(NISSAN) Manual de Taller Nissan Cube 2014

ENGINE
SECTION
ENGINE MECHANICAL
EM EM
E
CONTENTS
SYMPTOM DIAGNOSIS ............................... 3 Inspection and Adjustment ......................................18 F
NOISE, VIBRATION AND HARSHNESS COMPRESSION PRESSURE ........................... 21

(NVH) TROUBLESHOOTING ............................. 3 Inspection ................................................................21
G
NVH troubleshooting Chart ....................................... 3
REMOVAL AND INSTALLATION ............... 22
PRECAUTION ............................................... 5
ENGINE COVER ............................................... 22 H
PRECAUTIONS ................................................... 5 Exploded View .........................................................22
Precautions for Removing of Battery Terminal ......... 5 Removal and Installation .........................................22
Precaution for Procedure without Cowl Top Cover...... 5 I
DRIVE BELT AUTO TENSIONER AND IDLER
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
PULLEY ............................................................. 23
SIONER" ................................................................... 5 Exploded View .........................................................23
Removal and Installation .........................................23 J
Precautions For Engine Service ................................ 6
Parts Requiring Angle Tightening ............................. 6 AIR CLEANER AND AIR DUCT ....................... 24
Liquid Gasket ............................................................ 7 Exploded View .........................................................24
K
Removal and Installation .........................................24
PREPARATION ............................................ 9
Inspection ................................................................25
PREPARATION ................................................... 9
INTAKE MANIFOLD ......................................... 26 L
Special Service Tools ................................................ 9
Exploded View .........................................................26
Commercial Service Tools ...................................... 10
Removal and Installation .........................................26
PERIODIC MAINTENANCE ......................... 13 EXHAUST MANIFOLD ...................................... 29 M
DRIVE BELT .......................................................13 Exploded View .........................................................29

Exploded View ........................................................ 13 Removal and Installation .........................................29
Checking ................................................................. 13 Inspection ................................................................31 N
Tension Adjustment ................................................ 13 OIL PAN (LOWER) ........................................... 32
Removal and Installation ......................................... 13
Exploded View .........................................................32
O
AIR CLEANER FILTER ......................................15 Removal and Installation .........................................32
Removal and Installation ......................................... 15 Inspection ................................................................34
Inspection (Viscous Paper Type) ............................ 15 FUEL INJECTOR AND FUEL TUBE ................ 35 P
SPARK PLUG ....................................................16 Exploded View .........................................................35
Exploded View ........................................................ 16 Removal and Installation .........................................35
Removal and Installation ......................................... 16 Inspection ................................................................38
Inspection ................................................................ 17 IGNITION COIL, SPARK PLUG AND ROCK-
CAMSHAFT VALVE CLEARANCE ...................18 ER COVER ........................................................ 40
Exploded View .........................................................40
Revision: 2013 October EM-1 2014 CUBE

Removal and Installation ........................................ 40 ENGINE STAND SETTING ............................... 79
Setting ..................................................................... 79
TIMING CHAIN .................................................. 42
Exploded View ........................................................ 42 ENGINE UNIT .................................................... 81
Removal and Installation ........................................ 43 Disassembly ............................................................ 81
Inspection ............................................................... 51 Assembly ................................................................ 81
CAMSHAFT ....................................................... 53 OIL PAN (UPPER) ............................................. 82
Exploded View ........................................................ 53 Exploded View ........................................................ 82
Removal and Installation ........................................ 54 Removal and Installation ......................................... 82
Inspection ............................................................... 57 Inspection ................................................................ 85
OIL SEAL ........................................................... 62 CYLINDER BLOCK ........................................... 86
Exploded View ........................................................ 86
VALVE OIL SEAL ..................................................... 62
Disassembly and Assembly .................................... 87
VALVE OIL SEAL : Removal and Installation ......... 62
Inspection ................................................................ 95
FRONT OIL SEAL ..................................................... 62
HOW TO SELECT PISTON AND BEARING .. 106
FRONT OIL SEAL : Removal and Installation ........ 63
Description ............................................................ 106
REAR OIL SEAL ....................................................... 63 Piston .................................................................... 106
REAR OIL SEAL : Removal and Installation .......... 63 Connecting Rod Bearing ..................................... 107
Main Bearing ........................................................ 109
CYLINDER HEAD .............................................. 65
Exploded View ........................................................ 65 SERVICE DATA AND SPECIFICATIONS
Removal and Installation ........................................ 66 (SDS) ......................................................... 113
Disassembly and Assembly .................................... 67
Inspection ............................................................... 71 SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................ 113
UNIT REMOVAL AND INSTALLATION ..... 74 General Specification ............................................ 113
Drive Belt .............................................................. 113
ENGINE ASSEMBLY ......................................... 74 Spark Plug ............................................................ 113
Exploded View ........................................................ 74 Exhaust Manifold .................................................. 114
Removal and Installation ........................................ 74 Camshaft ............................................................... 114
Inspection ............................................................... 78 Cylinder Head ....................................................... 116
Cylinder Block ....................................................... 118
UNIT DISASSEMBLY AND ASSEMBLY ... 79
Connecting Rod Bearing ....................................... 122
Main Bearing ......................................................... 122

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
NVH troubleshooting Chart INFOID:0000000009944906
EM
PBIC3932E
1. Locate the area where noise occurs.

2. Confirm the type of noise.
3. Specify the operating condition of engine.

< SYMPTOM DIAGNOSIS >
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-18
gine clicking noise
Rocker
cover Camshaft Camshaft journal oil
Cylinder Rattle C A — A B C bearing clearance EM-114
head noise Camshaft runout
Piston to piston pin oil

Slap or Piston pin clearance
— A — B B — EM-118
knock noise Connecting rod bushing
oil clearance
Piston to cylinder bore
Crank- clearance
shaft pul- Piston ring side clear-
Slap or Piston
ley A — — B B A ance EM-118
rap slap noise
Cylinder Piston ring end gap
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-118
Knock A B C B B B
bearing Connecting rod bearing EM-122
noise oil clearance
Main bearing oil clear-
Main bear- EM-122
Knock A B — A B C ance
ing noise EM-118
Crankshaft runout
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear EM-51
A A — B B B chain ten-
Front cov- ticking Timing chain tensioner EM-42
sioner
er operation
noise
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-13
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water CO-19,
Squall
A B — B A B pump Water pump operation "Exploded
Creak
noise View"
A: Closely related B: Related C: Sometimes related —: Not related

PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precautions for Removing of Battery Terminal INFOID:0000000010190653
EM
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
NOTE: C
ECU may be active for several tens of seconds after the ignition
switch is turned OFF. If the battery terminal is removed before ECU
stops, then a DTC detection error or ECU data corruption may D
occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE: E
If the ignition switch is turned ON with any one of the terminals of
SEF289H
main battery and sub battery disconnected, then DTC may be
detected. F
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
G
Precaution for Procedure without Cowl Top Cover INFOID:0000000009944907
When performing the procedure after removing cowl top cover, cover H
the lower end of windshield with urethane, etc to prevent damage to
windshield.
PIIB3706J
K
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000010190654
L
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 M
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 “SRS AIR BAG” and “SEAT BELT” of this
Service Manual. N
WARNING:
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in O
the event of a collision that 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 P
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:

PRECAUTIONS
< PRECAUTION >
Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precautions For Engine Service INFOID:0000000009944910
DISCONNECTING FUEL PIPING

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

Drain engine coolant and engine oil when the engine is cooled.
INSPECTION, REPAIR AND REPLACEMENT

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

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

• Use torque wrench to tighten bolts or nuts to specification.
• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
• After disassembling, or exposing any internal engine parts, change engine oil and replace oil filter with a new
one.
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Parts Requiring Angle Tightening INFOID:0000000009944911
• Use the angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts:
- Camshaft sprocket (INT) bolt
- Cylinder head bolts
- Main bearing cap bolts
- Connecting rod cap bolts

PRECAUTIONS
< PRECAUTION >
- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle
tightening) A
• 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.
EM
Liquid Gasket INFOID:0000000009944912
REMOVAL OF LIQUID GASKET SEALING C

• After removing mounting nuts and bolts, separate the mating sur-
face using the seal cutter [SST: KV10111100 (J-37228)] (A) and
remove old liquid gasket sealing. D
CAUTION:
Be careful not to damage the mating surfaces.
• Tap the seal cutter [SST: KV10111100 (J-37228)] to insert it (B),
and then slide it (C) by tapping on the side as shown in the figure. E
• In areas where the seal cutter [SST: KV10111100 (J-37228)] is dif-
ficult to use, lightly tap the parts using a plastic hammer to remove
it. F
CAUTION:
JPBIA0052ZZ
If for some unavoidable reason tool such as a screwdriver is
used, be careful not to damage the mating surfaces.
G
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper (A), remove old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface. H
• Remove liquid gasket completely from the groove of the liquid
gasket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur- I
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
JPBIA0053ZZ
K
3. Attach liquid gasket tube to the tube presser (commercial ser-
vice tool).
Use Genuine RTV Silicon Sealant or equivalent. Refer to GI-
22, "Recommended Chemical Products and Sealants". L
4. Apply liquid gasket without gaps to the specified location accord-
ing to the specified dimensions.
• If there is a groove for liquid gasket application, apply liquid M
gasket to the groove.
N
EMA0622D
• As for bolt holes (B), normally apply liquid gasket inside the O
holes. Occasionally, it should be applied outside the holes.
Check to read the text of this manual.
A : Groove P
: Inside
• Within five minutes of liquid gasket application, install the mat-

ing component.
• If liquid gasket protrudes, wipe it off immediately.
• Do not retighten mounting bolts or nuts after the installation.
JPBIA0010ZZ

PRECAUTIONS
< PRECAUTION >
• 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 them.

PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000009944913
EM
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description C
Tool name
KV10111100 Removing oil pan (upper and lower) etc.
(J-37228) D
Seal cutter
S-NT046
KV10116200 Disassembling and assembling valve mecha- F

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

(BT8653-A) head, etc.
I
Angle wrench
S-NT014
KV10117100 Loosening or tightening air fuel ratio sensor 1 K

(J-3647-A) For 22 mm (0.87 in) width hexagon nut
Heated oxygen sensor wrench
NT379 M
KV10107902 Removing valve oil seal
(J-38959)
Valve oil seal puller N
O
NT011
KV10115600 Installing valve oil seal

(J-38958) Use side A (G). P
Valve oil seal drift a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421)
c: 10.3 (0.406) dia. f: 5 (0.20)
H: Side B
Unit: mm (in)
JPBIA0396ZZ

PREPARATION
< PREPARATION >
Tool number
(Kent-Moore No.) Description
Tool name
EM03470000 Installing piston assembly into cylinder bore
(J-8037)
Piston ring compressor
S-NT044
ST16610001 Removing pilot converter

(J-23907)
Pilot bushing puller
S-NT045
KV11103000 Removing crankshaft pulley

( — )
Pulley puller
NT676
KV11105210 Fixing drive plate

(J-44716)
Stopper plate
ZZA0009D
Commercial Service Tools INFOID:0000000009944914
(Kent-Moore No.)
Description
Tool name
(J-45488) Removing fuel tube quick connectors in en-
Quick connector release gine room
PBIC0198E
( — ) Removing and installing spark plug

Spark plug wrench a: 14 mm (0.55 in)
JPBIA0399ZZ

PREPARATION
< PREPARATION >
(Kent-Moore No.)
Description
Tool name A
( — ) Crankshaft pulley removing and installing
Pulley holder
EM
C
ZZA1010D
( — ) Finishing valve seat dimensions

Valve seat cutter set D
S-NT048
F
( — ) Removing and installing piston ring
Piston ring expander
H
S-NT030
( — ) Removing and installing valve guide

Valve guide drift
I
PBIC4012E
( — ) 1: Reaming valve guide inner hole K

Valve guide reamer 2: Reaming hole for oversize valve guide
PBIC4013E M
(J-43897-18) Reconditioning the exhaust system threads
(J-43897-12) before installing a new air fuel ratio sensor
Oxygen sensor thread cleaner (Use with anti-seize lubricant shown below.)
N
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 O
C: Mating surface shave cylinder
JPBIA0238ZZ D: Flutes
( — ) Lubricating oxygen sensor thread cleaning
Anti-seize lubricant (Permatex 133AR tool when reconditioning exhaust system P
or equivalent meeting MIL specifica- threads
tion MIL-A-907)
AEM489

PREPARATION
< PREPARATION >
(Kent-Moore No.)
Description
Tool name
( — ) Removing and installing engine
Manual lift table caddy
ZZA1210D
( — ) Pressing the tube of liquid gasket

Tube presser
S-NT052

DRIVE BELT
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE A
DRIVE BELT
Exploded View INFOID:0000000009944915
EM
E
PBIC3137J
1. Alternator 2. Drive belt auto-tensioner 3. Crankshaft pulley F

A/C compressor (models with A/C)
4. 5. Water pump 6. Drive belt
Idler pulley (models without A/C)
Range when new drive belt is in- G
A. Possible use range B. C. Indicator
stalled
Checking INFOID:0000000009944916
H
WARNING:
Perform this step when engine is stopped.
• Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range I
(A) in the figure.
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold. J
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the fig-
ure.
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt. K
Tension Adjustment INFOID:0000000009944917
L
Refer to : EM-113, "Drive Belt".
Removal and Installation INFOID:0000000009944918 M
REMOVAL
1. Remove front wheel and tire (RH). N
2. Remove front fender protector (RH). Refer to EXT-21, "FENDER PROTECTOR : Exploded View".
3. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with
a wrench securely. Then move the wrench handle in the direc- O
tion of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur P
if the holding tool accidentally comes off.
4. Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole (B) of the retaining boss to
fix drive belt auto-tensioner.
• Keep drive belt auto-tensioner pulley arm locked after drive
belt is removed. PBIC3936E
5. Remove drive belt.

DRIVE BELT
INSTALLATION
1. Install drive belt.
CAUTION:
• Confirm drive belt is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each
pulley groove.
2. Release drive belt auto-tensioner, and apply tension to drive belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to
EM-13, "Exploded View".

AIR CLEANER FILTER
AIR CLEANER FILTER
A
Removal and Installation INFOID:0000000009944919
REMOVAL EM
1. Push the tabs (A) of both ends of the air cleaner cover (1) into
the inside (B).
2. Pull up the air cleaner cover forward (C) and remove it. C
E
PBIC3557J
3. Remove the air cleaner filter (1) and holder (2) assembly from F
the air cleaner case.
4. Remove the air cleaner filter from the holder.
G
I
PBIC3558J
INSTALLATION
Note the following, and install in the reverse order of removal. J
• Install the air cleaner cover (1) in the direction as shown in the fig-
ure.
2 : Air cleaner filter K

3 : Holder
M
PBIC3559J
Inspection (Viscous Paper Type) INFOID:0000000010208825

N
INSPECTION AFTER REMOVAL
Examine with eyes that there is no stain, clogging, or damage on air cleaner element.
• Remove dusts (such as dead leafs) on air cleaner element surface and inside cleaner case. O
• If clogging or damage is observed, replace the air cleaner element.
CAUTION:
Never clean the viscous paper type air cleaner element by blowing as there is a risk of deterioration of P
its performance
MAINTENANCE INTERVAL
Refer to MA-6, "Introduction of Periodic Maintenance".

SPARK PLUG
SPARK PLUG
PBIC4366J
1. PCV hose 2. Rocker cover 3. Spark plug

4. Ignition coil 5. PCV hose 6. PCV valve
7. O-ring 8. Rocker cover gasket
Comply with the assembly procedure
A. To air duct assembly B. C. To intake manifold
when tightening. Refer to EM-40
: Always replace after every disassembly.
REMOVAL
1. Remove ignition coil. Refer to EM-40, "Exploded View".
2. Remove spark plug with a spark plug wrench (commercial ser-
vice tool).
a : 14 mm (0.55 in)
CAUTION:
Never drop or shock spark plug.
JPBIA0030ZZ
INSTALLATION

SPARK PLUG
Install in the reverse order of removal.
A
Inspection INFOID:0000000009944922

EM
Use the standard type spark plug for normal condition.
Spark plug (Standard type) : Refer to EM-113, "Spark Plug".

C
CAUTION:
• Never drop or shock spark plug.
• Never use a wire brush for cleaning.
• If plug tip is covered with carbon, spark plug cleaner may be D
used.
Cleaner air pressure : Less than 588 kPa (6 kg/cm2, E

85 psi)
Cleaning time : Less than 20 seconds
F
SMA773C
G
• Spark plug gap adjustment is not required between replace-
ment intervals.
• Measure spark plug gap. when it exceeds the limit, replace
spark plug even if it is with in the specified replacement mile- H
age. Refer to EM-113, "Spark Plug".
J
JPBIA0031ZZ

CAMSHAFT VALVE CLEARANCE
Inspection and Adjustment INFOID:0000000009944923
INSPECTION
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-40, "Exploded View".
2. Measure the valve clearance with the following procedure:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) clockwise and align TDC mark (no
paint) (B) to timing indicator (A) on front cover.
C : White paint mark (Not use for service)
PBIC3960E
• At the same time, check that both intake and exhaust cam
noses of No. 1 cylinder face inside ( ) as shown in the figure.
1 : Camshaft (INT)
2 : Camshaft (EXH)
: Engine front
• If they do not face inside, rotate crankshaft pulley once more

(360 degrees) and align as shown in the figure.
PBIC3359J
b. Use a feeler gauge, measure the clearance between valve lifter

and camshaft.
Valve clearance : Refer to EM-114, "Camshaft".
PBIC3192J
• By referring to the figure, measure the valve clearances at

locations marked “×” as shown in the table below [locations
indicated with black arrow ( ) in the figure] with a feeler
gauge.
A : Exhaust side
B : No. 1 cylinder
C : No. 2 cylinder
D : No. 3 cylinder
E : No. 4 cylinder
PBIC3193J

F : Intake side
: Engine front A
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
EM
EXH × ×
No. 1 cylinder at compression TDC
INT × ×
C
c. Set No. 4 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) one revolution (360 degrees) and
align TDC mark (no paint) (B) to timing indicator (A) on front
cover. D

E
PBIC3960E
G
• 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 ( ) in the figure] with a feeler gauge.
H
A : Exhaust side
B : No. 1 cylinder
C : No. 2 cylinder I
D : No. 3 cylinder
E : No. 4 cylinder
F : Intake side J
PBIC3194J
: Engine front
K
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
EXH × ×
No. 4 cylinder at compression TDC
INT × × L
3. If out of standard, perform adjustment. Refer to “ADJUSTMENT”.

ADJUSTMENT M
• Perform adjustment depending on selected head thickness of valve lifter.
1. Remove camshaft. Refer to EM-53, "Exploded View".
2. Remove valve lifters at the locations that are out of the standard. N
3. Measure the center thickness of the removed valve lifters with a
micrometer (A).
O
PBIC3195J
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
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.30 mm (0.012 in)
Exhaust : 0.33 mm (0.013 in)
• Thickness of new valve lifter (B) can be identified by stamp
mark (A) on the reverse side (inside the cylinder).
• Stamp mark “302” indicates 3.02 mm (0.1189 in) in thickness.
PBIC3196J
NOTE:
Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.1181 to 0.1378 in) in steps of 0.02
mm (0.0008 in) (when manufactured at factory). Refer to EM-114, "Camshaft".
5. Install the selected valve lifter.
6. Install camshaft. Refer to EM-53, "Exploded View".
7. Install timing chain and related parts. Refer to EM-42, "Exploded View".
8. Manually rotate crankshaft pulley a few rotations.
9. Check that the valve clearances is within the standard. Refer to “INSPECTION”.
10. Install remaining parts in the reverse order of removal.
11. Warm up the engine, and check for unusual noise and vibration.

COMPRESSION PRESSURE
COMPRESSION PRESSURE
A
1. Warm up engine thoroughly. Then, stop it. EM

2. Release fuel pressure. Refer to EC-478, "Inspection".
3. Remove ignition coil and spark plug from each cylinder. Refer to EM-40, "Exploded View".
4. Connect engine tachometer (not required in use of CONSULT). C
5. Install compression gauge (B) with an adapter (A) (commercial
service tool) onto spark plug hole.
D
F
PBIC3541J
G
• 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.
H
a : 20 mm (0.79 in)
J
JPBIA0171ZZ
6. 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 K
cylinder.
Compression pressure : Refer to EM-113, "General Specification". L

CAUTION:
Always use a fully charged battery to obtain the specified engine speed.
• If the engine speed is out of the specified range, check battery liquid for proper gravity. Check the M
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, and cylinder
head gasket). After the checking, measure compression pressure again. N
• If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole
of the cylinder to recheck it for compression.
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis- O
ton rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
• If two adjacent cylinders have respectively low compression pressure and their compression remains P
low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
7. After inspection is completed, install removed parts.
8. Start the engine, and check that the engine runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-121, "Description".

ENGINE COVER
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
ENGINE COVER
JPBIA2354GB
1. Engine cover
: N·m (kg-m, in-lb)
REMOVAL
Remove engine cover.
CAUTION:
Never damage or scratch engine cover when installing or removing.
INSTALLATION

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
A
EM
I
JPBIA2908GB
1. Front cover 2. Drive belt auto-tensioner 3. Idler pulley (models without A/C) J
4. Idler pulley bracket (models without A/C) 5. Shaft (models without A/C)
: N·m (kg-m, ft-lb)
K
Removal L
1. Remove the following parts.
• Engine cover: Refer to EM-22, "Exploded View".
• Cowl top cover and extension cowl top: Refer to EXT-19, "Exploded View". M
• Vacuum lines: Refer to BR-31, "Exploded View".
• Air duct: Refer to EM-24, "Exploded View".
• Front fender protector (RH): Refer to EXT-21, "FENDER PROTECTOR : Exploded View".
N
• Ground cable (between front cover and radiator core support)
2. Remove drive belt. Refer to EM-13, "Removal and Installation".
• Keep drive belt auto-tensioner pulley arm locked after drive belt are removed.
O
3. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket (RH) and the engine mounting insulator (RH). Refer to EM-74, "Exploded View".
CAUTION:
Never damage or scratch oil pan (lower) when supporting. P
4. Loosen mounting bolt and remove drive belt auto-tensioner.
• Lift the front side of the engine with a jack sustaining engine base to remove mounting bolt.
Installation
CAUTION:
When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.

AIR CLEANER AND AIR DUCT
JPBIA2909GB
1. Air cleaner filter 2. Mass air flow sensor 3. O-ring

4. Holder 5. Cleaner cover 6. Clamp
7. Air duct 8. PCV hose 9. Air duct (inlet)
10. Air duct 11. Resonator 12. Grommet
13. Grommet 14. Air cleaner case
A. To electric throttle control actuator B. To rocker cover
REMOVAL
NOTE:
Mass air flow sensor is removable under the car-mounted condition.
1. Remove air duct (inlet) and resonator assembly.
2. Remove engine cover. Refer to EM-22, "Exploded View".
3. Remove the air cleaner filter from the air cleaner case.
4. Remove air duct [between air duct (inlet) and air cleaner case] from the air cleaner case.
5. Disconnect PCV hose.
6. Remove the air duct (between air cleaner case and electric throttle control actuator).
• Add matching marks if necessary for easier installation.
7. Remove air cleaner case with the following procedure.
a. Remove battery. Refer to PG-82, "Exploded View".
b. Disconnect mass air flow sensor harness connector.

c. Remove the air cleaner case.
8. Remove mass air flow sensor from air cleaner case, if necessary. A
CAUTION:
Handle the mass air flow sensor with following cares.
• Never shock the mass air flow sensor. EM
• Never disassemble the mass air flow sensor.
• Never touch the sensor of the mass air flow sensor.
INSTALLATION C
CAUTION:
Do not reuse O-rings.
Note the following, and install in the reverse order of removal.
D
• Align marks. Attach each joint. Screw clamps firmly.
E
Inspect air duct and resonator assembly for crack or tear.
• If anything found, replace air duct and resonator assembly. F

INTAKE MANIFOLD
INTAKE MANIFOLD
JPBIA2910GB
1. Clamp 2. Harness bracket 3. Clamp

4. PCV hose 5. Gasket 6. Vacuum hose
7. Clamp 8. Intake manifold 9. Bracket
10. Clamp 11. EVAP hose 12. O-ring
EVAP canister purge volume control
13. 14. EVAP vacuum tank 15. Clamp
solenoid valve
16. EVAP hose 17. EVAP service port 18. EVAP hose
19. Clamp 20. Water hose 21. Water hose
22. Electric throttle control actuator 23. Gasket
A. To brake booster B. To centralized under-floor piping C. To water outlet
REMOVAL
1. Remove engine cover. Refer to EM-22, "Exploded View".
2. Pull out oil level gauge.
CAUTION:
Cover the oil level gauge guide openings to avoid entry of foreign materials.

INTAKE MANIFOLD
3. Disconnect PCV hose from intake manifold and rocker cover.
4. Remove air duct (inlet), resonator and air duct assembly. Refer to EM-24, "Exploded View". A
5. Disconnect vacuum hose from intake manifold.
6. Disconnect water hoses from electric throttle control actuator as follows:
• Drain engine coolant from radiator or attach plug to prevent engine coolant leakage when engine cool- EM
ant is not drained. Refer to CO-8, "Draining".
CAUTION:
Perform this step when the engine is cold. C
7. Remove electric throttle control actuator.
CAUTION:
• Handle carefully to avoid any shock to electric throttle control actuator. D
• Never disassemble electric throttle control actuator.
8. Remove intake manifold (1) with the following procedure:
E
: Engine front
a. Loosen and remove intake manifold mounting bolts (A) and (B).
b. Remove harness clip from intake manifold side. F
c. Disconnect EVAP hose from intake manifold.
d. Disconnect harness connector from EVAP canister purge vol-
ume control valve. G
PBIC3939E
K
e. Loosen mounting bolts in the order of 5 to 1 as shown in the fig-

ure. L
: Engine front
CAUTION: M
Cover engine openings to avoid entry of foreign materials.
PBIC3527J
O
9. Remove brackets from intake manifold, if necessary.
10. Remove engine cover bracket, if necessary.
11. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary. P
INSTALLATION
Intake Manifold
1. Check if gasket is not dropped from the installation groove of intake manifold.
2. Install intake manifold with the following procedure:

INTAKE MANIFOLD
a. Tighten in the order of 1 to 5 as shown in the figure.
: Engine front
b. Tighten No. 1 bolt again.
PBIC3527J
c. Tighten intake manifold mounting bolt (A). Then tighten intake

manifold mounting bolt (B).
1 : Intake manifold
: Engine front
PBIC3939E
Electric Throttle Control Actuator

• Tighten bolts of electric throttle control actuator equally and diagonally in several steps.
• Perform “Throttle Valve Closed Position Learning” after repair when removing harness connector of the elec-
tric throttle control actuator. Refer to EC-19, "THROTTLE VALVE CLOSED POSITION LEARNING :
Description".
• Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when replacing
electric throttle control actuator. Refer to EC-19, "THROTTLE VALVE CLOSED POSITION LEARNING :
Description" and EC-20, "IDLE AIR VOLUME LEARNING : Description" .

EXHAUST MANIFOLD
EXHAUST MANIFOLD
A
EM
I
PBIC4735E
1. Exhaust manifold cover 2. Exhaust manifold 3. Gasket J

4. Stud bolt 5. Harness bracket 6. Air fuel ratio sensor 1
7. Exhaust manifold stay
: Always replace after every disassembly. K
L
REMOVAL
1. Remove exhaust front tube. Refer to EX-5, "Exploded View".
2. Remove exhaust manifold cover. M
3. Remove the air fuel ratio sensor 1.
• Using heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], remove air fuel ratio sensor 1.
CAUTION: N
Handle air fuel ratio sensor 1 carefully and avoid impacts.
NOTE:
The exhaust manifold can be removed and installed without removing the air fuel ratio sensor 1 (Disas-
sembly of harness connector is necessary). O
4. Remove exhaust manifold stay.
5. Remove exhaust manifold.
P

EXHAUST MANIFOLD
• Loosen nuts in the order of 5 to 1 as shown in the figure.
: Engine front
NOTE:
• Disregard No. 6 to 8 when loosening.
JPBIA2356ZZ
6. Remove gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSTALLATION
Exhaust manifold
1. Install gasket to cylinder head as shown in the figure.
: Engine front
PBIC3943E
2. Install exhaust manifold with the following procedure:

a. Tighten nuts in the order of 1 to 8 as shown in the figure.
: Engine front
NOTE:
• No. 6 to 8 mean double tightening of nuts No. 1 to 3.
JPBIA2356ZZ
b. Install exhaust manifold stay (2) in the direction as shown in the

figure.
1 : Exhaust manifold
3 : Drive shaft support bearing bracket
A : Upper mark
: Vehicle front
PBIC3255J

AIR FUEL RATIO SENSOR 1
CAUTION:

EXHAUST MANIFOLD
• Before installing a new air fuel ratio sensor 1, clean exhaust system threads using heated oxygen
sensor thread cleaner tool (commercial service tool) and apply anti-seize lubricant. A
• Never over torque air fuel ratio sensor 1. Doing so may cause damage to air fuel ratio sensor 1,
resulting in the “MI” coming on.
• Prevent rust preventives from adhering to the sensor body.
EM
INSPECTION AFTER REMOVAL C

Surface Distortion
• Using feeler gauge (A) and straightedge (B), check the surface dis-
tortion of exhaust manifold mating surface in each exhaust port D
and entire part.
Limit : Refer to EM-114, "Exhaust Manifold". E

• If it exceeds the limit, replace exhaust manifold.
PBIC3530J
G

OIL PAN (LOWER)
OIL PAN (LOWER)
PBIC4463J
1. Oil level gauge 2. Oil level gauge guide 3. Rear oil seal
4. O-ring 5. Oil pan (upper) 6. Oil pump drive chain
7. Crankshaft sprocket 8. Oil pump sprocket 9. Oil pump chain tensioner
10. Oil pump 11. Drain plug 12. Drain plug washer
13. Oil pan (lower) 14. Oil filter 15. Connector bolt
16. O-ring
A. Comply with the assembly proce- B. Oil pan side
dure when tightening. Refer to LU-11
: Should be lubricated with oil.
: Sealing point
REMOVAL
1. Drain engine oil. Refer to LU-9, "Draining".

OIL PAN (LOWER)
2. Remove oil pan (lower) with the following procedure:
a. Loosen mounting bolts in the order of 10 to 1 as shown in the A
figure.
: Engine front EM
PBIC3146J
D
b. Insert seal cutter [SST: KV10111100 (J-37228)] (A) between oil

pan (upper) and oil pan (lower). E
CAUTION:
• Be careful not to damage the mating surface.
• Never insert a screwdriver. This damages the mating sur-
faces. F
c. Slide the seal cutter [SST: KV10111100 (J-37228)] by tapping on
the side of tool with a hammer.
d. Remove oil pan (lower). G
JPBIA0276ZZ
INSTALLATION H
CAUTION:
Do not reuse drain plug washer.
1. Install oil pan (lower) as follows: I
a. Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Also remove old liquid gasket from mating surface of oil pan J
(upper).
• Remove old liquid gasket from the bolt holes and threads.
CAUTION: K
Never scratch or damage the mating surface when cleaning
off old liquid gasket.
L
PBIC3953E

OIL PAN (LOWER)
b. Apply a continuous bead of liquid gasket (A) with a tube presser
(commercial service tool) as shown in the figure.
1 : Oil pan (lower)

: Engine outside

22, "Recommended Chemical Products and Sealants".
CAUTION:
Attaching should be done within 5 minutes after liquid gas-
ket application.
PBIC4590E
c. Tighten bolts in the order of 1 to 10 as shown in the figure.
: Engine front
PBIC3146J
2. Install oil pan drain plug.

• Refer to the figure of components of former page for installation direction of drain plug washer. Refer to
EM-32, "Exploded View".
3. Install in the reverse order of removal after this step.

Clean oil strainer if any object attached.
INSPECTION AFTER INSTALLATION
1. Check the engine oil level and adjust engine oil. Refer to LU-8, "Inspection".
2. Start engine, and check there is no leakage of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check the engine oil level again. Refer to LU-8, "Inspection".

FUEL INJECTOR AND FUEL TUBE
A
EM
I
PBIC3537J
1. Fuel feed tube 2. Bracket 3. Quick connector cap J

4. Fuel tube 5. O-ring (black) 6. Clip
7. Injector 8. O-ring (green)
A. To centralized under-floor piping K

L
CAUTION:
Never remove or disassemble parts unless instructed as shown in the figure.
M
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop. N
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
REMOVAL O
1. Release the fuel pressure. Refer to EC-478, "Inspection".
2. Remove intake manifold. Refer to EM-26, "Exploded View".
P

3. Disconnect quick connector with the following procedure. Dis-
connect fuel feed tube (1) from fuel tube (3).
NOTE:
There is no fuel return path.
a. Remove quick connector cap (engine side) (2) from quick con-
nector connection.
PBIC3157J
b. With the sleeve side of quick connector release facing quick connector, install quick connector release
(commercial service tool) onto fuel tube.
c. Insert quick connector release (A) into quick connector (2) until
sleeve (B) contacts and goes no further. Hold quick connector
release on that position.
D : Insert and retain

CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
d. Draw and pull out quick connector straight from fuel tube (1).
CAUTION: JPBIA2255ZZ
• Pull quick connector (E) holding position (C) in the figure.

• Never pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth beforehand as fuel will leakage out.
• Avoid fire and sparks.
• Keep parts away from heat source. Especially, be careful when welding is performed around
them.
• Never expose parts to battery electrolyte or other acids.
• Never bend or twist connection between quick connector and fuel feed tube during installation/
removal.
• To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags, etc. (A) or something similar.
JPBIA2888ZZ
4. Disconnect harness connector from fuel injector.

5. Remove fuel tube and fuel injector assembly.
• Loosen mounting bolts in the order of 2, 1 as shown in the fig-
ure.
: Engine front
CAUTION:
• When removing, be careful to avoid any interference with fuel
injector.
• Use a shop cloth to absorb any fuel leakage from fuel tube.
PBIC3154J

6. Remove fuel injector from fuel tube with the following procedure: A
a. Open and remove clip (2).
b. Remove fuel injector (3) from fuel tube (1) by pulling straight.
CAUTION: EM
• Be careful with remaining fuel that may go out from fuel
tube.
• Be careful not to damage fuel injector nozzle during
removal. C
• Never bump or drop fuel injector.
• Never disassemble fuel injector.
D
JPBIA0290ZZ
INSTALLATION E
CAUTION:
1. Note the following, and install O-rings to fuel injector. F
CAUTION:
• Do not reuse O-ring.
• Upper and lower O-rings are different. Be careful not to confuse them.
G
Fuel tube side : Black
Nozzle side : Green
H
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material. I
• 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 is stretched while installing, never insert it quickly into fuel tube.
• Insert O-ring straight into fuel tube. Never decenter or twist it. J
2. Install fuel injector to fuel tube with the following procedure:
a. Insert clip (2) into clip mounting groove (F) on fuel injector (4).
K
3 : O-ring (black)
5 : O-ring (green)
• Insert clip so that protrusion (G) of fuel injector matches cut- L
out (D) of clip.
CAUTION:
• Never reuse clip. Replace it with a new one. M
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube (1) with clip attached.
N
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (B) of fuel tube matches
cut-out (C) of clip.
• Check that fuel tube flange (A) is securely fixed in flange fixing O
groove (E) on clip.
c. Check that installation is complete by checking that fuel injector
does not rotate or come off. P
PBIC3155J
3. Set fuel tube and fuel injector assembly at its position for installation on cylinder head.
CAUTION:

For installation, be careful not to interfere with fuel injector nozzle.
4. Install fuel tube and injector assembly onto cylinder.
• Tighten mounting bolts in the order of 1, 2 as shown in the fig-
ure.
: Engine front
PBIC3154J
5. Connect harness connector to fuel injector.

6. Connect fuel feed tube with the following procedure.
a. Check for damage or foreign material on the fuel tube and quick connector.
b. Apply new engine oil lightly to area around the top of fuel tube.
c. Align center to insert quick connector straightly into fuel tube.
• Insert quick connector (1) to fuel tube until the top spool (C) on
fuel tube is inserted completely and the 2nd level spool (D) is
positioned slightly below quick connector bottom end.
B : Upright insertion
E : Fitted condition
CAUTION:
• Hold (A) position in the figure when inserting fuel tube
into quick connector.
• Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector. JPBIA2256ZZ
• 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.
d. Pull quick connector hard by hand holding position. Check it is completely engaged (connected) so that it
does not come out from fuel tube.
e. Install quick connector cap (engine side) (2) to quick connector
connection.
1. Fuel feed hose

3. Fuel tube
• Install quick connector cap (engine side) with the side arrow
facing quick connector side (fuel feed tube side).
CAUTION:
• Check that the quick connector and fuel tube are
securely engaged with the quick connector cap (engine
side) mounting groove. PBIC3157J
• Quick connector may not be connected correctly if

quick connector cap (engine side) cannot be installed easily. Remove the quick connector cap
(engine side), and then check the connection of quick connector again.
f. Install fuel feed hose to hose clamp.


Check on Fuel Leakage
1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there A
are no fuel leakage at connection points.
NOTE:
Use mirrors for checking at points out of clear sight. EM
2. Start the engine. With engine speed increased, check again that there are no fuel leakage at connection
points.
CAUTION: C
Never touch the engine immediately after stopped, as the engine becomes extremely hot.

IGNITION COIL, SPARK PLUG AND ROCKER COVER
PBIC4366J
1. PCV hose 2. Rocker cover 3. Spark plug

4. Ignition coil 5. PCV hose 6. PCV valve
7. O-ring 8. Rocker cover gasket
A. To air duct assembly B. C. To intake manifold
REMOVAL
1. Remove intake manifold. Refer to EM-26, "Exploded View".
2. Remove ignition coil.
CAUTION:
• Never drop or shock ignition coil.
• Never disassemble ignition coil.
3. Remove rocker cover.

• Loosen bolts in the order of 7 to 1 as shown in the figure.
A
: Engine front
EM
PBIC3151J
D
4. Remove PCV valve and PCV hose, if necessary.
5. Remove rocker cover gasket from rocker cover.
6. Use scraper to remove all traces of liquid gasket from cylinder head and front cover. E
CAUTION:
Never scratch or damage the mating surface when cleaning off old liquid gasket.
INSTALLATION F
CAUTION:
1. Install the rocker cover gasket to rocker cover. G
CAUTION:
Check the gasket is not dropped.
2. Install rocker cover. H
• Tighten bolts in two steps separately in the order of 1 to 7 as
shown in the figure.
: Engine front I
1st step : 1.96 N·m (0.20 kg-m, 17 in-lb) J

2nd step : 8.33 N·m (0.85 kg-m, 74 in-lb)
3. Install in the reverse order of removal, for the rest of parts.
K
PBIC3151J

TIMING CHAIN
TIMING CHAIN
PBIC3538J
1. Timing chain slack guide 2. Timing chain tensioner 3. Camshaft sprocket (EXH)
4. Timing chain 5. Oil filler cap 6. Front cover
Intake valve timing control solenoid
7. O-ring 8. 9. Crankshaft pulley bolt
valve
10. Crankshaft pulley 11. Front oil seal 12. Drive belt auto-tensioner
Timing chain tension guide (front cov-
13. 14. Crankshaft sprocket 15. Oil pump sprocket
er side)

TIMING CHAIN
16. Oil pump drive chain 17. Camshaft sprocket (INT) 18. Timing chain tension guide
19. O-ring 20. Oil pump chain tensioner A
Comply with the assembly procedure Comply with the assembly procedure
A. B.
when tightening. Refer to EM-43 when tightening. Refer to EM-54
: Always replace after every disassembly. EM
: Sealing point C
D
REMOVAL
CAUTION:
The rotating direction in the text indicates all directions seen from the engine front. E
1. Remove front fender protector (RH). Refer to EXT-21, "FENDER PROTECTOR : Exploded View".
CAUTION: F
Perform this step when engine is cold.
3. Remove the following parts:
• Intake manifold: Refer to EM-26, "Exploded View".
G
• Rocker cover: Refer to EM-40, "Exploded View".
• Drive belt: Refer to EM-13, "Removal and Installation".
• Ground cable (between front cover and radiator core support)
4. Set No. 1 cylinder at TDC on its compression stroke with the following procedure: H
a. Rotate crankshaft pulley (1) clockwise and align TDC mark (no
paint) (B) to timing indicator (A) on front cover.
I
K
PBIC3960E
b. At the same time, check that the cam noses of the No. 1 cylinder L
are located ( ) as shown in the figure.
1 : Camshaft (INT) M
2 : Camshaft (EXH)
: Engine front
• If not, rotate crankshaft pulley one revolution (360 degrees) N

and align as shown in the figure.
PBIC3359J O
5. Remove crankshaft pulley with the following procedure:

P

TIMING CHAIN
a. Fix crankshaft pulley (1) with a pulley holder (commercial ser-
vice tool) (A), loosen crankshaft pulley bolt, and locate bolt seat-
ing surface at 10 mm (0.39 in) from its original position.
CAUTION:
Never remove the crankshaft pulley bolt as they will be
used as a supporting point for the pulley puller [SST:
KV11103000 ( — )].
PBIC3961E
b. Attach a pulley puller [SST: KV11103000 ( — )] (A) in the M6

thread hole on crankshaft pulley (1), and remove crankshaft pul-
ley.
PBIC3962E
6. Remove oil pan (lower). Refer to EM-32, "Exploded View".

NOTE:
If crankshaft sprocket and oil pump drive component are not removed, this step is unnecessary.
7. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket (RH) and the engine mounting insulator (RH). Refer to EM-74, "Exploded View".
8. Remove intake valve timing control solenoid valve.
9. Remove drive belt auto-tensioner. Refer to EM-23, "Exploded View".
10. Remove front cover with the following procedure:
a. Loosen mounting bolts in the order of 22 to 1 as shown in the
figure.
PBIC3164J

TIMING CHAIN
b. Cut liquid gasket by prying the position ( ) shown in the figure,
and then remove the front cover. A
CAUTION:
• A more adhesive liquid gasket is applied compared to pre- EM
vious types when shipped, so it should not be forced off
the position not specified.
PBIC3357J
D
11. Remove front oil seal from front cover.
CAUTION:
Be careful not to damage front cover.
E
• Lift up front oil seal using a screwdriver.
12. Remove timing chain tensioner with the following procedure:
a. Push in timing chain tensioner plunger.
F
b. Insert a stopper pin (A) into the body hole, and then fix it with the
plunger pushed in.
NOTE:
Use approximately 1.5 mm (0.059 in) diameter. hard metal pin G
as a stopper pin.
c. Remove timing chain tensioner (1).
H
I
PBIC3165J
13. Remove slack guide (2), tension guide (3) and timing chain (1).
CAUTION: J
Never rotate each crankshaft and camshaft individually
while timing chain is removed. It causes interference
between valve and piston. K
NOTE:
If timing chain is difficult to remove, remove camshaft sprocket
(EXH) first to remove timing chain.
L
P
JPBIA0830ZZ
14. Remove crankshaft sprocket and oil pump drive component with the following procedure:

TIMING CHAIN
a. Press stopper tab (A) in the direction shown in the figure to push
the oil pump chain tensioner slack guide (B) toward oil pump
chain tensioner (1).
• The oil pump chain tensioner slack guide is released by press-
ing the stopper tab. As the result, the oil pump chain tensioner
slack guide can be moved.
b. Insert a stopper pin (D) into tensioner body hole (C) to secure
the oil pump chain tensioner slack guide.
NOTE:
Use a hard metal pin with the diameter of approximately 1.2 mm
(0.047 in) as a stopper pin.
c. Remove oil pump chain tensioner.
• When the holes on lever and tensioner body cannot be
aligned, align these holes by slightly moving the oil pump
chain tensioner slack guide.
PBIC5314E
d. Hold the WAF part of oil pump shaft [WAF: 10 mm (0.39 in)] (A),
and then loosen the oil pump sprocket bolt and remove it.
1 : Oil pan (upper)

2 : Oil pump
: Engine front
CAUTION:
• Secure the oil pump shaft with the WAF part.
• Never loosen the oil pump sprocket bolt by tightening the
oil pump drive chain.
e. Remove crankshaft sprocket, oil pump sprocket, and oil pump
drive chain as a set.
PBIC3539J
15. Remove tension guide (front cover side) from front cover, if necessary.
INSTALLATION
CAUTION:
NOTE:

TIMING CHAIN
The figure shows the relationship between the matching mark on
each timing chain and that on the corresponding sprocket, with the A
components installed.
1 : Timing chain
EM
2 : Camshaft sprocket (EXH)
3 : Slack guide
4 : Timing chain tensioner
C
5 : Oil pump sprocket
6 : Oil pump drive chain
7 : Oil pump chain tensioner
D
8 : Crankshaft sprocket
9 : Tension guide
10 : Camshaft sprocket (INT) E
A : Matching mark (dark blue link)
B : Matching mark (stamping)
C : Crankshaft key position (straight up) F
D : Matching mark (stamping)
E : Matching mark (orange link)
F : Matching mark (outer groove*) G
JPBIA0831ZZ
*: There are two outer grooves in camshaft sprocket (INT). The wider one is a match-
ing mark.
1. Check that crankshaft key points straight up. H
2. If the tension guide (front cover side) is removed, install it to the front cover.
CAUTION:
Check the joint condition by sound or feeling. I
3. Install crankshaft sprocket (2), oil pump sprocket (3), and oil
pump drive chain (1).
J
A : Matching mark (stamping)
B : Matching mark (orange link)
C : Matching mark (dark blue link)
K
• Install it by aligning matching marks on each sprockets and oil
pump drive chain.
• If these matching marks are not aligned, rotate the oil pump L
shaft slightly to correct the position.
CAUTION: PBIC3171J
Check matching mark position of each sprockets after

installing the oil pump drive chain. M

TIMING CHAIN
4. Hold the WAF part of oil pump (2) shaft [WAF: 10 mm (0.39 in)]
(A), and then tighten the oil pump shaft sprocket bolt.
1 : Oil pan (upper)

: Engine front
CAUTION:
• Secure the oil pump shaft with the WAF part.
• Never loosen the oil pump shaft sprocket bolt by tighten-
ing the oil pump drive chain.
PBIC3539J
5. Install oil pump chain tensioner (1).

• Fix the plunger at the most compressed position using a stop-
per pin (A), and then install it.
• Securely pull out ( ) the stopper pin after installing the oil
pump chain tensioner.
• Check matching mark position of oil pump drive chain and
each sprockets again.
PBIC5315E

TIMING CHAIN
6. Align the matching marks of each sprockets with the matching
marks of timing chain. A

2 : Camshaft sprocket (INT) EM
3 : Timing chain
A : Matching mark (dark blue link)
B : Matching mark (stamping) C
C : Matching mark (outer groove*)
D : Matching mark (orange link)
E : Matching mark (stamping) D
*: There are 2 outer grooves in camshaft sprocket (INT). The wider one is a
matching mark.
• If these matching marks are not aligned, rotate the camshaft E
slightly by holding the hexagonal portion to correct the posi-
tion.
CAUTION:
Check matching mark position of each sprocket and timing F
chain again after installing the timing chain.
G
PBIC3172J
7. Install the slack guide (2) and the tension guide (3).
H
1 : Timing chain
N
JPBIA0830ZZ
8. Install timing chain tensioner (1). O

• Fix the plunger at the most compressed position using a stop-
per pin (A), and then install it.
• Securely pull out the stopper pin after installing the timing
chain tensioner. P
PBIC3165J

TIMING CHAIN
9. Check matching mark position of timing chain and each sprockets again.
10. Install front oil seal. Refer to EM-63, "FRONT OIL SEAL : Removal and Installation".
11. Install front cover with the following procedure:
a. Install new O-ring to cylinder block.
CAUTION:
Never misalign O-ring.
b. Apply a continuous bead of liquid gasket (B) with a tube presser
(commercial service tool) to front cover as shown in the figure.
A : Liquid gasket application area

c : 4.0 - 5.6 mm (0.157 - 0.220 in)
d : φ3.4 - 4.4 mm (0.134 - 0.173 in)
: Engine outside

JPBIA2257ZZ
c. Check that matching marks of timing chain and each sprockets are still aligned. Then install front cover.
CAUTION:
• Check O-ring on cylinder block is correctly installed.
• Be careful not to damage front oil seal by interference with front end of crankshaft.
d. Install front cover, and tighten mounting bolts in the order of 1 to
22 as shown in the figure.
• Refer to the following for the installation position of bolts.
M6 bolt : No. 1
M10 bolts : No. 6, 7, 10, 11, 14
M12 bolts : No. 2, 4, 8, 12
M8 bolts : Except the above
CAUTION:
Attaching should be done within 5 minutes after liquid gas-
ket application.
e. After all bolts are tightened, retighten them to specified torque in
numerical order as shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking.
PBIC3164J
12. Install crankshaft pulley with the following procedure:

TIMING CHAIN
a. When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION: A
Never damage front oil seal lip section.
b. Secure crankshaft pulley (1) with a pulley holder (commercial
service tool) (A). EM
c. Apply new engine oil to thread and seat surfaces of crankshaft
pulley bolt.
d. Tighten crankshaft pulley bolt. C
: 68.6 N·m (7.0 kg-m, 51 ft-lb)

D
e. Completely loosen.
PBIC3961E
: 0 N·m (0 kg-m, 0 ft-lb) E

f. Tighten crankshaft pulley bolt.
F
: 29.4 N·m (3.0 kg-m, 22 ft-lb)
g. Put a paint mark (B) on crankshaft pulley (2), matching with any
one of six easy to recognize angle marks (A) on crankshaft pul- G
ley bolt (1) flange.
h. Turn another 60 degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark. H
i. Check that crankshaft rotates clockwise smoothly.
PBIC3963E
J
K
Timing Chain L
Check for cracks (A) and any excessive wear (B) at link plates and
roller links of timing chain. Replace timing chain if necessary.
M
O
PBIC3169J

P
Inspection for Leakage
The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-10, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.

TIMING CHAIN
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise
will stop after hydraulic pressure rises.
• Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission / AT & CVT Models Leakage Level / Leakage Leakage

transaxle fluid MT Models Level / Leakage Leakage Level / Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.

CAMSHAFT
CAMSHAFT
A
EM
L
JPBIA2151GB
1. Camshaft position sensor (PHASE) 2. O-ring 3. Camshaft bracket M

4. Camshaft (EXH) 5. Camshaft sprocket (EXH) 6. Camshaft sprocket (INT)
7. Camshaft (INT) 8. Valve lifter (EXH) 9. Valve lifter (INT)
10. Signal plate N
A.
O

P
: Sealing point
: Select with proper thickness.

CAMSHAFT
CAUTION:
The rotating direction in the text indicates all directions seen from the engine front.
REMOVAL
• Front cover and timing chain related parts: Refer to EM-42, "Exploded View".
NOTE:
Removal of oil pump drive related part is not necessary.
2. Remove camshaft position sensor (PHASE) from camshaft bracket.
CAUTION:
• Handle camshaft position sensor (PHASE) carefully and avoid impacts.
• Never disassemble camshaft position sensor (PHASE).
• Never place sensor where it is exposed to magnetism.
3. Put the matching mark (A) on the camshaft sprocket (INT) (2)
and the camshaft bracket (1) as shown in the figure.
: Engine front
NOTE:
It prevents the knock pin of the camshaft (INT) from engaging
with the incorrect pin hole when installing the camshaft sprocket
(INT).
PBIC3992J
4. Remove camshaft sprockets (INT and EXH).

• Secure hexagonal part (A) of camshaft with a wrench. Loosen
camshaft sprocket mounting bolts and remove camshaft
sprocket.
1 : Camshaft sprocket (INT)

CAUTION:
• Never rotate crankshaft or camshaft while timing chain
is removed. It causes interference between valve and
piston.
• Never loosen the mounting bolts with securing anything PBIC3454J
other than the camshaft hexagonal part or with tension-

ing the timing chain.
5. Remove camshaft bracket with the following procedure:

a. Loosen mounting bolts in the order of 17 to 1 as shown in the
figure.
: Engine front
PBIC3176J

CAMSHAFT
b. Cut liquid gasket by prying the position ( ) shown in the figure,
and then remove the camshaft bracket. A
: Engine front
CAUTION: EM
• A more adhesive liquid gasket is applied compared to pre-
vious types when shipped, so it should not be forced off C
the position not specified.
PBIC3358J
D
6. Remove camshafts.
7. Remove valve lifters.
• Identify installation positions, and store them without mixing them up. E
8. Remove signal plate from camshaft (INT), if necessary.
INSTALLATION F
CAUTION:
1. Install valve lifters.
G
• Install them in the original positions.
2. Install camshafts.
• Clean camshaft journal to remove any foreign material.
• Distinguish between the intake and the exhaust by looking at H
the different shapes of the front and rear ends of the camshaft
or using the identification colors (A) and (B).
I
1 : Camshaft (EXH)
2 : Camshaft (INT)
J
Identification color A B
Camshaft (EXH) — Yellow
K
Camshaft (INT) Yellow — PBIC3188J
• Install camshafts so that camshaft dowel pins (A) on the front

side are positioned as shown in the figure. L
1 : Camshaft (EXH)
2 : Camshaft (INT)
M
NOTE:
Though camshaft does not stop at the positions as shown in
the figure, for the placement of cam nose, it is generally
accepted camshaft is placed for the same direction of the fig- N
ure.
PBIC3189J
O
3. Install camshaft bracket with the following procedure:
a. Remove foreign material completely from camshaft bracket backside and from cylinder head installation
face.
P

CAMSHAFT
b. Apply liquid gasket (A) to camshaft bracket as shown in the fig-
ure.
B : Plug hole inner wall

: Engine front
: Engine outside
Use Genuine Liquid Gasket or equivalent.
PBIC3964E
c. Tighten mounting bolts of camshaft brackets in the following

steps, in the order of 1 to 17 as shown in the figure.
: Engine front
• There are two types of mounting bolts. Refer to the following

for locating bolts.
M6 bolts [thread length: 57.5 mm (2.264 in)]

: 13, 14, and 15 in the figure
M6 bolts [thread length: 35.0 mm (1.378 in)] PBIC3176J
: Except the above

i. Tighten mounting bolts in numerical order.
: 1.96 N·m (0.20 kg-m, 17 in-lb)

ii. Tighten mounting bolts in numerical order.
: 5.88 N·m (0.60 kg-m, 52 in-lb)

iii. Tighten mounting bolts in numerical order.
: 9.5 N·m (0.97 kg-m, 84 in-lb)

CAUTION:
After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket
from the mating surface of cylinder head.
4. Install the camshaft sprocket (INT) to the camshaft (INT) with the following procedure.

CAMSHAFT
a. When the camshaft sprocket (INT) (2) is removed, refer to the
paint mark (A) put according to step “3”. Securely align the A
knock pin and the pin hole, and then install them.
1 : Camshaft bracket
EM
: Engine front
PBIC3992J
D
b. Tighten bolts in the following steps.
• Secure the hexagonal part of camshaft (INT) using wrench to tighten mounting bolt.
i. Tighten camshaft (INT) mounting bolt. E
: 35.0 N·m (3.6 kg-m, 26 ft-lb)

F
ii. Turn 67 degrees clockwise (angle tightening).
CAUTION:
Check the tightening angle by using an angle wrench [SST:
KV10112100 (BT8653-A)] (B) or protractor. Never judge by G
visual inspection without an angle wrench.
1 : Camshaft sprocket (INT) H

A : Camshaft (INT) hexagonal part
PBIC3455J
J
5. Install camshaft sprocket (EXH) (2).
1 : Camshaft sprocket (INT)

K
• Secure the hexagonal part (A) of camshaft (EXH) using
wrench to tighten mounting bolt.
L
M
PBIC3454J
6. Install timing chain and related parts. Refer to EM-42, "Exploded View".
N
7. Inspect and adjust valve clearance. Refer to EM-18, "Inspection and Adjustment".
O

P
Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 journal of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.

CAMSHAFT
2. Set dial indicator (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on dial indicator. (Total indicator reading)
Standard and Limit : Refer to EM-114, "Camshaft".

4. If it exceeds the limit, replace camshaft.
PBIC3177J
Camshaft Cam Height

1. Measure the camshaft cam height with a micrometer (A).
PBIC3178J
2. If it exceeds the limit, replace camshaft.

Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER
Measure the outer diameter of camshaft journal with a micrometer
(A).
Standard : Refer to EM-114, "Camshaft".
PBIC3179J
CAMSHAFT BRACKET INNER DIAMETER

• Tighten camshaft bracket bolts with specified torque. Refer to EM-54, "Removal and Installation".
• Measure the inner diameter of camshaft bracket with a bore gauge
(A).
B : Measuring direction of inner diameter
PBIC3180J
CAMSHAFT JOURNAL OIL CLEARANCE

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

• If it exceeds the limit, replace camshaft or cylinder head, or both.

CAMSHAFT
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head. A
Replace whole cylinder head assembly.
Camshaft End Play
1. Install camshaft in cylinder head. Refer to EM-54, "Removal and Installation". EM
2. Install dial indicator in thrust direction on front end of camshaft.
Read the end play of dial indicator (A) when camshaft is moved
forward/backward (in direction to axis). C

D
E
PBIC3181J
• Measure the following parts if out of the standard. F

- Dimension (A) for groove of cylinder head No. 1 journal
Standard : 4.000 - 4.030 mm (0.1575 - 0.1587 in) G

- Dimension (B) for camshaft flange
Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in) H

• Refer to the standards above, and then replace camshaft and/
or cylinder head.
I
PBIC3183J
Camshaft Sprocket Runout

J
1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations. K
2. Measure the camshaft sprocket runout with a dial indicator (A).
(Total indicator reading)
L
Limit : Refer to EM-114, "Camshaft".
• If it exceeds the limit, replace camshaft sprocket. M
N
PBIC3182J
Valve Lifter O
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-114,
"Camshaft".
P
KBIA0182E

CAMSHAFT
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
• Measure the outer diameter of valve lifter with a micrometer (A).
PBIC3185J
VALVE LIFTER HOLE DIAMETER

Measure the inner diameter of valve lifter hole of cylinder head with
an inside micrometer (A).

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

• If out of the standard, referring to the each standard of valve lifter PBIC3184J
outer diameter and valve lifter hole diameter, replace either or both
valve lifter and cylinder head.
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT and
it is directed according to inspection procedure of EC section. Refer to EC-135, "Diagnosis Proce-
dure".
• Check when engine is cold so as to prevent burns by the splashing engine oil.
1. Check engine oil level. Refer to LU-8, "Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release the fuel pressure. Refer to EC-478, "Inspection".
b. Remove intake manifold. Refer to EM-26, "Exploded View".
c. Disconnect ignition coil and injector harness connectors.
d. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket (RH) and engine mounting insulator (RH). Refer to EM-74, "Exploded View".
3. Remove intake valve timing control solenoid valve. Refer to EM-42, "Exploded View".
• Lift the front side of the engine with a jack base to remove intake valve timing control solenoid valve.
4. Clean the mounting area of intake valve timing control solenoid valve, and then insert a clean waste with
no oil adhesion into the oil hole of the cylinder head.
5. Install engine mounting insulator (RH) and engine mounting bracket (RH). (After the removal of intake
valve timing control solenoid valve and insertion of a waste into the oil hole.)
6. Perform cranking to check that engine oil comes out from the oil hole (mounting hole of intake valve timing
control solenoid valve) of cylinder head.
• Regarding the engine oil check, judge it by the amount of oil adhered to the wasted inserted into the oil
hole.
WARNING:
• Never insert fingers into the oil hole.
• Be careful not to touch rotating parts (drive belt, idler pulleys and crankshaft pulley, etc.).

CAMSHAFT
CAUTION:
• Never perform cranking without installing the engine mounting insulator (RH) and engine mount- A
ing bracket (RH).
• Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil
and so as to prevent engine oil contamination.
EM
• Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belt,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
7. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid C
valve oil hole of the cylinder head.
• Remove oil filter (for intake valve timing control), and then clean it. Refer to EM-86, "Exploded View".
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-2, D
"Engine Lubrication System" and LU-2, "Engine Lubrication System Schematic".
8. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging. E
• Clean oil groove if necessary. Refer to LU-2, "Engine Lubrication System" and LU-2, "Engine Lubrica-
tion System Schematic".
9. After inspection, install removed parts in the reverse order.
F

OIL SEAL
OIL SEAL
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation INFOID:0000000009944951
REMOVAL
1. Remove camshafts. Refer to EM-53, "Exploded View".
2. Remove valve lifters. Refer to EM-53, "Exploded View".
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
4. Remove valve collet.
• Compress valve spring with the valve spring compressor [SST:
KV10116200 (J-26336-A)] (A), the attachment [SST:
KV10115900 (J-26336-20)] (C), and the adapter [SST:
KV10109220 ( — )] (B). Remove valve collet with magnet
hand.
CAUTION:
Be careful not to damage valve lifter holes.
JPBIA1365ZZ
5. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
Never remove valve spring seat from valve spring.
6. Remove valve oil seal with the valve oil seal puller [SST:
KV10107902 (J-38959)] (A).
PBIC3210J
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) shown in the figure with
the valve oil seal drift [SST: KV10115600 (J-38958)] (A).
Height (H) : 15.1 - 15.7 mm (0.594 - 0.618 in)
PBIC3211J

FRONT OIL SEAL

OIL SEAL
FRONT OIL SEAL : Removal and Installation INFOID:0000000009944952
A
REMOVAL
• Front fender protector (RH): Refer to EXT-21, "FENDER PROTECTOR : Exploded View". EM
• Drive belt: Refer to EM-13, "Exploded View".
• Crankshaft pulley: Refer to EM-42, "Exploded View".
2. Remove front oil seal with a suitable tool. C
CAUTION:
Be careful not to damage front cover and crankshaft.
D
INSTALLATION
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 in E
the figure.
A : Dust seal lip

F
B : Oil seal lip
: Engine outside
: Engine inside G
PBIC3485J
H
• Press-fit front oil seal using a suitable drift with outer diameter 57 mm (2.24 in) and inner diameter 45
mm (1.77 in). I
Within 0.3 mm (0.012 in) toward engine front (crankshaft pulley side)
Within 0.5 mm (0.020 in) toward engine rear (crankshaft sprocket side) J
CAUTION:
• Be careful not to damage front cover and crankshaft.
• Press-fit oil seal straight to avoid causing burrs or tilting. K

REAR OIL SEAL L
REAR OIL SEAL : Removal and Installation INFOID:0000000009944953
M
REMOVAL
1. Remove transaxle assembly. Refer to TM-235, "Exploded View" (CVT models) or TM-25, "Exploded View"
(M/T models). N
2. Remove clutch cover and clutch disk (M/T models). Refer to CL-18, "Exploded View".
3. Remove drive plate (CVT models) or flywheel (M/T models). Refer to EM-86, "Exploded View".
4. Remove rear oil seal with a suitable tool. O
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION P
1. Apply the liquid gasket lightly to entire outside area of new rear oil seal.
Use Genuine RTV Silicon Sealant or equivalent. Refer to GI-22, "Recommended Chemical Prod-
ucts and Sealants".

OIL SEAL
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.
A : Dust seal lip

B : Oil seal lip
: Engine outside
: Engine inside
PBIC3485J
• Press-fit rear oil seal with a suitable drift (A) outer diameter
115 mm (4.53 in) and inner diameter 90 mm (3.54 in).
CAUTION:
• Be careful not to damage crankshaft and cylinder block.
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
• Never touch grease applied onto oil seal lip.
PBIC3951E
• Press in rear oil seal (1) to the position as shown in the figure.
A : Rear end surface of cylinder block
PBIC3952E

CYLINDER HEAD
CYLINDER HEAD
A
REMOVAL EM
PBIC3542J
H
1. Cylinder head assembly 2. Cylinder head bolt 3. Cylinder head gasket
A.
I

J
DISASSEMBLY

CYLINDER HEAD
JPBIA1753GB
Valve spring (EXH)

1. Valve collet 2. Valve spring retainer 3.
(with valve spring seat)
4. Valve oil seal 5. Valve guide (EXH) 6. Valve seat (EXH)
7. Valve (EXH) 8. Valve (INT) 9. Valve seat (INT)
10. Cylinder head 11. Valve guide (INT) 12. Spark plug
Valve spring (INT)
13.
(with valve spring seat)
Replacement must be following the
A. disassembly and assembly proce-
dure. Refer to EM-67
REMOVAL
2. Drain engine coolant and engine oil. Refer to CO-8, "Draining" and LU-9, "Draining".
3. Remove the following components and related parts.
• Exhaust manifold: Refer to EM-29, "Exploded View".
• Fuel injector and fuel tube assembly: Refer to EM-35, "Exploded View".
• Water outlet: Refer to CO-23, "Exploded View".
• Front cover, timing chain: Refer to EM-42, "Exploded View".

CYLINDER HEAD
• Camshaft: Refer to EM-53, "Exploded View".
4. Remove cylinder head. A
• Loosen cylinder head bolts in the order of 10 to 1 as shown in
the figure.
EM
: Engine front
• Using TORX socket, loosen cylinder head bolts.

C
D
PBIC3206J
5. Remove cylinder head gasket. E
INSTALLATION
1. Install cylinder head gasket. F
2. Install cylinder head, and tighten cylinder head bolts in the order
of 1 to 10 as shown in the figure with the following procedure.
G
: Engine front
CAUTION:
If cylinder head bolts are reused, check their outer diame- H
ters before installation. Refer to EM-71, "Inspection".
a. Apply new engine oil to threads and seating surface of mounting
bolts. I
b. Tighten all cylinder head bolts. PBIC3206J
: 40.0 N·m (4.1 kg-m, 30 ft-lb) J

c. Turn all cylinder head bolts 100 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using an angle K
wrench [SST: KV10112100 (BT8653-A)] (A) or protractor.
Never judge by visual inspection without the tool.
d. Completely loosen. L
: 0 N·m (0 kg-m, 0 ft-lb)

M
CAUTION:
In this step, loosen cylinder head bolts in reverse order that
indicated in the figure.
e. Tighten all cylinder head bolts. PBIC3208J N
: 40.0 N·m (4.1 kg-m, 30 ft-lb)

O
f. Turn all cylinder head bolts 100 degrees clockwise (angle tightening).
g. Turn all cylinder head bolts 100 degrees clockwise again (angle tightening).
3. Install in the reverse order of removal, for the rest of parts. P
Disassembly and Assembly INFOID:0000000009944956
DISASSEMBLY
1. Remove spark plug with spark plug wrench (commercial service tool).
2. Remove valve lifter.
• Identify installation positions, and store them without mixing them up.

CYLINDER HEAD
3. Remove valve collet.
KV10109220 ( — )] (B). Remove valve collet with a magnet
hand.
CAUTION:
Be careful not to damage valve lifter holes.
JPBIA1365ZZ
4. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
5. Push valve stem to combustion chamber side, and remove valve.
• Identify installation positions, and store them without mixing them up.
6. Remove valve oil seal with a valve oil seal puller [SST:
KV10107902 (J-38959)] (A).
PBIC3210J
7. When valve seat must be replaced.

• 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-116, "Cylinder Head".
CAUTION:
Never bore excessively to prevent cylinder head from scratching.
8. When valve guide must be replaced.
a. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil (A).
PBIC3214J
b. Drive out valve guide with a hammer and valve guide drift (com-
mercial service tool).
CAUTION:
Cylinder head contains heat, wear protective equipment to
avoid getting burned.
SEM931C

CYLINDER HEAD
ASSEMBLY
A
1. When valve guide is removed, install it.
CAUTION:
Replace with oversize [0.2 mm (0.008 in)] valve guide.
EM
a. Ream cylinder head valve guide hole with a valve guide reamer
(commercial service tool) (A).
For service parts: Oversize [0.2 mm (0.008 in)] C

Refer to EM-116, "Cylinder Head".
D
E
PBIC3215J
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil (A). F
PBIC3214J
I
c. Press valve guide (1) from camshaft side to dimensions as
J
2 : Cylinder head
Projection (H) : Refer to EM-116, "Cylinder Head".

K
CAUTION:
Cylinder head contains heat, wear protective equipment to
avoid getting burned. L
PBIC3217J
d. Apply reamer finish to valve guide with a valve guide reamer M

(commercial service tool) (A).
Standard : Refer to EM-116, "Cylinder Head".

N
PBIC3215J
P
2. When valve seat is removed, install it.
CAUTION:
Replace with oversize [0.5 mm (0.020 in)] valve seat.

CYLINDER HEAD
a. Ream cylinder head (1) recess diameter for service valve seat
(2).
For service parts: Oversize [0.5 mm (0.020 in)]

Refer to EM-116, "Cylinder Head".
• Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.
PBIC3218J
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil (A).
PBIC3214J
c. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head.
CAUTION:
• Never touch cold valve seats directly.
• Cylinder head contains heat, wear protective equipment to avoid getting burned.
d. Using valve seat cutter set (commercial service tool) or valve
seat grinder, finish valve seat to the specified dimensions. For
dimensions, refer to EM-116, "Cylinder Head".
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.
SEM934C
e. Using compound, grind to adjust valve fitting.

f. Check again for normal contact. Refer to EM-71, "Inspection".
3. Install valve oil seal.
• Install with a valve oil seal drift [SST: KV10115600 (J-38958)]
(A) to match dimension in the figure.
NOTE:
Dimension is height that measured before installing valve
spring (with valve spring seat).
Height (H) : 15.1 - 15.7 mm (0.594 - 0.618 in)
PBIC3211J
4. Install valve.
• Install larger diameter to intake side.
5. Install valve spring (with valve spring seat).

CYLINDER HEAD
• Install smaller pitch (valve spring seat side) to cylinder head
side (B). A
1 : Valve spring seat (Do not remove from valve spring.)

• Confirm identification color (A) of valve spring. EM
Intake : White
Exhaust : Orange C
PBIC3462J
D
6. Install valve spring retainer.
7. Install valve collet.
E
KV10109220 ( — )] (B). Install valve collet with a magnet
hand. F
CAUTION:
When working care not to damage valve lifter holes.
• Tap valve stem edge lightly with a plastic hammer after instal-
G
lation to check its installed condition.
JPBIA1365ZZ
H
8. Install valve lifter.
• Install it in the original position.
9. Install spark plug with spark plug wrench (commercial service tool). I
J
Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening K
method. Whenever the size difference between (d1) and (d2)
exceeds the limit, replace them with a new one.
L
Limit [(d1) – (d2)]: 0.15 mm (0.0059 in)
• If reduction of outer diameter appears in a position other than (d2),
use it as (d2) point. M
PBIC3994E N
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-95, "Inspec- O
tion".
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION: P
Never allow gasket debris to enter passages for engine oil or water.

CYLINDER HEAD
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions using straightedge (A)
and feeler gauge (B).
Limit: Refer to EM-116, "Cylinder Head".

• If it exceeds the limit, replace cylinder head.
PBIC3207J
INSPECTION AFTER DISASSEMBLY

VALVE DIMENSIONS
• Check the dimensions of each valve. For the dimensions, refer to EM-116, "Cylinder Head".
• If dimensions are out of the standard, replace valve and check valve seat contact. Refer to “VALVE SEAT
CONTACT”.
VALVE GUIDE CLEARANCE
Valve Stem Diameter

• Measure the diameter of valve stem with micrometer (A).
Standard: Refer to EM-116, "Cylinder Head".
Valve Guide Inner Diameter

• Measure the inner diameter of valve guide with bore gauge.
Standard: Refer to EM-116, "Cylinder Head".
Valve Guide Clearance

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve
stem diameter) PBIC3213J
Standard and Limit: Refer to EM-116, "Cylinder Head".

• If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be
replaced. Refer to EM-67, "Disassembly and Assembly".
VALVE SEAT CONTACT
• After confirming that the dimensions of valve guides and valves are within the specifications, perform this
procedure.
• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve
contact on the surface.
• Check if the contact area band is continuous all around the circum-
ference.
A : OK
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions (B) even after the recheck,
replace valve seat. Refer to EM-67, "Disassembly and Assembly".
JPBIA0187ZZ
VALVE SPRING SQUARENESS

CYLINDER HEAD
• Set a try square (A) along the side of valve spring and rotate
spring. Measure the maximum clearance between the top of spring A
and try square.
B : Contact
EM
Limit : Refer to EM-116, "Cylinder Head".

• If it exceeds the limit, replace valve spring. C
PBIC3219J
D
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
• Check valve spring pressure with valve spring seat installed at the
specified spring height.
CAUTION: E
Standard : Refer to EM-116, "Cylinder Head". F

• If the installation load or load with valve open is out of the stan-
dard, replace valve spring (with valve spring seat).
G
SEM113
INSPECTION AFTER INSTALLATION H

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required I
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak- J
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including K
engine oil and engine coolant.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the L
M
Transmission / AT & CVT Models Leakage Level / Leakage Leakage N

O
*: Power steering fluid, brake fluid, etc. P

ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >
UNIT REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
JPBIA2912GB
1. Upper torque rod (RH) 2. Washer 3. Engine mounting insulator (RH)

4. Engine mounting bracket (RH) 5. Rear engine mounting bracket 6. Washer
Engine mounting bracket support
7. Rear torque rod 8. Engine mounting bracket (LH) 9.
(LH)
10. Engine mounting insulator (LH)
A. Front mark B. M/T models
CAUTION:
Check that the stud bolt (*2) is tight at the specified torque before tightening the mounting nut (*1)
shown in the figure. [Stud bolt (*2) may be loosened after loosening the mounting nut (*1)]
WARNING:

ENGINE ASSEMBLY
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels. A
• 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.
EM
• Never start working until exhaust system and coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid- C
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-32, "Garage Jack and D
Safety Stand and 2-Pole Lift".
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing. E
REMOVAL
Outline F
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.
Preparation G
2. Drain engine coolant from radiator. Refer to CO-8, "Draining".
CAUTION: H
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belts.
3. Remove the following parts. I
• Engine undercover
• Front road wheels and tires
• Front fender protector (RH and LH): Refer to EXT-21, "FENDER PROTECTOR : Exploded View".
J
• Drive belt: Refer to EM-13, "Removal and Installation".
• Engine cover: Refer to EM-22, "Exploded View".
• Battery and battery tray: Refer to PG-82, "Exploded View".
• Air duct (inlet), resonator, air duct, and air cleaner case assembly: Refer to EM-24, "Exploded View". K
• Radiator hose (upper and lower): Refer to CO-14, "Exploded View".
• Exhaust front tube: Refer to EX-5, "Exploded View".
• Radiator cooling fan assembly: Refer to CO-17, "Exploded View". L
• Alternator: Refer to CHG-30, "Exploded View".
Engine Room LH
1. Disconnect all connections of engine harness around the battery, and then temporarily secure the engine M
harness into the engine side.
CAUTION:
Protect connectors using a resin bag against foreign materials during the operation.
N
2. Disconnect fuel feed tube at engine side. Refer to EM-35, "Exploded View".
3. Disconnect heater hoses. Refer to CO-23, "Exploded View".
4. Disconnect control cable from transaxle. (CVT models) Refer to TM-219, "Exploded View". O
5. Disconnect control linkage from transaxle. (M/T models) Refer to TM-19, "Exploded View".
6. Remove EVAP hoses. Refer to EM-26, "Exploded View".
7. Disconnect clutch tube on transaxle side from clutch damper. (M/T models) Refer to CL-15, "Exploded P
View".
Engine Room RH
1. Disconnect vacuum hose from intake manifold. Refer to EM-26, "Exploded View".
2. Remove A/C compressor. (with A/C models) Refer to HA-31, "Exploded View".
3. Remove ground cable at engine side.

ENGINE ASSEMBLY
Vehicle Underbody
1. Remove ground cable at transaxle side.
2. Remove drive shafts (RH and LH). Refer to FAX-15, "Exploded View".
3. Remove rear torque rod (1).
2 : Rear engine mounting bracket

A : Front mark
: Vehicle front
PBIC3584J
4. Preparation for the separation work of transaxle is as follows:

• Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-32, "Exploded
View".
Removal
1. Use a manual lift table caddy (commercial service tool) (A) or
equivalently rigid tool such as a transmission jack. Securely sup-
port bottom of the engine and the transaxle assembly.
CAUTION:
Put a piece of wood or an equivalent as the supporting sur-
face, secure a completely stable condition.
PBIC3223J
2. Remove upper torque rod (1), engine mounting bracket (RH)

(2), and engine mounting insulator (RH) (3).
: Vehicle front
PBIC3585J
3. Remove engine mounting bracket (LH) through bolt-securing

nut (B).
1 : Engine mounting insulator (LH)

2 : Engine mounting bracket support (LH)
A : Through not
: Vehicle front
PBIC3586J
4. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. When performing work,
observe the following caution.
CAUTION:
• Check that no part interferes with the vehicle side.

ENGINE ASSEMBLY
• Before and during this lifting, always check if any harnesses are left connected.
• During the removal, always be careful to prevent the vehicle from falling off the lift due to A
changes in the center of gravity.
• If necessary, support the vehicle by setting jack or suitable tool at the rear.
Separation EM
1. Install engine slinger to front cover front left side (A) and cylinder
head rear right side (B).
C
: Engine front
Slinger bolts D
Front cover front left
: 32.9 N·m (3.4 kg-m, 24 ft-lb)
side:
E
Cylinder head rear
: 25.0 N·m (2.6 kg-m, 18 ft-lb)
right side: JPBIA2293ZZ
2. Remove starter motor. Refer to STR-25, "Exploded View". F

3. Lift with a hoist and separate the engine from the transaxle assembly. Refer to TM-235, "Exploded View"
(CVT models) or TM-25, "Exploded View" (M/T models).
INSTALLATION G
CAUTION:
• Never allow engine oil to get on engine mounting insulator. Be careful not to damage engine mount- H
ing insulator.
• Check that each mounting insulator is seated properly, and tighten mounting nuts and bolts.
• When installation directions are specified, install parts according to the direction marks on them I
referring to the figure of components. Refer to EM-74, "Exploded View".
Upper Torque Rod (RH)
• Install upper torque rod (RH) (1), positioning dynamic damper (A) J
as shown in the figure.
2 : Engine mounting bracket (RH)

K
3 : Engine mounting insulator (RH)
: Vehicle front
PBIC3546J M
Engine Mounting Bracket (RH)
• Install engine mounting bracket (RH) to the engine side according to the following procedure.
1. Temporarily tighten mounting bolts in the order of 1 to 4 as N
: Vehicle front O
2. Tighten mounting bolts to the specified torque in the order of 1 to
4 as shown in the figure.
P
PBIC3545J

ENGINE ASSEMBLY

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
Transmission / AT & CVT Models Leakage Level / Leakage Leakage

*: Power steering fluid, brake fluid, etc.

ENGINE STAND SETTING
< UNIT DISASSEMBLY AND ASSEMBLY >
UNIT DISASSEMBLY AND ASSEMBLY A
Setting INFOID:0000000009944961
EM
NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc. C
1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to EM-74, "Exploded View".
2. Install engine to engine stand with the following procedure: D
a. Remove flywheel (M/T models) or drive plate (CVT models).
• Secure flywheel (M/T models) or drive plate (CVT models) (1)
with a stopper plate [SST: KV11105210 (J-44716)] (A), and E
remove mounting bolts.
CAUTION:
• Never disassemble them. F
• Any dropped drive plate shall not be used.
NOTE:
This figure shows CVT models as an example.
G
PBIC3226J
H
b. Remove pilot converter (1) using pilot bushing puller [SST:
ST16610001 (J-23907)] (A) or suitable tool. (CVT models)
NOTE: I
M/T models have no pilot bushing.
K
PBIC3229J
c. Lift the engine with a hoist to install it onto widely use engine stand. L
CAUTION:
• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large
enough for supporting the engine weight.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten- M
tial risk of overturning stand.
- Intake manifold: Refer to EM-26, "Exploded View".
- Exhaust manifold: Refer to EM-29, "Exploded View". N
- Rocker cover: Refer to EM-40, "Exploded View".
NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel (M/T O
models) or drive plate (CVT models) removed.
CAUTION:
Before removing the hanging chains, check the engine P
stand is stable and there is no risk of overturning.
PBIC3227J

CAUTION:
Be sure to clean drain plug and install with new drain plug washer.
4. Drain engine coolant by removing water drain plug (1) from
inside of the engine.
: Engine front
Tightening torque : Refer to EM-87, "Disassembly and

Assembly".
PBIC3228J

ENGINE UNIT
ENGINE UNIT
A
Disassembly INFOID:0000000009944962
1. Remove intake manifold. Refer to EM-26, "Exploded View". EM

2. Remove exhaust manifold. Refer to EM-29, "Exploded View".
4. Remove ignition coil, spark plug, and rocker cover. Refer to EM-40, "Exploded View". C
5. Remove fuel injector and fuel tube. Refer to EM-35, "Exploded View".
6. Remove timing chain. Refer to EM-42, "Exploded View".
D
7. Remove camshaft. Refer to EM-53, "Exploded View".
8. Remove water inlet. Refer to CO-21, "Exploded View".
9. Remove water outlet. Refer to CO-23, "Exploded View". E
10. Remove cylinder head. Refer to EM-65, "Exploded View".
Assembly INFOID:0000000009944963
F
Assemble in the reverse order of disassembly.

OIL PAN (UPPER)
OIL PAN (UPPER)
PBIC4463J
1. Oil level gauge 2. Oil level gauge guide 3. Rear oil seal
4. O-ring 5. Oil pan (upper) 6. Oil pump drive chain
7. Crankshaft sprocket 8. Oil pump sprocket 9. Oil pump chain tensioner
10. Oil pump 11. Drain plug 12. Drain plug washer
13. Oil pan (lower) 14. Oil filter 15. Connector bolt
16. O-ring
A. Comply with the assembly proce- B. Oil pan side
dure when tightening. Refer to LU-11
: Sealing point
REMOVAL

OIL PAN (UPPER)
2. Remove oil filter. Refer to LU-11, "Removal and Installation".
3. Remove front cover, timing chain, oil pump drive chain, and other related parts. Refer to EM-42, A
"Exploded View".
4. Remove oil level gauge and oil level gauge guide.
5. Remove oil pump. Refer to LU-12, "Exploded View". EM
NOTE:
The oil pan (upper) can be removed and installed without removing the oil pump.
6. Remove oil pan (upper) with the following procedure: C
a. Loosen bolts in the order of 10 to 1 as shown in the figure.
: Engine front D
F
PBIC3533J
b. Insert a screwdriver shown by the arrow ( ) in the figure and G

open up a crack between oil pan (upper) and cylinder block.
: Engine front H
CAUTION:
A more adhesive liquid gasket is applied compared to previ-
ous types when shipped, so it should not be forced off the I
position not specified.
PBIC3534J J
c. Insert seal cutter [SST: KV10111100 (J-37228)] between oil pan (upper) and cylinder block, and slide it by
tapping on the side of the tool with a hammer.
K
CAUTION:
Be careful not to damage the mating surface.
7. Remove O-ring between cylinder block and oil pan (upper). L

INSTALLATION
1. Install oil pan (upper) with the following procedure:
M
a. Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Remove the old liquid gasket from mating surface of cylinder
block. N
• Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Never scratch or damage the mating surfaces when clean- O
ing off old liquid gasket.
P
PBIC3949E

OIL PAN (UPPER)
b. Apply a continuous bead of liquid gasket (C) with a tube presser
(commercial service tool) as shown in the figure.
1 : Oil pan (upper)

A : 2 mm (0.08 in) protruded to outside
B : 2 mm (0.08 in) protruded to rear oil seal mounting side
: Engine front
: Engine outside

CAUTION:
• Apply liquid gasket to outside of bolt hole for the posi-
tions shown by marks.
• Attaching should be done within 5 minutes after liquid
gasket application.
JPBIA0288ZZ
c. Install new O-ring at cylinder block side.

CAUTION:
Install avoiding misalignment of O-ring.
d. Tighten bolts in the order of 1 to 10 as shown in the figure.
: Engine front
PBIC3533J
2. Install rear oil seal with the following procedure.

CAUTION:
• The installation of rear oil seal should be completed within 5 minutes after installing oil pan
(upper).
• Always replace rear oil seal with new one.
• Never touch oil seal lip.
a. Wipe off liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block
using a scraper.
b. Apply engine oil to entire outside area of rear oil seal.
c. Press-fit the rear oil seal using a suitable drift (A) with outer
diameter 115 mm (4.53 in) and inner diameter 90 mm (3.54 in).
PBIC3951E

OIL PAN (UPPER)
• Press-fit to the specified dimensions as shown in the figure. A

1 : Rear oil seal
A : Cylinder block rear end surface
EM
CAUTION:
• Never touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting part of
oil pan (upper) and cylinder block or the crankshaft. C
• Press-fit straight, checking that rear oil seal does not curl
or tilt.
NOTE: PBIC3952E
D
The standard surface of the dimension is the rear end surface of
cylinder block.
3. Install in the reverse order of removal, for the rest of parts. E
INSPECTION AFTER REMOVAL F

Clean oil strainer portion (part of the oil pump) if any object attached.

CYLINDER BLOCK
CYLINDER BLOCK
JSBIA4440GB
1. Cylinder block 2. O-ring 3. Crankshaft position sensor (POS)

4. Crankshaft position sensor (POS) cover 5. Oil filter (for intake valve timing control) 6. Knock sensor
7. Oil pressure switch 8. Cylinder block heater (for Canada) 9. Top ring

CYLINDER BLOCK
10. Second ring 11. Oil ring 12. Snap ring
13. Piston 14. Piston pin 15. Connecting rod A
16. Thrust bearing 17. Connecting rod bearing (upper) 18. Main bearing (upper)
19. Crankshaft key 20. Main bearing (lower) 21. Connecting rod bearing (lower)
22. Connecting rod cap 23. Connecting rod cap bolt 24. Main bearing cap EM
25. Main bearing cap bolt 26. Crankshaft 27. Pilot converter (CVT models)
28. Signal plate 29. Rear oil seal 30. Drive plate (CVT models)
31. Reinforcement plate (CVT models) 32. Flywheel (M/T models) C
Comply with the assembly procedure when
A. B. Chamfered
tightening. Refer to EM-87
: Crankshaft side D
: N·m (kg-m, ft-lb) E

: Should be lubricated with oil. F

: Sealing point
: Select with proper thickness.

G
Disassembly and Assembly INFOID:0000000009944968
DISASSEMBLY H
1. Remove oil pan (upper). Refer to EM-82, "Exploded View".

2. Remove thermostat housing. Refer to CO-21, "Exploded View".
I
3. Remove knock sensor.
CAUTION:
Carefully handle sensor avoiding shocks.
J
4. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS).
CAUTION:
• Avoid impacts such as a dropping.
• Never disassemble. K
• Keep it away from metal particles.
• Never place sensor in a location where it is exposed to magnetism.
5. Remove oil filter (for intake valve timing control). L
6. Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-95, "Inspection". M
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod cap.
c. Using a hammer handle or similar tool, push piston and connect- N
ing rod assembly out to the cylinder head side.
CAUTION:
• Be careful not to damage matching surface with connect- O
ing rod cap.
• Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end. P
PBIC0259E
7. Remove connecting rod bearings.

CAUTION:
When removing them, note the installation position. Keep them in the correct.

CYLINDER BLOCK
8. Remove piston rings from piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-95, "Inspection".
• Use a piston ring expander (commercial service tool) (A).
CAUTION:
• When removing piston rings, be careful not to damage
the piston.
• Be careful not to damage piston rings by expanding
them excessively.
PBIC3233J
9. Remove piston from connecting rod with the following procedure:

a. Using snap ring pliers (A), remove snap rings.
PBIC3230J
b. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use

drier (A) or equivalent.
PBIC3231J
c. Push out piston pin with stick of outer diameter approximately 18

mm (0.71 in).
PBIC0262E
10. Remove main bearing cap bolts.

• Measure crankshaft end play before loosening main bearing cap bolts. Refer to EM-95, "Inspection".

CYLINDER BLOCK
• Loosen and remove main bearing cap bolts in the order of 10
to 1 as shown in the figure. A
: Engine front
• Use TORX socket. EM
PBIC3235J
D
11. Remove main bearing caps.
• Tap main bearing caps lightly with a plastic hammer for removal.
CAUTION:
E
Be careful not to damage the mounting surface.
12. Remove crankshaft.
CAUTION:
• Be careful not to damage or deform signal plate (1) F
mounted on rear end of crankshaft (A).
• When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate G
and the floor surface.
• Never remove signal plate unless it is necessary to do so.
NOTE:
When removing or installing signal plate, use TORX socket. H
PBIC3234J
I
13. Pull rear oil seal out from rear end of crankshaft.
J
14. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION:
Identify installation positions, and store them without mixing them up.
K
ASSEMBLY
CAUTION:
Do not reuse O-rings or washers.
L
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. M
2. Install each plug to cylinder block as shown in the figure.
2 : Washer N
: Engine front
• Apply liquid gasket to the thread of water drain plug (4).

Use Genuine RTV Silicon Sealant or equivalent. Refer to O
GI-22, "Recommended Chemical Products and Sealants".
• Apply sealant to the thread of plug (1).
Use genuine high strength thread locking sealant or P
equivalent. Refer to GI-22, "Recommended Chemical
PBIC3999E
Products and Sealants".
CAUTION:
Do not reuse washers.
NOTE:
Do not apply liquid gasket or high strength thread locking sealant to the plug (3).

CYLINDER BLOCK
• Tighten each plug as specified below.
Part Washer Tightening torque

1 Yes 54.0 N·m (5.5 kg-m, 40 ft-lb)
3 No 19.6 N·m (2.0 kg-m, 14 ft-lb)
4 No 9.8 N·m (1.0 kg-m, 87 in-lb)
3. Install main bearings and thrust bearings with the following procedure:
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and main bearing cap.
b. Install thrust bearings to the both sides of the No. 3 journal hous-
ing (B) on cylinder block.
: Engine front
• Install thrust bearings with the oil groove (A) facing crankshaft
arm (outside).
PBIC3258J
c. Install the main bearings paying attention to the direction.

• Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply new
engine oil to the back surface, but thoroughly clean it.
• When installing, align main bearing to the center position of cylinder block and main bearing cap.
• The difference (A) between main bearing (upper) (1) and main
bearing (lower) (3) should be 0.85 mm (0.0335 in) or less
when installing.
2 : Cylinder block
4 : Main bearing cap
PBIC3237J
• Ensure the oil holes on cylinder block and oil holes (A) on the
main bearings (1) are aligned.
PBIC3236J
4. Install signal plate to crankshaft if removed.

a. Set the signal plate with the flange facing toward the counter weight side (engine front side) to the crank-
shaft rear surface.
b. Apply new engine oil to threads and seat surfaces of mounting bolts.

CYLINDER BLOCK
c. Position crankshaft (2) and signal plate (1) using a dowel pin
(service part), and tighten mounting bolts in numerical order as A
shown in the figure using TORX socket.
A : Dowel pin hole

EM
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.
C
d. Tighten mounting bolts in numerical order as shown in the figure
again.
PBIC3238J
e. Remove dowel pin. (service parts) D
CAUTION:
Be sure to remove dowel pin.
5. Install crankshaft to cylinder block.
• While turning crankshaft by hand, check that it turns smoothly. E
6. Install main bearing caps with the following procedure:
a. Install main bearing caps referring to the journal No. stamp (A)
and front mark (B) as shown in the figure. F
: Engine front
G
NOTE:
Main bearing cap cannot be replaced as a single part, because it
is machined together with cylinder block.
H
PBIC3239J
I
b. Tighten main bearing cap bolts in the order of 1 to 10 as shown
in the figure with the following procedure:
J
: Engine front
i. Apply new engine oil to threads and seat surfaces of mounting

bolts. K
ii. Tighten main bearing cap bolts.
: 34.3 N·m (3.5 kg-m, 25 ft-lb) L

PBIC3235J
iii. Turn main bearing cap bolts 60 degrees clockwise (angle tightening) in order from No. 1 to 10 in the fig- M
ure.
CAUTION:
Confirm the tightening angle by using an angle wrench
[SST: KV10112100 (BT8653-A)] (A) or protractor. Never N
judge by visual inspection without the tool.
PBIC3240J
• After installing mounting bolts, check that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-95, "Inspection".
7. Install piston to connecting rod with the following procedure:

CYLINDER BLOCK
a. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
• Insert it fully into groove to install.
b. Assemble piston to connecting rod.
• Using an industrial use drier or similar tool, heat the piston until the piston pin can be pushed in by hand
without excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston
pin into piston and connecting rod.
• Assemble so that the front mark (A) on the piston head and
the oil hole (B) and the cylinder number (C) on connecting rod
are positioned as shown in the figure.
D : Big end diameter grade

E : Small end diameter grade
F : Front mark (connecting rod)
c. Install new snap ring to the groove of the piston front side.
• Insert it fully into groove to install.
• After installing, check that connecting rod moves smoothly. PBIC3241J
8. Using a piston ring expander (commercial service tool), install
piston rings.
CAUTION:
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.
• Position each ring with the gap as shown in the figure referring
to the piston front mark.
A : Oil ring upper or lower rail gap

B : Front mark
C : Second ring and oil ring spacer gap
D : Top ring gap
E : Stamped mark
CAUTION:
Never contact the rail end gap under the oil ring with the PBIC3242J
oil drain cast groove of piston.
• Install second ring with the stamped surface facing upward.
9. Install connecting rod bearing upper (2) and lower (3) to con-
necting rod (1) and connecting rod cap (4).
C : Oil hole (connecting rod)

D : View D
E : OK
F : NG
g : 2.55 - 2.95 mm (0.1004 - 0.1161 in)
: Engine front
• Install the connecting rod in the dimension shown in the figure.

• Check that connecting rod bearing oil hole (A) is completely in
the inside of connecting rod oil hole chamfered area (B).
• When installing connecting rod bearings, apply new engine oil
to the bearing surface (inside). Do not apply new engine oil to
the back surface, but thoroughly clean it.
NOTE:
• There is no positioning tab.
• Install the connecting rod bearings in the center of connect-
ing rod and connecting rod cap as shown in the figure. For
service operation, the center position can be checked, visu-
ally.
JPBIA2155ZZ

CYLINDER BLOCK
10. Install piston and connecting rod assembly to crankshaft.
• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. A
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cylinder number (C) on
connecting rod to install.
EM
B : Oil hole
E : Small end diameter grade C
• Install so that front mark (A) on the piston head faces the front
D
of engine.
PBIC3241J
E
• Using a piston ring compressor [SST: EM03470000 (J-8037)]
(A) or suitable tool, install piston with the front mark on the pis-
ton head facing the front of the engine.
CAUTION: F
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end. G
H
PBIC3244J
11. Install connecting rod cap.

I
• Match the stamped cylinder number marks (C) on connecting
rod with those on connecting rod cap to install.
A : Front mark (piston) J

B : Oil hole
K
L
PBIC3241J
12. Tighten connecting rod cap bolt with the following procedure:
CAUTION: M
• Check that there is no gap in the thrust surface (A) of the
joint between connecting rod (1) and connecting rod cap
(2) and that these parts are in the correct position. And N
then, tighten the connecting rod cap bolts.
• If the connecting rod cap bolts are reused, measure the
outer diameter. Refer to EM-95, "Inspection".
O
a. Apply new engine oil to the threads and seats of connecting rod
cap bolts.
b. Tighten connecting rod cap bolts.
P
PBIC3510J
: 27.5 N·m (2.8 kg-m, 20 ft-lb)
c. Completely loosen connecting rod cap bolts.
: 0 N·m (0 kg-m, 0 ft-lb)

d. Tighten connecting rod cap bolts.

CYLINDER BLOCK
: 19.6 N·m (2.0 kg-m, 14 ft-lb)

e. Then turn all connecting rod cap bolts 60 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using an angle
wrench [SST: KV10112100 (BT8653-A)] (A) or protractor.
Never judge by visual inspection without the tool.
PBIC3245J
• After tightening connecting rod cap bolt, check that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-95, "Inspection".
13. Install oil pan (upper). Refer to EM-82, "Exploded View".
NOTE:
Install the rear oil seal after installing the oil pan (upper).
14. Install rear oil seal. Refer to EM-63, "REAR OIL SEAL : Removal and Installation".
15. Install flywheel (M/T models) or drive plate (CVT models).
Drive plate (CVT models)
• Secure crankshaft with a stopper plate [SST: KV11105210 (J-
44716)], (A) and tighten mounting bolts crosswise over several
times.
1 : Drive plate
PBIC3226J
• Install pilot converter (1), drive plate (2), and reinforcement

plate (3) as shown in the figure.
A : Crankshaft rear end

B :R
• Using a drift of 33 mm (1.30 in) in dia meter, press-fit pilot con-
verter into the end of crankshaft until it stops.
PBIC4075E
Fly wheel (M/T models)

• Secure crankshaft with a stopper plate [SST: KV11105210 (J-44716)] and tighten mounting bolts cross-
wise over several times.
NOTE:
M/T models have no pilot bushing and reinforcement plate.
16. Install knock sensor.

CYLINDER BLOCK
• Install knock sensor (1) with harness connector facing toward
the rear of engine. A
A : Cylinder block left side

: Engine front EM
CAUTION:
• Never tighten mounting bolts while holding the harness
connector. C
• If any impact by dropping is applied to knock sensor,
replace it with a new one.
PBIC3246J
NOTE:
D
• Check that there is no foreign material on the cylinder block mating surface and the back surface of
knock sensor.
• Check that knock sensor does not interfere with other parts.
17. Install crankshaft position sensor (POS) and crankshaft position sensor (POS) cover. E
CAUTION:
• Do not reuse O-ring.
• Handle crankshaft position sensor (POS) carefully and avoid impacts. F
• Never disassemble.
• Never place crankshaft position sensor (POS) in a location where it is exposed to magnetism.
18. Install oil filter (for intake valve timing control) (1) in the direction G
• Check that the oil filter (for intake valve timing control) does
not protrude from the upper surface of cylinder block (2) after H
installation.
J
PBIC3260J
19. Assemble in the reverse order of disassembly.

K
CRANKSHAFT END PLAY

L
• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator (A).
M
Standard and Limit : Refer to EM-118, "Cylinder
Block".
• If the measured value exceeds the limit, replace thrust bearings, N
and measure again. If it still exceeds the limit, replace crankshaft
also.
O
PBIC3252J
CONNECTING ROD SIDE CLEARANCE

P

CYLINDER BLOCK
• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A).

Block".
• If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the limit, replace crankshaft
also.
PBIC3251J
PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer (A).
Standard : Refer to EM-118, "Cylinder Block".
PBIC3265J
Piston Pin Outer Diameter

Measure the outer diameter of piston pin with a micrometer (A).
PBIC3266J
Piston to Piston Pin Oil Clearance

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

• If oil clearance is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly. Refer to EM-106, "Description".
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
grades can be selected. (Only grade “0” is available.)
PISTON RING SIDE CLEARANCE

CYLINDER BLOCK
• Measure the side clearance of piston ring and piston ring groove
with a feeler gauge (A). A

Block". EM
• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also.
C
PBIC3280J
D
PISTON RING END GAP
• Check that cylinder bore inner diameter is within specification. Refer to “PISTON TO CYLINDER BORE
CLEARANCE”.
• Lubricate with new engine oil to piston (1) and piston ring (2), and E
then insert (A) piston ring until middle of cylinder (B) with piston,
and measure piston ring end gap with a feeler gauge (C).
F
Block".
• If the measured value exceeds the limit, replace piston ring, and G
measure again. If it still exceeds the limit, rebore cylinder and use
oversized piston and piston rings.
PBIC3267J
H
CONNECTING ROD BEND AND TORSION

• Check with a connecting rod aligner.
I
A : Bend
B : Torsion
J
C : Feeler gauge
Limit : Refer to EM-118, "Cylinder Block".

K
• If it exceeds the limit, replace connecting rod assembly.
O
PBIC3268J
CONNECTING ROD BIG END DIAMETER

P

CYLINDER BLOCK
• Install connecting rod cap (1) without connecting rod bearing
installed, and tightening connecting rod cap bolts to the specified
torque. Refer to EM-87, "Disassembly and Assembly".
2 : Connecting rod
A : Example
B : Measuring direction of inner diameter
• Measure the inner diameter of connecting rod big end with an
inside micrometer.
PBIC3269J
• If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).
PBIC3270J
Piston Pin Outer Diameter

Measure the outer diameter of piston pin with a micrometer (A).
PBIC3266J
Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
Standard and Limit : Refer to EM-118, "Cylinder Block".

• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly. Refer to EM-106, "Piston".
• If replacing connecting rod assembly. Refer to EM-107, "Connecting Rod Bearing".
CYLINDER BLOCK TOP SURFACE DISTORTION

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

CYLINDER BLOCK
• Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge (A) and feeler A
gauge (B).
Limit : Refer to EM-118, "Cylinder Block". EM

• If it exceeds the limit, replace cylinder block.
PBIC3250J
D
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap without main bearings installed, and tighten main bearing cap mounting bolts to the
specified torque. Refer to EM-87, "Disassembly and Assembly".
• Measure the inner diameter of main bearing housing with a bore gauge. E
• Measure the position shown in the figure [5 mm (0.20 in)] back-
ward from main bearing housing front side in the 2 directions as
shown in the figure. The smaller one is the measured value. F
1 : Cylinder block
2 : Main bearing cap
G
: Engine front
Standard : Refer to EM-118, "Cylinder Block". H

• If out of the standard, replace cylinder block and main bearing PBIC4005E
caps assembly.
NOTE: I
Main bearing caps cannot be replaced as a single, because it is machined together with cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
J
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. [(A) and (B)
directions at (C), (D), and (E)] [(A) is in longitudinal direction of K
engine]
f : 10 mm (0.39 in) L
g : 60 mm (2.36 in)
h : 130 mm (5.12 in)
NOTE: M
When determining cylinder bore grade, measure the cylinder bore
(B) direction at (D) position. JPBIA2059ZZ
N
Standard:
Cylinder bore inner diameter
: Refer to EM-118, "Cylinder Block". O
Limit:
P
Out-of-round [Difference between (A) and (B)]
Taper [Difference between (C) and (D)]
: Refer to EM-118, "Cylinder Block".
• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
replace cylinder block.
NOTE:
Oversize piston is not provided.

CYLINDER BLOCK
Piston Skirt Diameter
Measure the outer diameter of piston skirt with a micrometer (A).
PBIC3272J
Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter
[direction (B), position (D)].
A : Direction A
C : Position C
E : Position E
f : 10 mm (0.39 in)
g : 60 mm (2.36 in)
h : 130 mm (5.12 in)
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diame- JPBIA2059ZZ
ter)
Standard and Limit : Refer to EM-118, "Cylinder Block".

• If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to EM-106, "Pis-
ton".
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals with a
micrometer (A).

• If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to EM-122, "Main Bearing".
PBIC3457J
CRANKSHAFT PIN JOURNAL DIAMETER

• Measure the outer diameter of crankshaft pin journal with a micrometer.

• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer
to EM-122, "Connecting Rod Bearing".
OUT-OF-ROUND AND TAPER OF CRANKSHAFT

CYLINDER BLOCK
• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer. A
• 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
EM
(B) at (X) and (Y).
Limit:
C
Out-of-round [Difference between (X) and (Y)]
Taper [Difference between (A) and (B)]
PBIC3459J
: Refer to EM-118, "Cylinder Block". D
• 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-107, "Connecting Rod Bearing" and/or EM-109, E
"Main Bearing".
CRANKSHAFT RUNOUT
• Place a V-block on a precise flat table to support the journals on the both end of the crankshaft. F
• Place a dial indicator (A) straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on the
dial indicator. (Total indicator reading)
G
Block".
H
• If it exceeds the limit, replace crankshaft.
I
PBIC3458J
CONNECTING ROD BEARING OIL CLEARANCE

J
Method by Calculation
• Install connecting rod bearings (2) to connecting rod (3) and con-
necting rod bearing cap (1), and tighten connecting rod cap bolts to
K
the specified torque. Refer to EM-87, "Disassembly and Assem-
bly".
A : Example L
B : Inner diameter measuring direction
• Measure the inner diameter of connecting rod bearing with an
inside micrometer. M
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter) PBIC3275J
N
Standard and Limit : Refer to EM-122, "Connecting Rod Bearing".
• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end
diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-107, O
"Connecting Rod Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely. P
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod cap bolts to the speci-
fied torque. Refer to EM-87, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.

CYLINDER BLOCK
• Remove connecting rod cap and bearing, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
PBIC3276J
MAIN BEARING OIL CLEARANCE

Method by Calculation
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap mounting bolts to the specified
torque. Refer to EM-87, "Disassembly and Assembly".
A : Example
B : Inner diameter measuring direction
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
Standard and Limit : Refer to EM-122, "Main Bearing". PBIC3277J
• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and
crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-109, "Main Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap mounting bolts to
the specified torque. Refer to EM-87, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.
• Remove main bearing cap and bearings, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
PBIC3278J
MAIN BEARING CRUSH HEIGHT

CYLINDER BLOCK
• When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of A
bearing must protrude (B). Refer to EM-87, "Disassembly and
Assembly".
EM
A : Example
Standard : There must be crush height.

C
• If the standard is not met, replace main bearings.
PBIC3279J
D
CONNECTING ROD BEARING CRUSH HEIGHT
• When connecting rod cap is removed after being tightened to the
specified torque with connecting rod bearings (1) installed, the tip
end of bearing must protrude (B). Refer to EM-87, "Disassembly E
and Assembly".
A : Example F
Standard : There must be crush height.

• If the standard is not met, replace connecting rod bearings. G
PBIC3279J
MAIN BEARING CAP BOLT OUTER DIAMETER H

• Measure the outer diameters (d1) and (d2) at two positions as
I
A : (d1) measuring position
B : (d2) measuring position
• If reduction appears in places other than (B) range, regard it as J
(d2).
Limit [(d1) – (d2)]: 0.15 mm (0.0059 in)

K
• If it exceeds the limit (a large difference in dimensions), replace PBIC4015E
main bearing cap mounting bolt with a new one.
CONNECTING ROD CAP BOLT OUTER DIAMETER L
• Measure the outer diameter (d) at position as shown in the figure.
• If reduction appears in a position other than (d), regard it as (d).
M
Limit: 7.75 mm (0.3051 in)
• When (d) exceeds the limit (when it becomes thinner), replace
connecting rod cap bolt with a new one. N
O
PBIC4016E
CLOGGED OR DAMAGED OIL FILTER (FOR INTAKE VALVE TIMING CONTROL)

P

CYLINDER BLOCK
• Check that there is no foreign material on the oil filter and check it
for clogging.
- Clean it if necessary.
• Check the oil filter for damage.
- Replace it if necessary.
PBIC3273J
FLYWHEEL DEFLECTION (M/T MODELS)

• Measure the deflection of flywheel contact surface to torque with a
dial indicator (A).
• Measure the deflection at 210 mm (8.27 in) diameter.
Limit : 0.45 mm (0.0177 in) or less.

• If measured value is out of the standard, replace flywheel.
• If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.
CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft. PBIC4006E
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)

CAUTION:
Never 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 : 1.8 mm (0.071 in) or less

Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install clutch cover mounting bolt (1) to clutch cover mounting
hole, and place a torque wrench (A) on the extended line of the
flywheel (2) center line.
• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it
from loosening.
2. Put a matching mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transaxle
side. PBIC4007E
4. Measure the dimensions of movement amounts “A” and “B” on

circumference of the flywheel on the transaxle side.
Limit : 33.2 mm (1.307 in) or less.

DRIVE PLATE (CVT MODELS)

CYLINDER BLOCK
• Check drive plate and signal plate for deformation or damage.
CAUTION: A
• Never disassemble drive plate.
• Never place drive plate with signal plate facing down.
• When handling signal plate, take care not to damage or
EM
scratch it.
• Handle signal plate in a manner that prevents it from becom-
ing magnetized.
• If anything is found, replace drive plate. C
JPBIA0192ZZ

HOW TO SELECT PISTON AND BEARING
Description INFOID:0000000009944970
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 outer diam- Piston grade = cylinder bore
(piston is available together with
ton eter) grade (inner diameter of bore)
piston pin as an assembly.)
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
Piston INFOID:0000000009944971
WHEN NEW CYLINDER BLOCK IS USED

• Check the cylinder bore grade on rear left side of cylinder block (L),
and select piston of the same grade.
A : Correction stamp
B : Standard stamp
C : Cylinder No. 1 bore grade
D : Cylinder No. 2 bore grade
E : Cylinder No. 3 bore grade
F : Cylinder No. 4 bore grade
G : No. 1 main bearing housing grade
H : No. 2 main bearing housing grade
I : No. 3 main bearing housing grade
J : No. 4 main bearing housing grade
K : No. 5 main bearing housing grade
: Engine front
• If there is a correction stamp mark on the cylinder block, use it as a

correct reference.
PBIC3264J
WHEN CYLINDER BLOCK IS REUSED

1. Measure the cylinder bore inner diameter. Refer to EM-118, "Cylinder Block".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”.

3. Select piston of the same grade.
A
A : Piston grade number
B : Front mark
C : Identification code EM
D : Sub grade number
PBIC4397J
D
PISTON SELECTION TABLE
Unit: mm (in)
Grade number (Mark) 1 2 [or no mark (piston only)]
E
Cylinder bore Inner diameter 84.000 - 84.010 (3.3071 - 3.3075) 84.010 - 84.020 (3.3075 - 3.3079)
Piston skirt diameter 83.970 - 83.980 (3.3059 - 3.3063) 83.980 - 83.990 (3.3063 - 3.3067)
NOTE: F
Piston is available together with piston pin as an assembly.
Connecting Rod Bearing INFOID:0000000009944972
G
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED

1. Apply connecting rod big end diameter grade stamped on con- H
necting rod side face to the row in the “Connecting Rod Bearing
Selection Table”.
I
A : Oil hole
B : Management code
C : Cylinder number
J
F : Front mark
PBIC4003E K
2. Apply crankshaft pin journal diameter grade stamped on crank-

L
shaft front side to the column in the “Connecting Rod Bearing
Selection Table”.
A : No. 1 pin journal diameter grade M

B : No. 2 pin journal diameter grade
C : No. 3 pin journal diameter grade
D : No. 4 pin journal diameter grade N
E : No. 1 main journal diameter grade
F : No. 2 main journal diameter grade PBIC3261J
G : No. 3 main journal diameter grade O
H : No. 4 main journal diameter grade
I : No. 5 main journal diameter grade
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.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-95, "Inspection".

2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
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
PBIC4077E
CONNECTING ROD BEARING GRADE TABLE
Connecting rod bearing grade table : Refer to EM-122, "Connecting Rod Bearing".
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). A
Bearing undersize table

: Refer to EM-122, "Connecting Rod Bearing". EM
PBIC3263J
D
Main Bearing INFOID:0000000009944973
WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED E

1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on rear left side of cylinder block (L).
F
A : Correction stamp
B : Standard stamp
C : Cylinder No. 1 bore grade
G
D : Cylinder No. 2 bore grade
E : Cylinder No. 3 bore grade
F : Cylinder No. 4 bore grade
H
G : No. 1 main bearing housing grade
H : No. 2 main bearing housing grade
I : No. 3 main bearing housing grade
I
J : No. 4 main bearing housing grade
K : No. 5 main bearing housing grade
: Engine front J
• If there is a correction stamp mark on cylinder block, use it as
a correct reference.
K
PBIC3264J
L
2. Apply main journal diameter grade stamped on crankshaft front

side to column in the “Main Bearing Selection Table”.
M
A : No. 1 pin journal diameter grade
B : No. 2 pin journal diameter grade
N
C : No. 3 pin journal diameter grade
D : No. 4 pin journal diameter grade
E : No. 1 main journal diameter grade
O
F : No. 2 main journal diameter grade
G : No. 3 main journal diameter grade PBIC3261J
H : No. 4 main journal diameter grade

P
I : No. 5 main journal diameter grade
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 No. 1, 4, and 5 journals and the other is for
No. 2 and 3 journals. 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.
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-95, "Inspection".
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 No. 1, 4, and 5 journals and the other is for
No. 2 and 3 journals. 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, 4, AND 5 JOURNAL)
PBIC4078E

MAIN BEARING SELECTION TABLE (No. 2 AND 3 JOURNAL)
A
EM
L
PBIC4079E
MAIN BEARING GRADE TABLE (ALL JOURNALS) M
Main bearing grade table (All journals) : Refer to EM-122, "Main Bearing".
N
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 O
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
P

In grinding crankshaft main journal to use undersize bearings,
keep the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
Bearing undersize table:

Refer to EM-122, "Main Bearing".
PBIC3263J

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
General Specification INFOID:0000000009944974
EM
GENERAL SPECIFICATIONS
C
Engine type MR18DE
Cylinder arrangement In-line 4
Displacement cm3 (cu in) 1,797 (109.65) D

Bore and stroke mm (in) 84.0×81.1 (3.307×3.193)
Valve arrangement DOHC
E
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1 F
Compression ratio 9.9
Standard 1,500 (15.3, 217.5)
Compression pressure G
Minimum 1,200 (12.2, 174)
kPa (kg/cm2, psi)/250 rpm
Differential limit between cylinders 100 (1.0, 14.5)
Unit: degree H
J
Valve timing
: Intake valve
: Exhaust valve
K
PBIC5304E
a b c d e f L
8 (−32) 52 (12)
212 224 7 25
ATDC ABDC
( ): Valve timing control “ON”
M
Drive Belt INFOID:0000000009944975
N
DRIVE BELT
Tension of drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner. O
Spark Plug INFOID:0000000009944976
SPARK PLUG P
Unit: mm (in)
Make DENSO
Standard type FXE20HR11
Standard 1.1 (0.043)
Gap (Nominal)
Limit 1.4 (0.055)

Exhaust Manifold INFOID:0000000009944977
EXHAUST MANIFOLD
Unit: mm (in)
Items Limit
Each exhaust port 0.3 (0.012)
Surface distortion
Entire part 0.7 (0.028)
Camshaft INFOID:0000000009944978
CAMSHAFT
Unit: mm (in)
Items Standard Limit

No. 1 0.045 - 0.086 (0.0018 - 0.0034)
Camshaft journal oil clearance 0.15 (0.0059)
No. 2, 3, 4, 5 0.030 - 0.071 (0.0012 - 0.0028)
No. 1 28.000 - 28.021 (1.1024 - 1.1032) —
Camshaft bracket inner diameter
No. 2, 3, 4, 5 25.000 - 25.021 (0.9843 - 0.9851) —
No. 1 27.935 - 27.955 (1.0998 - 1.1006) —
Camshaft journal diameter
No. 2, 3, 4, 5 24.950 - 24.970 (0.9823 - 0.9831) —
Camshaft end play 0.075 - 0.153 (0.0030 - 0.0060) 0.24 (0.0094)
Intake 44.605 - 44.795 (1.7561 - 1.7636) 44.405 (1.7482)
Camshaft cam height “A”
Exhaust 43.175 - 43.365 (1.6998 - 1.7073) 42.975 (1.6919)
Camshaft runout [TIR*] Less than 0.02 (0.0008) 0.05 (0.0020)
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
SEM671
*: Total indicator reading
VALVE LIFTER
Unit: mm (in)
Items Standard
Intake 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter outer diameter
Exhaust 29.977 - 29.987 (1.1802 - 1.1806)
Intake 34.000 - 34.021 (1.3386 - 1.3394)
Valve lifter hole diameter
Exhaust 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.013 - 0.044 (0.0005 - 0.0017)
VALVE CLEARANCE

Unit: mm (in)
Items Cold Hot* (reference data) A

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

Unit: mm (in) C
Identification mark Thickness
KBIA0119E
G
300 3.00 (0.1181)

302 3.02 (0.1189) H
304 3.04 (0.1197)
306 3.06 (0.1205)
308 3.08 (0.1213) I
310 3.10 (0.1220)
312 3.12 (0.1228)
J
314 3.14 (0.1236)
316 3.16 (0.1244)
318 3.18 (0.1252) K
320 3.20 (0.1260)
322 3.22 (0.1268)
L
324 3.24 (0.1276)
326 3.26 (0.1283)
328 3.28 (0.1291) M
330 3.30 (0.1299)
332 3.32 (0.1307)
N
334 3.34 (0.1315)
336 3.36 (0.1323)
338 3.38 (0.1331) O
340 3.40 (0.1339)
342 3.42 (0.1346)
344 3.44 (0.1354) P
346 3.46 (0.1362)
348 3.48 (0.1370)
350 3.50 (0.1378)

Cylinder Head INFOID:0000000009944979
CYLINDER HEAD
Unit: mm (in)

Head surface distortion — 0.1 (0.004)
Normal cylinder head height “H” 130.9 (5.15) —
PBIC0924E
VALVE DIMENSIONS
Unit: mm (in)
SEM188A
Intake 33.8 - 34.1 (1.331 - 1.343)

Valve head diameter “D”
Exhaust 27.6 - 27.9 (1.087 - 1.098)
Intake 106.27 (4.18)
Valve length “L”
Exhaust 105.26 (4.14)
Intake 5.465 - 5.480 (0.2152 - 0.2157)
Valve stem diameter “d”
Exhaust 5.455 - 5.470 (0.2148 - 0.2154)
Valve seat angle “α” 45°15′ - 45°45′
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 1.2 (0.047)
VALVE GUIDE

Unit: mm (in)
A
EM
D
PBIC2187E
Items Standard Oversize (service) [0.2 (0.008)]

E
Outer diameter 9.523 - 9.534 (0.3749 - 0.3754) 9.723 - 9.734 (0.3828 - 0.3832)
Valve guide
Inner diameter (Finished size) 5.500 - 5.518 (0.2165 - 0.2172)
Cylinder head valve guide hole diameter 9.475 - 9.496 (0.3730 - 0.3739) 9.675 - 9.696 (0.3809 - 0.3817)
F
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Intake 0.020 - 0.053 (0.0008 - 0.0021) G
Valve guide clearance 0.1 (0.004)
Exhaust 0.030 - 0.063 (0.0012 - 0.0025)
Projection length “H” 13.35 - 13.65 (0.5256 - 0.5374)
H
VALVE SEAT
Unit: mm (in)
I
L
PBIC2745E
Items Standard Oversize (service) [0.5 (0.020)]

M
Intake 34.700 - 34.727 (1.3661 - 1.3672) 35.200 - 35.227 (1.3858 - 1.3869)
Cylinder head seat recess diameter “D”
Exhaust 28.700 - 28.727 (1.1299 - 1.1310) 29.200 - 29.227 (1.1496 - 1.1507)
Intake 34.808 - 34.824 (1.3704 - 1.3710) 35.308 - 35.324 (1.3901 - 1.3907) N
Valve seat outer diameter “d”
Exhaust 28.808 - 28.824 (1.1342 - 1.1348) 29.308 - 29.324 (1.1539 - 1.1545)
Valve seat interference fit 0.081 - 0.124 (0.0032 - 0.0049)
Intake 31.8 (1.252) O
Diameter “d1”*1
Exhaust 25.3 (0.996)
Intake 33.1 - 33.6 (1.303 - 1.323)
Diameter “d2”*2 P
Exhaust 26.9 - 27.4 (1.059 - 1.079)
Intake 60°
Angle “α1”
Exhaust 45°
Angle “α2” 88°45′ - 90°15′
Angle “α3” 120°

Intake 1.0 - 1.4 (0.039 - 0.055)
Contacting width “W”*3
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Intake 5.03 - 5.13 (0.1980 - 0.2020)
Height “h” 5.9 - 6.0 (0.232 - 0.236)
Exhaust 4.95 - 5.05 (0.1949 - 0.1988)
Intake 6.04 (0.2378)
Depth “H”
Exhaust 6.05 (0.2382)
*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
Standard
Items
Intake Exhaust
Free height 44.90 - 45.10 mm (1.7677 - 1.7756 in) 45.74 - 45.94 mm (1.8008 - 1.8087 in)
Installation height 35.30 mm (1.390 in) 35.30 mm (1.390 in)
Installation load 151 - 175 N (15.4 - 17.9 kg, 34 - 39 lb) 137 - 159 N (14.0 - 16.2 kg, 31 - 36 lb)
Height during valve open 26.36 mm (1.0378 in) 27.80 mm (1.0945 in)
Load with valve open 333 - 379 N (34.0 - 38.7 kg, 75 - 85 lb) 264 - 299 N (26.9 - 30.5 kg, 59 - 67 lb)
Identification color White Orange
Unit: mm (in)
Items Limit
Valve spring squareness 2.0 (0.079)
Cylinder Block INFOID:0000000009944980
CYLINDER BLOCK
Unit: mm (in)
PBIC4017E
Cylinder block top surface distortion Limit 0.1 (0.004)

Grade No. 1 84.000 - 84.010 (3.3071 - 3.3075)
Cylinder bore inner diameter Standard
Grade No. 2 84.010 - 84.020 (3.3075 - 3.3079)
Out-of-round 0.015 (0.0006)
Limit
Taper 0.010 (0.0004)

Grade No. A 55.997 - 55.998 (2.2046 - 2.2046)
A
Grade No. B 55.998 - 55.999 (2.2046 - 2.2047)
Grade No. C 55.999 - 56.000 (2.2047 - 2.2047)
Grade No. D 56.000 - 56.001 (2.2047 - 2.2048) EM
Grade No. E 56.001 - 56.002 (2.2048 - 2.2048)
Grade No. F 56.002 - 56.003 (2.2048 - 2.2048)
Grade No. G 56.003 - 56.004 (2.2048 - 2.2049) C
Grade No. H 56.004 - 56.005 (2.2049 - 2.2049)
Grade No. J 56.005 - 56.006 (2.2049 - 2.2050)
D
Grade No. K 56.006 - 56.007 (2.2050 - 2.2050)
Main bearing housing inner diameter grade
Grade No. L 56.007 - 56.008 (2.2050 - 2.2050)
Grade No. M 56.008 - 56.009 (2.2050 - 2.2051) E
Grade No. N 56.009 - 56.010 (2.2051 - 2.2051)
Grade No. P 56.010 - 56.011 (2.2051 - 2.2052)
F
Grade No. R 56.011 - 56.012 (2.2052 - 2.2052)
Grade No. S 56.012 - 56.013 (2.2052 - 2.2052)
Grade No. T 56.013 - 56.014 (2.2052 - 2.2053) G
Grade No. U 56.014 - 56.015 (2.2053 - 2.2053)
Grade No. V 56.015 - 56.016 (2.2053 - 2.2053)
H
Grade No. W 56.016 - 56.017 (2.2053 - 2.2054)
AVAILABLE PISTON
Unit: mm (in) I
PBIC0188E
Grade No. 1 83.970 - 83.980 (3.3059 - 3.3063) M

Piston skirt diameter “A” Standard
Grade No. 2 83.980 - 83.990 (3.3063 - 3.3067)
Measure point “H” 39.9 (1.571)
N
Piston pin hole diameter 19.993 - 19.999 (0.7871 - 0.7874)
Standard 0.020 - 0.040 (0.0008 - 0.0016)
Piston to cylinder bore clearance
Limit 0.08 (0.0031) O
PISTON RING
Unit: mm (in)
P
Top 0.04 - 0.08 (0.0016 - 0.0031) 0.11 (0.0043)
Piston ring side clearance 2nd 0.03 - 0.07 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.015 - 0.185 (0.006 - 0.0073) —

Top 0.20 - 0.30 (0.0079 - 0.0118) 0.51 (0.0201)
Piston ring end gap 2nd 0.50 - 0.65 (0.0197 - 0.0256) 0.83 (0.0327)
Oil (rail ring) 0.15 - 0.45 (0.0059 - 0.0177) 0.78 (0.0307)
PISTON PIN
Unit: mm (in)

Piston pin outer diameter 19.989 - 19.995 (0.7870 - 0.7872) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
CONNECTING ROD
Unit: mm (in)
Center distance 143.44 - 143.54 (5.65 - 5.65)

Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
Connecting rod bushing inner diameter* Standard 20.000 - 20.012 (0.7874 - 0.7879)
Standard 0.005 - 0.023 (0.0002 - 0.0009)
Connecting rod bushing oil clearance
Limit 0.03 (0.0012)
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Connecting rod side clearance
Limit 0.4 (0.016)
Grade No. A 47.000 - 47.001 (1.8504 - 1.8504)
Grade No. B 47.001 - 47.002 (1.8504 - 1.8505)
Grade No. C 47.002 - 47.003 (1.8505 - 1.8505)
Grade No. D 47.003 - 47.004 (1.8505 - 1.8505)
Grade No. E 47.004 - 47.005 (1.8505 - 1.8506)
Grade No. F 47.005 - 47.006 (1.8506 - 1.8506)
Connecting rod big end diameter grade Grade No. G 47.006 - 47.007 (1.8506 - 1.8507)
Grade No. H 47.007 - 47.008 (1.8507 - 1.8507)
Grade No. J 47.008 - 47.009 (1.8507 - 1.8507)
Grade No. K 47.009 - 47.010 (1.8507 - 1.8508)
Grade No. L 47.010 - 47.011 (1.8508 - 1.8508)
Grade No. M 47.011 - 47.012 (1.8508 - 1.8509)
Grade No. N 47.012 - 47.013 (1.8509 - 1.8509)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
SEM645 PBIC3459J
Center distance “r” 40.41 - 40.49 (1.5909 - 1.5940)

Out-of-round Limit
0.0035 (0.0001) A
Taper Limit
Standard 0.05 (0.0020)
Runout [TIR*]
Limit 0.10 (0.0039) EM
Standard 0.10 - 0.26 (0.0039 - 0.0102)
Crankshaft end play
Limit 0.30 (0.0118)
Grade No. A 43.970 - 43.971 (1.7311 - 1.7311) C
Grade No. B 43.969 - 43.970 (1.7311 - 1.7311)
Grade No. C 43.968 - 43.969 (1.7310 - 1.7311)
D
Grade No. D 43.967 - 43.968 (1.7310 - 1.7310)
Grade No. E 43.966 - 43.967 (1.7309 - 1.7310)
Grade No. F 43.965 - 43.966 (1.7309 - 1.7309) E
Grade No. G 43.964 - 43.965 (1.7309 - 1.7309)
Grade No. H 43.963 - 43.964 (1.7308 - 1.7309)
F
Grade No. J 43.962 - 43.963 (1.7308 - 1.7308)
Crankshaft pin journal diameter “Dp” grade.
Grade No. K 43.961 - 43.962 (1.7307 - 1.7308)
Grade No. L 43.960 - 43.961 (1.7307 - 1.7307) G
Grade No. M 43.959 - 43.960 (1.7307 - 1.7307)
Grade No. N 43.958 - 43.959 (1.7306 - 1.7307)
H
Grade No. P 43.957 - 43.958 (1.7306 - 1.7306)
Grade No. R 43.956 - 43.957 (1.7305 - 1.7306)
Grade No. S 43.955 - 43.956 (1.7305 - 1.7305) I
Grade No. T 43.954 - 43.955 (1.7305 - 1.7305)
Grade No. U 43.953 - 43.954 (1.7304 - 1.7305)
Grade No. A 51.978 - 51.979 (2.0464 - 2.0464)
J
Grade No. B 51.977 - 51.978 (2.0463 - 2.0464)

Grade No. C 51.976 - 51.977 (2.0463 - 2.0463)
K
Grade No. D 51.975 - 51.976 (2.0463 - 2.0463)
Grade No. E 51.974 - 51.975 (2.0462 - 2.0463)
Grade No. F 51.973 - 51.974 (2.0462 - 2.0462) L
Grade No. G 51.972 - 51.973 (2.0461 - 2.0462)
Grade No. H 51.971 - 51.972 (2.0461 - 2.0461)
M
Grade No. J 51.970 - 51.971 (2.0461 - 2.0461)
Grade No. K 51.969 - 51.970 (2.0460 - 2.0461)
Crankshaft main journal diameter “Dm” grade.
Grade No. L 51.968 - 51.969 (2.0460 - 2.0460) N
Grade No. M 51.967 - 51.968 (2.0459 - 2.0460)
Grade No. N 51.966 - 51.967 (2.0459 - 2.0459)
O
Grade No. P 51.965 - 51.966 (2.0459 - 2.0459)
Grade No. R 51.964 - 51.965 (2.0458 - 2.0459)
Grade No. S 51.963 - 51.964 (2.0458 - 2.0458) P
Grade No. T 51.962 - 51.963 (2.0457 - 2.0458)
Grade No. U 51.961 - 51.962 (2.0457 - 2.0457)
Grade No. V 51.960 - 51.961 (2.0457 - 2.0457)
Grade No. W 51.959 - 51.960 (2.0456 - 2.0457)
*: Total indicator reading

Connecting Rod Bearing INFOID:0000000009944981
CONNECTING ROD BEARING GRADE TABLE

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

0 1.494 - 1.497 (0.0588 - 0.0589) Black
1 1.497 - 1.500 (0.0589 - 0.0591) Brown
Grade and color are the same
2 1.500 - 1.503 (0.0591 - 0.0592) Green
for upper and lower bearings.
3 1.503 - 1.506 (0.0592 - 0.0593) Yellow
4 1.506 - 1.509 (0.0593 - 0.0594) Blue
UPR 1.494 - 1.497 (0.0588 - 0.0589) Black
01
LWR 1.497 - 1.500 (0.0589 - 0.0591) Brown
UPR 1.497 - 1.500 (0.0589 - 0.0591) Brown
12
LWR 1.500 - 1.503 (0.0591 - 0.0592) Green Grade and color are different
between upper and lower bear-
UPR 1.500 - 1.503 (0.0591 - 0.0592) Green ings.
23
LWR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
UPR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
34
LWR 1.506 - 1.509 (0.0593 - 0.0594) Blue
UNDERSIZE TABLE
Unit: mm (in)
Items Thickness Crank pin journal diameter

US 0.25 (0.0098) 1.623 - 1.631 (0.0639 - 0.0642) Grind so that bearing clearance is the specified value.
CONNECTING ROD BEARING OIL CLEARANCE

Unit: mm (in)
Standard 0.037 - 0.047 (0.0015 - 0.0019)

Connecting rod bearing oil clearance
Limit 0.07 (0.0028)
Main Bearing INFOID:0000000009944982
MAIN BEARING GRADE TABLE (ALL JOURNALS)

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

0 1.996 - 1.999 (0.0786 - 0.0787) Black
1 1.999 - 2.002 (0.0787 - 0.0788) Brown
2 2.002 - 2.005 (0.0788 - 0.0789) Green
3 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are the same
4 2.008 - 2.011 (0.0791 - 0.0792) Blue for upper and lower bearings.
5 2.011 - 2.014 (0.0792 - 0.0793) Pink

6 2.014 - 2.017 (0.0793 - 0.0794) Purple
7 2.017 - 2.020 (0.0794 - 0.0795) White

UPR 1.996 - 1.999 (0.0786 - 0.0787) Black
01 A
LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown
UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown
12
LWR 2.002 - 2.005 (0.0788 - 0.0789) Green EM
UPR 2.002 - 2.005 (0.0788 - 0.0789) Green
23
LWR 2.005 - 2.008 (0.0789 - 0.0791) Yellow
UPR 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are different C
34 between upper and lower bear-
LWR 2.008 - 2.011 (0.0791 - 0.0792) Blue ings.
UPR 2.008 - 2.011 (0.0791 - 0.0792) Blue
45 D
LWR 2.011 - 2.014 (0.0792 - 0.0793) Pink
UPR 2.011 - 2.014 (0.0792 - 0.0793) Pink
56
LWR 2.014 - 2.017 (0.0793 - 0.0794) Purple E
UPR 2.014 - 2.017 (0.0793 - 0.0794) Purple
67
LWR 2.017 - 2.020 (0.0794 - 0.0795) White
F
UNDERSIZE TABLE
Unit: mm (in)
Items Thickness Main journal diameter G

US 0.25 (0.0098) 2.126 - 2.134 (0.0837 - 0.0840) Grind so that bearing clearance is the specified value.
MAIN BEARING OIL CLEARANCE H

Unit: mm (in)
No. 1, 4 and 5 0.024 - 0.034 (0.0009 - 0.0013)

Standard
Main bearing oil clearance No. 2 and 3 0.012 - 0.022 (0.0005 - 0.0009) I
Limit 0.065 (0.0026)

(NISSAN) Manual de Taller Nissan Cube 2014

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ENGINE

NOISE, VIBRATION AND HARSHNESS COMPRESSION PRESSURE ........................... 21

DRIVE BELT .......................................................13 Exploded View .........................................................29

Revision: 2013 October EM-1 2014 CUBE

Revision: 2013 October EM-2 2014 CUBE

1. Locate the area where noise occurs.

Revision: 2013 October EM-3 2014 CUBE

Operating condition of engine

Piston to piston pin oil

Revision: 2013 October EM-4 2014 CUBE

Revision: 2013 October EM-5 2014 CUBE

DISCONNECTING FUEL PIPING

DRAINING ENGINE COOLANT

INSPECTION, REPAIR AND REPLACEMENT

REMOVAL AND DISASSEMBLY

ASSEMBLY AND INSTALLATION

Parts Requiring Angle Tightening INFOID:0000000009944911

Revision: 2013 October EM-6 2014 CUBE

REMOVAL OF LIQUID GASKET SEALING C

• Within five minutes of liquid gasket application, install the mat-

Revision: 2013 October EM-7 2014 CUBE

Revision: 2013 October EM-8 2014 CUBE

KV10116200 Disassembling and assembling valve mecha- F

KV10112100 Tightening bolts for main bearing cap, cylinder

KV10117100 Loosening or tightening air fuel ratio sensor 1 K

KV10115600 Installing valve oil seal

Revision: 2013 October EM-9 2014 CUBE

ST16610001 Removing pilot converter

KV11103000 Removing crankshaft pulley

KV11105210 Fixing drive plate

Commercial Service Tools INFOID:0000000009944914

( — ) Removing and installing spark plug

Revision: 2013 October EM-10 2014 CUBE

( — ) Finishing valve seat dimensions

( — ) Removing and installing valve guide

( — ) 1: Reaming valve guide inner hole K

Revision: 2013 October EM-11 2014 CUBE

( — ) Pressing the tube of liquid gasket

Revision: 2013 October EM-12 2014 CUBE

1. Alternator 2. Drive belt auto-tensioner 3. Crankshaft pulley F

Tension Adjustment INFOID:0000000009944917

Removal and Installation INFOID:0000000009944918 M

5. Remove drive belt.

Revision: 2013 October EM-13 2014 CUBE

Revision: 2013 October EM-14 2014 CUBE

2 : Air cleaner filter K

Inspection (Viscous Paper Type) INFOID:0000000010208825

Revision: 2013 October EM-15 2014 CUBE

1. PCV hose 2. Rocker cover 3. Spark plug

Removal and Installation INFOID:0000000009944921

Revision: 2013 October EM-16 2014 CUBE

INSPECTION AFTER REMOVAL

Spark plug (Standard type) : Refer to EM-113, "Spark Plug".

Cleaner air pressure : Less than 588 kPa (6 kg/cm2, E

Revision: 2013 October EM-17 2014 CUBE

C : White paint mark (Not use for service)

• If they do not face inside, rotate crankshaft pulley once more

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