: Cam wear limit

*2: Total indicator reading
CYLINDER BLOCK

Unit: mm (in)
PBIC0281E
Surface distortion Limit 0.1 (0.004)

Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047)
Standard
Cylinder bore Inner diameter Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.2 (0.008)
Out-of-round (Difference between “X” and “Y”) 0.015 (0.0006)
Limit
Taper (Difference between “A” and “C”) 0.01 (0.0004)
Grade No. A 58.944 - 58.945 (2.3206 - 2.3207)
Grade No. B 58.945 - 58.946 (2.3207 - 2.3207)
Grade No. C 58.946 - 58.947 (2.3207 - 2.3207)
Grade No. D 58.947 - 58.948 (2.3207 - 2.3208)
Grade No. E 58.948 - 58.949 (2.3208 - 2.3208)
Grade No. F 58.949 - 58.950 (2.3208 - 2.3209)
Grade No. G 58.950 - 58.951 (2.3209 - 2.3209)
Grade No. H 58.951 - 58.952 (2.3209 - 2.3209)
Grade No. J 58.952 - 58.953 (2.3209 - 2.3210)
Grade No. K 58.953 - 58.954 (2.3210 - 2.3210)
Grade No. L 58.954 - 58.955 (2.3210 - 2.3211)
Grade No. M 58.955 - 58.956 (2.3211 - 2.3211)
Main bearing housing inner diameter grade
Grade No. N 58.956 - 58.957 (2.3211 - 2.3211)
Grade No. P 58.957 - 58.958 (2.3211 - 2.3212)
Grade No. R 58.958 - 58.959 (2.3212 - 2.3212)
Grade No. S 58.959 - 58.960 (2.3212 - 2.3213)
Grade No. T 58.960 - 58.961 (2.3213 - 2.3213)
Grade No. U 58.961 - 58.962 (2.3213 - 2.3213)
Grade No. V 58.962 - 58.963 (2.3213 - 2.3214)
Grade No. W 58.963 - 58.964 (2.3214 - 2.3214)
Grade No. X 58.964 - 58.965 (2.3214 - 2.3215)
Grade No. Y 58.965 - 58.966 (2.3215 - 2.3215)
Grade No. 4 58.966 - 58.967 (2.3215 - 2.3215)
Grade No. 7 58.967 - 58.968 (2.3215 - 2.3216)
Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)
PISTON, PISTON RING AND PISTON PIN

Available Piston

Unit: mm (in)
A
EM
D
PBIC0188E
Grade No. 2 88.990 - 89.000 (3.5035 - 3.5039)

E
Piston skirt diameter “A” Standard Grade No. 3 89.000 - 89.010 (3.5039 - 3.5043)
0.20 (0.008) oversize (Service) 89.180 - 89.210 (3.5110 - 3.5122)
Piston height “H” dimension 42.98 (1.692)
F
Grade No. 0 19.993 - 19.999 (0.7871 - 0.7874)
Grade No. 1 19.999 - 20.005 (0.7874 - 0.7876)
Standard 0.010 - 0.030 (0.0004 - 0.0012) G
Piston to cylinder bore clearance
Limit 0.08 (0.0031)
Piston Ring H
Unit: mm (in)

Top 0.040 - 0.080 (0.0016 - 0.0031) 0.11 (0.0043) I
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring (rail ring) 0.065 - 0.135 (0.0026 - 0.0053) —
J
Top 0.21- 0.31 (0.0083 - 0.0122) 0.54 (0.0213)
End gap 2nd 0.32 - 0.47 (0.0146 - 0.0205) 0.65 (0.0257)
Oil ring (rail ring) 0.20 - 0.60 (0.0079 - 0.0236) 0.95 (0.0374) K
Piston Pin
Unit: mm (in)
L
Grade No. 0 19.989 - 19.995 (0.7870 - 0.7872)
Grade No. 1 19.995 - 20.001 (0.7872 - 0.7874)
Piston to piston pin oil clearance Standard 0.002 - 0.006 (0.0001 - 0.0002) M
Connecting rod bushing oil clearance Standard 0.005 - 0.017 (0.0002 - 0.0007)
CONNECTING ROD
N
Unit: mm (in)
Center distance 143.00 - 143.10 (5.630 - 5.634)

Bend [per 100 (3.94)] Limit 0.15 (0.0059) O
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
Grade No. 0 20.000 - 20.006 (0.7874 - 0.7876)
Connecting rod bushing inner diameter* P
Grade No. 1 20.006 - 20.012 (0.7876 - 0.7879)

Standard 0.20 - 0.35 (0.0079 - 0.0138)
Side clearance
Limit 0.50 (0.0197)
Grade No. 0 48.000 - 48.001 (1.8898 - 1.8898)
Grade No. 1 48.001 - 48.002 (1.8898 - 1.8898)
Grade No. 2 48.002 - 48.003 (1.8898 - 1.8899)
Grade No. 3 48.003 - 48.004 (1.8899 - 1.8899)
Grade No. 4 48.004 - 48.005 (1.8899 - 1.8900)
Grade No. 5 48.005 - 48.006 (1.8900 - 1.8900)
Connecting rod big end diameter Grade No. 6 48.006 - 48.007 (1.8900 - 1.8900)
Grade No. 7 48.007 - 48.008 (1.8900 - 1.8901)
Grade No. 8 48.008 - 48.009 (1.8901 - 1.8901)
Grade No. 9 48.009 - 48.010 (1.8901 - 1.8902)
Grade No. A 48.010 - 48.011 (1.8902 - 1.8902)
Grade No. B 48.011 - 48.012 (1.8902 - 1.8902)
Grade No. C 48.012 - 48.013 (1.8902 - 1.8903)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
SEM645 SBIA0535E
Center distance “r” 49.96 - 50.04 (1.9669 - 1.9701)

Out-of-round (Difference between “X” and “Y”) Limit 0.0025 (0.0001)
Taper (Difference between “A” and “B”) Limit 0.0025 (0.0001)
Runout [TIR*] Limit 0.05 (0.0020)
Standard 0.10 - 0.26 (0.0039 - 0.0102)
Crankshaft end play
Limit 0.30 (0.0118)

Grade No. A 44.974 - 44.973 (1.7706 - 1.7706)
Grade No. B 44.973 - 44.972 (1.7706 - 1.7705) A
Grade No. C 44.972 - 44.971 (1.7705 - 1.7705)
Grade No. D 44.971 - 44.970 (1.7705 - 1.7705)
Grade No. E 44.970 - 44.969 (1.7705 - 1.7704)
Grade No. F 44.969 - 44.968 (1.7704 - 1.7704) EM
Grade No. G 44.968 - 44.967 (1.7704 - 1.7704)
Grade No. H 44.967 - 44.966 (1.7704 - 1.7703)
Grade No. J 44.966 - 44.965 (1.7703 - 1.7703)
Pin journal diameter grade. “DP”
Grade No. K 44.965 - 44.964 (1.7703 - 1.7702)
C
Grade No. L 44.964 - 44.963 (1.7702 - 1.7702)
Grade No. M 44.963 - 44.962 (1.7702 - 1.7702)
Grade No. N 44.962 - 44.961 (1.7702 - 1.7701) D
Grade No. P 44.961 - 44.960 (1.7701 - 1.7701)
Grade No. R 44.960 - 44.959 (1.7701 - 1.7700)
Grade No. S 44.959 - 44.958 (1.7700 - 1.7700)
Grade No. T 44.958 - 44.957 (1.7700 - 1.7700) E
Grade No. U 44.957 - 44.956 (1.7700 - 1.7699)
Grade No. A 54.979 - 54.978 (2.1645 - 2.1645)
Grade No. B 54.978 - 54.977 (2.1645 - 2.1644)
F
Grade No. C 54.977 - 54.976 (2.1644 - 2.1644)
Grade No. D 54.976 - 54.975 (2.1644 - 2.1644)
Grade No. E 54.975 - 54.974 (2.1644 - 2.1643)
Grade No. F 54.974 - 54.973 (2.1643 - 2.1643) G
Grade No. G 54.973 - 54.972 (2.1643 - 2.1642)
Grade No. H 54.972 - 54.971 (2.1642 - 2.1642)
Grade No. J 54.971 - 54.970 (2.1642 - 2.1642)
Grade No. K 54.970 - 54.969 (2.1642 - 2.1641) H
Grade No. L 54.969 - 54.968 (2.1641 - 2.1641)
Grade No. M 54.968 - 54.967 (2.1641 - 2.1641)
Main journal diameter grade. “Dm”
Grade No. N 54.967 - 54.966 (2.1641 - 2.1640)
Grade No. P 54.966 - 54.965 (2.1640 - 2.1640) I
Grade No. R 54.965 - 54.964 (2.1640 - 2.1639)
Grade No. S 54.964 - 54.963 (2.1639 - 2.1639)
Grade No. T 54.963 - 54.962 (2.1639 - 2.1639)
Grade No. U 54.962 - 54.961 (2.1639 - 2.1638)
J
Grade No. V 54.961 - 54.960 (2.1638 - 2.1638)
Grade No. W 54.960 - 54.959 (2.1638 - 2.1637)
Grade No. X 54.959 - 54.958 (2.1637 - 2.1637) K
Grade No. Y 54.958 - 54.957 (2.1637 - 2.1637)
Grade No. 4 54.957 - 54.956 (2.1637 - 2.1636)
Grade No. 7 54.956 - 54.955 (2.1636 - 2.1636)
*: Total indicator reading
L
MAIN BEARING
Unit: mm (in) M
SEM685D

0 1.973 - 1.976 (0.0777 - 0.0778) Black
1 1.976 - 1.979 (0.0778 - 0.0779) Brown
2 1.979 - 1.982 (0.0779 - 0.0780) Green
3 1.982 - 1.985 (0.0780 - 0.0781) Yellow Grade and color are the same
4 1.985 - 1.988 (0.0781 - 0.0783) Blue for upper and lower bearings.
5 1.988 - 1.991 (0.0783 - 0.0784) Pink

6 1.991 - 1.994 (0.0784 - 0.0785) Purple
7 1.994 - 1.997 (0.0785 - 0.0786) White
UPR 1.973 - 1.976 (0.0777 - 0.0778) Black
01
LWR 1.976 - 1.979 (0.0778 - 0.0779) Brown
UPR 1.976 - 1.979 (0.0778 - 0.0779) Brown
12
LWR 1.979 - 1.982 (0.0779 - 0.0780) Green
UPR 1.979 - 1.982 (0.0779 - 0.0780) Green
23
LWR 1.982 - 1.985 (0.0780 - 0.0781) Yellow
Grade and color are different
UPR 1.982 - 1.985 (0.0780 - 0.0781) Yellow for upper and lower bearings.
34
LWR 1.985 - 1.988 (0.0781 - 0.0783) Blue
UPR 1.985 - 1.988 (0.0781 - 0.0783) Blue
45
LWR 1.988 - 1.991 (0.0783 - 0.0784) Pink
UPR 1.988 - 1.991 (0.0783 - 0.0784) Pink
56
LWR 1.991 - 1.994 (0.0784 - 0.0785) Purple
UPR 1.991 - 1.994 (0.0784 - 0.0785) Purple
67
LWR 1.994 - 1.997 (0.0785 - 0.0786) White
Undersize
Unit: mm (in)
Item Thickness Main journal diameter

US 0.25 (0.0098) 2.106 - 2.114 (0.0829 - 0.0832) Grind so that bearing clearance is the specified value.
Bearing Oil Clearance

Unit: mm (in)
No. 1, 3 and 5 0.028 - 0.042 (0.0011 - 0.0017)

Standard
Main bearing oil clearance No. 2 and 4 0.041 - 0.056 (0.0016 - 0.0022)
Limit 0.1 (0.004)
CONNECTING ROD BEARING
Grade number Thickness mm (in) Identification color

0 1.493 - 1.496 (0.0588 - 0.0589) Black
1 1.496 - 1.499 (0.0589 - 0.0590) Brown
2 1.499 - 1.502 (0.0590 - 0.0591) Green
3 1.502 - 1.505 (0.0591 - 0.0593) Yellow
4 1.505 - 1.508 (00.593 - 0.0594) Blue
Undersize
Unit: mm (in)
Item Thickness Crank pin journal diameter

US 0.25 (0.0098) 1.624 - 1.632 (0.0639 - 0.0643) Grind so that bearing clearance is the specified value.
Bearing Oil Clearance

Unit: mm (in)

Standard 0.035 - 0.045 (0.0014 - 0.0018)
Connecting rod bearing oil clearance A
Limit 0.10 (0.0039)
EM

PRECAUTIONS
< PRECAUTION > [VQ40DE]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000003220168
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
Precaution for Drain Engine Coolant INFOID:0000000003220169
Drain engine coolant when engine is cooled.

Precaution for Disconnecting Fuel Piping INFOID:0000000003220170
• 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.
Precaution for Removal and Disassembly INFOID:0000000003220171
• When instructed to use special service tools, use the 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 nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
Precaution for Inspection, Repair and Replacement INFOID:0000000003220172
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and Installation INFOID:0000000003220173
• Use torque wrench to tighten bolts or nuts to specification.

• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.

PRECAUTIONS
• Release air within route when refilling after draining engine coolant.
• Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). A
Then make sure that there are no leaks at fuel line connections.
• After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gasses for leakage.
EM
Parts Requiring Angle Tightening INFOID:0000000003220174
• For the final tightening of the following engine parts use Tool: C

- Cylinder head bolts D
- Lower cylinder block bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No angle wrench is required as bolt flange is provided with notches for angle tighten-
E
ing)
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil. F
Precaution for Liquid Gasket INFOID:0000000003220175
G
REMOVAL OF LIQUID GASKET SEALING
• After removing nuts and bolts, separate the mating surface and
remove old liquid gasket sealing using Tool.
H
Tool number : KV10111100 (J-37228)
CAUTION:
Be careful not to damage the mating surfaces. I
• Tap seal cutter to insert it (1), and then slide it by tapping on the
side (2) as shown.
• In areas where Tool is difficult to use, use plastic hammer to lightly J
tap the parts, to remove it.
CAUTION: WBIA0566E
If for some unavoidable reason tool such as screwdriver is

K
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Remove the old liquid gasket adhering to the gasket application L
surface and the mating surface using suitable tool.
• Remove liquid gasket completely from the groove of the gas-
ket application surface, bolts, and bolt holes.
M
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign materials.
N
PBIC0003E O

PRECAUTIONS
3. Attach liquid gasket tube to the Tool.

4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
WBIA0567E
• If there is a groove for the liquid gasket application, apply the

liquid gasket to the groove.
• As for bolt holes, normally apply the liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Make sure to read the text of this manual.
• Within five minutes of liquid gasket application, install the mat-
ing component.
• If the liquid gasket protrudes, wipe it off immediately.
• Do not retighten nuts or bolts after the installation.
• Wait 30 minutes or more after installation, before refilling the
engine with engine oil and engine coolant.
SEM159F
CAUTION:
If there are specific instructions in this manual, observe them.

PREPARATION
< PREPARATION > [VQ40DE]
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000003220176
EM
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
(Kent-Moore No.) C
Tool name
ST0501S000 Disassembling and assembling engine
( — ) D
Engine stand assembly
1. ST05011000
( — )
Engine stand E
2. ST05012000
( — )
Base NT042
F
— Removing fuel tube quick connectors in en-
(J-45488) gine room
Quick connector release (Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210) G
H
PBIC0198E
KV10111100 Removing oil pan (lower and upper), front and

(J-37228) rear timing chain case, etc.
I
Seal cutter
NT046
WS39930000 Pressing the tube of liquid gasket K

( — )
Tube presser
NT052 M
KV991J0050 Loosening or tightening air fuel ratio A/F sen-
(J-44626) sor
Air fuel sensor Socket a: 22 mm (0.87 in) N
O
LBIA0444E
KV10114400 Loosening or tightening heated oxygen sen-

(J-38365) sor 1 P
Heated oxygen sensor wrench a: 22 mm (0.87 in)
NT636

PREPARATION
(Kent-Moore No.)
Tool name
KV10116200 Disassembling valve mechanism
(J-26336-A) Part (1) is a component of KV10116200 (J-
Valve spring compressor 26336-A), but Part (2) is not so.
1. KV10115900
(J-26336-20)
Attachment
2.KV10109220
( — )
Adapter PBIC1650E
KV10107902 Replacing valve oil seal

(J-38959)
Valve oil seal puller
NT011
— Installing valve oil seal

(J-39386)
Valve oil seal drift
NT024
EM03470000 Installing piston assembly into cylinder bore

(J-8037)
Piston ring compressor
NT044
KV10112100 Tightening bolts for bearing cap, cylinder

(BT-8653-A) head, etc. in angle
Angle wrench
NT014
ST16610001 Removing pilot converter

(J-23907)
Pilot bushing puller
NT045

PREPARATION
(Kent-Moore No.) A
Tool name
KV991J0120 Installing rear main seal
(J-47128) EM
Seal installer
LBIA0452E
KV10117700 Removing and installing crankshaft pulley D

(J-44716)
Ring gear stopper
E
NT822 F
Commercial Service Tool INFOID:0000000003220177

G
Tool number
(Kent-Moore No.) Description H
Tool name
( — ) Loosening nuts and bolts
Power tool
I
PBIC0190E
KV991J0100 Removing and installing flywheel K

(J-46531) Size: T55
TORX socket
PBIC1113E M
( — ) Removing and installing spark plug
Spark plug wrench
N
O
NT047
(J-24239-01) Loosening and tightening cylinder head bolt,

Cylinder head bolt wrench and used with angle wrench [SST: P
KV10112100 (BT8653-A)]
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
NT583

PREPARATION
Tool number
Tool name
( — ) Finishing valve seat dimensions
Valve seat cutter set
NT048
( — ) Removing and installing piston ring

Piston ring expander
NT030
( — ) Removing and installing valve guide

Valve guide drift Intake and Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
NT015
( — ) (1): Reaming valve guide inner hole

Valve guide reamer (2): Reaming hole for oversize valve guide
Intake and Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
dia.
NT016
(J-43897-18) Reconditioning the exhaust system threads

(J-43897-12) before installing a new heated oxygen sensor
Oxygen sensor thread cleaner (Use with anti-seize lubricant shown below.)
a: J-43897-18 [18 mm (0.71 in) dia.] for zir-
conia heated oxygen sensor
b: J-43897-12 [12 mm (0.47 in) dia.] for tita-
nia heated oxygen sensor
AEM488
( — ) Lubricating oxygen sensor thread cleaning

Anti-seize lubricant (Permatex 133AR tool when reconditioning exhaust system
or equivalent meeting MIL specifica- threads
tion MIL-A-907)
AEM489
( — ) Removing and installing engine

Manual lift table caddy
ZZA1210D

< FUNCTION DIAGNOSIS > [VQ40DE]
FUNCTION DIAGNOSIS A
NVH Troubleshooting - Engine Noise INFOID:0000000003220178
EM
PBIC2873E
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000003220179
1. Locate the area where noise occurs.

< FUNCTION DIAGNOSIS > [VQ40DE]
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-128
gine clicking noise
Rocker
cover Camshaft Camshaft runout
EM-193
Cylinder Rattle C A — A B C bearing Camshaft journal oil
EM-193
head noise clearance
Piston to piston pin oil

Slap or Piston pin clearance EM-229
— A — B B —
knock noise Connecting rod bushing EM-229
oil clearance
Piston to cylinder bore
Crank- clearance
EM-229
shaft pul- Piston ring side clear-
Slap or Piston EM-229
ley A — — B B A ance
rap slap noise EM-229
Cylinder Piston ring end gap
EM-229
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-229
Knock A B C B B B
bearing Connecting rod bearing EM-229
noise oil clearance
Main bearing oil clear-
Main bear- EM-229
Knock A B — A B C ance
ing noise EM-229
Crankshaft runout
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear EM-173
A A — B B B chain ten-
Timing ticking Timing chain tensioner EM-173
sioner
chain case operation
noise
Drive belts
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belts deflection
or slip-
ing EM-123
ping)
Front of Drive belts Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water
Squall
A B — B A B pump Water pump operation CO-49
Creak
noise
Rattle — — A — — — VTC VTC lock pin clearance EM-173
A: Closely related B: Related C: Sometimes related —: Not related

DRIVE BELTS
< ON-VEHICLE MAINTENANCE > [VQ40DE]
ON-VEHICLE MAINTENANCE A
DRIVE BELTS
EM
G
LBIA0427E
1. Drive belt 2. Power steering oil pump pulley 3. Generator pulley

4. Crankshaft pulley 5. A/C compressor 6. Cooling fan pulley
H
7. Idler pulley 8. Drive belt tensioner
Checking Drive Belts INFOID:0000000003220181 I
WARNING:
Be sure to perform when the engine is stopped. J
1. Remove air duct and resonator assembly when inspecting drive belt. Refer to EM-135, "Removal and
Installation".
2. Visually check entire belt for wear, damage or cracks. K
Adjustment INFOID:0000000003220182
Belt tensioning is not necessary, as it is automatically adjusted by auto tensioner. L
M
REMOVAL
1. Remove air duct and resonator assembly. Refer to EM-135, "Removal and Installation".
2. Rotate the drive belt auto tensioner in the direction of arrow N
(loosening direction of tensioner) as shown, using suitable tool.
CAUTION:
Avoid placing hand in a location where pinching may occur
if the tool accidentally comes off. O
3. Remove the drive belt.
LBIA0428E
INSTALLATION
CAUTION:

DRIVE BELTS
Make sure belt is securely installed around all pulleys.
Drive Belt Auto Tensioner and Idler Pulley INFOID:0000000003220184
LBIA0429E
1. Idler pulley 2. Drive belt auto tensioner
REMOVAL
1. Remove air duct and resonator assembly. Refer to EM-135, "Removal and Installation".
2. Remove drive belt. Refer to EM-123, "Removal and Installation".
3. Remove engine cooling fan assembly (motor driven type). Refer to CO-47, "Removal and Installation
(Motor driven type)".
4. Remove auto tensioner and idler pulley using power tool.
INSTALLATION

AIR CLEANER FILTER
AIR CLEANER FILTER
A
EM
G
AWBIA0133GB
1. Air cleaner case (lower) 2. Air cleaner filter 3. Air cleaner case (upper)
4. Air duct and resonator ⇐ Front
H
I
REMOVAL
1. Unhook clips, and lift air cleaner case (upper).
2. Remove air cleaner filter. J
INSTALLATION
K

SPARK PLUG
SPARK PLUG
PBIC2901E
1. Ignition coil 2. Spark plug
REMOVAL
1. Remove the ignition coil. Refer to EM-151, "Removal and Installation".
2. Remove the spark plug using a suitable tool.
CAUTION:
Do not drop or shock it.
SEM294A

• Do not use a wire brush to clean the spark plug.
SMA773C
• If plug tip is covered with carbon, spark plug cleaner may be used.

SPARK PLUG
Cleaner air pressure : Less than 588 kPa (5.9 bar, 6 kg/cm2, 85 psi) A
Cleaning time : Less than 20 seconds
• Checking and adjusting plug gap is not required between change
EM
intervals.
SMA806CA
E
INSTALLATION
Installation is in the reverse order of removal. F
CAUTION:
Make NGK G
Standard type DILFR5A-11
H

Valve Clearance INFOID:0000000003220189
INSPECTION
NOTE:
Perform the following inspection after removal, installation or replacement of camshaft or valve-related parts,
or if there are unusual engine conditions due to changes in valve clearance over time (starting, idling, and/or
noise).
1. Warm up the engine. Then stop the engine.
2. Remove rocker covers (right and left banks). Refer to EM-152, "Removal and Installation".
3. Measure the valve clearance as follows:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley clockwise to align timing mark
(grooved line without color) with timing indicator.
KBIA1717J
• Make sure that intake and exhaust cam noses on No. 1 cylin-
der (engine front side of RH bank) are located as shown.
• If not, rotate crankshaft one revolution (360°) and align as
shown.
SEM418G
b. Use feeler gauge, measure the clearance between valve lifter

and camshaft.
SEM139D
Valve clearance:
Unit: mm (in)
Cold Hot * (reference data)

Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)

• Measure the valve clearances at locations marked “×” as
shown in the table below (locations indicated in the illustration) A
with feeler gauge.
• No. 1 cylinder at compression TDC
EM
Measuring position (RH bank) No. 1 CYL. No. 3 CYL. No. 5 CYL.
No. 1 cylinder at EXH ×

compression TDC INT × C
Measuring position (LH bank) No. 2 CYL. No. 4 CYL. No. 6 CYL.
No. 1 cylinder at INT ×

compression TDC EXH ×
D
G
PBIC2054E
c. Rotate crankshaft by 240° clockwise (when viewed from engine

front) to align No. 3 cylinder at TDC of its compression stroke. H
NOTE:
Crankshaft pulley bolt flange has a stamped line every 60°. They
can be used as a guide to rotation angle.
I
PBIC2916E
K
shown in the table below (locations indicated in the illustration)
with feeler gauge. L
M
compression TDC INT ×
Measuring position (LH bank) No. 2 CYL. No. 4 CYL. No. 6 CYL. N

O
PBIC2055E

d. Rotate crankshaft by 240° clockwise (when viewed from engine
front) to align No. 5 cylinder at TDC of compression stroke.
PBIC2916E

shown in the table below (locations indicated in the illustration)
with feeler gauge.

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

PBIC2056E
4. For the measured value out of the standard, perform adjustment.

ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
1. Measure the valve clearance.
3. Remove valve lifters at the locations that are out of the standard.
4. Measure the center thickness of removed valve lifters with
micrometer.
KBIA0057E
5. Use the equation below to calculate valve lifter thickness for replacement.

Valve lifter thickness calculation: t = t1+ (C1– C2) A

t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
EM
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.26 - 0.34 mm (0.010 - 0.013 in)* C
Exhaust : 0.29 - 0.37 mm (0.011 - 0.015 in)*
D
• Thickness of new valve lifter can be identified by stamp marks
on the reverse side (inside the cylinder).
G
KBIA0119E
Intake
Stamp mark Thickness
H
788U 7.88 mm (0.3102 in)
790U 7.90 mm (0.3110 in)
· · I
· ·
840U 8.40 mm (0.3307 in)
J
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-245, "Standard and Limit".
Exhaust K
Stamp mark Thickness
N788 7.88 mm (0.3102 in)
N790 7.90 mm (0.3110 in) L
· ·
· ·
M
N836 8.36 mm (0.3291 in)
Available thickness of valve lifter: 25 sizes with range 7.88 to 8.36 mm (0.3102 to 0.3291 in) in steps of
0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-245, "Standard and Limit". N
CAUTION:
Install identification letter at the end and top, “U” and “N”, at each of proper positions. (Be care-
ful of mis-installation between intake and exhaust.)
6. Install selected valve lifter. O
7. Install camshaft. Refer to EM-193, "Removal and Installation".
8. Manually turn crankshaft pulley a few turns.
P
9. Make sure that the valve clearances for cold engine are within the specifications by referring to the speci-
fied values.
11. Start the engine, and check for unusual noise and vibration.

Compression Pressure INFOID:0000000003220190
CHECKING COMPRESSION PRESSURE

1. Warm up engine thoroughly.
3. Disconnect fuel pump fuse to avoid fuel injection during mea-
surement.
BBIA0534E
4. Remove intake manifold collector. Refer to EM-136, "Removal and Installation".

5. Remove spark plug from each cylinder. Refer to EM-126, "Removal and Installation".
6. Connect engine tachometer (not required in use of CONSULT-lIl).
7. Install compression tester with adapter onto spark plug hole.
PBIC0900E
• Use compression gauge whose pick up end inserted to spark

plug hole is smaller than 20 mm (0.79 in) in diameter. Other-
wise, it may be caught by cylinder head during removal.
SBIA0533E
8. Turn ignition switch to “START” for cranking. When the gauge pointer stabilizes, read the compression
pressure and engine rpm. Perform these steps to check each cylinder.
Compression pressure:
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 charged 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 A
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.
EM
• 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. C
• 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. D
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-523, "Description". E

ENGINE ROOM COVER
< ON-VEHICLE REPAIR > [VQ40DE]
ON-VEHICLE REPAIR
ENGINE ROOM COVER
REMOVAL
1. Remove bolts using power tool.
2. Lift up on engine cover firmly to dislodge snap fit mounts.
CAUTION:
Do not damage or scratch cover when installing or remov-
ing.
WBIA0622E
INSTALLATION

A
EM
G
AWBIA0133GB
1. Air cleaner case (lower) 2. Air cleaner filter 3. Air cleaner case (upper)
4. Air duct and resonator ⇐ Front
H
I
REMOVAL
1. Remove the engine room cover using power tool. Refer to EM-134, "Removal and Installation".
2. Disconnect the harness connector from air cleaner case (upper). J
3. Remove the air duct and resonator assembly and air cleaner case (upper).
4. Remove air cleaner filter and air cleaner case (lower).
K
• Add marks as necessary for easier installation.
CAUTION:
Handle mass air flow sensor with care.
• Do not shock it. L
• Do not disassemble it.
• Do not touch its sensor.
INSPECTION AFTER REMOVAL M
Inspect air duct for crack or tear.
• If anything found, replace air duct.
N
INSTALLATION

INTAKE MANIFOLD COLLECTOR
WBIA0731E
1. Vacuum tank 2. VIAS control solenoid valve 3. Vacuum hose

4. Intake manifold collector support 5. Water hose 6. Electronic throttle control actuator
7. Water hose 8. EVAP hose 9. Bracket
EVAP canister purge volume control
10. EVAP hose 11. 12. Gasket
solenoid valve
13. Gasket 14. Intake manifold collector 15. Clip
16. PCV hose 17. Connector 18. PCV hose
a. To intake manifold collector b. To power valve c. To throttle body
d. To cylinder head (RH bank)
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Remove engine cover. Refer to EM-134, "Removal and Installation".
2. Remove air cleaner case (upper) with mass air flow sensor and air duct assembly. Refer to EM-135,
"Removal and Installation".
3. Remove electronic throttle control actuator as follows:
a. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-39, "Changing Engine Coolant".
CAUTION:
• Perform when engine is cold.
• Do not spill engine coolant on drive belt.
b. Disconnect water hoses from electronic throttle control actuator.

• When engine coolant is not drained from radiator, attach plug to water hoses to prevent engine coolant
leakage. A
c. Disconnect harness connector.
d. Loosen bolts in reverse order as shown.
CAUTION: EM
• Handle carefully to avoid any shock to electronic throttle
control actuator.
C
PBIC2875E
E
4. Remove the following parts:
• Vacuum hose (to brake booster)
• PCV hose
F
5. Loosen bolts in reverse order as shown to remove intake mani-
fold collector support.
G
I
PBIC2876E
6. Disconnect EVAP hoses and harness connector from EVAP canister purge volume control solenoid valve.
J
7. Remove EVAP canister purge volume control solenoid valve.
8. Remove VIAS control solenoid valve and vacuum tank.
• Add mating marks as necessary for easier installation.
K
9. Loosen nuts and bolts in reverse order as shown with power
tool, and remove intake manifold collector.
CAUTION:
Cover engine openings to avoid entry of foreign materials. L
N
PBIC2877E
INSTALLATION
Installation is in the reverse order of removal. Note the following: O
Intake Manifold Collector
• If stud bolts were removed from intake manifold, install them and tighten to the specified torque.
P

• Tighten nuts and bolts in numerical order as shown.
Intake manifold collector : 11.0 N·m (1.1 kg-m, 8 ft-lb)

bolts and nuts
Stud bolts : 6.9 N·m (7.0kg-m, 61 in-lb)
PBIC2877E
Electronic Throttle Control Actuator

• Tighten bolts in numerical order as shown.
• Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electronic throttle control actuator is discon-
nected. Refer to EC-464, "Throttle Valve Closed Position
Learning".
• Perform the “Idle Air Volume Learning” and “Throttle Valve Closed
Position Learning” when electronic throttle control actuator is
replaced. Refer to EC-464, "Idle Air Volume Learning".
PBIC2875E

INTAKE MANIFOLD
INTAKE MANIFOLD
A
EM
G
PBIC2878E
1. Intake manifold 2. Gasket

H
REMOVAL I
3. Remove fuel tube and fuel injector assembly. Refer to EM-157, "Removal and Installation". J
4. Loosen nuts and bolts with power tool in reverse order as shown
to remove intake manifold.
K
PBIC2879E
5. Remove gaskets. N
CAUTION:
INSPECTION AFTER REMOVAL O
Surface Distortion
P

INTAKE MANIFOLD
• Check the surface distortion of the intake manifold mating surface
with straightedge and feeler gauge.
Limit : 0.1 mm (0.004 in)

• If it exceeds the limit, replace intake manifold.
PBIC0870E
INSTALLATION
Installation is in the reverse order of removal. Note the following:
Intake Manifold
• If stud bolts were removed from cylinder head, install them and tighten to the specified torque.
Intake manifold studs : 11.0 N·m (1.1kg-m, 8 ft-lb)

• Tighten all nuts and bolts to the specified torque in two or more
steps in numerical order as shown.
Intake manifold bolt and nuts

2nd step and after : 29.0 N·m (3.0 kg-m, 21 ft-lb)
PBIC2879E

A
EM
I
PBIC2880E
1. Exhaust manifold cover (RH) 2. Exhaust manifold (RH) 3. Gasket J

4. Exhaust manifold (LH) 5. Exhaust manifold cover (LH)

K
REMOVAL (LH)
WARNING: L
Perform the work when the exhaust and cooling system have cooled sufficiently.
1. Remove air cleaner case and air duct. Refer to EM-135, "Removal and Installation".
2. Remove the air dam using power tool. M
3. Remove engine undercover using power tool.
4. Disconnect harness connector and remove LH and RH heated
oxygen sensor 2 using Tool. N
Tool number : KV10114400 (J-38365)

CAUTION: O
• Be careful not to damage heated oxygen sensor 2.
• Discard any heated oxygen sensor 2 which has been
dropped from a height of more than 0.5 m (19.70 in) onto a
P
hard surface such as a concrete floor; replace with a new
sensor.
LBIA0446E
5. Remove center exhaust tube, main muffler and left front exhaust tube. Refer to EX-5, "Exploded View".
6. Remove exhaust manifold cover (LH).

7. Disconnect harness connector and remove air fuel ratio sensor
1 (LH) using Tool.
Tool number : KV991J0050 (J-44626)

CAUTION:
• Be careful not to damage air fuel ratio sensor 1.
• Discard any air fuel ratio sensor 1 which has been
dropped from a height of more than 0.5 m (19.7 in) onto a
hard surface such as a concrete floor; replace with a new
sensor.
LBIA0447E
8. Remove three way catalyst LH).

9. Loosen nuts with power tool in reverse order as shown.
NOTE:
Disregard the numerical order No. 7 and 8 in removal.
PBIC2881E
10. Remove gaskets.

CAUTION:
Surface Distortion
• Check the surface distortion of the exhaust manifold mating sur-
face with straightedge and feeler gauge.
Limit : 0.3 mm (0.012 in)

• If it exceeds the limit, replace exhaust manifold.
PBIC1096E
INSTALLATION (LH)
Installation of the remaining components is in the reverse order of removal. Note the following:
Exhaust Manifold Gasket

Install the exhaust manifold gaskets in direction as shown.
A
EM
PBIC2882E
D
Exhaust Manifold
• If stud bolts were removed, install them and tighten to the specified torque.
Exhaust manifold stud torque : 14.7 N·m (1.5 kg-m, 11 ft-lb) E
• Install exhaust manifold and tighten nuts in numerical order as

shown.
CAUTION: F
Use new exhaust manifold nuts for installation.
NOTE:
Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7 G
and 8 show second step.
PBIC2881E L
Heated Oxygen Sensor
CAUTION:
• Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system M
threads using oxygen sensor thread cleaner and apply anti-seize lubricant.
Tool number : — (J-43897-12) N

: — (J-43897 18)
• Do not over torque air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage
to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the “MIL” coming on. O
REMOVAL (RH)
1. Remove engine assembly. Refer to EM-214, "Removal and Installation". P

2. Loosen nuts with power tool in reverse order as shown.
NOTE:
Disregard the numerical order No. 7 and 8 in removal.
PBIC2881E
3. Remove gaskets.
CAUTION:
Surface Distortion
• Check the surface distortion of the exhaust manifold mating sur-
face with straightedge and feeler gauge.
Limit : 0.3 mm (0.012 in)

• If it exceeds the limit, replace exhaust manifold.
PBIC1096E
INSTALLATION (RH)
Installation of the remaining components is in the reverse order of removal. Note the following:
Exhaust Manifold Gasket
Install the exhaust manifold gaskets in direction as shown.
PBIC2882E
Exhaust Manifold
• If stud bolts were removed, install them and tighten to the specified torque.

Exhaust manifold stud torque : 14.7 N·m (1.5 kg-m, 11 ft-lb) A

• Install exhaust manifold and tighten nuts in numerical order as
shown.
CAUTION: EM
Use new exhaust manifold nuts for installation.
NOTE:
Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7
C
and 8 show second step.
PBIC2881E H
Heated Oxygen Sensor

CAUTION: I
• Do not over tighten air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage
to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the “MIL” coming on.
• Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system
threads using oxygen sensor thread cleaner and apply anti-seize lubricant. J
Tool number : — (J-43897-12)

: — (J-43897-18) K

OIL PAN AND OIL STRAINER
PBIC2883E
1. Oil pan (upper) 2. Oil pressure switch 3. O-ring

4. Relief valve 5. O-ring 6. Oil cooler
7. Connector bolt 8. Oil filter 9. Drain plug
10. Drain plug washer 11. Oil pan (lower) 12. Rear cover plate
13. Oil strainer 14 O-ring 15. Oil level gauge guide
16. Oil level gauge
REMOVAL (Lower)
WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
2. Remove oil pan (lower) as follows:

a. Loosen bolts with power tool in reverse order as shown.
A
EM
PBIC2890E
D
b. Remove oil pan (lower) using Tool.
Tool number : KV10111100 (J-37228) E

CAUTION:
• Be careful not to damage the mating surfaces.
• Do not insert screwdriver, this will damage the mating F
surfaces.
NOTE:
Tap (1) Tool to insert it and then slide (2) it by tapping on the side
of the Tool as shown. G
WBIA0566E

Clean oil strainer if any object attached. H
INSTALLATION (Lower)
1. Install oil pan (lower) as follows: I
a. Use scraper to remove old liquid gasket from mating surfaces.
• Also remove old liquid gasket from mating surface of oil pan
(upper). J
• Remove old liquid gasket from the bolt holes and thread.
CAUTION:
ing off old liquid gasket. K
L
PBIC2888E
b. Apply a continuous bead of liquid gasket using Tool to the oil M

pan (lower) as shown.

N
CAUTION:
Attaching should be done within 5 minutes after coating. O
PBIC2889E
P
c. Install oil pan (lower).

PBIC2890E
2. Install oil pan drain plug. Refer to EM-146, "Removal and Installation".
3. After 30 minutes fill with engine oil and inspect for leaks. Refer to LU-22, "Changing Engine Oil".
CAUTION:
Do not fill the engine with oil for at least 30 minutes after oil pan is installed.
1. Check engine oil level and adjust engine oil. Refer to LU-21, "Inspection".
2. Start engine, and check there is no leak of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-21, "Inspection".
REMOVAL (Upper)
WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
CAUTION:
• Perform this procedure when engine is cold.
• Do not spill engine oil on drive belts.
• Do not spill engine coolant on drive belts.
1. Remove engine cover with power tool. Refer to EM-134, "Removal and Installation".
2. Remove air duct. Refer to EM-135, "Removal and Installation".
4. Drain engine coolant. Refer to CO-39, "Changing Engine Coolant".
5. Remove front final drive (4WD models). Refer to DLN-179, "Removal and Installation".
6. Disconnect steering gear lower joint shaft bolt and steering gear nuts and bolts, position out of the way.
Refer to ST-15, "Removal and Installation".
7. Remove starter motor. Refer to STR-37, "Removal and Installation (VQ40DE)".
8. Disconnect A/T fluid cooler tube brackets and position out of the way. Refer to TM-380, "Component".
9. Remove oil filter, as necessary. Refer to LU-24, "Removal and Installation".
10. Remove oil cooler. Refer to LU-25, "Removal and Installation".
11. Remove oil pan (lower). Refer to EM-146, "Removal and Installation".
12. Remove oil strainer.
13. Remove transmission joint bolts which pierce oil pan (upper). Refer to TM-75, "Removal and Installation
from Vehicle (For 2WD Models)" (2WD M/T models), TM-77, "Removal and Installation from Vehicle (For
4WD Models)" (4WD M/T models), TM-384, "Removal and Installation for VQ40DE 2WD Models" (2WD
A/T models), TM-386, "Removal and Installation for VQ40DE 4WD Models" (4WD A/T models).
14. Remove rear cover plate.

15. Loosen bolts with power tool in reverse order as shown.
A
EM
PBIC2887E
D
• Insert Tool between oil pan (upper) and lower cylinder block.
Tap (1) Tool to insert it and then slide (2) it by tapping on the
side as shown. E
Tool number : KV10111100 (J-37228)

CAUTION: F
Be careful not to damage mating surfaces.
G
WBIA0566E
16. Remove O-rings from bottom of lower cylinder block and oil H
pump.
PBIC2885E K
Clean oil strainer if any object attached.
L
INSTALLATION (Upper)
1. Install oil pan (upper) as follows:
a. Use scraper to remove old liquid gasket from mating surfaces. M
• Also remove the old liquid gasket from mating surface of lower
cylinder block.
• Remove old liquid gasket from the bolt holes and threads. N
CAUTION:
ing off old liquid gasket.
O
PBIC2884E P

b. Install new O-rings on the bottom of lower cylinder block and oil
pump.
PBIC2885E
c. Apply a continuous bead of liquid gasket using Tool to the lower

cylinder block mating surfaces of oil pan (upper) as shown.

CAUTION:
• For bolt holes with mark, apply liquid gasket outside
the hole.
• Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 in) in diame-
ter to area “A”. PBIC2886E
• Attaching should be done within 5 minutes after coating.
d. Install oil pan (upper).

CAUTION:
Install avoiding misalignment of both oil pan gaskets and O-rings.
• There are two types of bolts.
M8 × 100 mm (3.97 in) : 7, 11, 12, 13

M8 × 25 mm (0.98 in) : Except the above
PBIC2887E
e. Tighten transmission joint bolts. Refer to TM-75, "Removal and Installation from Vehicle (For 2WD Mod-
els)" (2WD M/T models), TM-77, "Removal and Installation from Vehicle (For 4WD Models)" (4WD M/T
models), TM-384, "Removal and Installation for VQ40DE 2WD Models" (2WD A/T models), TM-386,
"Removal and Installation for VQ40DE 4WD Models" (4WD A/T models).
2. Install oil strainer to oil pan (upper).
1. Check engine oil level and adjust engine oil. Refer to LU-21, "Inspection".
2. Start engine, and check there is no leak of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-21, "Inspection".

IGNITION COIL
IGNITION COIL
A
EM
G
PBIC2901E
1. Ignition coil 2. Spark plug

H
REMOVAL (LH) I
1. Remove engine room cover using power tool. Refer to EM-134, "Removal and Installation".
2. Remove air cleaner case and air duct. Refer to EM-135, "Removal and Installation".
3. Move aside harness, harness bracket, and hoses located above ignition coil. J
K
CAUTION:
Do not shock ignition coil.
INSTALLATION (LH) L
REMOVAL (RH)
1. Remove intake manifold collector with power tool. Refer to EM-136, "Removal and Installation". M
2. Move aside harness, harness bracket, and hoses located above ignition coil.
N
CAUTION:
Do not shock ignition coil.
O
INSTALLATION (RH)
P

ROCKER COVER
ROCKER COVER
PBIC2905E
1. Oil filler cap 2. PCV hose 3. PCV valve

4. O-ring 5. Rocker cover (RH) 6. PCV hose
7. Rocker cover gasket (RH) 8. Rocker cover gasket (LH) 9. Rocker cover (LH)
10. PCV hose
REMOVAL (LH)
2. Separate engine harness removing their brackets from rocker covers.
3. Remove harness bracket from cylinder head, if necessary.
4. Remove ignition coils. Refer to EM-151, "Removal and Installation".
5. Remove PCV hoses from rocker covers.
6. Remove oil filler cap from rocker cover (LH), if necessary.

ROCKER COVER
A
EM
G
PBIC2906E
8. Remove rocker cover gaskets from rocker covers.

H
CAUTION:
I
INSTALLATION (LH)
1. Apply liquid gasket using Tool to joint part among rocker cover,
cylinder head and camshaft bracket (No. 1) as follows: J
Use Genuine RTV Silicone Sealant or equivalent. Refer to K
NOTE:
The figure shows an example of LH side [zoomed in shows
camshaft bracket (No. 1)]. L
a. Apply liquid gasket to joint part of camshaft bracket "a" (No. 1)
and cylinder head.
b. Apply liquid gasket "b" to the figure “a” squarely. M
PBIC2474E
P

• Check to be sure rocker cover gasket is not dropped from installation groove of rocker cover.

ROCKER COVER
4. Tighten bolts in two steps in numerical order as shown.

PBIC2906E
5. Install oil filer cap to rocker cover (LH), if removed.

6. Install PCV hose.
• Insert PCV hose by 25 to 30 mm (0.98 to 1.18 in) from connector end.
• When installing, be careful not to twist or come in contact with other parts.
REMOVAL (RH)
CAUTION:
Perform this step when engine is cold.
3. Separate engine harness removing their brackets from rocker covers.
4. Remove harness bracket from cylinder head (RH). Refer to EM-204, "Removal and Installation".
5. Remove ignition coils. Refer to EM-151, "Removal and Installation".
6. Remove PCV hoses from rocker cover.
7. Remove PCV valve and O-ring from rocker cover (RH), if necessary.

ROCKER COVER
A
EM
G
PBIC2906E
9. Remove rocker cover gaskets from rocker covers.

H
CAUTION:
I
INSTALLATION (RH)
1. Apply liquid gasket using Tool to joint part among rocker cover,
cylinder head and camshaft bracket (No. 1) as follows: J
Use Genuine RTV Silicone Sealant or equivalent. Refer to K
NOTE:
The figure shows an example of LH side [zoomed in shows
camshaft bracket (No. 1)]. L
a. Apply liquid gasket to joint part of camshaft bracket "a" (No. 1)
and cylinder head.
b. Apply liquid gasket "b" to the figure “a” squarely. M
PBIC2474E
P

• Check to be sure rocker cover gasket is not dropped from installation groove of rocker cover.

ROCKER COVER
4. Tighten bolts in two steps in numerical order as shown.

PBIC2906E
5. Install new O-ring and PCV valve to rocker cover (RH), if removed.
6. Install PCV hose.
• Insert PCV hose by 25 to 30 mm (0.98 to 1.18 in) from connector end.
• When installing, be careful not to twist or come in contact with other parts.

A
EM
J
PBIC2957E
1. Fuel tube (RH) 2. O-ring 3. Fuel tube (LH) K

4. Clip 5. O-ring (blue) 6. Fuel injector
7. O-ring (brown) 8. O-ring 9. Spacer
10. Fuel damper 11. Fuel damper cap 12. Quick connector cap L
13. Fuel feed hose
Removal and Installation INFOID:0000000003220207 M
REMOVAL
WARNING: N
• 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. O
• To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
CAUTION:
Perform this step when engine is cold. P

2. Disconnect the fuel quick connector on the engine side.
a. Remove quick connector cap.
LBIA0090E
b. With the sleeve side of Tool facing quick connector, install Tool
onto fuel tube.

c. Insert Tool into quick connector until sleeve contacts and goes
no further. Hold the Tool on that position.
CAUTION:
Inserting the Tool hard will not disconnect quick connector.
Hold Tool where it contacts and goes no further.
d. Pull the quick connector straight out from the fuel tube. WBIA0295E
CAUTION:
• Pull quick connector holding it at the ″A″ position, as shown.
• Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth beforehand as fuel will leak out.
• Avoid fire and sparks.
• Be sure to cover openings of disconnected pipes with
plug or plastic bag to avoid fuel leakage and entry of for-
eign materials.
PBIC1899E
3. Remove PCV hose between rocker covers (right and left banks).
4. Disconnect harness connector from fuel injector.
5. Loosen bolts in reverse order as shown, and remove fuel tube
and fuel injector assembly.
CAUTION:
Do not tilt it, or remaining fuel in pipes may flow out from
pipes.
PBIC2902E
6. Remove bolts which connects fuel tube (RH) and fuel tube (LH).

7. Remove fuel injector from fuel tube as follows:
a. Carefully open and remove clip. A
b. Remove fuel injector from fuel tube by pulling straight.
CAUTION:
• Be careful with remaining fuel that may leak out from fuel EM
tube.
• Be careful not to damage injector nozzles during removal.
• Do not bump or drop fuel injectors.
C
• Do not disassemble fuel injectors.
G
PBIC2999E
8. Disconnect fuel tube (RH) from fuel tube (LH).

H
9. Loosen bolts, to remove fuel damper cap and fuel damper, if necessary.
INSTALLATION
1. Install fuel damper as follows: I
a. Install new O-ring to fuel tube as shown.
• When handling new O-rings, be careful of the following cau-
tion: J
CAUTION:
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate new O-ring with new engine oil.
• Do not clean O-ring with solvent. K
• Make sure that O-ring and its mating part are free of for-
eign material.
• When installing O-ring, do not scratch it with tool or fin- L
gernails. Also be careful not to twist or stretch O-ring. If
O-ring was stretched while it was being attached, allow
it to retract before inserting it into fuel tube.
• Insert new O-ring straight into fuel tube. Do not twist it. M
b. Install spacer to fuel damper.
c. Insert fuel damper straight into fuel tube.
N
CAUTION:
• Insert straight, making sure that the axis is lined up.
• Do not pressure-fit with excessive force.
O
Reference value : 130 N (13.3 kg, 29.2 lb)
PBIC2903E
• Insert fuel damper until “B” is touching “A” of fuel tube.

P
d. Tighten bolts evenly in turn.
• After tightening bolts, make sure that there is no gap between fuel damper cap and fuel tube.
2. Install new O-rings to fuel injector, paying attention to the following.
CAUTION:
• Upper and lower O-ring are different colors.

Fuel tube side : Blue

Nozzle side : Brown
• Handle O-ring with bare hands. Never 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, allow it to retract
before inserting it into fuel tube.
• Insert O-ring straight into fuel injector. Do not twist it.
3. Install fuel injector to fuel tube as follows:
a. Insert clip into clip mounting groove on fuel injector.
• Insert clip so that protrusion of fuel injector matches cutout of
clip.
CAUTION:
• Do not reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion of fuel tube matches cut-
out of clip.
• Make sure that fuel tube flange is securely fixed in flange fixing
groove on clip.
c. Make sure that installation is complete by checking that fuel
injector does not rotate or come off.
• Make sure that protrusions of fuel injectors are aligned with
cutouts of clips after installation.
PBIC3000E
4. Connect fuel tube (RH) to fuel tube (LH), and tighten bolts temporarily.
• Tighten bolts with the specified torque after installing fuel tube and fuel injector assembly.
CAUTION:
• 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, allow it to retract
before inserting it into fuel tube.
• Insert new O-ring straight into fuel tube. Do not twist it.
5. Install fuel tube and fuel injector assembly to intake manifold.
CAUTION:
Do not let the tip of the injector nozzle come in contact with other parts.

• Tighten bolts in two steps in numerical order as shown.
A
Fuel injector tube assembly bolts
1st step : 10.1 N·m (1.0 kg-m, 7 ft-lb)
2nd step : 22.0 N·m (2.2 kg-m, 16 ft-lb) EM
PBIC2902E
D
6. Tighten bolts which connects fuel tube (RH) and fuel tube (LH) with the specified torque.
7. Connect fuel injector harness connector.
8. Install intake manifold collector. Refer to EM-136, "Removal and Installation". E
F
Check on Fuel Leakage
1. Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points. G
NOTE:
Use mirrors for checking at points out of clear sight.
2. Start engine. With engine speed increased, check again for fuel leakage at connection points.
H
CAUTION:
Do not touch engine immediately after stopping, as engine becomes extremely hot.

FRONT TIMING CHAIN CASE
AWBIA0272GB
1. Timing chain tensioner (secondary) (LH) 2. Internal chain guide 3. Timing chain tensioner (secondary) (RH)
4. Camshaft sprocket (EXH) 5. Timing chain (secondary) 6. Timing chain (primary)
7. Camshaft sprocket (INT) 8. Camshaft sprocket (INT) 9. Slack guide

10. Timing chain tensioner (primary) 11. Crankshaft sprocket 12. Collared O-ring
13. O-ring 14. Intake valve timing control cover 15. Idler pulley A
16. Drive belt auto tensioner 17. Cooling fan bracket 18. Crankshaft pulley
19. Front oil seal 20. Water pump cover 21. Chain tensioner cover
22. Front timing chain case 23. Rear timing chain case 24. Water drain plug (front) EM
25. Tension guide 26. O-ring A. Refer to EM-163
Removal and Installation INFOID:0000000003220209 C
NOTE:
• This section describes removal/installation procedure of front timing chain case and timing chain related
parts without removing oil pan (upper) on vehicle. D
• When oil pan (upper) needs to be removed or installed, or when rear timing chain case is removed or
installed, remove oil pans (upper and lower) first. Then remove front timing chain case, timing chain related
parts, and rear timing chain case in this order, and installation is in the reverse order of removal. Refer to E
EM-173.
REMOVAL
1. Remove engine room cover with power tool. Refer to EM-134, "Removal and Installation". F
2. Release the fuel pressure. Refer to EC-928, "Fuel Pressure Check".
CAUTION: G
4. Drain engine coolant from radiator. Refer to CO-39, "Changing Engine Coolant". H
CAUTION:
• Do not spill engine coolant on drive belts. I
5. Remove radiator cooling fan assembly. Refer to CO-47, "Removal and Installation (Motor driven type)".
6. Separate engine harnesses removing their brackets from front timing chain case.
7. Remove drive belts. Refer to EM-123, "Removal and Installation". J
8. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
9. Remove power steering oil pump bracket. Refer to ST-17, "Component". K
10. Remove generator. Refer to CHG-22, "Removal and Installation - VQ40DE Models".
11. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
L
12. Remove right and left intake valve timing control covers.
• Loosen bolts in reverse order as shown.
• Cut liquid gasket for removal using Tool.
M
Tool number : KV10111100 (J-37228)
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) cen- N
ter hole. When removing, keep it horizontal until it is com-
pletely disconnected.
O
SEM728G

13. Remove collared O-rings from front timing chain case (left and
right side).
PBIC2631E
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed.
15. 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.
• If not, turn crankshaft one revolution (360°) and align as
shown.
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
its compression TDC, remove front timing chain case first. Then
check mating marks on camshaft sprockets. Refer to EM-173,
SEM418G
16. Remove crankshaft pulley as follows:

a. Remove starter motor and set Tool. Refer to STR-37, "Removal
and Installation (VQ40DE)".
Tool number : KV10117700 (J-44716)
WBIA0580E

b. Loosen crankshaft pulley bolt and locate bolt seating surface as
10 mm (0.39 in) from its original position. A
CAUTION:
Do not remove crankshaft pulley bolt. Keep loosened
crankshaft pulley bolt in place to protect the crankshaft pul-
EM
ley from dropping.
PBIC2918E
D
c. Pull crankshaft pulley with both hands to remove it.
17. Loosen two bolts in front of oil pan (upper) in reverse order as
shown. E
PBIC2907E
H
18. Remove front timing chain case as follows:
I
PBIC2908E
L
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).
• Cut liquid gasket for removal using Tool. M
Tool number : KV10111100 (J-37228)

N
CAUTION:
• Do not use screwdriver or something similar.
• After removal, handle front timing chain case carefully so
it does not twist, bend, or warp under a load. O
SEM156F

19. Remove O-rings from rear timing chain case.
PBIC2548E
20. Remove water pump cover and chain tensioner cover from front timing chain case, if necessary.
Tool number : KV10111100 (J-37228)

21. Remove front oil seal from front timing chain case using suitable
tool.
CAUTION:
Be careful not to damage front timing chain case.
PBIC2909E
22. Remove timing chain and related parts. Refer to EM-173, "Removal and Installation".
23. Use a scraper to remove all traces of old liquid gasket from front
and rear timing chain cases and oil pan (upper), and liquid gas-
ket mating surfaces.
CAUTION:
Be careful not to allow gasket fragments to enter oil pan.
PBIC2910E
• Remove old liquid gasket from bolt hole and thread.
PBIC2084E

24. Use a scraper to remove all traces of old liquid gasket from
water pump cover, chain tensioner cover and intake valve timing A
control covers.
EM
SEM926E
D
INSTALLATION
1. Hammer dowel pins (right and left) into front timing chain case
up to a point close to taper in order to shorten protrusion length.
E
PBIC2615E
H
2. Install new front oil seal on the front timing chain case.
• Apply new engine oil to both oil seal lip and dust seal lip.
• Install it so that each seal lip is oriented as shown.
I
SEM715A
L
• Press-fit oil seal until it becomes flush with front timing chain
case end face using suitable drift [outer diameter: 60 mm (2.36
in)]. M
• Make sure the garter spring is in position and seal lip is not
inverted.
N
O
PBIC2911E
3. Install water pump cover and chain tensioner cover to front timing chain case, if removed. P

• Apply a continuous bead of liquid gasket using Tool to front
timing chain case as shown.

PBIC2912E
4. Install front timing chain case as follows:

a. Apply a continuous bead of liquid gasket using Tool to front timing chain case back side as shown.

PBIC2913E
b. Install new O-rings on rear timing chain case.

c. Assemble front timing chain case as follows:
PBIC2548E

i. Fit lower end of front timing chain case tightly onto top face of oil
pan (upper). From the fitting point, make entire front timing chain A
case contact rear timing chain case completely.
EM
PBIC1100E
D
ii. Since front timing chain case is offset for difference of bolt holes,
tighten bolts temporarily while holding front timing chain case
from front and top as shown.
E
iii. Same as the previous step, insert dowel pin while holding front
timing chain case from front and top completely.
F
G
PBIC2915E
d. Tighten bolts to the specified torque in numerical order as

H
shown.
e. After all bolts are tightened, retighten them to the specified
• There are four type of bolts. I
Bolt position Bolt diameter

1-5 : 10 mm (0.39 in) J
6 – 25 : 6 mm (0.24 in)
PBIC2908E
K
Bolt position Tightening specification
1-5 : 55.0 N·m (5.6 kg-m, 41 ft-lb)
6 – 25 : 12.7 N·m (1.3 kg-m, 9 ft-lb) L
5. Install two bolts in front of oil pan (upper) in numerical order as

shown.
M
Front oil pan bolt torque : 22.0 N·m (2.2 kg-m, 16 ft-lb)
PBIC2907E
6. Install right and left intake valve timing control covers as follows: P
a. Install new seal rings in shaft grooves.

b. Apply a continuous bead of liquid gasket using Tool to intake
valve timing control covers as shown.

SBIA0492E
c. Install new collared O-rings in front timing chain case oil hole
(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.
e. Tighten bolts in numerical order as shown.
PBIC0918E
7. Install crankshaft pulley as follows:

a. 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).
b. Tighten crankshaft pulley bolt in two steps.
Step 1 : 44.1 N·m (4.5 kg-m, 33 ft-lb)

Step 2 :84° - 90° degrees clockwise
c. Remove Tool.
Tool number : KV10117700 (J-44716)
WBIA0580E

8. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns
smoothly. A
9. Installation of the remaining components is in the reverse order of removal after this step.
EM
The following are procedures for checking fluid leaks, lubricant leaks and exhaust gases leaks.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
C
quantity, fill to the specified level. Refer to MA-12, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
age at connection points. D
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE: E
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 includ- F
ing engine oil and engine coolant.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the G
specified level, if necessary.
Item Before starting engine Engine running After engine stopped H
Other oils and fluid* Level Leakage Level I
* Transmission fluid, power steering fluid, brake fluid, etc.
J

TIMING CHAIN
TIMING CHAIN
AWBIA0272GB
1. Timing chain tensioner (secondary) (LH) 2. Internal chain guide 3. Timing chain tensioner (secondary) (RH)
4. Camshaft sprocket (EXH) 5. Timing chain (secondary) 6. Timing chain (primary)
7. Camshaft sprocket (INT) 8. Camshaft sprocket (INT) 9. Slack guide

TIMING CHAIN
10. Timing chain tensioner (primary) 11. Crankshaft sprocket 12. Collared O-ring
13. O-ring 14. Intake valve timing control cover 15. Idler pulley A
16. Drive belt auto tensioner 17. Cooling fan bracket 18. Crankshaft pulley
19. Front oil seal 20. Water pump cover 21. Chain tensioner cover
22. Front timing chain case 23. Rear timing chain case 24. Water drain plug (front) EM
25. Tension guide 26. O-ring A. Refer to EM-173
Removal and Installation INFOID:0000000003220211 C
NOTE:
• This section describes procedures for removing/installing front timing chain case and timing chain related
parts, and rear timing chain case, when oil pan (upper) needs to be removed/installed for engine overhaul, D
etc.
• To remove/install front timing chain case, timing chain, and its related parts without removing oil pan (upper),
refer to EM-163. E
REMOVAL
F
2. Release the fuel pressure. Refer to EC-928, "Fuel Pressure Check".
CAUTION:
• Perform this step when engine is cold. G
4. Drain engine coolant from radiator. Refer to CO-39, "Changing Engine Coolant".
CAUTION: H
• Do not spill engine coolant on drive belts.
5. Remove radiator cooling fan assembly. Refer to CO-47, "Removal and Installation (Motor driven type)". I
6. Separate engine harnesses removing their brackets from front timing chain case.
7. Remove drive belts. Refer to EM-123, "Removal and Installation".
8. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside. J
9. Remove power steering oil pump bracket. Refer to ST-17, "Component".
K
11. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
12. Remove right and left intake valve timing control covers. L
• Loosen bolts in reverse order as shown.
Tool number : KV10111100 (J-37228) M
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) cen-
ter hole. When removing, keep it horizontal until it is com- N
pletely disconnected.
O
SEM728G

TIMING CHAIN
13. Remove collared O-rings from front timing chain case (left and
right side).
PBIC2631E
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed.
15. 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.
• If not, turn crankshaft one revolution (360°) and align as
shown.
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
its compression TDC, remove front timing chain case first. Then
check mating marks on camshaft sprockets. Refer to EM-193,
SEM418G
16. Remove crankshaft pulley as follows:

a. Remove starter motor and set Tool. Refer to STR-37, "Removal
and Installation (VQ40DE)".
Tool number : KV10117700 (J-44716)
WBIA0580E

TIMING CHAIN
b. Loosen crankshaft pulley bolt and locate bolt seating surface as
10 mm (0.39 in) from its original position. A
CAUTION:
Do not remove crankshaft pulley bolt. Keep loosened
crankshaft pulley bolt in place to keep crankshaft pulley
EM
from dropping.
PBIC2918E
D
c. Pull crankshaft pulley with both hands to remove it.
17. Loosen two bolts in front of oil pan (upper) in reverse order as
shown. E
PBIC2907E
H
18. Remove front timing chain case as follows:
I
PBIC2908E
L
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).
• Cut liquid gasket for removal using Tool. M
Tool number : KV10111100 (J-37228)

N
CAUTION:
• Do not use screwdriver or something similar.
• After removal, handle front timing chain case carefully so
it does not twist, bend, or warp under a load. O
SEM156F

TIMING CHAIN
19. Remove O-rings from rear timing chain case.
PBIC2548E
20. Remove water pump cover and chain tensioner cover from front timing chain case, if necessary.
21. Remove front oil seal from front timing chain case using suitable
tool.
CAUTION:
Be careful not to damage front timing chain case.
PBIC2909E
22. Use a scraper to remove all traces of old liquid gasket from front
and rear timing chain cases and oil pan (upper), and liquid gas-
ket mating surfaces.
CAUTION:
Be careful not to allow gasket fragments to enter oil pan.
PBIC2910E
PBIC2084E

TIMING CHAIN
23. Use a scraper to remove all traces of old liquid gasket from
water pump cover, chain tensioner cover and intake valve timing A
control covers.
EM
SEM926E
D
24. Remove timing chain tensioner (primary) as follows:
a. Loosen clip of timing chain tensioner (primary), and release
plunger stopper (1). E
b. Insert plunger into tensioner body by pressing slack guide (2).
c. Keep slack guide pressed and hold plunger in by pushing stop-
per pin through the tensioner body hole and plunger groove (3). F
PBIC2919E
H
d. Remove bolts and remove timing chain tensioner (primary).
25. Remove internal chain guide, tension guide and slack guide.
NOTE: I
Tension guide can be removed after removing timing chain (pri-
mary).
PBIC2266E
O
26. Remove timing chain (primary) and crankshaft sprocket.

CAUTION: P
After removing timing chain (primary), do not turn crankshaft and camshaft separately, or valves
will strike the piston heads.
27. Remove timing chain (secondary) and camshaft sprockets as follows:

TIMING CHAIN
a. Attach suitable stopper pin to the right and left timing chain ten-
sioners (secondary).
NOTE:
• Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a
stopper pin.
• For removal of timing chain tensioner (secondary), refer to
EM-193. [Removing camshaft bracket (No. 1) is required.]
PBIC2047E
b. Remove camshaft sprocket (INT and EXH) bolts.

• Secure the hexagonal portion of camshaft using wrench to
loosen bolts.
CAUTION:
Do not loosen bolts by securing anything other than the
camshaft hexagonal portion.
KBIA1698J
c. Remove timing chain (secondary) together with camshaft sprockets.

• Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.
• Insert 0.5 mm (0.020 in)-thick metal or resin plate between tim-
ing chain and timing chain tensioner plunger (guide). Remove
timing chain (secondary) together with camshaft sprockets
with timing chain loose from guide groove.
CAUTION:
Be careful of plunger coming off when removing timing
chain (secondary).
NOTE:
Camshaft sprocket (INT) is a one piece integrated design
sprockets for timing chain (primary) and for timing chain (sec-
ondary).
PBIC1978E
• When handling camshaft sprocket (INT), be careful of the fol-
lowing:
CAUTION:
• Handle carefully to avoid any shock to camshaft
sprocket.
• Do not disassemble. (Do not loosen bolts (A) as shown).
PBIC2920E
28. Remove water pump. Refer to CO-49, "Removal and Installation".
29. Remove rear timing chain case as follows:

TIMING CHAIN
a. Loosen and remove bolts using power tool in reverse order as
shown. A
b. Cut liquid gasket using Tool and remove rear timing chain case.
Tool number : KV10111100 (J-37228) EM
PBIC2921E
D
CAUTION:
• Do not remove plate metal cover of oil passage.
• After removal, handle rear timing chain case carefully so E
it does not twist, bend, or warp under a load.
PBIC2922E
H
30. Remove O-rings from cylinder head and camshaft bracket (No.
1).
I
K
SBIA0496E
31. Remove O-rings from cylinder block.

L
PBIC0788E
O
32. Remove timing chain tensioners (secondary) from cylinder head if necessary.
a. Remove camshaft brackets (No. 1). Refer to EM-193, "Removal and Installation".
b. Remove timing chain tensioners (secondary) with stopper pin attached. P

TIMING CHAIN
33. Use scraper to remove all traces of old liquid gasket from front
and rear timing chain cases, and opposite mating surfaces.
PBIC2910E
PBIC2084E
34. Use scraper to remove all traces of liquid gasket from water
pump cover, chain tensioner cover and intake valve timing con-
trol covers.
SEM926E

Check for cracks and any excessive wear at link plates. Replace
chain if necessary.
• In the same way as for the LH bank, inspect the timing chain and
associated parts on the RH bank.
PBIC0282E

TIMING CHAIN
INSTALLATION
A
EM
H
WBIA0716E
1. Internal chain guide 2. Camshaft sprocket (intake) 3. Mating mark (copper link)
4. Mating mark (punched) 5. Secondary timing chain tensioner 6. Mating mark (yellow link) I
7. Secondary timing chain 8. Camshaft sprocket (exhaust) 9. Tensioner guide
10. Water pump 11. Crankshaft sprocket 12. Mating mark (notched)
13. Primary timing chain 14. Slack guide 15. Primary timing chain tensioner J
16. Mating mark (back side) 17. Crankshaft key
NOTE: K
The figure above shows the relationship between the mating mark on each timing chain and that on the corre-
sponding sprocket, with the components installed.
1. Install timing chain tensioners (secondary) to cylinder head if removed.
L
a. Install timing chain tensioners (secondary) with stopper pin attached and new O-ring.
b. Install camshaft brackets (No. 1). Refer to EM-193, "Removal and Installation".
2. Install rear timing chain case as follows: M
a. Install new O-rings onto cylinder block.
P
PBIC0788E

TIMING CHAIN
b. Install new O-rings to cylinder head and camshaft bracket
(No. 1).
SBIA0496E
c. Apply liquid gasket using Tool to rear timing chain case back side as shown.

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-26, "Recommended Chemical Prod-
ucts and Sealants".
CAUTION:
• For “A”, completely wipe off liquid gasket covering the area shown.
• Apply liquid gasket on installation position of water pump and cylinder head very completely.
PBIC2924E
d. Align rear timing chain case 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, cylinder head and camshaft bracket
(No. 1).

TIMING CHAIN
• There are two type of bolts. A
Bolt length: Bolt position

20 mm (0.79 in) : 1, 2, 3, 6, 7, 8, 9, 10 EM
16 mm (0.63 in) : Except the above
C
Rear timing case bolt : 12.7 N·m (1.3 kg-m, 9 ft-lb)
torque
PBIC2921E
f. After all bolts are tightened, retighten them to the specified D
• If liquid gasket protrudes, wipe it off immediately.
g. After installing rear timing chain case, check the surface height E
difference between following parts on oil pan (upper) mounting
surface.
F
Standard
Rear timing chain case to lower cylinder block:
–0.24 to 0.14 mm (–0.0094 to 0.0055 in) G
• If not within the standard, repeat the installation procedure.
PBIC2925E
H
3. Install water pump with new O-rings. Refer to CO-49, "Removal and Installation".
4. Make sure that dowel pin hole, dowel pin of camshaft and crank- I
shaft key are located as shown. (No. 1 cylinder at compression
TDC)
• NOTE: J
Though camshaft does not stop at the position as shown, for
the placement of cam nose, it is generally accepted camshaft
is placed for the same direction of the figure.
K
Camshaft dowel pin hole (intake side)
: At cylinder head upper face side in each bank.
L
Camshaft dowel pin (exhaust side) KBIA1073E
: At cylinder head upper face side in each bank.

Crankshaft key M
: At cylinder head side of right bank.
CAUTION:
Hole on small dia. side must be used for intake side dowel pin hole. Do not misidentify (ignore big N
dia. side).
5. Install timing chains (secondary) and camshaft sprockets as follows:
CAUTION: O
Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions
repeatedly during the installation process.
P

TIMING CHAIN
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with stopper pin.
SEM430G
b. Install timing chains (secondary) and camshaft sprockets (INT

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

Left bank : Use oval type.
• Align dowel pin and pin hole on camshafts with the groove and
dowel pin on sprockets, and install them.
• On the intake side, align pin hole on the small diameter side of
the camshaft front end with dowel pin on the back side of cam-
shaft sprocket, and install them.
• On the exhaust side, align dowel pin on camshaft front end
with pin groove on camshaft sprocket, and install them.
• In case that positions of each mating mark and each dowel pin
PBIC2926E
are not fit on mating parts, make fine adjustment to the posi-
tion holding the hexagonal portion on camshaft with wrench or equivalent.
• Bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to
prevent the dislocation of dowel pins.
• It may be difficult to visually check the dislocation of mating
marks during and after installation. To make the matching eas-
ier, make a mating mark on the top of sprocket teeth and its
extended line in advance with paint.
PBIC2927E

TIMING CHAIN
c. After confirming the mating marks are aligned, tighten camshaft
sprocket bolts. A
• Secure camshaft using wrench at the hexagonal portion to
tighten bolts.
EM
KBIA1698J
D
d. Pull stopper pins out from timing chain tensioners (secondary).
G
PBIC2110E
6. Install tension guide.

H
7. Install timing chain (primary) as follows:
a. Install crankshaft sprocket.
• Make sure the mating marks on crankshaft sprocket face the I
front of engine.
SEM929E

TIMING CHAIN
b. Install the primary timing chain.
• Water pump (G).
• Install primary timing chain so the mating mark punched (B) on
camshaft sprocket is aligned with the copper link (A) on the
timing chain, while the mating mark notched (E) on the crank-
shaft sprocket (D) is aligned with the yellow link (F) on the tim-
ing chain, as shown.
• When it is difficult to align mating marks (A) with (B) and (E)
with (F) of the primary timing chain with each sprocket, gradu-
ally turn the camshaft using a wrench on the hexagonal por-
tion to align it with the mating marks.
• During alignment, be careful to prevent dislocation of mating
mark alignments of the secondary timing chains.
WBIA0721E
8. Install internal chain guide, slack guide and timing chain ten-
sioner (primary).
PBIC2109E
CAUTION:

TIMING CHAIN
Do not overtighten slack guide bolts. It is normal for a gap
to exist under the bolt seats when bolts are tightened to A
specification.
EM
PBIC2633E
D
• When installing timing chain tensioner (primary), push in plunger and keep it pressed in with stopper pin.
• Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing
chain tensioner (primary). E
• After installation, pull out stopper pin.
9. Make sure again that the mating marks on camshaft sprockets and timing chain have not slipped out of
alignment. F
10. Install new O-rings on rear timing chain case.
G
PBIC2548E
11. Install new front oil seal on front timing chain case. J
• Apply new engine oil to both oil seal lip and dust seal lip.
• Install it so that each seal lip is oriented as shown.
K
SEM715A

TIMING CHAIN
• Press-fit oil seal until it becomes flush with front timing chain
case end face using suitable drift [outer diameter: 60 mm (2.36
in)].
• Make sure the garter spring is in position and seal lip is not
inverted.
PBIC2911E
12. Install water pump cover and chain tensioner cover to front timing chain case.
• Apply a continuous bead of liquid gasket using Tool to front
timing chain case as shown.

PBIC2912E
13. Install front timing chain case as follows:

a. Apply a continuous bead of liquid gasket using Tool to front tim-
ing chain case back side as shown.

PBIC2913E

TIMING CHAIN
b. Install new O-rings on rear timing chain case.
c. Assemble front timing chain case as follows: A
EM
PBIC2548E
i.
D
Fit lower end of front timing chain case tightly onto top face of oil
pan (upper). From the fitting point, make entire front timing chain
case contact rear timing chain case completely.
E
G
PBIC1100E
ii. Since front timing chain case is offset for difference of bolt holes,
H
tighten bolts temporarily while holding front timing chain case
from front and top as shown.
iii. Same as the previous step, insert dowel pin while holding front
timing chain case from front and top completely. I
PBIC2915E
K
d. Tighten bolts to the specified torque in numerical order as
shown.
e. After all bolts tightened, retighten them to the specified torque in L
numerical order as shown.
Bolt position Bolt diameter M

1-5 : 10 mm (0.39 in)
6 – 25 : 6 mm (0.24 in)
N
Bolt position Tightening specification PBIC2908E
1-5 : 55.0 N·m (5.6 kg-m, 41 ft-lb) O

6 – 25 : 12.7 N·m (1.3 kg-m, 9 ft-lb)

TIMING CHAIN
14. Install two bolts in front of oil pan (upper) in numerical order as
shown.
Front oil pan bolt torque : 22.0 N·m (2.2 kg-m, 16 ft-lb)
PBIC2907E
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 using Tool to intake
valve timing control covers as shown.

SBIA0492E
c. Install new collared O-rings in front timing chain case oil hole
(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
16. Install crankshaft pulley as follows:

a. 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).
b. Tighten crankshaft pulley bolt in two steps.

TIMING CHAIN
Step 1 : 44.1 N·m (4.5 kg-m, 33 ft-lb) A

Step 2 :84° - 90° degrees clockwise
c. Remove Tool. EM
Tool number : KV10117700 (J-44716)
C
WBIA0580E
E
17. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns
smoothly.
18. Install oil pans (upper and lower). Refer to EM-146, "Removal and Installation". F
19. Install rocker covers (right and left banks). Refer to EM-152, "Removal and Installation".
20. Installation of the remaining components is in the reverse order of removal after this step.
G
Inspection for Leaks H
• Use procedure below to check for fuel leakage. I
• Start engine. With engine speed increased, check again for fuel leakage at connection points. J
NOTE:
K
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids includ-
ing engine oil and engine coolant. L
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary. M
Engine coolant Level Leakage Level N
O

CAMSHAFT
CAMSHAFT
PBIC2930E
Intake valve timing control solenoid

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

CAMSHAFT
A
REMOVAL
1. Remove front timing chain case, camshaft sprocket, timing chain and rear timing chain case. Refer to EM-
173, "Removal and Installation". EM
2. Remove camshaft position sensor (PHASE) (right and left
banks) from cylinder head back side.
CAUTION: C
• Handle carefully to avoid dropping and shocks.
• Do not allow metal powder to adhere to magnetic part at D
sensor tip.
• Do not place sensors in a location where they are
exposed to magnetism.
E
KBIA1046E
3. Remove intake valve timing control solenoid valves. F

• Discard intake valve timing control solenoid valve gaskets and
use new gaskets for installation.
G
SEM443GA
I
4. Remove camshaft brackets.

• Mark camshafts, camshaft brackets and bolts so they are placed in the same position and direction for J
installation.
• Equally loosen camshaft bracket bolts in several steps in
reverse order as shown.
K
PBIC2050E
5. Remove camshafts.
6. Remove valve lifters.
CAMSHAFT
7. Remove timing chain tensioner (secondary) from cylinder head.
• Remove timing chain tensioner (secondary) with its stopper
pin attached.
NOTE:
Stopper pin was attached when timing chain (secondary) was
removed.
PBIC2111E

Camshaft Runout
1. Put V-block on precise flat table, and support No. 2 and 4 journal
of camshaft.
CAUTION:
Do not support journal No. 1 (on the side of camshaft
sprocket) because it has a different diameter from the other
three locations.
2. Set dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on dial indicator. (Total indicator reading)
PBIC0929E
Standard : Less than 0.02 mm (0.0008 in)
Limit : 0.05 mm (0.0020 in)
4. If it exceeds the limit, replace camshaft.
Camshaft Cam Height
1. Measure the camshaft cam height with micrometer.
Standard:
Intake : 45.465 - 45.655 mm (1.7900 - 1.7974 in)
Exhaust : 45.075 - 45.265 mm (1.7746 - 1.7821 in)
Limit:
Intake : 45.265 mm (1.7821 in)
Exhaust : 44.875 mm (1.7667 in)
2. If wear exceeds the limit, replace camshaft. EMQ0072D
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL DIAMETER

• Measure the outer diameter of camshaft journal with micrometer.
Standard:
No. 1 : 25.935 - 25.955 mm (1.0211 - 1.0218 in)
No. 2, 3, 4 : 23.445 - 23.465 mm (0.9230 - 0.9238 in)
PBIC0040E
CAMSHAFT BRACKET INNER DIAMETER

• Tighten camshaft bracket bolt with the specified torque.
CAMSHAFT
• Measure the inner diameter “A” of camshaft bracket with bore
gauge. A
Standard:
No. 1 : 26.000 - 26.021 mm (1.0236 - 1.0244 in) EM
No. 2, 3, 4 : 23.500 - 23.521 mm (0.9252 - 0.9260 in)
PBIC1645E
D
CAMSHAFT JOURNAL OIL CLEARANCE
• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter).
E
Standard:
No. 1 : 0.045 - 0.086 mm (0.0018 - 0.0034 in)
No. 2, 3, 4 : 0.035 - 0.076 mm (0.0014 - 0.0030 in) F
Limit : 0.15 mm (0.0059 in)
• If the calculated value exceeds the limit, replace either or both camshaft and cylinder head.
NOTE: G
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
H
Camshaft End Play
• Install dial indicator in thrust direction on front end of camshaft.
Measure the end play of dial indicator when camshaft is moved for-
ward/backward (in direction to axis). I
Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in)

Limit : 0.24 mm (0.0094 in) J
K
SEM864E
• Measure the following parts if out of the limit. L

- Dimension “A” for camshaft No. 1 journal
Standard : 27.500 - 27.548 mm (1.0827 - 1.0846 in) M

- Dimension “B” for cylinder head No. 1 journal bearing
Standard : 27.360 - 27.385 mm (1.0772 - 1.0781 in) N

• Following the standards above, replace camshaft and/or cylinder
head.
KBIA2404J
O
Camshaft Sprocket Runout

1. Put V-block on precise flat table, and support No. 2 and 4 journal of camshaft. P
CAUTION:
Do not support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter
from the other three locations.

CAMSHAFT
2. Measure the camshaft sprocket runout with dial indicator. (Total
indicator reading)
Limit : 0.15 mm (0.0059 in)

• If it exceeds the limit, replace camshaft sprocket.
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-245,
"Standard and Limit".
KBIA0182E
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER

• Measure the outer diameter at 1/2 height of valve lifter with
micrometer since valve lifter is in barrel shape.
Standard (Intake and exhaust)

: 33.977 - 33.987 mm (1.3377 - 1.3381 in)
JEM798G
VALVE LIFTER HOLE DIAMETER

• Measure the inner diameter of valve lifter hole of cylinder head with
inside micrometer.

: 34.000 - 34.016 mm (1.3386 - 1.3392 in)
SEM867E
VALVE LIFTER CLEARANCE

• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter), Refer to EM-128, "Valve
Clearance".

: 0.013 - 0.039 mm (0.0005 - 0.0015 in)

CAMSHAFT
• 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. A
INSTALLATION
1. Install timing chain tensioners (secondary) on both sides of cyl-
inder head. EM
• Install timing chain tensioner with its stopper pin attached.
• Install timing chain tensioner with sliding part facing downward
on right-side cylinder head, and with sliding part facing upward C
on left-side cylinder head.
• Install new O-rings as shown.
D
PBIC2111E
E
2. Install valve lifters.
• Install it in the original position.
3. Install camshafts. F
• Install camshaft with dowel pin attached to its front end face on
the exhaust side.
G
I
KBIA1071E
• Follow your identification marks made during removal, or fol- J

low the identification marks that are present on new camshafts
for proper placement and direction.
K
Paint marks Identification
Bank INT/EXH Dowel pin
M1 M2 mark
L
INT No Green No RE
RH
EXH Yes No White RE
INT No Green No LH M
LH KBIA1009E
EXH Yes No White LH
• Install camshaft so that dowel pin hole and dowel pin on front N
end face are positioned as shown. (No. 1 cylinder TDC on its
compression stroke)
NOTE:
O
• Large and small pin holes are located on front end face of
camshaft (INT), at intervals of 180°. Face small dia. side pin
hole upward (in cylinder head upper face direction).
• Though camshaft does not stop at the portion as shown, for P
the placement of cam nose, it is generally accepted cam-
shaft is placed for the same direction as shown.
PBIC2478E

CAMSHAFT
4. Install camshaft brackets.
• Remove foreign material completely from camshaft bracket
backside and from cylinder head installation face.
• Install camshaft bracket in original position and direction as
shown.
PBIC2051E
• Install camshaft brackets (No. 2 to 4) aligning the stamp marks

as shown.
NOTE:
There are no identification marks indicating left and right for
camshaft bracket (No. 1).
PBIC2052E
• Apply liquid gasket to mating surface of camshaft bracket (No.

1) as shown on right and left banks.
PBIC2660E

CAMSHAFT
5. Tighten camshaft bracket bolts in the following steps, in numeri-
cal order as shown. A
Camshaft bracket bolts

Step 1 (bolts 7 - 10) : 1.96 N·m (0.2 kg-m, 17 in-lb) EM
Step 3 : 5.88 N·m (0.6 kg-m, 52 in-lb)
C
Step 4 : 10.4 N·m (1.1 kg-m, 92 in-lb)
G
PBIC2050E
6. Measure the difference in levels between front end faces of

camshaft bracket (No. 1) and cylinder head. H
Standard : –0.14 to 0.14 mm (–0.0055 to 0.0055 in)

• Measure two positions (both intake and exhaust side) for a I
single bank.
• If the measured value is out of the standard, re-install cam-
shaft bracket (No. 1). J
EMQ0044D
K
7. Check and adjust the valve clearance. Refer to EM-128, "Valve Clearance".
L
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION: M
• Perform this inspection only when DTC P0011 or P0021 are detected in self-diagnostic results of
CONSULT-III and it is directed according to inspection procedure of EC section. Refer to EC-537,
"DTC Confirmation Procedure".
• Check when engine is cold so as to prevent burns from any splashing engine oil. N
1. Check the engine oil level. Refer to LU-21, "Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
O
checking.
a. Release fuel pressure. Refer to EC-928, "Fuel Pressure Check".
b. Disconnect ignition coil and injector harness connectors.
P
3. Remove intake valve timing control solenoid valve. Refer to EM-163, "Removal and Installation".

CAMSHAFT
4. Crank the engine, and then make sure that engine oil comes out
from camshaft bracket (No. 1) oil hole. End crank after checking.
WARNING:
Be careful not to touch rotating parts (drive belts, idler pul-
ley, and crankshaft pulley, etc.).
CAUTION:
Engine oil may squirt from intake valve timing control sole-
noid valve installation hole during cranking. Use a shop
cloth to prevent the engine components and the vehicle. Do
not allow engine oil to get on rubber components such as
drive belt or engine mount insulators. Immediately wipe off PBIC2869E
any splashed engine oil.
• Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not
come out from camshaft bracket (No. 1) oil hole. Refer to LU-20, "Lubrication Circuit", LU-20, "System
Chart".
5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-20, "Lubrication Circuit", LU-20, "System Chart".
6. After inspection, install removed parts.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
NOTE:

OIL SEAL
OIL SEAL
A
Removal and Installation of Valve Oil Seal INFOID:0000000003220214
REMOVAL EM
1. Turn crankshaft until the cylinder requiring new oil seals is at TDC. This will prevent valve from dropping
into cylinder.
2. Remove camshaft relating to valve oil seal to be removed. Refer to EM-193, "Removal and Installation". C
3. Remove valve lifters. Refer to EM-193, "Removal and Installation".
using Tool. D
CAUTION:
When working, take care not to damage valve lifter holes.
E
: KV10115900 (J-26336-20)
: KV10109220 ( — ) F
• Compress valve spring using Tool attachment, adapter.
Remove valve collet with magnet hand. WBIA0578E
G

H
Tool number : KV10107902 (J-38959)
WBIA0489E
K
INSTALLATION
1. Apply new engine oil to new valve oil seal joint surface and seal lip.
2. Press in valve oil seal to specified height "H" using Tool. L

NOTE: M
Dimension "H": height measured before valve spring seat instal-
lation.
N
Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
3. Installation of the remaining components is in the reverse order
of removal. WBIA0490E O
Removal and Installation of Front Oil Seal INFOID:0000000003220215
P
REMOVAL
1. Remove engine undercover using power tools.
2. Remove drive belts. Refer to EM-123, "Removal and Installation".
3. Remove engine cooling fan assembly. Refer to CO-46, "Removal and Installation (Crankshaft driven
type)".
4. Remove crankshaft pulley. Refer to EM-173, "Removal and Installation".

OIL SEAL
5. Remove front oil seal using suitable tool.
CAUTION:
Be careful not to damage front timing chain case and crank-
shaft.
PBIC2931E
INSTALLATION
1. Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal.
2. Install front oil seal.
• Install front oil seal so that each seal lip is oriented as shown.
SEM715A
• Press-fit until the height of front oil seal is level with the mount-
ing surface using suitable tool.
- Suitable drift: outer diameter 60 mm (2.36 in), inner diameter
50 mm (1.97 in).
CAUTION:
• Be careful not to damage front timing chain case and
crankshaft.
• Press-fit straight and avoid causing burrs or tilting oil
seal.
PBIC2931E
3. Installation is in the reverse order of removal after this step.

Removal and Installation of Rear Oil Seal INFOID:0000000003220216
REMOVAL
1. Remove transmission assembly. Refer to TM-75, "Removal and Installation from Vehicle (For 2WD Mod-
els)" (2WD M/T models), TM-77, "Removal and Installation from Vehicle (For 4WD Models)" (4WD M/T
models), TM-384, "Removal and Installation for VQ40DE 2WD Models" (2WD A/T models), TM-386,
"Removal and Installation for VQ40DE 4WD Models" (4WD A/T models).

OIL SEAL
2. Remove rear oil seal with a suitable tool.
CAUTION: A
Be careful not to damage crankshaft and cylinder block.
EM
PBIC2932E
D
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown. E
SEM715A H
• Install new rear oil seal using Tool.

I
Tool number : KV991J0120 (J-47128)
CAUTION:
• Be careful not to damage crankshaft and cylinder block. J
ing.
K
LBIA0454E
L
• Press in rear oil seal to the position as shown.
O
SBIA0281E
3. Installation of the remaining components is in the reverse order of removal. P

CYLINDER HEAD
CYLINDER HEAD
PBIC2934E
1. Rubber plug 2. Cylinder head (left bank) 3. Cylinder head bolt

4. Cylinder head (right bank) 5. Harness bracket 6. Cylinder head gasket (right bank)
7. Cylinder head gasket (left bank)
REMOVAL
2. Remove intake manifold. Refer to EM-139, "Removal and Installation".
3. Remove exhaust manifold. Refer to EM-141, "Removal and Installation".
4. Remove water inlet and thermostat assembly. Refer to CO-53, "Removal and Installation".
5. Remove water outlet, water pipe and heater pipe. Refer to CO-55, "Removal and Installation".

CYLINDER HEAD
6. Remove cylinder head bolts in reverse order as shown using
commercial service tool and power tool to remove cylinder A
heads (right and left banks).
Tool number : (J-24239-01) EM
G
PBIC2057E
7. Remove cylinder head gaskets.

H
Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening I
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace the bolt with a new one.
J
Limit (“d1” – “d2”) : 0.11 mm (0.0043 in)
• If reduction of outer diameter appears in a position other than “d2”,
use it as “d2” point.
K
PBIC2480E L
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-229, "Inspec- M
1. Using suitable tool, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.
CAUTION: N
Do not allow gasket fragments to enter engine oil or engine coolant passages.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions.
O
Limit : 0.1 mm (0.004 in)
• If it exceeds the limit, replace cylinder head. P
SEM861E
INSTALLATION

CYLINDER HEAD
1. Install new cylinder head gasket.
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.
SEM532G
3. Install cylinder head follow the steps below to tighten cylinder

head bolts in numerical order as shown.
CAUTION:
If cylinder head bolts re-used, check their outer diameters
before installation. Refer to EM-204, "Removal and Installa-
tion" (Cylinder Head Bolts Outer Diameter).
Step a : 98 N·m (10 kg-m, 72 ft-lb)

Step b : Loosen to 0 N·m in the reverse order of tight-
ening.
Step c : 39.2 N·m (4.0 kg-m, 29 ft-lb)
Step d : 90° clockwise
Step e : 90° clockwise
PBIC2057E
WBIA0581E
4. After installing cylinder head, measure distance between front

end faces of cylinder block and cylinder head (left and right
banks).
Standard : 14.1 - 14.9 mm (0.555 - 0.587 in)

• If the measured value is out of the standard, re-install cylinder
head.
EMQ0662D

CYLINDER HEAD
5. Installation of the remaining parts is in the reverse order of removal.
A
Inspection for Leaks EM
• Use procedure below to check for fuel leakage. C
- Start engine. With engine speed increased, check again for fuel leakage at connection points. D
E
F
G
Fuel Leakage Leakage Leakage H
* Transmission, power steering fluid, brake fluid, etc.
I
PBIC2637E
1. Valve lifter 2. Valve collet 3. Valve spring retainer

4. Valve spring 5. Valve oil seal 6. Valve spring seat

CYLINDER HEAD
7. Valve guide 8. Spark plug 9. Spark plug tube
10. Cylinder head (right bank) 11. Valve seat 12. Valve (EXH)
13. Valve (INT) 14. Cylinder head (left bank)
DISASSEMBLY
1. Remove spark plug.
2. Remove valve lifter.
3. Remove valve collet.
• Compress valve spring and remove valve collet with magnet
hand using Tool.
CAUTION:
When working, take care not to damage valve lifter holes.
Tool numbers : KV10109220 ( — )

: KV10116200 (J-26336-A)
: KV10115900 (J-26336-20)
WBIA0578E
4. Remove valve spring retainer, valve spring and valve spring seat.
5. Push valve stem to combustion chamber side, and remove valve.
6. Remove valve oil seals using Tool.
Tool number : KV10107902 (J-38959)
WBIA0489E
7. If valve seat must be replaced, refer to EM-210, "Inspection After Disassembly".

8. If valve guide must be replaced, refer to EM-210, "Inspection After Disassembly".
9. Remove spark plug tube, as necessary.
• Using pair of pliers, pull spark plug tube out of cylinder head.
CAUTION:
• Take care not to damage cylinder head.
• Once removed, spark plug tube will be deformed and cannot be reused. Do not remove it unless
absolutely necessary.
ASSEMBLY
1. When valve guide is removed, install it. Refer to EM-210, "Inspection After Disassembly".
2. When valve seat is removed, install it. Refer to EM-210, "Inspection After Disassembly".

CYLINDER HEAD
3. Install valve oil seals using Tool.
A
Height "H" (Without valve spring seat installed) EM

Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
4. Install valve spring seat. C
5. Install valves.
WBIA0490E
NOTE: D
Larger diameter valves are for intake side.
6. Install valve spring (uneven pitch type).

E
• Install narrow pitch end (paint mark) to cylinder head side
(valve spring seat side).
SEM085D
H
7. Install valve spring retainer.
8. Install valve collet.
• Compress valve spring using Tool, attachment and adapter I
using Tool. Install valve collet with magnet hand.
Tool numbers : KV10109220 ( — ) J

: KV10116200 (J-26336-A)
: KV10115900 (J-26336-20)
K
CAUTION:
When working, take care not to damage valve lifter holes
or valve stems. WBIA0578E
• Tap valve stem edge lightly with plastic hammer after installa- L
tion to check its installed condition.
9. Install valve lifter. M

10. Install spark plug tube.
• Press-fit spark plug tube as follows: N
a. Remove old liquid gasket adhering to cylinder head mounting hole.
b. Apply sealant to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side.
Use Genuine High Strength Locking Sealant or equivalent. Refer to GI-26, "Recommended Chemi- O
cal Products and Sealants".

CYLINDER HEAD
c. Press-fit spark plug tube so that its height “H” is as specified
using suitable drift.
Standard press-fit height “H”

: 38.1 - 39.1 mm (1.500 - 1.539 in)
CAUTION:
• When press-fitting, take care not to deform spark plug
tube.
• After press-fitting, wipe off liquid gasket protruding onto
cylinder-head upper face.
PBIC2638E
11. Install spark plug.
VALVE DIMENSIONS
• Check dimensions of each valve. For dimensions, refer to EM-245, "Standard and Limit".
• If dimensions are out of the standard, replace valve and check the valve seat contact. Follow the "VALVE
SEAT CONTACT" procedure.
VALVE GUIDE CLEARANCE
Valve Stem Diameter
Measure the diameter of valve stem with micrometer.
Standard
Intake : 5.965 - 5.980 mm (0.2348 - 0.2354 in)
Exhaust : 5.955 - 5.970 mm (0.2344 - 0.2350 in)
SEM938C
Valve Guide Inner Diameter

Measure the inner diameter of valve guide with inside micrometer.
Standard
Intake and Exhaust : 6.000 - 6.018 mm (0.2362 - 0.2369 in)
Valve Guide Clearance
(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
Valve guide clearance:

Standard
Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in)
Limit
Intake : 0.08 mm (0.003 in)
Exhaust : 0.09 mm (0.004 in)
• If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be
replaced, follow the "VALVE GUIDE REPLACEMENT" procedure.
VALVE GUIDE REPLACEMENT
When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.

CYLINDER HEAD
1. To remove valve guide, heat cylinder head to 110° to 130°C
(230° to 266°F) by soaking in heated oil. A
EM
SEM008A
D
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US
ton, 2.0 Imp ton) pressure] or hammer and valve guide drift
(commercial service tool).
E
CAUTION:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
F
G
SEM931C
3. Ream cylinder head valve guide hole; using suitable reamer.

H
Valve guide hole diameter (for service parts):
Intake and exhaust
I
: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
K
in heated oil.
L
N
SEM008A
5. Press valve guide from camshaft side to the dimensions as O

shown using suitable tool.
Projection “L”
P
Intake and exhaust
: 12.6 - 12.8 mm (0.496 - 0.504 in)
CAUTION:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
SEM950E

CYLINDER HEAD
6. Apply reamer finish to valve guide using suitable reamer.
Standard:
Intake and exhaust
: 6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM932C
VALVE SEAT CONTACT

• After confirming that the dimensions of valve guides and valves are
within the specifications, perform this procedure.
• Apply prussian blue (or white lead) onto contacting surface of valve
seat to check the condition of the valve contact on the surface.
• Check if the contact area band is continuous all around the circum-
ference.
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions even after the re-check, replace
valve seat. Follow the "VALVE SEAT REPLACEMENT" procedure.
SBIA0322E
VALVE SEAT REPLACEMENT

When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-245, "Standard and Limit".
CAUTION:
Prevent to scratch cylinder head by excessive boring.
2. Ream cylinder head recess diameter for service valve seat.
Oversize [0.5 mm (0.020 in)]

Intake : 38.500 - 38.516 mm (1.5157 - 1.5164 in)
Exhaust : 32.700 - 32.716 mm (1.2874 - 1.2880 in)
• Be sure to ream in circles concentric to valve guide center.
This will enable valve to fit correctly.
SEM795A

in heated oil.
SEM008A
4. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head.
CAUTION:
• Avoid directly touching cold valve seats.
• Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.

CYLINDER HEAD
5. Finish seat to the specified dimensions using suitable tool. Refer
to EM-245, "Standard and Limit". A
CAUTION:
When using valve seat cutter, firmly grip cutter handle with
both hands. Then, press on the contacting surface all
EM
around the circumference to cut in a single drive. Improper
pressure on with cutter or cutting many different times may
result in staged valve seat.
C
SEM934C
D
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact. Follow the "VALVE SEAT CONTACT" procedure.
VALVE SPRING SQUARENESS E
• Set try square along the side of valve spring and rotate spring.
Measure the maximum clearance between the top face of spring
and try square. F
Limit : 2.1 mm (0.083 in)

• If it exceeds the limit, replace valve spring. G
H
PBIC0080E
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD I

• Check valve spring pressure at the specified spring height.
Standard:
J
Intake and exhaust
Free height
: 47.07 mm (1.8531 in) K
Installation height
: 37.00 mm (1.4567 in)
L
Installation load SEM113
: 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)

Height during valve open M
: 27.20 mm (1.0709 in)
Load with valve open
: 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb) N
• If the installation load or load with valve open is out of the standard, replace valve spring.
O

ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > [VQ40DE]
REMOVAL AND INSTALLATION

ENGINE ASSEMBLY
LBIA0432E
1. Rear engine mounting insulator 4WD 2. Rear engine mounting insulator 2WD 3. LH engine mounting bracket (upper)
4. LH heat shield plate 5. LH engine mounting insulator 6. LH engine mounting bracket (lower)
7. RH engine mounting bracket (lower) 8. RH engine mounting insulator 9. RH heat shield plate
10. RH engine mounting bracket (upper)
WARNING:
• Situate vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.

ENGINE ASSEMBLY
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations. A
• Do not start working until exhaust system and engine coolant are cooled sufficiently.
• If items or work required are not covered by the engine section, follow the procedures in the applica-
ble sections.
EM
• Always use the support point specified for lifting.
• Use either 2-point lift type or separate type lift. If board-on type is used for unavoidable reasons,
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. C
• For supporting points for lifting and jacking point at rear axle, refer to GI-43, "Garage Jack and
Safety Stand".
REMOVAL D
Preparation
1. Drain engine coolant. Refer to CO-39, "Changing Engine Coolant". E
2. Partially drain A/T fluid. Refer to TM-341, "Changing the A/T Fluid (ATF)".
4. Remove the engine hood. Refer to DLK-113, "Removal and Installation of Hood Assembly". F
5. Remove engine room cover using power tools.
6. Remove the air duct and air cleaner case assembly. Refer to EM-135, "Removal and Installation".
7. Disconnect vacuum hose between vehicle and engine and set it aside. G
8. Remove the radiator assembly and hoses. Refer to CO-43, "Removal and Installation".
9. Remove the drive belts. Refer to EM-123, "Removal and Installation".
H
10. Remove the engine cooling fan. Refer to CO-46, "Removal and Installation (Crankshaft driven type)".
11. Disconnect the engine room harness from the engine side and set it aside for easier work.
12. Disconnect the engine harness grounds. I
13. Disconnect the reservoir tank for power steering from engine and move it aside for easier work.
14. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for eas-
ier work. Refer to ST-18, "Removal and Installation". J
15. Remove the A/C compressor bolts and set aside. Refer to HA-33, "Removal and Installation for Compres-
sor".
16. Disconnect brake booster vacuum line. K
17. Disconnect EVAP line.
18. Disconnect the fuel hose at the engine side connection. Refer to EM-157, "Removal and Installation".
19. Disconnect the heater hoses at cowl, and install plugs to avoid leakage of engine coolant. L
20. Remove the A/T oil level indicator and indicator tube.
21. Remove front final drive assembly (4WD models). Refer to DLN-179, "Removal and Installation".
M
22. Remove three way catalyst. Refer to EM-141, "Removal and Installation".
23. Install engine slingers into left bank and right bank.
N
Engine slinger torque: 28.0 N·m (2.9 kg-m, 21 ft-lb)
24. Remove transmission. Refer to TM-75, "Removal and Installa-
tion from Vehicle (For 2WD Models)" (2WD M/T models) TM-77, O
"Removal and Installation from Vehicle (For 4WD Models)"
(4WD M/T models), TM-384, "Removal and Installation for
VQ40DE 2WD Models" (2WD A/T models), TM-386, "Removal
and Installation for VQ40DE 4WD Models" (4WD A/T models). P
25. Lift with hoist and secure the engine in position. WBIA0624E
26. Remove engine assembly from vehicle, avoiding interference

with vehicle body.
CAUTION:
• Before and during this lifting, always check if any harnesses are left connected.
27. Remove the parts that may restrict installation of engine to engine stand.

ENGINE ASSEMBLY
NOTE:
The procedure is described assuming that you use a engine holding the surface, to which transmission is
installed.
a. Remove flywheel (M/T models) or drive plate (A/T models).
• Holding crankshaft pulley bolts, lock crankshaft to remove flywheel or drive plate bolts.
• Loosen bolts diagonally.
CAUTION:
• Be careful not to damage drive plate. Especially avoid
deforming and damaging of signal plate teeth (circum-
ference position).
• Place the drive plate with signal plate surface facing
other than downward.
• Keep magnetic materials away from signal plate.
KBIA2491E
CAUTION:
Use an engine stand that has a load capacity [approximately 240kg (529 lb) or more] large enough
for supporting the engine weight.
• If the load capacity of the stand is not adequate, remove the following parts beforehand to
reduce the potential risk of overturning the stand.
- Remove fuel tube and fuel injector assembly. Refer to EM-157, "Removal and Installation".
- Remove intake manifold. Refer to EM-139, "Removal and Installation".
- Remove rocker cover. Refer to EM-152, "Removal and Installation".
- Other removable brackets.
CAUTION:
Before removing the hanging chains, make sure the engine stand is stable and there is no risk of
overturning.
29. Remove engine mounting insulator bracket (upper) with power tool.
INSTALLATION
• Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less than required
quantity, fill to the specified level.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Warm up engine thoroughly to make sure there is no leakage of engine coolant, engine oil, working fluid, fuel
and exhaust gas.
• Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
• After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to
• Summary of the inspection items:

Working fluid Level Leakage Level
Exhaust gas — Leakage —

ENGINE ASSEMBLY
*Transmission fluid, power steering fluid, brake fluid, etc.
A
EM

ENGINE UNIT
< DISASSEMBLY AND ASSEMBLY > [VQ40DE]
DISASSEMBLY AND ASSEMBLY

ENGINE UNIT
WBIA0582E
1. Reinforcement plate 2. Drive plate (A/T models), Flywheel 3. Rear oil seal
(M/T models)
4. Sub harness 5. Knock sensor 6. Water connector
7. Cylinder block 8. Oil jet 9. Thrust bearing
10. Pilot converter (A/T models) 11. Main bearing 12. Crankshaft
13. Crankshaft key 14. Lower cylinder block 15. Lower cylinder block bolt
16. Connecting rod bolt 17. Connecting rod bearing cap 18. Connecting rod bearing
19. Connecting rod 20. Snap ring 21. Piston pin
22. Piston 23. Oil ring 24. Second ring
25. Top ring

ENGINE UNIT
EM
H
PBIC2936E
1. Cylinder block 2. Gasket 3. Cylinder block heater

4. Connector protector cap I
J
DISASSEMBLY
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ- K
ent type of engine stand, some steps may be different.
1. Remove engine assembly from vehicle. Refer to EM-214, "Removal and Installation".
2. Remove both exhaust manifolds. Refer to EM-141, "Removal and Installation". L

ENGINE UNIT
3. Lift engine, and mount to engine stand.
CAUTION:
Before removing the hanging chains, make sure engine
stand is stable and there is no risk of overturning.
PBIC0805E
• A widely use engine stand can be used.

CAUTION:
Use engine stand that has a load capacity [approximately
220 kg (441 lb) or more] large enough for supporting the
engine weight.
PBIC0085E

ENGINE UNIT
5. Drain engine coolant by removing the cylinder block drain plugs
"A", "B", "C" and "D" from cylinder block as shown. A
NOTE:
For Canada, “D” is not plug but block heater.
EM
G
WLIA0020E
6. Remove flywheel (M/T models) or drive plate (A/T models) using Tool.
H
Tool number : KV10117700 (J-44716)
• Loosen bolts in diagonal order.
• Use TORX socket for drive plate bolts. I
CAUTION:
• Do not disassemble drive plate. J
• Do not place drive plate with signal plate facing down.
• When handling signal plate, take care not to damage or
scratch it. K
• Handle signal plate in a manner that prevents it from
becoming magnetized.
L
M
PBIC2938E
7. Remove cylinder head. Refer to EM-204, "Removal and Installation".

8. Remove sub harness, and remove knock sensors. N
CAUTION:
Carefully handle sensor avoiding shocks.
9. Remove pilot converter using Tool as necessary. O
Tool number : ST16610001 (J-23907)

P
WBIA0583E

ENGINE UNIT
10. Remove piston and connecting rod assembly as follows:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-229, "Inspection After Disassembly".
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
11. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
12. Remove connecting rod bearing cap.
13. Push piston and connecting rod assembly out to the cylinder
head side using suitable tool.
CAUTION:
pin, resulting from an interference of the connecting rod big
end.
PBIC2940E
14. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
Identify installation position, and store them without mixing them up.
15. Remove piston rings form piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-229, "Inspection After
Disassembly".
• Remove piston rings using piston ring expander or suitable
tool.
CAUTION:
• When removing piston rings, be careful not to damage
piston.
• Be careful not to damage piston rings by expanding them
excessively.
PBIC0087E
16. Remove piston from connecting rod as follows:

a. Remove snap ring using snap ring pliers.
PBIC1638E

ENGINE UNIT
b. Heat piston to 60° to 70°C (140° to 158°F) with industrial use
drier or equivalent. A
EM
PBIC1639E
D
c. Push out piston pin with stick of outer diameter approximately 20
mm (0.79 in).
E
G
PBIC0262E
17. Remove lower cylinder block bolts.

H
• Before loosening lower cylinder block bolts, measure the crankshaft end play. Refer to EM-229, "Inspec-
• Loosen lower cylinder block bolts in reverse order as shown in
several different steps. I
NOTE:
Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).
J
PBIC2941E
L
18. Remove lower cylinder block.
• Cut liquid gasket for removal. Refer to EM-115, "Precaution for Liquid Gasket".
M
Tool number : KV10111100 (J-37228)
CAUTION:
Be careful not to damage the mounting surfaces. N
19. Remove crankshaft.
20. Pull rear oil seal out from rear end of crankshaft.
NOTE: O
When replacing rear oil seal without removing lower cylinder block, use a suitable to pull the rear oil seal
installed between crankshaft and cylinder block out.
CAUTION:
Be careful not to damage crankshaft and cylinder block. P
21. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
• Be careful not to drop main bearing, and to scratch the surface.
22. Remove oil jet.
ASSEMBLY
ENGINE UNIT
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
2. Install each plug to cylinder block as shown.
• Apply sealant to the thread of water drain plugs “A” and “B”.
• Apply sealant to the thread of plugs “C”.
Use Genuine High Strength Thread Locking Sealant or
equivalent. Refer to GI-26, "Recommended Chemical
Products and Sealants".
• Apply sealant to the thread of plug “D”.
Use Anaerobic Liquid Gasket or equivalent. Refer to GI-
26, "Recommended Chemical Products and Sealants".
NOTE:
For Canada, “D” is not plug but block heater. Refer to EM-219,
"Disassembly and Assembly".
• Replace washers with new one.
WLIA0020E
• Tighten each plug as specified below.

Block Plug and Block Heater Installation
Part Washer Tightening Torque
A No 19.6 N·m (2.0 kg-m, 14 ft-lb)
Reuse 9.8 N·m (1.0 kg-m, 87 in-lb)
B No
New 6.0 N·m (0.61 kg-m, 53 in-lb)
C Yes 116 N·m (11.8 kg-m, 85 ft-lb)
Plug 62 N·m (6.3 kg-m, 46 ft-lb)
D Yes
Block heater 73.5 N·m (7.5 kg-m, 54 ft-lb)
3. Install oil jet.
• Insert oil jet dowel pin into cylinder block dowel pin hole, and
tighten bolts.
PBIC0898E
4. Install main bearings and thrust bearings as follows:

a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.

ENGINE UNIT
b. Install thrust bearings to the both sides of the No. 3 journal hous-
ing on cylinder block. A
• Install thrust bearings with the oil groove facing crankshaft arm
(outside).
• Install thrust bearing with a projection on one end on cylinder
EM
block, Align projection with mating notch.
PBIC2968E
D
c. Install main bearings paying attention to the direction.
• Main bearing with oil hole and groove goes on cylinder block.
The one without them goes on lower cylinder block.
E
• Before installing main bearings, apply engine oil to the bearing
surface (inside). Do not apply engine oil to the back surface,
but thoroughly clean it.
• When installing, align main bearing stopper protrusion to cut- F
out of cylinder block and lower cylinder block.
• Ensure the oil holes on cylinder block and those on the corre-
sponding bearing are aligned.
G
PBIC2969E
5. Install crankshaft to cylinder block.

H
• While turning crankshaft by hand, check that it turns smoothly.
6. Inspect the outer diameter of lower cylinder block bolt. Refer to EM-229, "Inspection After Disassembly".
7. Install lower cylinder block as follows: I
NOTE:
Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder
block.
a. Apply a continuous bead of liquid gasket using Tool to lower cyl- J
inder block as shown.
Tool number : WS39930000 ( — ) K

CAUTION: L
After liquid gasket is applied, rear oil seal installation must
be finished within 5 minutes. Therefore, the following pro-
cedure must be performed quickly. M
PBIC2942E
b. Tighten lower cylinder block as follows:
i. Apply new engine oil to threads and seat surfaces of the bolts.
ii. Tighten M8 bolts in numerical order as shown from No. 17 to 24. N
Bolts 17 - 24 : 22.1 N·m (2.3 kg-m, 16 ft-lb)

CAUTION: O
Wipe off completely any protruding liquid gasket on rear oil
seal installation surface.
NOTE: P
There are more processes to complete the tightening bolts.
However stop procedure here to install rear oil seal.
PBIC2941E
c. Install rear oil seal. Refer to EM-202, "Removal and Installation of Rear Oil Seal".
d. Restart tightening of lower cylinder block bolts as follows:

ENGINE UNIT
i. Tighten M10 bolts in numerical order as shown from No. 1 to 16.
NOTE:
Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).
Bolts 1 - 16 : 35.3 N·m (3.6 kg-m, 26 ft-lb)
PBIC2941E
ii. Turn M10 bolts 90° clockwise in numerical order from No. 1 to
16 using Tool.

CAUTION:
Use angle wrench Tool to check tightening angle. Do not
make judgement by visual inspection.
WBIA0584E
• After installing the bolts, make sure that crankshaft can be rotated smoothly by hand.
• Wipe off completely any protruding liquid gasket on front side of the engine.
• Check the crankshaft end play. Refer to EM-229, "Inspection After Disassembly".
8. Inspect the outer diameter of connecting rod bolt. Refer to EM-229, "Inspection After Disassembly".
9. Install piston to connecting rod as follows:
a. Install new snap ring to the groove of piston rear side using suitable tool.
• Insert it fully into groove to install.
b. Install piston to connecting rod.
• 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 pis-
ton and connecting rod.
• Assemble so that the front mark on the piston head and the
cylinder number on connecting rod are positioned as shown.
c. Install new snap ring to the groove of the piston front side.
• Insert it fully into groove to install.
• After installing, make sure that connecting rod moves
smoothly.
SEM838F
10. Install piston rings using piston ring expander or suitable tool.
CAUTION:
• When installing piston rings, be careful not to damage
piston.
• Be careful not to damage piston rings by expending them
excessively.
PBIC0087E

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

NOTE:
If there is no stamp on ring, no specific orientation is required
for installation.
EM
Stamped mark:
Top ring :—
C
Second ring : R
SEM757G
D
• Position each ring with the gap as shown referring to the pis-
ton front mark.
E
PBIC0808E
H
• Check the piston ring side clearance. Refer to EM-229, "Inspection After Disassembly".
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
• Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply I
engine oil to the back surface, but thoroughly clean it.
• When installing, align connecting rod bearing stopper protru-
sion with cutout of connecting rods and connecting rod bearing
caps to install. J
• Ensure the oil hole on connecting rod and that on the corre-
sponding bearing are aligned.
K
PBIC2067E
12. Install piston and connecting rod assembly to crankshaft. M

13. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
14. Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
N
15. Match the cylinder position with the cylinder number on connecting rod to install.
NOTE:
Be sure that front mark on piston head is facing front of engine.
16. Install piston with the front mark on the piston head facing the O
front of engine using Tool.
Tool number : EM03470000 (J-8037) P

CAUTION:
pin, resulting from an interference of the connecting rod big
end.
WBIA0585E

ENGINE UNIT
17. Install connecting rod bearing cap.
• Match the stamped cylinder number marks on connecting rod
with those on connecting rod bearing cap to install.
• Be sure that front mark on connecting rod bearing cap is fac-
ing front of engine.
PBIC0809E
18. Tighten connecting rod bolts as follows:

a. Apply engine oil to the threads and seats of connecting rod bolts.
b. Tighten connecting rod bolts.
Connecting rod bolt : 19.6 N·m (2.0 kg-m, 14 ft-lb)

c. Then tighten all connecting rod bolts 90° clockwise.
CAUTION:
Always use Tool. Avoid tightening based on visual check
alone.

• After tightening connecting rod bolts, make sure that crank-
shaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-229,
"Inspection After Disassembly".
WBIA0586E
19. Install pilot converter.

• With drift of the following outer diameter, press-fit as far as it
will go.
Pilot converter : Approx. 33 mm (1.30 in)
PBIC2947E
• Press-fit pilot converter with its chamfer facing crankshaft as

shown.
SEM537E

ENGINE UNIT
20. Install knock sensors.
• Install knock sensor so that connector faces rear of engine. A
• After installing knock sensor, connect harness connector, and
lay it out to rear of engine.
CAUTION:
EM
• Do not tighten bolts while holding connector.
• If any impact by dropping is applied to knock sensor,
replace it with new one.
NOTE: C
• Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of knock sensor.
• Make sure that knock sensor does not interfere with other D
parts.
G
PBIC2948E
21. Assemble in the reverse order of disassembly after this step.

H
Drive plate (A/T models)
• Install drive plate and reinforcement plate as shown.
• Holding ring gear using Tool.
I
Tool number : KV10117700 (J-44716)
• Tighten bolts crosswise over several times. J
PBIC0910E

L
CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft M
arm when crankshaft is moved fully forward or backward with dial
indicator.
N
Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit : 0.30 mm (0.0118 in)
• If the measured value exceeds the limit, replace thrust bearings, O
also.
PBIC2953E P
CONNECTING ROD SIDE CLEARANCE

ENGINE UNIT
• Measure the side clearance between connecting rod and crank-
shaft arm with feeler gauge.
Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in)

Limit : 0.40 mm (0.0157 in)
• If the measured value exceeds the limit, replace connecting rod,
also.
PBIC2954E
PISTON TO PISTON PIN CLEARANCE

Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with inside microme-
ter.
Standard : 21.993 - 22.005 mm (0.8659 - 0.8663 in)
PBIC0116E

Measure the outer diameter of piston pin with micrometer.
Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 in)
PBIC0117E
Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
Standard : 0.002 - 0.006 mm (0.0001 - 0.0002 in)

• If the calculated value is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly, refer to EM-240, "How to Select Piston and Bearing".
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.)
PISTON RING SIDE CLEARANCE

ENGINE UNIT
• Measure side clearance of piston ring and piston ring groove with
feeler gauge. A
Standard:
Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in) EM
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in)
C
Limit:
Top ring : 0.11 mm (0.0043 in)
SEM024AA
2nd ring : 0.10 mm (0.0039 in) D
replace piston also.
E
PISTON RING END GAP
• Make sure that the cylinder bore inner diameter is within the speci-
fication. Follow the "Cylinder Bore Inner Diameter" procedure.
• Lubricate with new engine oil to piston and piston ring, and then F
insert piston ring until middle of cylinder with piston, and measure
the piston ring end gap with feeler gauge.
G
Standard:
Top ring : 0.23 - 0.33 mm (0.0091 - 0.0130 in)
2nd ring : 0.33 - 0.48 mm (0.0130 - 0.0189 in) H
Oil ring : 0.20 - 0.50 mm (0.0079 - 0.0197 in) PBIC0118E
Limit:
I
Top ring : 0.56 mm (0.0220 in)
2nd ring : 0.68 mm (0.0268 in)
Oil ring : 0.85 mm (0.0335 in) J
re-bore cylinder and use oversize piston and piston rings.
K
CONNECTING ROD BEND AND TORSION
• Check with connecting rod aligner.
Bend: L
Torsion:
M
• If it exceeds the limit, replace connecting rod assembly.
N
PBIC2077E

ENGINE UNIT
CONNECTING ROD DIAMETER (BIG END)
• Install connecting rod bearing cap without installing connecting rod
bearing, and tightening connecting rod bolts to the specified
torque. Refer to EM-219, "Disassembly and Assembly" for the
tightening procedure.
• Measure the inner diameter of connecting rod big end with inside
micrometer.
Standard : 57.000 - 57.013 mm (2.2441 - 2.2446 in)

• If out of the standard, replace connecting rod assembly.
PBIC1641E
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)

Connecting Rod Bushing Inside Diameter (Small End)
Measure inside diameter of connecting rod bushing using suitable
tool.
Standard : 22.000 - 22.012 mm (0.8661 - 0.8666 in)
PBIC0120E
Piston Pin Diameter

Measure diameter of piston pin using suitable tool.
Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 in)
PBIC0117E
Connecting Rod Bushing Oil Clearance (Small End)

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 in)

Limit : 0.030 mm (0.0012 in)
• If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly, refer to EM-240, "How to Select Piston and Bearing".

ENGINE UNIT
• If replacing connecting rod assembly, follow the "CONNECTING
ROD BEARING OIL CLEARANCE" procedure to select the con- A
necting rod bearing.
EM
PBIC0809E
D
Factory installed parts grading:
• Only grade “0”.
Unit: mm (in) E
Grade 0 1
Connecting rod bushing 22.000 - 22.006 22.006 - 22.012
inner diameter * (0.8661 - 0.8664) (0.8664 - 0.8666) F
21.993 - 21.999 21.999 - 22. 005
(0.8659 - 0.8661) (0.8661 - 0.8663)
21.989 - 21.995 21.995 - 22.001 G
(0.8657- 0.8659) (0.8659 - 0.8662)
*: After installing in connecting rod PBIC2950E
H
CYLINDER BLOCK DISTORTION
• Remove any oil, scale, gasket, sealant and carbon deposits from the cylinder block surface.
CAUTION:
Do not allow any debris to enter engine oil or engine coolant passages. I
• Measure the distortion on the cylinder block upper face at some
different points in six directions with straightedge and feeler gauge.
J
Limit : 0.1 mm (0.004 in)
• If it exceeds the limit, replace cylinder block.
K
L
SEM123C
MAIN BEARING HOUSING INNER DIAMETER M

• Install lower cylinder block without installing main bearings, and
tighten lower cylinder block bolts to the specified torque. Refer to
EM-219, "Disassembly and Assembly" for the tightening proce-
dure. N
• Measure the inner diameter of main bearing housing with bore
gauge.
O
Standard : 74.993 - 75.017 mm (2.9525 - 2.9534 in)
• If out of the standard, replace cylinder block and lower cylinder
block as assembly. P
NOTE: PBIC2012E
Cylinder block cannot be replaced as a single part, because it is

PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter

ENGINE UNIT
• Using bore gauge, measure cylinder bore for wear, out-of-round
and taper at six different points on each cylinder. (“X” and “Y” direc-
tions at “A”, “B” and “C”) (“X” is in longitudinal direction of engine)
Standard inner diameter:

95.500 - 95.530 mm (3.7598 - 3.7610 in)
Out-of-round (Difference between “X” and “Y”):
0.015 mm (0.0006 in)
Taper limit (Difference between “A” and “C”):
PBIC2955E
0.01 mm (0.0004 in)
• If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or re-bore the inner
wall.
• Oversize piston is provided. When using oversize piston, re-bore
cylinder so that the clearance of the piston-to-cylinder bore satis-
fies the standard.
CAUTION:
When using oversize piston, use oversize pistons for all cylin-
ders with oversize piston rings.
Oversize (OS) : 0.2 mm (0.008 in) SEM843E
Piston Skirt Diameter

Measure the outer diameter of piston skirt with micrometer.
Measure point
: Distance from the top 43.03 mm (1.6941 in)
Standard
: 95.480 - 95.510 mm (3.7590 - 3.7602 in)
PBIC2956E
Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter (direction “X”, 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 the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to EM-240, "How to
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
B: Piston to cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
2. Install lower cylinder block, and tighten to the specified torque. Otherwise, cylinder bores may be distorted
in final assembly.

ENGINE UNIT
3. Cut cylinder bores.
NOTE: A
• When any cylinder needs boring, all other cylinders must also be bored.
• Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a
time.
EM
4. Hone cylinders to obtain the specified piston to cylinder bore clearance.
5. Measure finished the cylinder bore for out-of-round and taper.
NOTE:
C
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals with micrometer. D
Standard : 69.951 - 69.975 mm (2.7540 - 2.7549 in) dia.

• If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Follow the E
"MAIN BEARING OIL CLEARANCE" procedure.
CRANKSHAFT PIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft pin journal with F
micrometer.
Standard : 53.956 - 53.974 mm (2.1242 - 2.1250 in) dia. G

• If out of the standard, measure the connecting rod bearing oil
clearance. Then use undersize bearing. Follow the "CONNECT-
ING ROD BEARING OIL CLEARANCE" procedure. H
PBIC0127E
I
OUT-OF-ROUND AND TAPER OF CRANKSHAFT

• Measure the dimensions at four different points as shown on each J
main journal and pin journal with micrometer.
• Out-of-round is indicated by the difference in the dimensions
between “X” and “Y” at “A” and “B”.
• Taper is indicated by the difference in the dimensions between “A” K
and “B” at “X” and “Y”.
Limit: L
Out-of-round (Difference between “X” and “Y”)
: 0.002 mm (0.0001 in)
SBIA0535E
Taper (Difference between “A” and “B”) M
: 0.002 mm (0.0001 in)
• If the measured value exceeds the limit, correct or replace crankshaft. N
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
the main bearing and/or connecting rod bearing. Follow the "MAIN BEARING OIL CLEARANCE" and/or
"CONNECTING ROD BEARING OIL CLEARANCE" procedures.
O
CRANKSHAFT RUNOUT

ENGINE UNIT
• Place V-block on precise flat table, and support the journals on the
both end of crankshaft.
• Place dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on dial
indicator. (Total indicator reading)
Standard : Less than 0.05 mm (0.002 in)

Limit : 0.10 mm (0.0039 in)
• If it exceeds the limit, replace crankshaft.
SEM346D
CONNECTING ROD BEARING OIL CLEARANCE

• Install connecting rod bearings to connecting rod and cap, and
tighten connecting rod bolts to the specified torque. Refer to EM-
219, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of connecting rod bearing with inside
micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter) –
(Crankshaft pin journal diameter)
Standard : 0.034 - 0.059 mm (0.0013 - 0.0023 in) (actu-

al clearance)
Limit : 0.070 mm (0.0028 in) PBIC1642E
• If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to
EM-240, "How to Select Piston and Bearing".
• 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.
torque. Refer to EM-219, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
• Remove connecting rod bearing cap and bearing, and using scale
on plastigage bag, measure the plastigage width.
NOTE:
PBIC1149E
MAIN BEARING OIL CLEARANCE


ENGINE UNIT
• Install main bearings to cylinder block and lower cylinder block,
and tighten lower cylinder block bolts to the specified torque. Refer A
to EM-219, "Disassembly and Assembly" for the tightening proce-
dure.
• Measure the inner diameter of main bearing with bore gauge.
EM
(Bearing clearance) = (Main bearing inner diameter) – (Crankshaft
main journal diameter)
Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 in) C

(actual clearance)
Limit : 0.065 mm (0.0026 in) PBIC2204E
D
• If the calculated value exceeds the limit, select proper main bearing according to main bearing inner diame-
ter and crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-240, "How to
E
• Remove engine 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. F
• Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block bolts to the
CAUTION: G
• Remove lower cylinder block and bearings, and using scale on
plastigage bag, measure the plastigage width.
NOTE: H
I
PBIC1149E
CRUSH HEIGHT OF MAIN BEARING K

• When lower cylinder block is removed after being tightened to the
specified torque with main bearings installed, the tip end of bearing
must protrude. Refer to EM-219, "Disassembly and Assembly" for L
the tightening procedure.
Standard : There must be crush height.

M
• If the standard is not met, replace main bearings.
N
SEM502G
CRUSH HEIGHT OF CONNECTING ROD BEARING

O
• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings installed, the
tip end of bearing must protrude. Refer to EM-219, "Disassembly
and Assembly" for the tightening procedure. P
Standard : There must be crush height.

• If the standard is not met, replace connecting rod bearings.
PBIC1646E

ENGINE UNIT
LOWER CYLINDER BLOCK BOLT OUTER DIAMETER
• Measure the outer diameters (“d1”, “d2”) at two positions as shown.
Limit (“d1” – “d2”) : 0.11 mm (0.0051 in)

• If it exceeds the limit (large difference in dimensions), replace
lower cylinder block bolt with new one.
PBIC0911E
CONNECTING ROD BOLT OUTER DIAMETER

• Measure the outer diameter “d” at position shown.
• If the reduction appears in a position other than “d”, regard it as “d”.
Limit : 7.75 mm (0.3051 in)

• When “d” exceeds the limit (when it becomes thinner), replace
connecting rod bolt with new one.
PBIC0912E
FLYWHEEL RUNOUT (M/T)

NOTE:
• This inspection is for double mass flywheel only.
• Do not disassemble the double mass flywheel.
Flywheel Deflection
• Measure the deflection of the flywheel contact surface to the clutch
with a dial gauge.
• Measure the runout at 210 mm (8.27 in) diameter.
Limit : 0.45 mm (0.0177 in) or less

• When measured value exceeds the limit, replace the flywheel with
a new one.
PBIC2168E
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)

CAUTION:
Do not disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
• Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added
at the portion of 125 mm (4.92 in) radius from the center of flywheel.
Standard : 1.3 mm (0.051 in) or less

• If measured value is out of the standard, replace flywheel.
Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.
• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening.

ENGINE UNIT
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard A
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transmis- EM
sion side.
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of flywheel on the transmission side.
C
Standard: 44.3 mm (1.744 in) or less.

PBIC1263E
• If measured value is out of the standard, replace flywheel. D

• When “d” exceeds the limit (when it becomes thinner), replace connecting rod bolt with new one.
DRIVE PLATE (A/T MODELS)
• Check drive plate and signal plate for deformation or cracks. E
CAUTION:
• Do not disassemble drive plate.
• Do not place drive plate with signal plate facing down. F
• When handling signal plate, take care not to damage or
scratch it.
• Handle signal plate in a manner that prevents it from becom-
ing magnetized. G
• If anything is found, replace drive plate.
PBIC2938E
H
OIL JET
• Check nozzle for deformation and damage.
I
• Blow compressed air from nozzle, and check for clogs.
• If it is not satisfied, clean or replace oil jet.
OIL JET RELIEF VALVE J
• 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.
K
M
EMU0468D

How to Select Piston and Bearing INFOID:0000000003220227
DESCRIPTION
Selection points Selection parts Selection items Selection methods

Determined by match of cylin-
der block bearing housing
Between cylinder block and Main bearing grade grade (inner diameter of hous-
Main bearing
crankshaft (bearing thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block and pis- Piston grade Piston grade = cylinder bore
(Piston is available together
ton (piston skirt diameter) grade (inner diameter of bore)
with piston pin as assembly.)
Between piston and connecting
— — —
rod*
*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is available.) The
information at the shipment from the plant is described as a reference.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, follow the applicable procedures.
HOW TO SELECT PISTON
When New Cylinder Block is Used
Check the cylinder bore grade (“1”, “2”, or “3”) on rear side of cylin-
der block, and select piston of the same grade.
NOTE:
Piston is available with piston pin as a set for the service part. (Only
“0” grade piston pin is available.)
PBIC2949E
When Cylinder Block is Reused

1. Measure the cylinder bore inner diameter. Refer to EM-229, "Inspection After Disassembly".
2. Determine the bore grade by comparing the measurement with
the values under the cylinder bore inner diameter of the “Piston
Selection Table”.
PBIC2950E

3. Select piston of the same grade.
A
Piston Selection Table
Unit: mm (in)
Grade 1 2 (or no mark) 3 EM

95.500 - 95.510 95.510 - 95.520 95.520 - 95.530
Cylinder bore inner diameter
(3.7598 - 3.7602) (3.7602 - 3.7606) (3.7606 - 3.7610)
95.480 - 95.490 95.490 - 95.500 95.500 - 95.510 C
Piston skirt diameter
(3.7590 - 3.7594) (3.7594 - 3.7598) (3.7598 - 3.7602)
NOTE:
• Piston is available together with piston pin as assembly. D
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no pis-
ton pin grades can be selected. (Only “0” grade is available.)
• No second grade mark is available on piston.
E
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used
Check pin journal grade (“0”, “1”, or “2”) on front of crankshaft, and F
select connecting rod bearing of the same grade.
NOTE:
There is no grading for connecting rod big end diameter. G
PBIC2951E
I
When Crankshaft and Connecting Rod are Reused
1. Measure the connecting rod big end diameter. Refer to EM-229, "Inspection After Disassembly". J
2. Make sure that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to EM-229, "Inspection After Disassembly".
4. Determine the grade of crankshaft pin journal grade by corresponding to the measured dimension in K
“Crankshaft pin journal diameter” column of “Connecting Rod Bearing Selection Table”.
5. Select connecting rod bearing of the same grade.
Connecting Rod Bearing Selection Table L
Unit: mm (in)
Connecting rod big end diameter 57.000 - 57.013 (2.2441 - 2.2446)

M
Unit: mm (in)
Crankshaft Connecting rod bearing

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

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

In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
PBIC1908E

Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643)
HOW TO SELECT MAIN BEARING

When New Cylinder Block and Crankshaft are Used
1. “Main Bearing Selection Table” rows correspond to bearing
housing grade on rear left side of cylinder block.
PBIC2949E
2. “Main Bearing Selection Table” columns correspond to journal

diameter grade on front side of crankshaft.
PBIC2951E
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-229, "Inspection After Disassembly" and EM-229, "Inspection After Disassembly".
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.

Main Bearing Selection Table
A
EM
WBIA0625E
K
Main Bearing Grade Table (All Journals)

L
Thickness Width
Grade number Identification color Remarks
Unit: mm (in) Unit: mm (in)

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

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-
side (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
PBIC1908E

Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 2.633 - 2.641 (0.1037 - 0.1040)

< SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE]
SERVICE DATA AND SPECIFICATIONS (SDS) A

Standard and Limit INFOID:0000000003220228
EM
GENERAL SPECIFICATIONS
C
Cylinder arrangement V-6
Displacement cm3(cu in) 3,954 (241.30)

Bore and stroke mm (in) 95.5 × 92.0 (3.76 × 3.622) D
Valve arrangement DOHC
Firing order 1-2-3-4-5-6
E
Compression 2
Number of piston rings
Oil 1
Number of main bearings 4 F
Compression ratio 9.7
Standard 1,275 (13.0, 185)
Compression pressure kPa G
Minimum 981 (10.0, 142)
(kg/cm2, psi)/300 rpm
Differential limit between cylinders 98 (1.0, 14)
H
Cylinder number
J
K
SEM713A
M
Valve timing
(Intake valve timing control - “OFF”)
PBIC0187E
O
Unit: degree
a b c d e f
244 240 −4 64 6 58 P
DRIVE BELT
Tension of drive belts Auto adjustment by auto tensioner
INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD

Unit: mm (in)
Items Limit
Intake manifold 0.1 (0.004)
Surface distortion
Exhaust manifold 0.3 (0.012)
SPARK PLUG
Make NGK
Standard type DILFR5A-11
CAMSHAFT AND CAMSHAFT BEARING

Unit: mm (in)

No. 1 0.045 - 0.086 (0.0018 - 0.0034)
Camshaft journal oil clearance 0.15 (0.0059)
No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030)
No. 1 26.000 - 26.021 (1.0236 - 1.0244) —
Camshaft bracket inner diameter
No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) —
No. 1 25.935 - 25.955 (1.0211 - 1.0218) —
Camshaft journal diameter
No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) —
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)
Intake 45.465 - 45.655 (1.7900 - 1.7974) 45.265 (1.7821)
Camshaft cam height “A”
Exhaust 45.075 - 45.265 (1.7746 - 1.7821) 44.875 (1.7667)
Camshaft runout [TIR*1] Less than 0.02 mm (0.0008) 0.05 (0.002)
Camshaft sprocket runout [TIR*2] — 0.15 (0.0059)
SEM671
*1: Total indicator reading
Valve Lifter
Unit: mm (in)
Items Standard
Valve lifter outer diameter 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter hole diameter 34.000 - 34.016 (1.3386 - 1.3392)
Valve lifter clearance 0.013 - 0.039 (0.0005 - 0.0015)
Valve Clearance
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)

Available Valve Lifter A
VQ40DE
Unit: mm (in)
EM
Identification (stamped) mark
Thickness
Intake Exhaust
788U N788 7.88 (0.3102) C
790U N790 7.90 (0.3110)
792U N792 7.92 (0.3118)
D
794U N794 7.94 (0.3126)
796U N796 7.96 (0.3134)
798U N798 7.98 (0.3142) E
800U N800 8.00 (0.3150)
802U N802 8.02 (0.3157)
804U N804 8.04 (0.3165) F
806U N806 8.06 (0.3173)
808U N808 8.08 (0.3181)
G
810U N810 8.10 (0.3189)
812U N812 8.12 (0.3197)
814U N814 8.14 (0.3205) H
816U N816 8.16 (0.3213)
818U N818 8.18 (0.3220)
I
820U N820 8.20 (0.3228)
822U N822 8.22 (0.3236)
824U N824 8.24 (0.3244) J
826U N826 8.26 (0.3252)
828U N828 8.28 (0.3260)
K
830U N830 8.30 (0.3268)
832U N832 8.32 (0.3276)
834U N834 8.34 (0.3283) L
836U N836 8.36 (0.3291)
838U — 8.38 (0.3299)
840U — 8.40 (0.3307)
M
SEM758G
CYLINDER HEAD

Unit: mm (in)

Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Normal cylinder head height “H” 126.3 - 126.5 (4.972 - 4.980) —
PBIC0924E
Valve Dimensions
Unit: mm (in)
SEM188
Valve head diameter “D” Intake 37.0 - 37.3 (1.4567 - 1.4685)

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

Unit: mm (in)
A
EM
D
SEM950E
Items Standard 0.2 (0.008) oversize (Service)

E
Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
F
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.003) G
Valve guide clearance
Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.09 (0.004)
Projection length “L” 12.6 - 12.8 (0.496 - 0.504)
H
Valve Seat
Unit: mm (in)
I
L
PBIC2745E
Items Standard Oversize [0.5 (0.020)] (Service)

Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164)
M
Cylinder head seat recess diameter “D”
Exhaust 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880)
Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202)
Valve seat outer diameter “d” N
Exhaust 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2905 - 1.2912)
Intake 0.081 - 0.113 (0.0032 - 0.0044)
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038) O
Intake 35 (1.38)
Diameter “d1”*1
Exhaust 28.7 (1.130)
P
Intake 36.3 - 36.8 (1.429 - 1.449)
2
Diameter “d2”*
Exhaust 30.3 - 30.8 (1.193 - 1.213)
Intake 60°
Angle “α1”
Exhaust 60°
Intake 88°45′ - 90°15′
Angle “α2”
Exhaust 88°45′ - 90°15′

Intake 120°
Angle “α3”
Exhaust 120°
Intake 1.0 - 1.4 (0.039-0.055)
Contacting width “W”*3
Exhaust 1.2 - 1.6 (0.047-0.063)
Intake 5.9 - 6.0 (0.232 - 0.236) 5.05 - 5.15 (0.1988 - 0.2028)
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)
Depth “H” 6.0 (0.236)
*1: Diameter made by intersection point of conic angles “α1” and “α2”
*2: Diameter made by intersection point of conic angles “α2” and “α3”
*3
: Machining data
Valve Spring
Free height mm (in) 47.07 (1.8531)

Installation 166 - 188 (16.9 - 19.2, 37 - 42) at 37.00 (1.4567)
Pressure N (kg, lb) at height mm (in)
Valve open 373 - 421 (38.0 - 42.9, 84 - 95) at 27.20 (1.0709)
squareness mm (in) Limit 2.1 (0.083)
CYLINDER BLOCK
Unit: mm (in)
PBIC2955E
Standard Less than 0.03 (0.0012)

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

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

H
Available Piston
Unit: mm (in)
L
SEM882E
Items Standard 0.20 (0.0079) oversize

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

Top 0.045 - 0.080 (0.0018 - 0.0031) 0.11 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.065 - 0.135 (0.0026 - 0.0053) —
Top 0.23 - 0.33 (0.0091 - 0.0130) 0.56 (0.0220)
End gap 2nd 0.33 - 0.48 (0.0130 - 0.0189) 0.68 (0.0268)
Oil (rail ring) 0.20 - 0.50 (0.0079 - 0.0197) 0.85 (0.0335)
Piston Pin
Unit: mm (in)

Grade No. 0 21.989 - 21.995 (0.8657 - 0.8659) —
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)

Center distance 165.82 - 165.92 (6.5283 - 6.5323) —
Bend [per 100 (3.94)] — 0.15 (0.0059)
Torsion [per 100 (3.94)] — 0.30 (0.0118)
Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664) —
Connecting rod bushing inner diameter*
Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666) —
Connecting rod big end diameter (Without bearing) 57.000 - 57.013 (2.2441 - 2.2446) —
Side clearance 0.20 - 0.35 (0.0079 - 0.0138) : 40 mm (0.0157)
*: After installing in connecting rod
CRANKSHAFT

Unit: mm (in)
A
EM
D
SEM645 SBIA0535E
Grade No. A 69.975 - 69.974 (2.7549 - 2.7549)

Grade No. B 69.974 - 69.973 (2.7549 - 2.7548) E
Grade No. C 69.973 - 69.972 (2.7548 - 2.7548)
Grade No. D 69.972 - 69.971 (2.7548 - 2.7548)
Grade No. E 69.971 - 69.970 (2.7548 - 2.7547)
Grade No. F 69.970 - 69.969 (2.7547 - 2.7547) F
Grade No. G 69.969 - 69.968 (2.7547 - 2.7546)
Grade No. H 69.968 - 69.967 (2.7546 - 2.7546)
Grade No. J 69.967 - 69.966 (2.7546 - 2.7546)
Grade No. K 69.966 - 69.965 (2.7546 - 2.7545) G
Grade No. L 69.965 - 69.964 (2.7545 - 2.7545)
Grade No. M 69.964 - 69.963 (2.7545 - 2.7544)
Main journal diameter. “Dm” grade Standard
Grade No. N 69.963 - 69.962 (2.7544 - 2.7544) H
Grade No. P 69.962 - 69.961 (2.7544 - 2.7544)
Grade No. R 69.961 - 69.960 (2.7544 - 2.7543)
Grade No. S 69.960 - 69.959 (2.7543 - 2.7543)
Grade No. T 69.959 - 69.958 (2.7543 - 2.7542) I
Grade No. U 69.958 - 69.957 (2.7542 - 2.7542)
Grade No. V 69.957 - 69.956 (2.7542 - 2.7542)
Grade No. W 69.956 - 69.955 (2.7542 - 2.7541)
Grade No. X 69.955 - 69.954 (2.7541 - 2.7541) J
Grade No. Y 69.954 - 69.953 (2.7541 - 2.7540)
Grade No. 4 69.953 - 69.952 (2.7540 - 2.7540)
Grade No. 7 69.952 - 69.951 (2.7540 - 2.7540)
K
Grade No. 0 53.968 - 53.974 (2.1247 - 2.1250)
Pin journal diameter. “Dp” grade Standard Grade No. 1 53.962 - 53.968 (2.1245 - 2.1247)
Grade No. 2 53.956 - 53.962 (2.1242 - 2.1245) L
Center distance “r” 45.96 - 46.04 (1.8094 - 1.8126)
Taper (Difference between “A” and “B”) 0.002 (0.0001)
Limit M
Standard Less than 0.05 (0.002)
Crankshaft runout [TIR*]
Limit 0.10 (0.0039) N
Standard 0.10 - 0.25 (0.0039 - 0.0098)
Crankshaft end play
Limit 0.30 (0.0118)
*: Total indicator reading O
MAIN BEARING
P

PBIC2969E
Grade number UPR/LWR Thickness mm (in) Width mm (in) Identification color Remarks
0 — 2.500 - 2.503 (0.0984 - 0.0985) Black
1 — 2.503 - 2.506 (0.0985 - 0.0987) Brown
2 — 2.506 - 2.509 (0.0987 - 0.0988) Green
3 — 2.509 - 2.512 (0.0988 - 0.0989) Yellow Grade is the same
for upper and lower
4 — 2.512 - 2.515 (0.0989 - 0.0990) Blue bearings.
5 — 2.515 - 2.518 (0.0990 - 0.0991) Pink
6 — 2.518 - 2.521 (0.0991 - 0.0993) Purple
7 — 2.521 - 2.524 (0.0993 - 0.0994) White
UPR 2.503 - 2.506 (0.0985 - 0.0987) Brown
01
LWR 2.500 - 2.503 (0.0984 - 0.0985) Black
UPR 2.506 - 2.509 (0.0987 - 0.0988) 19.9 - 20.1 Green
12
LWR 2.503 - 2.506 (0.0985 - 0.0987) (0.783 - 0.791) Brown
UPR 2.509 - 2.512 (0.0988 - 0.0989) Yellow
23
LWR 2.506 - 2.509 (0.0987 - 0.0988) Green
UPR 2.512 - 2.515 (0.0989 - 0.0990) Blue Grade is different for
34 upper and lower
LWR 2.509 - 2.512 (0.0988 - 0.0989) Yellow bearings.
UPR 2.515 - 2.518 (0.0990 - 0.0991) Pink
45
LWR 2.512 - 2.515 (0.0989 - 0.0990) Blue
UPR 2.518 - 2.521 (0.0991 - 0.0993) Purple
56
LWR 2.515 - 2.518 (0.0990 - 0.0991) Pink
UPR 2.521 - 2.524 (0.0993 - 0.0994) White
67
LWR 2.518 - 2.521 (0.0991 - 0.0993) Purple
Undersize
Unit: mm (in)
Items Thickness Main journal diameter

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

Unit: mm (in)

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

Grade number Thickness mm (in) Identification color (mark) A

0 1.500 - 1.503 (0.0591 - 0.0592) Black
1 1.503 - 1.506 (0.0592 - 0.0593) Brown
EM
2 1.506 - 1.509 (0.0593 - 0.0594) Green
Undersize
Unit: mm (in) C
Items Thickness Crank pin journal diameter
0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643) Grind so that bearing clearance is the specified value.
D
Connecting Rod Bearing Oil Clearance
Unit: mm (in)
Items Standard Limit E

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

Engine Mechanical: Section

Uploaded by

Copyright:

Available Formats

Engine Mechanical: Section

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine Mechanical: Section

Uploaded by

Copyright:

Available Formats

ENGINE

NOISE, VIBRATION AND HARSHNESS Removal and Installation .........................................28

Revision: August 2007 EM-1 2008 Frontier

CAMSHAFT ....................................................... 51 FUNCTION DIAGNOSIS ........................... 121

Revision: August 2007 EM-2 2008 Frontier

Revision: August 2007 EM-3 2008 Frontier

• Use torque wrench to tighten bolts or nuts to specification.

Revision: August 2007 EM-4 2008 Frontier

Tool number : KV10112100 (BT-8653-A) D

- Cylinder head bolts

REMOVAL OF LIQUID GASKET SEALING

Tool number : KV10111100 (J-37228) I

If for some unavoidable reason tool such as screwdriver is

Revision: August 2007 EM-5 2008 Frontier

Tool number : WS39930000 ( — )

Revision: August 2007 EM-6 2008 Frontier

KV10116200 Disassembling valve mechanism F

KV10112100 Tightening bolts for connecting rod bearing

KV10117100 Loosening or tightening air fuel ratio sensor 1 K

KV10115600 Installing valve oil seal

Revision: August 2007 EM-7 2008 Frontier

ST16610001 Removing pilot bushing (M/T models) or pilot

WS39930000 Pressing the tube of liquid gasket

— Removing fuel tube quick connectors in en-

— Releasing drive belt tension

— Loosening or tightening air fuel ratio A/F sen-

KV10114400 Loosening or tightening heated oxygen sen-

Revision: August 2007 EM-8 2008 Frontier

(Kent-Moore No.) Description

( — ) Removing and installing spark plug

( — ) Removing and installing crankshaft pulley G

( — ) Checking compression pressure

Revision: August 2007 EM-9 2008 Frontier

TORX socket Removing and installing flywheel

Deep socket Removing and installing oil pressure switch

( — ) Removing and installing piston ring

( — ) Removing and installing valve guide

( — ) 1: Reaming valve guide inner hole

Revision: August 2007 EM-10 2008 Frontier

( — ) Lubricating oxygen sensor thread cleaning

Revision: August 2007 EM-11 2008 Frontier

Revision: August 2007 EM-12 2008 Frontier

Revision: August 2007 EM-13 2008 Frontier

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

Checking Drive Belt INFOID:0000000003261105

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

Revision: August 2007 EM-14 2008 Frontier

Tool number : — (J-46535)

Removal and Installation of Drive Belt Auto Tensioner INFOID:0000000003261108

Revision: August 2007 EM-15 2008 Frontier

Revision: August 2007 EM-16 2008 Frontier

1. Ignition coil 2. Spark plug 3. Rocker cover

INSPECTION AFTER REMOVAL

Revision: August 2007 EM-17 2008 Frontier

Revision: August 2007 EM-18 2008 Frontier

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

Cold Hot * (reference data) P

Revision: August 2007 EM-19 2008 Frontier

No. 1 cylinder at INT × ×