ENGINE

SECTION
ENGINE MECHANICAL
EM EM

E
CONTENTS
SYMPTOM DIAGNOSIS ............................... 3 Removal and Installation .........................................15 F

NOISE, VIBRATION AND HARSHNESS SPARK PLUG ................................................... 16

(NVH) TROUBLESHOOTING ............................. 3 Exploded View .........................................................16
G
NVH Troubleshooting - Engine Noise ....................... 3 Removal and Installation .........................................16
Use the Chart Below to Help You Find the Cause Inspection ................................................................17
of the Symptom ......................................................... 4
CAMSHAFT VALVE CLEARANCE .................. 18 H
PRECAUTION ............................................... 5 Inspection and Adjustment ......................................18

PRECAUTIONS ................................................... 5 COMPRESSION PRESSURE ........................... 23

Inspection ................................................................23 I
Precaution for Procedure without Cowl Top Cover...... 5
Precaution for Supplemental Restraint System
ON-VEHICLE REPAIR ................................. 25
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
J
SIONER" ................................................................... 5 ENGINE COVER ............................................... 25
Precaution Necessary for Steering Wheel Rota- Exploded View .........................................................25
tion after Battery Disconnect ..................................... 5 Removal and Installation .........................................25
Precaution for Drain Engine Coolant and Engine K
Oil .............................................................................. 6 DRIVE BELT AUTO TENSIONER AND IDLER
Precaution for Disconnecting Fuel Piping ................. 6 PULLEY ............................................................. 26
Precaution for Removal and Disassembly ................ 6 Exploded View .........................................................26 L
Precaution for Inspection, Repair and Replace- Removal and Installation .........................................26
ment .......................................................................... 6
Precaution for Assembly and Installation .................. 6 AIR CLEANER AND AIR DUCT ....................... 27
Exploded View .........................................................27 M
Precaution for Angle Tightening ................................ 6
Precaution for Liquid Gasket ..................................... 7 Removal and Installation .........................................27
Inspection ................................................................28
PREPARATION ............................................ 9 N
INTAKE MANIFOLD COLLECTOR .................. 29
PREPARATION ................................................... 9 Exploded View .........................................................29
Special Service Tool ................................................. 9 Removal and Installation .........................................29
O
Commercial Service Tool ........................................ 10
INTAKE MANIFOLD ......................................... 32
ON-VEHICLE MAINTENANCE .................... 13 Exploded View .........................................................32
Removal and Installation .........................................32 P
DRIVE BELT .......................................................13 Inspection ................................................................33
Exploded View ........................................................ 13
Checking ................................................................. 13 EXHAUST MANIFOLD AND THREE WAY
Tension Adjustment ................................................ 13 CATALYST ........................................................ 34
Removal and Installation ......................................... 13 Exploded View .........................................................34
Removal and Installation .........................................34
AIR CLEANER FILTER ......................................15 Inspection ................................................................38

Revision: 2008 October EM-1 Z51

OIL PAN AND OIL STRAINER .......................... 39 OIL SEAL ........................................................... 93
Exploded View ........................................................ 39
Removal and Installation ........................................ 39 VALVE OIL SEAL ..................................................... 93
Inspection ............................................................... 43 VALVE OIL SEAL : Removal and Installation ......... 93

FUEL INJECTOR AND FUEL TUBE ................. 45 FRONT OIL SEAL ..................................................... 93
Exploded View ........................................................ 45 FRONT OIL SEAL : Removal and Installation ........ 93
Removal and Installation ........................................ 45 REAR OIL SEAL ....................................................... 94
Inspection ............................................................... 49 REAR OIL SEAL : Removal and Installation ........... 94
IGNITION COIL, SPARK PLUG AND ROCK- CYLINDER HEAD .............................................. 96
ER COVER ......................................................... 50 Exploded View ........................................................ 96
Exploded View ........................................................ 50 Removal and Installation ......................................... 97
Removal and Installation ........................................ 50 Disassembly and Assembly .................................. 100
Inspection .............................................................. 104
TIMING CHAIN .................................................. 53
Exploded View ........................................................ 53 CYLINDER BLOCK .......................................... 107
Removal and Installation ........................................ 54 Exploded View ...................................................... 107
Inspection ............................................................... 66 Disassembly and Assembly .................................. 108
Inspection .............................................................. 116
REMOVAL AND INSTALLATION ............... 68
HOW TO SELECT PISTON AND BEARING .. 126
ENGINE ASSEMBLY ......................................... 68 Description ............................................................ 126
Exploded View ........................................................ 68 Piston .................................................................... 126
Removal and Installation ........................................ 68 Connecting Rod Bearing ..................................... 127
Inspection ............................................................... 75 Main Bearing ........................................................ 128
DISASSEMBLY AND ASSEMBLY ............. 76 SERVICE DATA AND SPECIFICATIONS
ENGINE STAND SETTING ................................ 76 (SDS) ......................................................... 131
Setting .................................................................... 76
SERVICE DATA AND SPECIFICATIONS
ENGINE UNIT .................................................... 78 (SDS) ................................................................ 131
Disassembly ........................................................... 78 General Specification ........................................... 131
Assembly ................................................................ 78 Drive Belt .............................................................. 131
Spark Plug ............................................................ 132
REAR TIMING CHAIN CASE ............................ 79 Intake Manifold ...................................................... 132
Exploded View ........................................................ 79 Exhaust Manifold .................................................. 132
Disassembly and Assembly .................................... 80 Camshaft ............................................................... 132
Cylinder Head ...................................................... 134
CAMSHAFT ....................................................... 84 Cylinder Block ...................................................... 137
Exploded View ........................................................ 84 Main Bearing ........................................................ 139
Removal and Installation ........................................ 84 Connecting Rod Bearing ..................................... 140
Inspection ............................................................... 88

Revision: 2008 October EM-2 Z51

 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting - Engine Noise INFOID:0000000004556025
EM

JPBIA1711GB

Revision: 2008 October EM-3 Z51

 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000004556026

1. Locate the area where noise occurs.

2. Confirm the type of noise.
3. Specify the operating condition of the engine.
4. Check specified noise source.
If necessary, repair or replace these parts.

Operating condition of engine

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-18
gine clicking noise
Rocker
cover Camshaft Camshaft runout
Cylinder Rattle C A — A B C bearing Camshaft journal oil EM-132
head noise clearance

Piston to piston pin oil

Slap or Piston pin clearance
— A — B B — EM-137
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-137
rap slap noise
Cylinder Piston ring end gap
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing EM-137
Oil pan ing rod oil clearance
Knock A B C B B B
bearing Connecting rod bearing EM-140
noise oil clearance
Main bearing oil clear- EM-139
Main bear-
Knock A B — A B C ance
ing noise
Crankshaft runout EM-137
Timing
Front of chain and Timing chain cracks
EM-66
engine Tapping or timing and wear
A A — B B B
Timing ticking chain ten- Timing chain tensioner
EM-53
chain case sioner 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-18,
Squall
A B — B A B pump Water pump operation "Exploded
Creak
noise View"
A: Closely related B: Related C: Sometimes related —: Not related

Revision: 2008 October EM-4 Z51

 PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Procedure without Cowl Top Cover INFOID:0000000004781403
EM
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
C

PIIB3706J

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT F
PRE-TENSIONER" INFOID:0000000004781401

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along G
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIRBAG” and
“SEAT BELT” of this Service Manual.
H
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. I
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIRBAG”. J
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
K
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the igni- L
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the M
battery, and wait at least 3 minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect N
INFOID:0000000004781402

NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi- O
tion, then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work. P
If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
This vehicle is equipped with a push-button ignition switch and a steering lock unit.
If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure
below before starting the repair operation.
OPERATION PROCEDURE

Revision: 2008 October EM-5 Z51

 PRECAUTIONS
< PRECAUTION >
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the push-button ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT-III.
Precaution for Drain Engine Coolant and Engine Oil INFOID:0000000004556030

Drain engine coolant and engine oil when the engine is cooled.
Precaution for Disconnecting Fuel Piping INFOID:0000000004556031

• Before starting work, check no fire or spark producing items are in the work area.
• Release fuel pressure before disconnecting and disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.
Precaution for Removal and Disassembly INFOID:0000000004556032

• When instructed to use SST, use the specified tools. Always be careful to work safely, avoid forceful or unin-
structed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position.
• Cover openings of engine system with a tape or the equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
Precaution for Inspection, Repair and Replacement INFOID:0000000004556033

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and Installation INFOID:0000000004556034

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

• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Precaution for Angle Tightening INFOID:0000000004556035

• Use the angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
- Cylinder head bolts

Revision: 2008 October EM-6 Z51

 PRECAUTIONS
< PRECAUTION >
- Main bearing cap bolts
- Connecting rod cap bolts A
- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle
tightening)
• Never use a torque value for final tightening.
EM
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000004556036
C

REMOVAL OF LIQUID GASKET SEALING

• After removing mounting nuts and bolts, separate the mating sur- D
face using the seal cutter [SST: KV10111100] (A) and remove old
liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces. E
• Tap (B) the seal cutter [SST: KV10111100] to insert it, and then
slide (C) it by tapping on the side as shown in the figure.
• In areas where the seal cutter [SST: KV10111100] is difficult to use, F
use a plastic hammer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason tool such as a screwdriver is
used, be careful not to damage the mating surfaces.
JPBIA0052ZZ
G

LIQUID GASKET APPLICATION PROCEDURE

1. Using a scraper (A), remove old liquid gasket adhering to the H
gasket application surface and the mating surface.
• Remove liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
I
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
J

JPBIA0053ZZ K

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

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

EMA0622D

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

Revision: 2008 October EM-7 Z51

 PRECAUTIONS
< PRECAUTION >
If there are specific instructions in this manual, observe them.

Revision: 2008 October EM-8 Z51

 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000004556037
EM

Tool number
Description C
Tool name
KV10116200 Disassembling valve mechanism
Valve spring compressor Part (1) is a component of KV10116200, but
1. KV10115900 Part (2) is not so. D
Attachment
2. KV10109220
Adapter
E
PBIC1650E

KV10107902 Replacing valve oil seal

Valve oil seal puller F

NT011
H
KV10115600 Installing valve oil seal
Valve oil seal drift Use side A.
a: 20 mm (0.79 in) dia.
b: 13 mm (0.51 in) dia. I
c: 10.3 mm (0.406 in) dia.
d: 8 mm (0.31 in) dia.
e: 10.7 mm (0.421 in)
f: 5 mm (0.20 in) J
S-NT603

EM03470000 Installing piston assembly into cylinder bore

Piston ring compressor
K

NT044

ST16610001 Removing pilot converter M

Pilot bushing puller

NT045 O
KV10111100 Removing oil pan (lower and upper), front and
Seal cutter rear timing chain case, etc.
P

NT046

Revision: 2008 October EM-9 Z51

 PREPARATION
< PREPARATION >
Tool number
Description
Tool name
KV10112100 Tightening bolts for connecting rod bearing
Angle wrench cap, cylinder head, etc. in angle

NT014

KV10117100 Loosening or tightening air fuel ratio sensor 1

Heated oxygen sensor wrench For 22 mm (0.87 in) width hexagon nut

NT379

KV10114400 Loosening or tightening heated oxygen sen-

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

NT636

Commercial Service Tool INFOID:0000000004556038

Tool name Description

Quick connector release Removing fuel tube quick connectors in en-
gine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)

PBIC0198E

Power tool Loosening bolts and nuts

PBIC0190E

Tube presser Pressing the tube of liquid gasket

NT052

Revision: 2008 October EM-10 Z51

 PREPARATION
< PREPARATION >
Tool name Description
A
Manual lift table caddy Removing and installing engine

EM

C
ZZA1210D

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

NT583

1. Compression tester Checking compression pressure F

2. Adapter

ZZA0008D
H
Spark plug wrench Removing and installing spark plug
a: 14 mm (0.55 in)

J
JPBIA0399ZZ

Pulley holder Removing and installing crankshaft pulley

K

ZZA1010D

Valve seat cutter set Finishing valve seat dimensions M

NT048
O
Piston ring expander Removing and installing piston ring

NT030

Revision: 2008 October EM-11 Z51

 PREPARATION
< PREPARATION >
Tool name Description
Valve guide drift Removing and installing valve guide
Intake and Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.

NT015

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

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

NT016

Oxygen sensor thread cleaner Reconditioning the exhaust system threads

before installing a new air fuel ratio sensor and
heated oxygen sensor (Use with anti-seize lu-
bricant shown below.)
a: 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor and air fuel ratio sensor
b: 12 mm (0.47 in) dia. for titania heated ox-
ygen sensor
AEM488

Anti-seize lubricant (Permatex 133AR Lubricating air fuel ratio sensor and oxygen
or equivalent meeting MIL specifica- sensor threads cleaning tool when recondi-
tion MIL-A-907) tioning exhaust system threads

AEM489

Revision: 2008 October EM-12 Z51

 DRIVE BELT
< ON-VEHICLE MAINTENANCE >
ON-VEHICLE MAINTENANCE A
DRIVE BELT
Exploded View INFOID:0000000004556039
EM

JPBIA1625ZZ
H
1. Idler pulley 2. Drive belt 3. Power steering oil pump
4. Drive belt auto-tensioner 5. Crankshaft pulley 6. Idler pulley
7. A/C compressor 8. Alternator I
A. Indicator B. Range when new drive belt is installed C. Possible use range
D. View D
: Engine front J

Checking INFOID:0000000004556040

K
WARNING:
Be sure to perform the this step when engine is stopped.
• Check that the indicator (A) of drive belt auto-tensioner is within the possible use range (C).
L
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator should be within the range (B) in the figure.
• Visually check entire drive belt for wear, damage or cracks. M
• If the indicator is out of the possible use range or belt is damaged, replace drive belt.
Tension Adjustment INFOID:0000000004556041
N
Refer to EM-131, "Drive Belt".
Removal and Installation INFOID:0000000004556042
O

REMOVAL
1. Remove front wheel and tire (RH). P
2. Remove splash guard (RH). Refer to EXT-25, "FENDER PROTECTOR : Exploded View".

Revision: 2008 October EM-13 Z51

 DRIVE BELT
< ON-VEHICLE MAINTENANCE >
3. Hold the hexagonal part in center of drive belt auto-tensioner
pulley with a box wrench securely. Then move the wrench han-
dle in the direction of arrow (loosening direction of drive belt).
CAUTION:
• Avoid placing hand in a location where pinching may
occur if the holding tool accidentally comes off.
• Never loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Never turn it counterclockwise). If
turned counterclockwise, the complete drive belt auto-
tensioner must be replaced as a unit, including the pulley.
4. Insert a rod approximately 6 mm (0.24 in) in diameter such as JPBIA1627ZZ
short-length screwdriver into the hole (A) of the retaining boss to
fix drive belt auto-tensioner pulley.
• Keep drive belt auto-tensioner pulley arm locked after drive belt is removed.
5. Loosen drive belt from water pump pulley in sequence, and remove it.
INSTALLATION
1. Hook drive belt onto all pulleys except for drive belt auto-tensioner pulley, and then onto drive belt auto-
tensioner pulley finally.
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 is within the possible use range. Refer to EM-13, "Exploded
View".

Revision: 2008 October EM-14 Z51

 AIR CLEANER FILTER
< ON-VEHICLE MAINTENANCE >
AIR CLEANER FILTER
A
Removal and Installation INFOID:0000000004556043

REMOVAL EM
1. Unhook air cleaner case (lower) side clips and lift up air cleaner case (upper).
2. Remove air cleaner filter from air cleaner case (lower).
C

PBIC1165E
F
INSTALLATION
Note the following, and install in the reverse order of removal.
• Install the air cleaner filter by aligning the seal with the notch of air cleaner case.
G

Revision: 2008 October EM-15 Z51

 SPARK PLUG
< ON-VEHICLE MAINTENANCE >
SPARK PLUG
Exploded View INFOID:0000000004556044

JPBIA1637GB

1. Ignition coil 2. Spark plug 3. PCV hose

4. Clamp 5. PCV valve 6. O-ring
7. Rocker cover (bank 1) 8. PCV hose 9. Rocker cover gasket (bank 1)
Camshaft position sensor (PHASE)
10. O-ring 11. 12. Oil filler cap
(bank 1)
Camshaft position sensor (PHASE)
13. Rocker cover (bank 2) 14. Rocker cover gasket (bank 2) 15.
(bank 2)
16. PCV hose 17. Clamp
A. To intake manifold collector B. Refer to EM-50 C. Camshaft bracket side
D. To air duct
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000004556045

REMOVAL
1. Remove engine cover. Refer to EM-25, "Exploded View".
2. Remove air cleaner cases (upper and lower) and air duct assembly. Refer to EM-27, "Exploded View".
3. Remove electric throttle control actuator. Refer to EM-29, "Exploded View".
4. Remove intake manifold collector. Refer to EM-29, "Exploded View".
5. Remove ignition coil. Refer to EM-50, "Exploded View".

Revision: 2008 October EM-16 Z51

 SPARK PLUG
< ON-VEHICLE MAINTENANCE >
6. Remove spark plug with a spark plug wrench (commercial ser-
vice tool). A

a : 14 mm (0.55 in)

EM

JPBIA0030ZZ

D
INSTALLATION
Install in the reverse order of removal.
Inspection INFOID:0000000004556046
E

INSPECTION AFTER REMOVAL

Use the standard type spark plug for normal condition. F

Spark plug (Standard type) : Refer to EM-132, "Spark Plug".

G
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 H
used.

Cleaner air pressure: Less than 588 kPa (5.88 bar, 6 kg/ I
cm2, 85 psi)
Cleaning time: Less than 20 seconds
J
SMA773C

• Spark plug gap adjustment is not required between replace- K

ment intervals.
• Measure spark plug gap. When it exceeds the limit, replace
spark plug even if it is within the specified replacement mile- L
age. Refer to EM-132, "Spark Plug".

JPBIA0031ZZ
N

Revision: 2008 October EM-17 Z51

 CAMSHAFT VALVE CLEARANCE
< ON-VEHICLE MAINTENANCE >
CAMSHAFT VALVE CLEARANCE
Inspection and Adjustment INFOID:0000000004556047

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.
In cases of removing/installing or replacing camshaft and valve-
related parts, or of unusual engine conditions due to changes in
valve clearance (found malfunctions during stating, idling or causing
noise), perform inspection as follows:

: Engine front

JPBIA0164ZZ

1. Remove rocker covers (bank 1 and bank 2). Refer to EM-50, "Exploded View".
2. Measure the valve clearance as follows:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley clockwise to align timing mark
(grooved line without color) ( ) with timing indicator.

SEM727G

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

(engine front side of bank 1) are located as shown in the fig-
ure.

: Engine front

• If not, turn crankshaft one revolution (360 degrees) and align

as shown in the figure.

JPBIA0044ZZ

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

and camshaft.

Valve clearance : Refer to EM-132, "Camshaft".

SEM139D

Revision: 2008 October EM-18 Z51

 CAMSHAFT VALVE CLEARANCE
< ON-VEHICLE MAINTENANCE >
• By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below (locations A
indicated in the figure).

: Engine front
EM
• No. 1 cylinder at compression TDC

Measuring position [bank 1 (A)] No. 1 CYL. No. 3 CYL. No. 5 CYL. C

No. 1 cylinder at com- EXH (C) × (B)

pression TDC INT (D) × (E)
D
Measuring position [bank 2 (H)] No. 2 CYL. No. 4 CYL. No. 6 CYL.

No. 1 cylinder at com- INT (D) × (F)

pression TDC EXH (C) × (G) E

G
JPBIA0165ZZ

c. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 3 cylinder at
TDC its compression stroke. H
NOTE:
Mark a position 240 degrees (b) from a corner of the hexagonal
part of crankshaft pulley mounting bolt as shown in the figure.
I
Use the hexagonal part as a guide.

1 : Crankshaft pulley
A : Paint mark J

JPBIA0166ZZ

Revision: 2008 October EM-19 Z51

 CAMSHAFT VALVE CLEARANCE
< ON-VEHICLE MAINTENANCE >
• By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below (locations
indicated in the figure).

: Engine front

• No. 3 cylinder at compression TDC

Measuring position [bank 1 (A)] No. 1 CYL. No. 3 CYL. No. 5 CYL.

No. 3 cylinder at com- EXH (C) × (B)

pression TDC INT (D) × (E)
Measuring position [bank 2 (H)] No. 2 CYL. No. 4 CYL. No. 6 CYL.

No. 3 cylinder at com- INT (D) × (F)

pression TDC EXH (C) × (G)

JPBIA0167ZZ

d. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 5 cylinder at
TDC of compression stroke.
NOTE:
Mark a position 240 degrees (b) from a corner of the hexagonal
part of crankshaft pulley mounting bolt as shown in the figure.
Use the hexagonal part as a guide.

1 : Crankshaft pulley
A : Paint mark

JPBIA0166ZZ

Revision: 2008 October EM-20 Z51

 CAMSHAFT VALVE CLEARANCE
< ON-VEHICLE MAINTENANCE >
• By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below (locations A
indicated in the figure).

: Engine front
EM
• No. 5 cylinder at compression TDC

Measuring position [bank 1 (A)] No. 1 CYL. No. 3 CYL. No. 5 CYL. C

No. 5 cylinder at EXH (C) × (B)

compression TDC INT (D) × (E)
D
Measuring position [bank 2 (H)] No. 2 CYL. No. 4 CYL. No. 6 CYL.

No. 5 cylinder at INT (D) × (F)

compression TDC EXH (C) × (G) E

G
JPBIA0168ZZ

3. Perform adjustment if the measured value is out of the standard. Refer to “ADJUSTMENT”.
H
ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
1. Measure the valve clearance. Refer to “INSPECTION”.
I
2. Remove camshaft. Refer to EM-84, "Exploded View".
3. Remove valve lifters at the locations that are out of the standard.
4. Measure the center thickness of the removed valve lifters with a J
micrometer (A).

JPBIA0169ZZ M

5. Use the equation below to calculate valve lifter thickness for replacement.
N
Valve lifter thickness calculation: t = t1+ (C1 – C2)
t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness O
C1 = Measured valve clearance
C2 = Standard valve clearance:
P
Intake : 0.30 mm (0.012 in)
Exhaust : 0.33 mm (0.013 in)

Revision: 2008 October EM-21 Z51

 CAMSHAFT VALVE CLEARANCE
< ON-VEHICLE MAINTENANCE >
• Thickness of new valve lifter can be identified by stamp marks
on the reverse side (inside the cylinder).
Stamp mark 788 indicates 7.88 mm (0.3102 in) in thickness.

A : Stamp
B : Thickness of valve lifter

JPBIA0170ZZ

Available thickness of valve lifter: 27 sizes with range 7.88 to 8.40 mm (0.3102 to 0.3307 in) in steps of
0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-132, "Camshaft".
6. Install selected valve lifter.
7. Install camshaft. Refer to EM-84, "Exploded View".
8. Manually turn crankshaft pulley a few turns.
9. Check that the valve clearances for cold engine are within the specifications by referring to the specified
values. Refer to EM-18, "Inspection and Adjustment".
10. Install all removal parts in the reverse order of removal.
11. Warm up the engine, and check for unusual noise and vibration.

Revision: 2008 October EM-22 Z51

 COMPRESSION PRESSURE
< ON-VEHICLE MAINTENANCE >
COMPRESSION PRESSURE
A
Inspection INFOID:0000000004556048

1. Warm up engine thoroughly. Then, stop it. EM

2. Release fuel pressure. Refer to EC-418, "Inspection" (TYPE 1) or EC-783, "Inspection" (TYPE 2).
3. Disconnect fuel pump fuse to avoid fuel injection during measurement. Refer to EC-36,
"Component Parts Location" (TYPE 1) or EC-446, "Component Parts Location" (TYPE 2). C
4. Remove engine cover. Refer to EM-25, "Exploded View".
5. Remove ignition coil and spark plug from each cylinder. Refer to EM-50, "Exploded View".
6. Connect engine tachometer (not required in use of CONSULT-III). D
7. Install compression gauge with an adapter (commercial service
tool) onto spark plug hole.
E

G
PBIC0900E

H
• 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.
I
a : 20 mm (0.79 in)

K
JPBIA0171ZZ

8. 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 L
cylinder.

Compression pressure : Refer to EM-131, "General Specification". M

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 N
engine speed again with normal battery gravity.
• If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again. O
• 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- P
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
low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
9. After inspection is completed, install removed parts.

Revision: 2008 October EM-23 Z51

 COMPRESSION PRESSURE
< ON-VEHICLE MAINTENANCE >
10. Start the engine, and check that the engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-128, "Description" (TYPE 1) or EC-529,
"Description" (TYPE 2).

Revision: 2008 October EM-24 Z51

 ENGINE COVER
< ON-VEHICLE REPAIR >
ON-VEHICLE REPAIR A
ENGINE COVER
Exploded View INFOID:0000000004556049
EM

JPBIA1712GB
H
1. Engine cover
Refer to GI-4, "Components" for symbols in the figure.
I
Removal and Installation INFOID:0000000004556050

REMOVAL J
1. Remove radiator core support covers (RH and LH) and air duct (inlet). Refer to EM-27, "Exploded View".
2. Remove engine cover mounting bolts (A) and (B).
K

JPBIA1718ZZ

N
3. Draw and pull out engine cover from engine cover mounting bolts (C), (D).
CAUTION:
Pull engine cover from mounting bolt (D) holding with hand the position (E) as shown in the figure.
O
4. Remove engine cover mounting bolts (C) and (D), if necessary.
INSTALLATION
Install in the reverse order of removal. P

Revision: 2008 October EM-25 Z51

 DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
< ON-VEHICLE REPAIR >
DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
Exploded View INFOID:0000000004556051

JPBIA1626GB

1. Drive belt auto-tensioner 2. Idler pulley 3. Idler pulley

4. Bracket
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000004556052

Removal
1. Remove drive belt. Refer to EM-13, "Removal and Installation".
• Keep auto-tensioner pulley arm locked after drive belt is removed.
2. Remove auto-tensioner and idler pulley.
• Keep auto-tensioner pulley arm locked to install or remove auto-tensioner.
Installation
Install in the reverse order of removal.
CAUTION:
If there is damage greater than peeled paint, replace drive belt auto-tensioner.

Revision: 2008 October EM-26 Z51

 AIR CLEANER AND AIR DUCT
< ON-VEHICLE REPAIR >
AIR CLEANER AND AIR DUCT
A
Exploded View INFOID:0000000004556053

EM

J
JPBIA2504GB

1. Mass air flow sensor 2. Air cleaner case (upper) 3. Air cleaner filter K
4. Clamp 5. Air duct assembly 6. Clamp
7. PCV hose 8. Air duct (inlet) 9. Grommet
10. Collar 11. Radiator core support cover (RH) 12. Radiator core support cover (LH) L
13. Grommet 14. Grommet 15. Bracket
16. Bracket 17. Collar 18. Grommet
19. Air cleaner case (lower) M
A. To electric throttle control actuator B. To rocker cover (bank 2)
Refer to GI-4, "Components" for symbols in the figure.
N
Removal and Installation INFOID:0000000004556054

REMOVAL O
NOTE:
Mass air flow sensor is removable under the car-mounted condition.
1. Remove radiator core support covers (RH and LH). P
2. Remove air duct (inlet).
3. Disconnect harness connector from mass air flow sensor.
4. Disconnect PCV hose.
5. Remove air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly disconnect-
ing their joints.
• Add mating marks for easier installation if necessary.

Revision: 2008 October EM-27 Z51

 AIR CLEANER AND AIR DUCT
< ON-VEHICLE REPAIR >
6. Remove mass air flow sensor from air cleaner case (upper) if necessary.
CAUTION:
Handle the mass air flow sensor with following cares.
• Never shock the mass air flow sensor.
• Never disassemble the mass air flow sensor.
• Never touch the sensor of the mass air flow sensor.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Align marks. Attach each joint. Screw clamps firmly.
Inspection INFOID:0000000004556055

INSPECTION AFTER REMOVAL

Inspect air duct assembly for crack or tear.
• If anything found, replace air duct assembly.

Revision: 2008 October EM-28 Z51

 INTAKE MANIFOLD COLLECTOR
< ON-VEHICLE REPAIR >
INTAKE MANIFOLD COLLECTOR
A
Exploded View INFOID:0000000004556056

EM

J
JPBIA2470GB

1. Vacuum hose 2. Clamp 3. Clamp K

4. PCV hose 5. Intake manifold collector 6. Gasket
Electronic controlled engine mount
7. Vacuum hose 8. Bracket 9.
control solenoid valve L
10. Vacuum hose 11. Vacuum hose 12. Vacuum hose
13. Vacuum gallery 14. Vacuum hose 15. Vacuum hose
EVAP canister purge volume control M
16. VIAS control solenoid valve 2 17. VIAS control solenoid valve 1 18.
solenoid valve
19. Clamp 20. EVAP hose 21. Vacuum tank
22. Bracket 23. EVAP hose 24. EVAP hose N
25. EVAP pipe 26. EVAP hose 27. Clamp
28. Water hose 29. Water hose 30. Bracket
31. Electric throttle control actuator 32. Gasket O
A. To brake booster B. To rocker cover (bank 1) C. To vacuum tube (rear)
D. To vacuum pipe E. To heater pipe F. To water outlet
: Engine front P
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000004556057

REMOVAL
WARNING:

Revision: 2008 October EM-29 Z51

 INTAKE MANIFOLD COLLECTOR
< ON-VEHICLE REPAIR >
To avoid the danger of being scalded, never drain engine coolant when the engine is hot.
1. Remove engine cover. Refer to EM-25, "Exploded View".
CAUTION:
Be careful not to damage or scratch engine cover.
2. Remove air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly. Refer to
EM-27, "Exploded View".
3. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-8, "Draining".
CAUTION:
Perform this step when the engine is cold.
4. Remove front wiper arm and extension cowl top. Refer to WW-124, "Exploded View" (for South Africa
models) or WW-272, "Exploded View" (except for South Africa models) and EXT-22, "Exploded View".
5. Disconnect water hoses from electric throttle control actuator.
• When engine coolant is not drained from radiator, attach plug to water hoses to prevent engine coolant
leakage.
6. Remove electric throttle control actuator as follows:
a. Disconnect harness connector.
b. Loosen mounting bolts in the reverse order as shown in the fig-
ure.
CAUTION:
• Handle carefully to avoid any shock to electric throttle
control actuator.
• Never disassemble.

JPBIA1631ZZ

7. Remove the following parts:

• Vacuum hose
• PCV hose
• High pressure piping from intake manifold: Refer to ST-41, "Exploded View".
• Electronic controlled engine mount control solenoid valve

8. Disconnect EVAP hoses and harness connector from EVAP canister purge volume control solenoid valve.
9. Remove EVAP canister purge volume control solenoid valve and bracket assembly.
10. Remove VIAS control solenoid valve mounting bolts and vacuum gallery mounting bolts, and then move
vacuum gallery.
• Add mating marks for easier installation if necessary.
11. Loosen mounting nuts and bolts in the reverse order as shown
in the figure, and remove intake manifold collector and gasket.

: Engine front

CAUTION:
Cover engine openings to avoid entry of foreign materials.

JPBIA1628ZZ

INSTALLATION
Note the following, and install in the reverse order of removal.
Intake Manifold Collector

Revision: 2008 October EM-30 Z51

 INTAKE MANIFOLD COLLECTOR
< ON-VEHICLE REPAIR >
Tighten mounting nuts and bolts in numerical order as shown in the
figure. A

: Engine front
EM

JPBIA1628ZZ

D
Electric Throttle Control Actuator
• Tighten mounting bolts in numerical order as shown in the figure.
• Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is disconnected. E
Refer to EC-22, "THROTTLE VALVE CLOSED POSITION
LEARNING : Description" (TYPE 1) or EC-432, "THROTTLE
VALVE CLOSED POSITION LEARNING : Description" (TYPE 2). F
• Perform the “Idle Air Volume Learning” and “Throttle Valve Closed
Position Learning” when electric throttle control actuator is
replaced. Refer to EC-22, "IDLE AIR VOLUME LEARNING :
Description" (TYPE 1) or EC-432, "IDLE AIR VOLUME LEARNING G
: Description" (TYPE 2).
JPBIA1631ZZ

Revision: 2008 October EM-31 Z51

 INTAKE MANIFOLD
< ON-VEHICLE REPAIR >
INTAKE MANIFOLD
Exploded View INFOID:0000000004556058

JPBIA1629GB

1. Intake manifold 2. Gasket

A. Refer to EM-32
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000004556059

REMOVAL
1. Release fuel pressure. Refer to EC-418, "Inspection" (TYPE 1) or EC-783, "Inspection" (TYPE 2).
2. Remove intake manifold collector. Refer to EM-29, "Exploded View".
3. Remove fuel tube and fuel injector assembly. Refer to EM-45, "Exploded View".
4. Loosen mounting nuts and bolts in the reverse order as shown
in the figure to remove intake manifold with power tool.

: Engine front

JPBIA1630ZZ

5. Remove gaskets.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSTALLATION
Note the following, and install in the reverse order or removal.
Intake Manifold
• If stud bolts were removed, install them and tighten to the specified torque below.

: 10.8 N·m (1.1 kg-m, 8 ft-lb)

Revision: 2008 October EM-32 Z51

 INTAKE MANIFOLD
< ON-VEHICLE REPAIR >
• Tighten all mounting nuts and bolts to the specified torque in two or
more steps in numerical order shown in the figure. A

: Engine front
EM
1st step : 7.4 N·m (0.75 kg-m, 5 ft-lb)
2nd step and after : 25.5 N·m (2.6 kg-m, 19 ft-lb)
C

JPBIA1630ZZ

D
Inspection INFOID:0000000004556060

INSPECTION AFTER REMOVAL E

Surface Distortion
• Check the surface distortion of the intake manifold mating surface
with a straightedge (A) and a feeler gauge (B). F

Limit : Refer to EM-132, "Intake Manifold".

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

JPBIA0015ZZ

Revision: 2008 October EM-33 Z51

 EXHAUST MANIFOLD AND THREE WAY CATALYST
< ON-VEHICLE REPAIR >
EXHAUST MANIFOLD AND THREE WAY CATALYST
Exploded View INFOID:0000000004556061

JPBIA2710GB

1. Gasket 2. Exhaust manifold (bank 1) 3. Exhaust manifold cover (bank 1)

4. Air fuel ratio sensor 1 (bank 1) 5. Ring gasket 6. Three way catalyst (bank 1)
7. Three way catalyst support (bank 1) 8. Heated oxygen sensor 2 (bank 1) 9. Three way catalyst (bank 2)
10. Three way catalyst support (bank 2) 11. Heated oxygen sensor 2 (bank 2) 12. Ring gasket
13. Exhaust manifold (bank 2) 14. Exhaust manifold cover (bank 2) 15. Air fuel ratio sensor 1 (bank 2)
Stud bolt and flange bolt type
A. To oil pan (upper) B. Upper mark C.
(bank 2)
D. Flange bolt type (bank 2)
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000004556062

REMOVAL
WARNING:
Perform the work when the exhaust and cooling system have completely cooled down.
1. Remove following parts:

Revision: 2008 October EM-34 Z51

 EXHAUST MANIFOLD AND THREE WAY CATALYST
< ON-VEHICLE REPAIR >
• Radiator core support covers (RH and LH), air duct (inlet), air cleaner case (upper) with mass air flow
sensor and air duct assembly: Refer to EM-27, "Exploded View". A
• Engine cover: Refer to EM-25, "Exploded View".
• Front wiper arm: Refer to WW-124, "Exploded View" (for South Africa models) or WW-272, "Exploded
View" (except for South Africa).
EM
• Extension cowl top: Refer to EXT-22, "Exploded View".
2. Remove exhaust front tube. Refer to EX-5, "Exploded View".
3. Disconnect harness connector and remove air fuel ratio sensor
C
1 on both banks with the heated oxygen sensor wrench [SST:
KV10117100] (B).
• Put marks to identify installation positions of each air fuel ratio
sensor 1. D
CAUTION:
• Be careful not to damage air fuel ratio sensor 1.
• Discard any air fuel ratio sensor 1 which has been E
dropped onto a hard surface such as a concrete floor.
Replace with a new sensor.
NOTE:
JPBIA1781ZZ
Figure is shown as an example of bank 2 (A). F

4. Disconnect harness connector and remove heated oxygen sen-

sor 2 on both banks with the heated oxygen sensor wrench G
[SST: KV10114400] (B).

A : Bank 1 H
C : Bank 2
• Put marks to identify installation positions of each heated oxy-
gen sensor 2. I
CAUTION:
• Be careful not to damage heated oxygen sensor 2.
• Discard any heated oxygen sensor 2 which has been JPBIA2247ZZ

dropped onto a hard surface such as a concrete floor. J

Replace with a new sensor.

5. Remove exhaust manifold covers (bank 1 and bank 2). K

6. Remove three way catalyst support mounting bolts (bank 1 and bank 2).

7. Remove three way catalysts (bank 1 and bank 2) by loosening bolts first and then removing nuts. L
CAUTION:
Handle carefully to avoid any shock to three way catalyst.
M

Revision: 2008 October EM-35 Z51

 EXHAUST MANIFOLD AND THREE WAY CATALYST
< ON-VEHICLE REPAIR >
8. Loosen mounting nuts in the reverse order as shown in the fig-
ure to remove exhaust manifolds (bank 1 and bank 2).

A : Bank 1
B : Bank 2
: Engine front

NOTE:
Disregard No. 7 and 8 when loosing.

JPBIA1633ZZ

9. Remove gaskets.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSTALLATION
Note the following, and install in the reverse order of removal.
Exhaust Manifold Gasket
Install in the direction indicated in the figure.

A : Bank 1
B : Triangle press
C : Bank 2
: Engine front

PBIC4954E

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

: 15.4 N·m (1.6 kg-m, 11 ft-lb)

Revision: 2008 October EM-36 Z51

 EXHAUST MANIFOLD AND THREE WAY CATALYST
< ON-VEHICLE REPAIR >
• Tighten mounting nuts in numerical order as shown in the figure.
A
A : Bank 1
B : Bank 2
: Engine front EM
NOTE:
No. 7 and 8 mean double tightening of nuts No. 1 and 2.
C

G
JPBIA1633ZZ

Three Way Catalyst (bank 2) Flange Bolt Type H

1. Temporarily tighten upper side bolts (B) and lower side bolt (A)
shown in the figure.
I
: Engine front
2. Tighten the upper side bolts (B) shown in the figure. (specified
torque) J
3. Tighten the all the lower side bolts [the other four except (B)].
(specified torque)
K
JPBIA2709ZZ

Three Way Catalyst Supports

L
1. Temporarily tighten three way catalyst support mounting bolts.
2. Tighten three way catalyst support mounting bolts to oil pan (upper).
3. Tighten three way catalyst support mounting bolts to three way catalyst.
M
Air Fuel Ratio Sensor 1 and Heated Oxygen Sensor 2
• Install air fuel ratio sensor 1 and heated oxygen sensor 2 in the original position.
• Install referring the following if the installation positions cannot be N
identified.

Glass tube color

O
Air fuel ratio sensor 1 : Black
Heated oxygen sensor 2 : White
CAUTION: P
• Before installing a new air fuel ratio sensor 1 and a new
heated oxygen sensor 2, clean exhaust system threads using
oxygen sensor thread cleaner (commercial service tool) and PBIC2652E
apply anti-seize lubricant (commercial service tool).
• Never over torque air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage
to air fuel ratio sensor and heated oxygen sensor, resulting in “MIL” coming on.

Revision: 2008 October EM-37 Z51

 EXHAUST MANIFOLD AND THREE WAY CATALYST
< ON-VEHICLE REPAIR >
Inspection INFOID:0000000004556063

INSPECTION AFTER REMOVAL

Surface Distortion
• Check the surface distortion of the exhaust manifold mating sur-
face with a straightedge and a feeler gauge.

Limit : Refer to EM-132, "Exhaust Manifold".

• If it exceeds the limit, replace exhaust manifold.

PBIC1173E

Revision: 2008 October EM-38 Z51

 OIL PAN AND OIL STRAINER
< ON-VEHICLE REPAIR >
OIL PAN AND OIL STRAINER
A
Exploded View INFOID:0000000004556064

EM

J
JPBIA1636GB

1. Oil pan (upper) 2. O-ring 3. Oil pan gasket (front) K

4. Relief valve 5. Oil pressure switch 6. Oil cooler
7. Connector bolt 8. Oil filter 9. Oil strainer
10. Drain plug 11. Drain plug washer 12. Oil pan (lower) L
13. Rear plate cover 14. Crankshaft position sensor (POS) 15. Oil pan gasket (rear)
A. Refer to LU-10 B. To oil pump C. Oil pan (lower) side
Refer to GI-4, "Components" for symbols in the figure. M

Removal and Installation INFOID:0000000004556065

N
REMOVAL
CAUTION:
To avoid the danger of being scalded, never drain engine oil when the engine is hot. O
NOTE:
When removing oil pan (lower) or oil strainer only, take step 1 then step 19 and 20.
1. Drain engine oil. Refer to LU-8, "Draining".
P
CAUTION:
Never spill engine oil on drive belt.
2. Drain engine coolant. Refer to CO-8, "Draining".
CAUTION:
Never spill engine coolant on drive belt.
3. Remove following parts:
• Front road wheel and tires (RH and LH).

Revision: 2008 October EM-39 Z51

 OIL PAN AND OIL STRAINER
< ON-VEHICLE REPAIR >
• Splash guard (RH and LH): Refer to EXT-25, "FENDER PROTECTOR : Exploded View".
• Exhaust front tube: Refer to EX-5, "Exploded View".
• Drive belt: Refer to EM-13, "Removal and Installation".
4. Remove A/C compressor with piping connected, and temporarily secure it to aside. Refer to HA-41,
"Exploded View".
5. Remove oil level gauge. Refer to EM-96, "Exploded View".
6. Remove front drive shaft (RH). Refer to FAX-15, "Exploded View".
7. Remove three way catalyst (bank 1 and bank 2) from exhaust manifolds (bank 1 and bank 2). Refer to
EM-34, "Exploded View".
8. Remove oil pressure switch.
9. Remove oil filter. Refer to LU-10, "Removal and Installation".
10. Remove oil cooler and water pipes. Refer to LU-11, "Exploded View".
11. Support transaxle assembly with a suitable jack.
CAUTION:
When setting the transmission jack, be careful not to allow it to collide against the drain plug.
12. Support front suspension member with a suitable jack.
13. Remove engine mounting insulator (rear). Refer to EM-68, "Exploded View".
14. Remove engine mounting insulator (LH) mounting bolts from transaxle. Refer to EM-68, "Exploded View".
15. Remove rear torque rod through bolts from rear torque rod bracket. Refer to EM-68, "Exploded View".
16. Remove member stay, front suspension member fixing bolts and nuts. Refer to FSU-16, "Exploded View".
17. Lower the jack for the front suspension member to the height.
18. Remove transfer assembly. Refer to DLN-51, "Exploded View".
19. Remove oil pan (lower) as follows:
a. Loosen mounting bolts in the reverse order as shown in the fig-
ure to remove.

PBIC0782E

b. Insert the seal cutter [SST: KV10111100] (A) between oil pan
(upper) and oil pan (lower).
CAUTION:
• Be careful not to damage the mating surfaces.
• Never insert a screwdriver, this will damage the mating
surfaces.
c. Slide the seal cutter by tapping on the side of tool with a ham-
mer. Remove oil pan (lower).

JPBIA0276ZZ

20. Remove oil strainer.

Revision: 2008 October EM-40 Z51

 OIL PAN AND OIL STRAINER
< ON-VEHICLE REPAIR >
21. Loosen mounting bolts in the reverse order as shown in the fig-
ure to remove. A
• Insert the seal cutter [SST: KV10111100] between oil pan
(upper) and cylinder block. Slide seal cutter by tapping on the
side of tool with a hammer. Remove oil pan (upper).
EM
CAUTION:
• Be careful not to damage the mating surfaces.
• Never insert a screwdriver, this will damage the mating
surfaces. C

PBIC1636E

D
22. Remove O-rings (2) from bottom of cylinder block (1) and oil
pump (3).
E
: Engine front

G
JPBIA1379ZZ

23. Remove oil pan gaskets (1).

H
A : Notch
B : Protrusion
I
: Engine front

JPBIA0433ZZ
K
INSTALLATION
1. Install oil pan (upper) as follows:
a. Use a scraper to remove old liquid gasket from mating surfaces. L
CAUTION:
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket. M
• Also remove old liquid gasket from mating surface of cylinder
block.
• Remove old liquid gasket from the bolt holes and threads.
N

MEM108A
O

b. Install new oil pan gaskets.

P

Revision: 2008 October EM-41 Z51

 OIL PAN AND OIL STRAINER
< ON-VEHICLE REPAIR >
• Apply liquid gasket to new oil pan gaskets as shown in the fig-
ure.

C : Sealing point
a : 15 mm (0.59 in)
b : 5 mm (0.20 in)
Use Genuine Liquid Gasket or equivalent.

JPBIA0432ZZ

• To install, align protrusion (B) of oil pan gasket with notches

(A) of front timing chain case and rear oil seal retainer.

: Engine front

• Install oil pan gasket (1) with smaller arc to front timing chain
case side.

JPBIA0433ZZ

c. Install new O-rings (2) on the bottom of cylinder block (1) and oil
pump (3).

: Engine front

JPBIA1379ZZ

d. Apply a continuous bead of liquid gasket with the tube presser

(commercial service tool) to the cylinder block mating surface of
oil pan (upper) to a limited portion as shown in the figure.

b : 35 mm (1.38 in)
c : φ3.5 - 4.5 mm (0.138 - 0.177 in)
: Engine front

Use Genuine Liquid Gasket or equivalent.

CAUTION:
• For bolt holes with marks (5 locations), apply liquid JPBIA0434ZZ
gasket outside the holes.
• Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 in) diameter to area (a).
• Attaching should be done within 5 minutes after coating.
e. Install oil pan (upper).
CAUTION:
Install avoiding misalignment of both O-rings.

Revision: 2008 October EM-42 Z51

 OIL PAN AND OIL STRAINER
< ON-VEHICLE REPAIR >
• Tighten mounting bolts in numerical order as shown in the fig-
ure. A
• There are three types of mounting bolts. Refer to the following
for locating bolts.
EM
M8 × 135 mm (5.31 in) : 11
M8 × 92 mm (3.62 in) : 5, 7, 8
M8 × 25 mm (0.98 in) : Except the above C

PBIC1636E

D
2. Install oil strainer to oil pump.
3. Install oil pan (lower) as follows:
a. Use scraper (A) to remove old liquid gasket from mating sur- E
faces.
• Remove old liquid gasket from the bolt holes and thread.
CAUTION:
Never scratch or damage the mating surfaces when clean- F
ing off old liquid gasket.

JPBIA0025ZZ H

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

(commercial service tool) (A) to the oil pan (lower) as shown in
the figure. I

b : φ4.0 - 5.0 mm (0.157 - 0.197 in)

J
Use Genuine Liquid Gasket or equivalent.
CAUTION:
Attaching should be done within 5 minutes after coating.
K

JPBIA0026ZZ

c. Install oil pan (lower). L

• Tighten mounting bolts in numerical order as shown in the fig-
ure.
4. Install oil pan drain plug. M
• Refer to the figure of components of former page for installa-
tion direction of drain plug washer. Refer to EM-39, "Exploded
View". N
5. Install in the reverse order of removal after this step.
NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.
O
PBIC0782E

Inspection INFOID:0000000004556066
P

INSPECTION AFTER REMOVAL

Clean oil strainer if any object attached.
INSPECTION AFTER INSTALLATION
1. Check the engine oil level and adjust engine oil. Refer to LU-7, "Inspection".
2. Start engine, and check there is no leakage of engine oil.

Revision: 2008 October EM-43 Z51

 OIL PAN AND OIL STRAINER
< ON-VEHICLE REPAIR >
3. Stop engine and wait for 10 minutes.
4. Check the engine oil level again. Refer to LU-7, "Inspection".

Revision: 2008 October EM-44 Z51

 FUEL INJECTOR AND FUEL TUBE
< ON-VEHICLE REPAIR >
FUEL INJECTOR AND FUEL TUBE
A
Exploded View INFOID:0000000004556067

EM

J
JPBIA2526GB

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

4. O-ring 5. Fuel damper 6. Fuel damper cap
7. Clip 8. O-ring (black) 9. Fuel injector
10. O-ring (green) L
A. Refer to EM-45
Refer to GI-4, "Components" for symbols in the figure.
M
CAUTION:
Never remove or disassemble parts unless instructed as shown in the figure.
Removal and Installation INFOID:0000000004556068 N

REMOVAL
WARNING: O
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area. P
• To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Remove radiator core support covers (RH and LH), air duct (inlet), air cleaner cases (upper and lower)
with mass air flow sensor, and air duct assembly. Refer to EM-27, "Exploded View".
2. Remove engine cover. Refer to EM-25, "Exploded View".
3. Release the fuel pressure. Refer to EC-418, "Inspection" (TYPE 1) or EC-783, "Inspection" (TYPE 2).
4. Remove front wiper arm and extension cowl top. Refer to WW-124, "Exploded View" (for South Africa
models) or WW-272, "Exploded View" (except for South Africa models) and EXT-22, "Exploded View".

Revision: 2008 October EM-45 Z51

 FUEL INJECTOR AND FUEL TUBE
< ON-VEHICLE REPAIR >
5. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-8, "Draining" or EM-29, "Exploded View".
CAUTION:
Perform this step when the engine is cold.
6. Remove intake manifold collector. Refer to EM-29, "Exploded View".
7. When separating fuel feed hose and fuel tube connection, disconnect quick connector as follows:
a. Remove quick connector cap from quick connector.
b. Disconnect quick connector from fuel tube as follows:
CAUTION:
Disconnect quick connector by using the quick connector release (commercial service tool), not
by picking out retainer tabs.
i. With the sleeve side of quick connector release facing to quick connector, install the quick connector
release onto fuel tube.
ii. Insert the quick connector release (A) into quick connector (2)
until sleeve (B) contacts and goes no further. Hold quick connec-
tor release on that position.

C : 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.
iii. Draw and pull out quick connector straight from fuel tube (1).
CAUTION: JPBIA0033ZZ

• Pull quick connector (E) holding position (D) as shown in

the figure.
• Never pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth beforehand as fuel will 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 hose (with damper) dur-
ing 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.

JPBIA0035ZZ

8. Disconnect harness connector from fuel injector.

9. Loosen mounting bolts in the reverse order as shown in the fig-
ure, and remove fuel tube and fuel injector assembly.

: Engine front

CAUTION:
Never tilt fuel tube, or remaining fuel in pipes may flow out
from pipes.

JPBIA1715ZZ

Revision: 2008 October EM-46 Z51

 FUEL INJECTOR AND FUEL TUBE
< ON-VEHICLE REPAIR >
10. Remove fuel injector from fuel tube as follows:
A
a. Open and remove clip (1).

3 : O-ring (green)
EM
4 : O-ring (black)
A : Installed condition
B : Clip mounting groove
C
b. Remove fuel injector (2) from fuel tube (5) by pulling straight.
CAUTION:
• Be careful with remaining fuel that may go out from fuel
tube. D
JPBIA1958ZZ
• Be careful not to damage injector nozzle during removal.
• Never bump or drop fuel injector.
• Never disassemble fuel injector. E

11. Remove fuel damper from fuel tube.

INSTALLATION F
1. Install fuel damper as follows:
a. Install new O-ring (2) to fuel tube (1) as shown in the figure.
When handling new O-ring, be careful of the following caution: G
CAUTION:
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil. H
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign
material.
• When installing O-ring, be careful not to scratch it with I
tool or fingernails. Also be careful not to twist or stretch
O-ring. If O-ring was stretched while it was being
attached, never insert it quickly into fuel tube. J
• Insert new O-ring straight into fuel tube. Never twist it.
b. Install spacer (3) to fuel damper (4).
c. Insert fuel damper straight into fuel tube. K
CAUTION:
• Insert straight, making sure that the axis is lined up.
• Never pressure-fit with excessive force.
L
Reference value : 130 N (13.3 kg, 29.2 lb)
• Insert fuel damper until (B) is touching (A) of fuel tube. M
d. Tighten bolts evenly in turn. JPBIA0316ZZ

• After tightening bolts, check that there is no gap between fuel

damper cap (5) and fuel tube.
N
2. Install new O-rings to fuel injector paying attention to the following.
CAUTION:
• Upper and lower O-ring are different. Be careful not to confuse them.
O
Fuel tube side : Black
Nozzle side : Green
P
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly
into fuel tube.
• Insert O-ring straight into fuel injector. Never decenter or twist it.

Revision: 2008 October EM-47 Z51

 FUEL INJECTOR AND FUEL TUBE
< ON-VEHICLE REPAIR >
3. Install fuel injector to fuel tube as follows:
a. Insert clip (3) into clip mounting groove (F) on fuel injector (5).

2 : O-ring (black)
4 : O-ring (green)
• Insert clip so that protrusion (E) of fuel injector matches cutout
(C) of clip.
CAUTION:
• Never reuse clip. Replace it with new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube (1) with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (A) of fuel tube matches
cutout (B) of clip.
• Check that fuel tube flange (G) is securely fixed in flange fixing
groove (D) on clip.
c. Check that installation is complete by checking that fuel injector
does not rotate or come off.
• Check that protrusions of fuel injectors and fuel tubes are
aligned with cutouts of clips after installation.

JPBIA1959ZZ

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

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

: Engine front

1st step : 10.1 N·m (1.0 kg-m, 7 ft-lb)

2nd step : 22.0 N·m (2.2 kg-m, 16 ft-lb)

JPBIA1715ZZ

5. Connect fuel injector harness.

6. Install intake manifold collector. Refer to EM-29, "Exploded View".
7. Connect quick connector between fuel feed hose and fuel tube connection with the following procedure:
a. Check no foreign substances are deposited in and around fuel tube and quick connector, and no damage
on them.
b. Thinly apply new engine oil around fuel tube from tip end to spool end.
c. Align center to insert quick connector straightly into fuel tube.
• Insert quick connector (1) to fuel tube until top spool (2) is
completely inside quick connector, and 2nd level spool (3)
exposes right below quick connector.

B : Fitted condition
: Upright insertion

CAUTION:
• Hold (A) position as shown in the figure when inserting
fuel tube into quick connector.
• Carefully align center to avoid inclined insertion to pre-
JPBIA0275ZZ
vent damage to O-ring inside quick connector.

Revision: 2008 October EM-48 Z51

 FUEL INJECTOR AND FUEL TUBE
< ON-VEHICLE REPAIR >
• 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. A
d. Pull quick connector 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 (3) to quick connector. EM

1 : Fuel feed hose

2 : Fuel tube C
B : Upper view
• Install quick connector cap with arrow (A) on surface facing in
direction of quick connector (fuel feed hose side). D
CAUTION:
If quick connector cap cannot be installed smoothly, quick
connector may have not been installed correctly. Check
E
connection again. JPBIA0039ZZ

f. Secure fuel feed hose to clamp of quick connector cap.

8. Install in the reverse order of removal after this step.
F
Inspection INFOID:0000000004556069

INSPECTION AFTER INSTALLATION G

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

Revision: 2008 October EM-49 Z51

 IGNITION COIL, SPARK PLUG AND ROCKER COVER
< ON-VEHICLE REPAIR >
IGNITION COIL, SPARK PLUG AND ROCKER COVER
Exploded View INFOID:0000000004556070

JPBIA1637GB

1. Ignition coil 2. Spark plug 3. PCV hose

4. Clamp 5. PCV valve 6. O-ring
7. Rocker cover (bank 1) 8. PCV hose 9. Rocker cover gasket (bank 1)
Camshaft position sensor (PHASE)
10. O-ring 11. 12. Oil filler cap
(bank 1)
Camshaft position sensor (PHASE)
13. Rocker cover (bank 2) 14. Rocker cover gasket (bank 2) 15.
(bank 2)
16. PCV hose 17. Clamp
A. To intake manifold collector B. Refer to EM-50 C. Camshaft bracket side
D. To air duct assembly
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000004556071

REMOVAL
1. Remove the following parts:
• Engine cover: Refer to EM-25, "Exploded View".
• Air cleaner cases (upper and lower) and air duct assembly: Refer to EM-27, "Exploded View".
• Intake manifold collector: Refer to EM-29, "Exploded View".
2. Disconnect PCV hose from rocker cover.

Revision: 2008 October EM-50 Z51

 IGNITION COIL, SPARK PLUG AND ROCKER COVER
< ON-VEHICLE REPAIR >
3. Remove camshaft position sensor (PHASE) (bank 1 and bank
2). A

A : Keep off any magnetic materials

CAUTION: EM
• Handle carefully to avoid dropping and shocks.
• Never disassemble
• Never allow metal powder to adhere to magnetic part at
C
sensor tip.
• Never place sensors in a location where they are exposed
to magnetism. JPBIA0454ZZ

4. Remove PCV valve and O-ring from rocker cover, if necessary. D

5. Remove oil filler cap from rocker cover, if necessary.
6. Remove ignition coil.
CAUTION: E
Never shock ignition coil.
7. Remove harness clips on the rocker cover.
8. Loosen bolts in the reverse order shown in the figure. F

: Engine front
G

JPBIA1634ZZ

M
9. Remove rocker cover gasket from rocker cover.
10. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 1).
CAUTION:
Never scratch or damage the mating surface when cleaning off old liquid gasket. N

INSTALLATION
O

Revision: 2008 October EM-51 Z51

 IGNITION COIL, SPARK PLUG AND ROCKER COVER
< ON-VEHICLE REPAIR >
1. Apply liquid gasket to the position shown in the figure with the
following procedure:

A : Liquid gasket application point

F : View F
b : 4 mm (0.16 in)
c : φ2.5 - 3.5 mm (0.098 - 0.138 in)
d : 5 mm (0.20 in)
g : 10 mm (0.39 in)
I : End surface of camshaft bracket (No. 1)
: Engine front

Use Genuine Liquid Gasket or equivalent.

a. Refer to the figure (E) to apply liquid gasket to joint part of cam-
shaft bracket (No. 1) (1) and cylinder head.
b. Refer to the figure (H) to apply liquid gasket in 90 degrees to the
figure.

JPBIA0274ZZ

2. Install rocker cover gasket to rocker cover.

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

: Engine front

1st step : 1.96 N·m (0.2 kg-m, 17 in-lb)

2nd step : 8.33 N·m (0.85 kg-m, 74 in-lb)

JPBIA1634ZZ

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

Revision: 2008 October EM-52 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
TIMING CHAIN
A
Exploded View INFOID:0000000004556072

EM

JPBIA2471GB

P
Timing chain tensioner (secondary) Timing chain tensioner (secondary)
1. 2. Internal chain guide 3.
(bank 2) (bank 1)
4. Oil temperature sensor 5. Camshaft sprocket (EXH) 6. O-ring
7. Timing chain (secondary) 8. Timing chain (primary) 9. Camshaft sprocket (INT)
10. Slack guide 11. Timing chain tensioner (primary) 12. Crankshaft sprocket
13. Rear timing chain case 14. Tension guide 15. O-ring
16. O-ring 17. O-ring 18. Front timing chain case

Revision: 2008 October EM-53 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
Valve timing control cover gasket Intake valve timing control solenoid valve
19. 20. Valve timing control cover (bank 1) 21.
(bank 1) (bank 1)
22. Seal ring 23. Water pump cover 24. Front oil seal
Intake valve timing control solenoid valve
25. Crankshaft pulley 26. Crankshaft pulley bolt 27.
(bank 2)
Valve timing control cover (bank 2) 29. Valve timing control cover gasket
28.
(bank 2)
A. Refer to EM-80 B. Refer to EM-54
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000004556073

REMOVAL
1. Drain engine oil. Refer to LU-8, "Draining".
2. Drain engine coolant from inside engine. Refer to EM-76, "Setting".
3. Remove intake manifold collector. Refer to EM-29, "Exploded View".
4. Remove rocker covers (bank 1 and bank 2). Refer to EM-50, "Exploded View".
5. Remove oil pans (lower and upper) and oil strainer. Refer to EM-39, "Exploded View".
6. Remove drive belt, idler pulleys, and bracket. Refer to EM-13, "Removal and Installation" and EM-26,
"Exploded View".
7. Remove power steering oil pump with piping connected, and temporarily secure it to aside. Refer to ST-
35, "Exploded View".
8. Separate engine harness removing their brackets from front timing chain case.
9. Remove valve timing control covers.
• Loosen mounting bolts in the reverse order as shown in the
figure.

A : Bank 1
B : Bank 2
C : Dowel pin hole
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) cen-
ter hole. When removing, keep it horizontal until it is com-
pletely disconnected.
JPBIA1639ZZ

10. Obtain No. 1 cylinder at TDC of its compression stroke as follows:

a. Rotate crankshaft pulley clockwise to align timing mark (grooved
line without color) ( ) with timing indicator.

SEM727G

Revision: 2008 October EM-54 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
b. Check that intake and exhaust cam noses on No. 1 cylinder
(engine front side of bank 1) are located as shown in the figure. A

: Engine front

• If not, turn crankshaft one revolution (360 degrees) and align EM

as shown in the figure.

JPBIA0044ZZ

D
11. Remove crankshaft pulley as follows:
a. Fix crankshaft with the pulley holder (commercial service tool)
(A). E

1 : Crankshaft pulley
b. Loosen crankshaft pulley bolt and locate bolt seating surface at F
10 mm (0.39 in) from its original position.
CAUTION:
Never remove crankshaft pulley bolt as it will be used as a
G
supporting point for suitable puller.
PBIC3961E

H
c. Place suitable puller tab on holes of crankshaft pulley, and pull
crankshaft pulley through.
CAUTION:
Never put suitable puller tab on crankshaft pulley periphery, I
as this will damage internal damper.

K
SEM915E

12. Remove front timing chain case as follows:

L
a. Loosen mounting bolts in the reverse order as shown in the fig-
ure.

O
JPBIA1640ZZ

Revision: 2008 October EM-55 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
b. Insert a suitable tool (A) into the notch at the top of front timing
chain case as shown in the figure.
c. Pry off case by moving the tool as shown in the figure.
• Use the seal cutter [SST: KV10111100] to cut liquid gasket for
removal.
CAUTION:
• Never use screwdrivers or something similar.
• After removal, handle front timing chain case carefully so
it does not tilt, cant, or warp under a load.

JPBIA0048ZZ

13. Remove water pump cover from front timing chain case.
• Use the seal cutter [SST: KV10111100] to cut liquid gasket for removal.
14. Remove front oil seal from front timing chain case using a suit-
able tool.
• Use a screwdriver for removal.
CAUTION:
Be careful not to damage front timing chain case.

EMQ0032D

15. Remove O-ring (1) from rear timing chain case.

A : Bank 1
B : Bank 2

JPBIA1111ZZ

16. Remove timing chain tensioner (primary) as follows:

a. Remove lower mounting bolt (1).
b. Loosen upper mounting bolt (2) slowly, and then turn timing
chain tensioner (primary) (3) on the mounting bolt so that
plunger (4) is fully expanded.
NOTE:
Even if plunger is fully expanded, it is not dropped from the body
of timing chain tensioner (primary).
c. Remove upper mounting bolt, and then remove timing chain ten-
sioner (primary).

JPBIA0085ZZ

Revision: 2008 October EM-56 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
17. Remove internal chain guide (1), tension guide (3), and slack
guide (2). A
NOTE:
Tension guide can be removed after removing timing chain (pri-
mary).
EM

G
JPBIA1104ZZ

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

CAUTION: H
After removing timing chain (primary), never turn crankshaft and camshaft separately, or valves
will strike the piston heads.
19. Remove timing chain (secondary) and camshaft sprockets as follows: I
a. Attach a suitable stopper pin (B) to the bank 1 (A) and bank 2
(C) timing chain tensioners (secondary) (1).
NOTE: J
• Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a
stopper pin.
• For removal of timing chain tensioner (secondary), refer to
EM-84, "Exploded View". [Removing camshaft bracket (No. 1) K
is required.]

L
JPBIA1727ZZ

b. Remove camshaft sprockets (INT and EXH) mounting bolts. M

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

P
KBIA1698J

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

• Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.

Revision: 2008 October EM-57 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
• Insert 0.5 mm (0.020 in) thick metal or resin plate between tim-
ing chain and timing chain tensioner plunger (guide) (E).
Remove timing chain (secondary) (2) together with camshaft
sprockets with timing chain loose from guide groove.

1 : Timing chain tensioner (secondary)

A : Bank 1
B : View B
C : Stopper pin
D : Plate
JPBIA2527ZZ
F : Timing chain tensioner (body)
CAUTION:
Be careful of plunger coming-off when removing timing chain (secondary). This is because
plunger of timing chain tensioner (secondary) moves during operation, leading to coming-off of
fixed stopper pin.
NOTE:
• Camshaft sprocket (INT) is two-for-one structure of sprockets for timing chain (primary) and for timing
chain (secondary).
• Figure is shown as an example of bank 1.
• When handling camshaft sprocket (INT), be careful of the following caution:
CAUTION:
• Handle carefully to avoid any shock to camshaft sprocket.
• Never disassemble. [Never loosen bolts (A) as shown in
the figure.]

PBIC2980E

20. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
• Remove timing chain tensioners (secondary) with a stopper pin attached.
21. Use a scraper to remove all traces of old liquid gasket from front
timing chain case, and opposite mating surfaces.

SEM737G

Revision: 2008 October EM-58 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
• Remove old liquid gasket from bolt hole (B) and thread.
A
A : Remove sticking old liquid gasket

EM

JPBIA0051ZZ

D
22. Use a scraper to remove all traces of old liquid gasket from
water pump cover.
E

G
SEM926E

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

P
JPBIA1716GB

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

4. Camshaft sprocket (EXH) 5. Timing chain tensioner (primary) 6. Slack guide
7. Timing chain (primary) 8. Crankshaft sprocket 9. Water pump
10. Tension guide 11. Timing chain tensioner (secondary) 12. Crankshaft key

Revision: 2008 October EM-59 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
A. Mating mark B. Mating mark (pink link) C. Mating mark (punched)
D. Mating mark (orange link) E. Mating mark (notched)

1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Refer to EM-84,
"Exploded View".
• Install timing chain tensioners (secondary) with a stopper pin attached and new O-ring.
2. Check that dowel pin (A) and crankshaft key (1) are located as
shown in the figure. (No. 1 cylinder at compression TDC)
NOTE:
Though camshaft does not stop at the position as shown in the
figure, for the placement of cam nose, it is generally accepted
camshaft is placed for the same direction of the figure.

Camshaft dowel pin

: At cylinder head upper face side in each bank
Crankshaft key
JPBIA0094ZZ
: At cylinder head side of bank 1
CAUTION:
Hole on small dia. side must be used for intake side dowel pin hole. Never misidentify (ignore big
dia. side).
3. Install timing chain (secondary) and camshaft sprockets (INT and EXH) as follows:
CAUTION:
Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions
repeatedly during the installation process.
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with stopper pin (A).

JPBIA0095ZZ

Revision: 2008 October EM-60 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
b. Install timing chain (secondary) (1) and camshaft sprockets (INT
and EXH). A

A : Camshaft sprocket (INT) back face

B : Orange link EM
C : Mating mark (Circle)
D : Camshaft sprocket (EXH) back face
E : Mating mark (2 circle on front face) C
F : Dowel pin groove
G : Mating mark (2 ovals on front face)
H : Mating mark (Oval) D
I : Dowel pin hole
NOTE:
Figure shows bank 1 (rear view). E
• Align the mating marks on timing chain (secondary) (orange
link) with the ones on camshaft sprockets (INT and EXH)
(punched), and install them.
F
NOTE:
• Mating marks for camshaft sprocket (INT) are on the back
side of camshaft sprocket (secondary).
• There are two types of mating mark, circle and oval types. G
They should be used for the bank 1 and bank 2, respectively. JPBIA1726ZZ

Bank 1 : Use circle type. H

Bank 2 : Use oval type.
• Align dowel pin on camshafts with the groove or hole on sprockets, and install them.
• On the intake side, align dowel pin of the camshaft front end with dowel pin hole on the back side of I
camshaft sprocket, and install them.
• On the exhaust side, align dowel pin on camshaft front end with dowel pin groove on camshaft sprocket,
and install them. J
• In case that positions of each mating mark and each dowel pin are not fit on mating parts, make fine
adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent.
• Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is
enough to prevent the dislocation of dowel pins. K
• It may be difficult to visually check the dislocation of mating
marks during and after installation. To make the matching eas-
ier, make a mating mark (A) on the top of sprocket teeth and L
its extended line in advance with paint.

B : Mating mark (orange link)

M

N
JPBIA2260ZZ

c. After confirming the mating marks are aligned, tighten camshaft sprocket mounting bolts.
O
• Secure camshaft using wrench at the hexagonal portion to
tighten mounting bolts.

KBIA1698J

Revision: 2008 October EM-61 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
d. Pull stopper pins (B) out from timing chain tensioners (second-
ary) (1).

A : Bank 1
C : Bank 2

JPBIA1727ZZ

4. Install tension guide.

5. Install timing chain (primary) as follows:
a. Install crankshaft sprocket (1).

A : Crankshaft side
B : Engine front side
C : Mating mark (front side)
• Check the mating marks on crankshaft sprocket face the front
of the engine.

JPBIA0273ZZ

b. Install timing chain (primary).

• Install timing chain (primary) so the mating mark (punched) (B)
on camshaft sprocket (INT) (1) is aligned with the pink link (A)
on timing chain, while the mating mark (notched) (C) on crank-
shaft sprocket (2) is aligned with the orange link (D) one on
timing chain, as shown in the figure.

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

JPBIA1601ZZ

Revision: 2008 October EM-62 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
6. Install internal chain guide (1) and slack guide (2).
A
3 : Tension guide

EM

G
JPBIA1104ZZ

CAUTION:
Never over tighten slack guide mounting bolt (2). It is nor- H
mal for a gap (A) to exist under the bolt seat when mounting
bolt is tightened to specification.
I
1 : Slack guide
3 : Cylinder block
J

K
JPBIA0117ZZ

7. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab (A) up (or turn lever downward) so as to L
remove plunger stopper tab from the ratchet of plunger (D).
NOTE:
Plunger stopper tab and lever (C) are synchronized.
M
b. Push plunger into the inside of tensioner body.
c. Hold plunger in the fully compressed position by engaging
plunger stopper tab with the tip of ratchet. N
d. To secure lever, insert stopper pin (E) through hole of lever into
tensioner body hole (B).
• The lever parts and the tab are synchronized. Therefore, the
plunger will be secured under this condition. JPBIA0118ZZ O
NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
P

Revision: 2008 October EM-63 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
e. Install timing chain tensioner (primary) (1).
• Remove any dirt and foreign materials completely from the
back and the mounting surfaces of timing chain tensioner (pri-
mary).
f. Pull out stopper pin (A) after installing, and then release plunger.

JPBIA0119ZZ

8. Check again that the mating marks on each sprocket and each timing chain have not slipped out of align-
ment.
9. Install new O-rings (1) on rear timing chain case.

A : Bank 1
B : Bank 2

JPBIA1111ZZ

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

A : Oil seal lip

B : Dust seal lip
: Engine inside
: Engine outside

JPBIA0054ZZ

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

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

PBIC0790E

11. Install water pump cover to front timing chain case.

Revision: 2008 October EM-64 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
• Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to water pump cover (1) as shown in A
the figure.

a : φ2.3 - 3.3 mm (0.091 - 0.130 in)

EM
Use Genuine Liquid Gasket or equivalent.

JPBIA1722ZZ

D
12. Install front timing chain case as follows:
a. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to front timing chain case back side as E
shown in the figure.

D : Bolt hole
F
E : Protrusion
f : φ2.6 - 3.6 mm (0.102 - 0.142 in)
Use Genuine Liquid Gasket or equivalent. G

K
JPBIA2472ZZ

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

M8 bolts : 1, 2
: 28.4 N·m (2.9 kg-m, 21 ft-lb) N
M6 bolts : Except the above
: 12.7 N·m (1.3 kg-m, 9 ft-lb) O
JPBIA1640ZZ
d. After all bolts tightening, retighten them to the specified torque in
numerical order as shown in the figure.
CAUTION: P
Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).

Revision: 2008 October EM-65 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
e. After installing front timing chain case, check the surface height
difference between the following parts on the oil pan (upper)
mounting surface.

Standard
Front timing chain case to rear timing chain case:
−0.14 to 0.14 mm (−0.006 to 0.006 in)
• If not within the standard, repeat the installation procedure.

SEM943G

13. Install intake valve timing control covers as follows:

a. Install new seal rings in shaft grooves.
b. Being careful not to move seal rings from the installation grooves, align dowel pins on front timing chain
case with the holes to install valve timing control covers.
c. Tighten mounting bolts in numerical order as shown in the fig-
ure.

A : Bank 1
B : Bank 2
C : Dowel pin hole

JPBIA1639ZZ

14. Install crankshaft pulley as follows:

a. Install crankshaft pulley, taking care not to damage front oil seal.
• When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
b. Fix crankshaft with the pulley holder (commercial service tool).
c. Tighten crankshaft pulley bolt.

: 44.1 N·m (4.5 kg-m, 33 ft-lb)

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

PBIC4627J

15. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns
smoothly.
16. Install in the reverse order of removal after this step.
Inspection INFOID:0000000004556074

INSPECTION AFTER REMOVAL

Timing Chain

Revision: 2008 October EM-66 Z51

 TIMING CHAIN
< ON-VEHICLE REPAIR >
Check for cracks and any excessive wear at link plates and roller
links of timing chain. Replace timing chain if necessary. A

A : Crack
B : Wear EM

JPBIA0091ZZ

D
INSPECTION AFTER INSTALLATION
Inspection for Leakage
E
The following are procedures for checking fluids leakage, lubricates 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-8, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage. F
- 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. G
• 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 H
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. I
• 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.
J
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
K
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage L
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

Revision: 2008 October EM-67 Z51

 ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
Exploded View INFOID:0000000004556075

JPBIA2757GB

1. Upper torque rod 2. Engine mounting insulator (RH) 3. Engine mounting bracket (RH)
4. Engine mounting bracket (front) 5. Engine mounting insulator (front) 6. Vacuum hose
7. Vacuum tube (front) 8. Vacuum hose 9. Engine mounting insulator (LH)
10. Engine mounting insulator (rear) 11. Engine mounting bracket (rear) 12. Rear torque rod
13. Rear torque rod bracket
To electronic controlled engine mount
A.
control solenoid valve
: Vehicle front
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000004556076

WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations.
• Never start working until exhaust system and engine coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.
• Always use the support point specified for lifting.

Revision: 2008 October EM-68 Z51

 ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION >
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with transmission jack or similar tool before A
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-31, "Garage Jack and
Safety Stand and 2-Pole Lift".
EM
REMOVAL
Outline
At first, remove the engine, the transaxle and the transfer assembly with front suspension member downward. C
Then separate the engine, the transaxle, and the transfer.
Preparation
D
1. Release fuel pressure. Refer to EC-418, "Inspection" (TYPE 1) or EC-783, "Inspection" (TYPE 2).
2. Drain engine coolant. Refer to CO-8, "Draining".
CAUTION:
E
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.
3. Remove the following parts:
• Engine cover: Refer to EM-25, "Exploded View". F
• Front road wheel and tires
• Splash guards (RH and LH): Refer to EXT-25, "FENDER PROTECTOR : Exploded View".
• Air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor, and air duct assembly: G
Refer to EM-27, "Exploded View".
• Battery and battery tray: Refer to PG-129, "Exploded View".
• Drive belt: Refer to EM-13, "Removal and Installation".
• Reservoir tank of radiator: Refer to CO-13, "Exploded View". H
• Front wiper arm and extension cowl top: Refer to WW-124, "Exploded View" (for South Africa models) or
WW-272, "Exploded View" (except for South Africa models) and EXT-22, "Exploded View".
4. Disconnect engine room harness at the TCM, ECM, and other sides. I
CAUTION:
To keep clean harness connector and avoid damage and foreign materials, cover them completely
with plastic bags or something similar. J
5. Remove battery bracket with ECM and TCM.
6. Remove sub-tank bracket mounting nut, and then temporarily secure sub-tank and bracket assembly to
aside. Refer to BR-25, "Exploded View" (LHD models) or BR-70, "Exploded View" (RHD models). K
Engine Room
1. Disconnect heater hoses. Refer to CO-25, "Exploded View".
• Install plug to avoid leakage of engine coolant. L
2. Remove EVAP hose. Refer to EM-29, "Exploded View".
3. Disconnect fuel feed hose quick connector at fuel tube side. Refer to EM-45, "Exploded View".
• Install plug to avoid leakage of fuel. M
4. Disconnect transaxle shift control cable at transaxle side. Refer to TM-174, "Exploded View".
5. Disconnect brake booster vacuum hose at engine side. Refer to EM-29, "Exploded View".
N
6. Disconnect ground cable.
7. Disconnect A/C compressor piping at A/C compressor side. Refer to HA-43, "Exploded View".
8. Disconnect suction hoses of power steering oil pump at reservoir tank side. Refer to ST-41, "Exploded O
View".
• Install plug to avoid leakage of power steering fluid.
9. Disconnect CVT fluid cooler hoses from radiator. Refer to CO-13, "Exploded View".
P
10. Remove starter motor. Refer to STR-15, "Exploded View".
Vehicle Underbody
1. Remove front drive shafts (RH and LH). Refer to FAX-15, "Exploded View".
2. Remove air guide. Refer to FSU-17, "Removal and Installation".
3. Remove exhaust front tube. Refer to EX-5, "Exploded View".
4. Remove propeller shaft. Refer to DLN-79, "Exploded View".

Revision: 2008 October EM-69 Z51

 ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION >
5. Remove heat insulator.
6. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.
Refer to ST-21, "Exploded View".
7. Disconnect front stabilizer connecting rod. Refer to FSU-14, "Exploded View".
8. Remove strut assembly and steering knuckle fixing nuts and bolts. Refer to FSU-9, "Exploded View" and
FAX-8, "Exploded View".
9. Remove front wheel sensor (RH and LH) for ABS from steering knuckle. Refer to BRC-108, "FRONT
WHEEL SENSOR : Exploded View".
10. Remove front brake caliper assembly with piping connected, and temporarily secure it to aside for vehicle
side. Refer to BR-34, "BRAKE CALIPER ASSEMBLY : Exploded View" (LHD models), BR-78, "BRAKE
CALIPER ASSEMBLY (1 PISTON TYPE) : Exploded View" [RHD models (1 piston type)] or BR-82,
"BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Exploded View" [RHD models (2 piston type)].
11. Disconnect power steering piping at a point between vehicle and engine. Refer to ST-41, "Exploded
View".
• Install plug to avoid leakage of power steering fluid.
12. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter.
Refer to EM-39, "Exploded View" and TM-189, "Removal and Installation".
13. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-39, "Exploded
View".
14. Remove crankshaft position sensor (POS). Refer to EM-39, "Exploded View".
CAUTION:
• Handle carefully to avoid dropping and shocks.
• Never disassemble.
• Never allow metal powder to adhere to magnetic part at sensor tip.
• Never place sensors in a location where they are exposed to magnetism.
Removal
1. Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a transmission jack. Securely support
bottom of front suspension member.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.

PBIC1190E

2. Remove engine mounting insulator (RH) and engine mounting bracket (RH).
3. Remove front suspension member mounting nuts and bolts. Refer to FSU-16, "Exploded View".
4. Carefully lower jack, or raise lift to remove the engine, the transaxle and transfer assembly and front sus-
pension member. When performing work, observe the following caution:
CAUTION:
• Confirm there is no interference with the vehicle.
• Check all connection points have been disconnected.
• Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support the vehi-
cle at rear jacking point(s) to prevent it from falling it off the lift.
Separation

Revision: 2008 October EM-70 Z51

 ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION >
1. Install engine slingers into front of cylinder head (bank 1) (3) and
rear of cylinder head (bank 2) (2). A

1 : Engine rear slinger

4 : Engine front slinger (upper) EM
5 : Engine front slinger (lower)
: Engine front
C

G
JPBIA1729ZZ

2. Remove power steering oil pump, power steering piping, and power steering bracket from engine, tran-
saxle and transfer assembly. Refer to ST-35, "Exploded View". H
3. Disconnect vacuum hoses of engine mounting insulator (front and rear).
4. Lift with hoist the engine, the transaxle and the transfer assembly and front suspension member.
CAUTION: I
• Before and during this lifting, always check if any harnesses are left connected.
• Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove rear torque rod and rear torque rod bracket. J
6. Remove each engine mounting insulator and each engine mounting bracket from engine, transaxle, and
front suspension member.
7. Separate engine, transaxle and transfer assembly from front suspension member. K
CAUTION:
• Before and during this lifting, always check if any harnesses are left connected.
• Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
L
8. Remove exhaust manifold. Refer to EM-34, "Exploded View".
9. Remove transfer. Refer to DLN-51, "Exploded View".
10. Separate engine and transaxle assembly. Refer to TM-189, "Exploded View". M
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION: N
• Never allow engine mounting insulator to be damage and careful no oil gets on it.
• Check all mounting insulators are seated properly, then tighten mounting nuts and bolts.
Preparation O
1. Install the engine mounting bracket (RH) to the engine as follows:

Revision: 2008 October EM-71 Z51

 ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION >
a. Tighten the bolt No. 7 as shown in the figure. (temporarily)

: Vehicle front

b. Tighten the bolts in numerical order as shown in the figure.

(specified torque)

JPBIA1730ZZ

2. Install the engine mounting bracket (front) to the engine as follows:

a. Tighten the bolt No. 4 as shown in the figure. (temporarily)

: Engine front

b. Tighten the bolts in numerical order as shown in the figure.

(specified torque)

JPBIA1744ZZ

3. Install the engine mounting bracket (rear) to the engine as follows:

a. Tighten the bolt No. 4 as shown in the figure. (temporarily)

: Engine front

b. Tighten the bolts in numerical order as shown in the figure.

(specified torque)

JPBIA1745ZZ

4. Install the rear torque rod bracket to the engine as follows:

Revision: 2008 October EM-72 Z51

 ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION >
a. Tighten the bolt No. 3 as shown in the figure. (temporarily)
A
: Engine front

b. Tighten the bolts in numerical order as shown in the figure.

EM
(specified torque)

JPBIA1733ZZ

D
5. Install the engine mounting insulator (LH) to the transaxle as follows:
a. Tighten the bolt No. 3 as shown in the figure. (temporarily)
E
: Vehicle front

b. Tighten the bolts in numerical order as shown in the figure.

(specified torque) F

JPBIA1734ZZ

H
6. Install the engine mounting insulator (front) to the front suspension member as follows:
a. Tighten the bolt No. 3 as shown in the figure. (temporarily)
I
: Vehicle front

b. Tighten the bolts in numerical order as shown in the figure.

(specified torque) J

JPBIA1735ZZ

L
7. Install the engine mounting insulator (rear) to the front suspension member as follows:
a. Tighten the bolt No. 4 as shown in the figure. (temporarily)
M
: Vehicle front

b. Tighten the bolts in numerical order as shown in the figure.

(specified torque) N

JPBIA1746ZZ

8. Install the rear torque rod to the front suspension member as follows: P

Revision: 2008 October EM-73 Z51

 ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION >
a. Tighten the bolt No. 3 as shown in the figure. (temporarily)

: Vehicle front

b. Tighten the bolts in numerical order as shown in the figure.

(specified torque)

JPBIA1738ZZ

9. Install the engine mounting brackets (front and rear) to the engine mounting insulators (front and rear).
10. Install the engine mounting insulator (LH) to the front suspension member.
• Tighten the bolts in numerical order as shown in the figure.

: Vehicle front

JPBIA1739ZZ

11. Install the rear torque rod to the rear torque rod bracket.
12. Install the vacuum tube (front) as follows:
a. Tighten the bolt No. 3 as shown in the figure. (temporarily)

: Engine front

b. Tighten the bolts in numerical order as shown in the figure.

(specified torque)

JPBIA1740ZZ

Installation
1. Install the engine mounting insulator (RH) as follows:
a. Tighten the bolt No. 1 as shown in the figure. (temporarily)

: Vehicle front

b. Tighten the bolts No. 2, 3 in numerical order as shown in the fig-

ure. (specified torque)
c. Tighten the bolt No. 1 as shown in the figure. (specified torque)
d. Tighten the bolts No. 4, 5, 6 in numerical order as shown in the
figure. (specified torque)

JPBIA1742ZZ

2. Install the upper torque rod as follows:

Revision: 2008 October EM-74 Z51

 ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION >
a. Tighten the bolt No. 2 as shown in the figure. (temporarily)
A
: Vehicle front

b. Tighten the bolts in numerical order as shown in the figure.

EM
(specified torque)

JPBIA1743ZZ

D
Inspection INFOID:0000000004556077

INSPECTION AFTER INSTALLATION E

Inspection for Leakage

The following are procedures for checking fluids leakage, lubricates leakage and exhaust gases leakage. F
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-8, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage. G
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration. H
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system. I
• 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: J
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level K
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
L
Exhaust gases — Leakage —
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

Revision: 2008 October EM-75 Z51

 ENGINE STAND SETTING
< DISASSEMBLY AND ASSEMBLY >
DISASSEMBLY AND ASSEMBLY
ENGINE STAND SETTING
Setting INFOID:0000000004556078

NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc.
1. Remove the engine assembly from the vehicle. Refer to EM-68, "Exploded View".
2. Remove the parts that may restrict installation of engine to widely use engine stand.
NOTE:
The procedure is described assuming that you use a widely use engine stand holding the surface, to
which transaxle is installed.
• Remove drive plate. Fix crankshaft pulley with the pulley holder (commercial service tool), and remove
mounting bolts.
• Loosen mounting bolts in diagonal order.
• Check for deformation or damage drive plate.
CAUTION:
• Never disassemble drive plate.
• Never place drive plate with signal plate facing down.
• When handling signal plate, take care not to damage or scratch it.
• Handle signal plate in a manner that prevents it from becoming magnetized.

3. Remove pilot converter using the pilot bushing puller (SST) if

necessary.

PBIC1618E

4. Lift the engine with hoist to install it onto the widely use engine stand.
CAUTION:
Use an engine stand that has a load capacity [220 kg (485 lb) or more] large enough for supporting
the engine weight.
• If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the
potential risk of overturning the stand.
- Remove intake manifold collector. Refer to EM-29, "Exploded View".
- Remove intake manifold. Refer to EM-32, "Exploded View".
- Remove fuel injector and fuel tube assembly. Refer to EM-45, "Exploded View".
- Remove ignition coil. Refer to EM-50, "Exploded View".
- Remove rocker cover. Refer to EM-50, "Exploded View".
- Remove exhaust manifold. Refer to EM-34, "Exploded View".
- Other removable brackets.
NOTE:

Revision: 2008 October EM-76 Z51

 ENGINE STAND SETTING
< DISASSEMBLY AND ASSEMBLY >
The figure shows an example of widely use engine stand (A)
that can hold mating surface of transaxle with drive plate A
removed.
CAUTION:
Before removing the hanging chains, check the engine
EM
stand is stable and there is no risk of overturning.

JPBIA0190ZZ

D
5. Drain engine oil. Refer to LU-8, "Draining".
6. Drain engine coolant by removing water drain plugs (A) and (B)
from cylinder block both sides as shown in the figure. E

C : Plug
D : Connector bolt
F

Tightening torque : Refer to EM-108, "Disassem-

bly and Assembly". G

K
PBIC2487E

Revision: 2008 October EM-77 Z51

 ENGINE UNIT
< DISASSEMBLY AND ASSEMBLY >
ENGINE UNIT
Disassembly INFOID:0000000004556079

1. Remove intake manifold collector. Refer to EM-29, "Exploded View".

2. Remove intake manifold. Refer to EM-32, "Exploded View".
3. Remove exhaust manifold. Refer to EM-34, "Exploded View".
4. Remove oil pan (lower and upper). Refer to EM-39, "Exploded View".
5. Remove ignition coil, spark plug, and rocker cover. Refer to EM-50, "Exploded View".
6. Remove fuel injector and fuel tube. Refer to EM-45, "Exploded View".
7. Remove timing chain and rear timing chain case. Refer to EM-53, "Exploded View" and EM-79, "Exploded
View".
8. Remove camshaft. Refer to EM-84, "Exploded View".
9. Remove cylinder head. Refer to EM-96, "Exploded View".
Assembly INFOID:0000000004556080

Assembly in the reverse order of disassembly.

Revision: 2008 October EM-78 Z51

 REAR TIMING CHAIN CASE
< DISASSEMBLY AND ASSEMBLY >
REAR TIMING CHAIN CASE
A
Exploded View INFOID:0000000004556081

EM

JPBIA2471GB

P
Timing chain tensioner (secondary) Timing chain tensioner (secondary)
1. 2. Internal chain guide 3.
(bank 2) (bank 1)
4. Oil temperature sensor 5. Camshaft sprocket (EXH) 6. O-ring
7. Timing chain (secondary) 8. Timing chain (primary) 9. Camshaft sprocket (INT)
10. Slack guide 11. Timing chain tensioner (primary) 12. Crankshaft sprocket
13. Rear timing chain case 14. Tension guide 15. O-ring
16. O-ring 17. O-ring 18. Front timing chain case

Revision: 2008 October EM-79 Z51

 REAR TIMING CHAIN CASE
< DISASSEMBLY AND ASSEMBLY >
Valve timing control cover gasket Intake valve timing control solenoid valve
19. 20. Valve timing control cover (bank 1) 21.
(bank 1) (bank 1)
22. Seal ring 23. Water pump cover 24. Front oil seal
Intake valve timing control solenoid valve
25. Crankshaft pulley 26. Crankshaft pulley bolt 27.
(bank 2)
Valve timing control cover (bank 2) 29. Valve timing control cover gasket
28.
(bank 2)
A. Refer to EM-80 B. Refer to EM-54
Refer to GI-4, "Components" for symbols in the figure.

Disassembly and Assembly INFOID:0000000004556082

DISASSEMBLY
1. Remove front timing chain case and timing chain. Refer to EM-53, "Exploded View".
2. Remove water pump. Refer to CO-18, "Exploded View".
3. Remove oil pans (upper and lower) and oil strainer. Refer to EM-39, "Exploded View".
4. Remove rear timing chain case as follows:
a. Loosen and remove mounting bolts in the reverse order as
shown in the figure.
b. Cut liquid gasket using the seal cutter [SST: KV10111100] and
remove rear timing chain case.

JPBIA1641ZZ

CAUTION:
• Never remove plate metal cover (1) of oil passage.
• After removal, handle rear timing chain case carefully so
it does not tilt, cant, or warp under a load.

JPBIA0088ZZ

5. Remove O-rings (1) from cylinder block.

: Engine front

JPBIA0090ZZ

6. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a. Remove camshaft brackets (No. 1). Refer to EM-84, "Exploded View".

Revision: 2008 October EM-80 Z51

 REAR TIMING CHAIN CASE
< DISASSEMBLY AND ASSEMBLY >
b. Remove timing chain tensioners (secondary) (1) with a stopper
pin (B) attached. A

A : Bank 1
C : Bank 2 EM

JPBIA1727ZZ

D
7. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases, and oppo-
site mating surfaces.
• Remove old liquid gasket from bolt hole (B) and thread. E
A : Remove sticking old liquid gasket

JPBIA0051ZZ H

ASSEMBLY
1. Install rear timing chain case as follows: I
• Install new O-rings (1) onto cylinder block.

: Engine front
J

L
JPBIA0090ZZ

a. Apply liquid gasket with the tube presser (commercial service tool) to rear timing chain case back side as
shown in the figure. M
Use Genuine Liquid Gasket or equivalent.
CAUTION:
• For (A) in the figure, completely wipe out liquid gasket extended on a portion touching at engine N
coolant.

Revision: 2008 October EM-81 Z51

 REAR TIMING CHAIN CASE
< DISASSEMBLY AND ASSEMBLY >
• Apply liquid gasket on installation position of water pump and cylinder head very completely.

PBIC2616E

b. Align rear timing chain case with dowel pins (bank 1 and bank 2) on cylinder block and install rear timing
chain case.
• Check O-rings stay in place during installation to cylinder block and cylinder head.
c. Tighten mounting bolts in numerical order as shown in the fig-
ure.
• There are two types of mounting bolts. Refer to the following
for locating bolts.

Bolt length: Bolt position

20 mm (0.79 in) : 1, 2, 3, 6, 7, 8, 9, 10
16 mm (0.63 in) : Except the above

: 12.7 N·m (1.3 kg-m, 9 ft-lb) JPBIA1641ZZ

d. After all bolts tightening, retighten them to the specified in numerical order as shown in the figure.
• If liquid gasket protrudes, wipe it off immediately.

e. After installing rear timing chain case (1), check the surface
height difference between the following parts on the oil pan
(upper) mounting surface.

2 : Cylinder block

Standard
Rear timing chain case to cylinder block:
−0.24 to 0.14 mm (−0.009 to 0.006 in)
• If not within the standard, repeat the installation procedure. JPBIA1944ZZ

Revision: 2008 October EM-82 Z51

 REAR TIMING CHAIN CASE
< DISASSEMBLY AND ASSEMBLY >
2. Install water pump with new O-rings. Refer to CO-18, "Exploded View".
A
3. Install front timing chain case and timing chain. Refer to EM-53, "Exploded View".
4. After installing front timing chain case, check the surface height
difference between the following parts on the oil pan (upper)
mounting surface. EM

Standard
Front timing chain case to rear timing chain case: C
−0.14 to 0.14 mm (−0.006 to 0.006 in)
• If not within the standard, repeat the installation procedure. D

SEM943G

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

Revision: 2008 October EM-83 Z51

 CAMSHAFT
< DISASSEMBLY AND ASSEMBLY >
CAMSHAFT
Exploded View INFOID:0000000004556083

JPBIA1719GB

1. Camshaft bracket (No. 3, 4) 2. Camshaft bracket (No. 2) 3. Seal washer

4. Camshaft bracket (No. 1) 5. Dowel pin 6. Camshaft (EXH) (bank 1)
Timing chain tensioner (secondary)
7. Camshaft (INT) (bank 1) 8. Valve lifter 9.
(bank 1)
Timing chain tensioner (secondary)
10. Spring 11. Plunger 12.
(bank 2)
13. Cylinder head (bank 2) 14. Dowel pin 15. Camshaft sensor bracket (bank 2)
16. Camshaft (EXH) (bank 2) 17. Camshaft signal plate (bank 2) 18. Camshaft (INT) (bank 2)
19. Cylinder head (bank 1) 20. Camshaft signal plate (bank 1) 21. Camshaft sensor bracket (bank 1)
A. Refer to EM-84
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000004556084

REMOVAL
1. Remove front timing chain case, camshaft sprocket, timing chain, and rear timing chain case. Refer to
EM-53, "Exploded View" and EM-79, "Exploded View".

Revision: 2008 October EM-84 Z51

 CAMSHAFT
< DISASSEMBLY AND ASSEMBLY >
2. Loosen camshaft sensor bracket bolts in the reverse order as
shown in the figure. A

: Engine front

NOTE: EM
The order of loosening bolts in the same for bank 1 and bank 2.

JPBIA1960ZZ

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

: Engine front F

JPBIA0257ZZ

L
4. Remove camshafts.
5. Remove valve lifters.
• Identify installation positions, and store them without mixing them up.
M
6. Remove timing chain tensioners (secondary) (1) from cylinder
head.

A : Bank 1 N
B : Bank 2
• Remove timing chain tensioner (secondary) with its stopper
pin (C) attached. O
NOTE:
Stopper pin should be attached when timing chain (secondary)
is removed. P
JPBIA0121ZZ

INSTALLATION

Revision: 2008 October EM-85 Z51

 CAMSHAFT
< DISASSEMBLY AND ASSEMBLY >
1. Install timing chain tensioners (secondary) (1) on both sides of
cylinder head.

A : Bank 1
B : Bank 2
• Install timing chain tensioner (secondary) with its stopper pin
(C) attached.
• Install timing chain tensioner (secondary) with sliding part fac-
ing downward on cylinder head (bank 1), and with sliding part
facing upward on cylinder head (bank 2).
JPBIA0121ZZ

2. Install valve lifters.

• Install it in the original position.
3. Install camshafts.

: Engine front

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

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

Dowel pin Paint marks

Bank INT/EXH
(1) M1 (D) M2 (E) M3 (C)
JPBIA1749ZZ
EXH (B) Yes No Light blue Light blue
1
INT (A) Yes Pink No Light blue
INT (A) Yes Pink No Light blue
2
EXH (B) Yes No Light blue Light blue

• Install camshaft so that dowel pin (A) on front end face are
positioned as shown in the figure. (No. 1 cylinder TDC on its
compression stroke)
NOTE:
Though camshaft does not stop at the portion as shown in the
figure, for the placement of cam nose, it is generally accepted
camshaft is placed for the same direction of the figure.

JPBIA2368ZZ

4. Install camshaft brackets.

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

Revision: 2008 October EM-86 Z51

 CAMSHAFT
< DISASSEMBLY AND ASSEMBLY >
• Install camshaft bracket in original position and direction as
shown in the figure. A

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

G
JPBIA0258ZZ

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

(A) as shown in the figure. H

B : Bank 1
C : Bank 2 I
: Engine front

NOTE: J
There are no identification marks indicating left and right for
camshaft bracket (No. 1).
JPBIA0272ZZ
K

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

1) as shown in the figure on bank 1 and bank 2.
L
a : 8.5 mm (0.335 in)
b : 2 mm (0.08 in)
c : Clearance 5 mm (0.20 in) M
d : φ2.0 - 2.3 mm (0.079 - 0.091 in)
* : Apply liquid gasket to rear timing chain case side
N
Use Genuine Liquid Gasket or equivalent.
JPBIA0255ZZ

Revision: 2008 October EM-87 Z51

 CAMSHAFT
< DISASSEMBLY AND ASSEMBLY >
5. Tighten camshaft bracket bolts in the following steps, in numeri-
cal order as shown in the figure.

: Engine front

a. Tighten No. 7 to 10 in order as shown.

: 1.96 N·m (0.20 kg-m, 1 ft-lb)

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

: 1.96 N·m (0.20 kg-m, 1 ft-lb)

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

: 5.88 N·m (0.60 kg-m, 4 ft-lb)

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

: 10.4 N·m (1.1 kg-m, 8 ft-lb)

CAUTION:
After tightening mounting bolts of camshaft brackets (No.
1), be sure to wipe off excessive liquid gasket from the JPBIA0257ZZ

parts list below.

• Mating surface of rocker cover
• Mating surface of rear timing chain case
6. Tighten camshaft sensor bracket bolts in numerical order as
shown in the figure.

: Engine front

NOTE:
The order of tightening bolts in the same for bank 1 and bank 2.

JPBIA1960ZZ

7. Measure difference in levels between front end faces of cam-

shaft bracket (No. 1) and cylinder head.

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

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

EMQ0044D

8. Inspect and adjust the valve clearance. Refer to EM-18, "Inspection and Adjustment".
9. Install in the reverse order of removal after this step.
Inspection INFOID:0000000004556085

INSPECTION AFTER REMOVAL

Camshaft Runout
1. Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft.

Revision: 2008 October EM-88 Z51

 CAMSHAFT
< DISASSEMBLY AND ASSEMBLY >
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter A
from the other three locations.
2. Set a dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the EM
camshaft runout on a dial indicator. (Total indicator reading)

Standard and limit : Refer to EM-132, "Camshaft". C

4. If it exceeds the limit, replace camshaft.

PBIC0929E

Camshaft Cam Height E

1. Measure the camshaft cam height with a micrometer.

F
Standard cam height : Refer to EM-132, "Cam-
(Intake and exhaust) shaft".
Cam wear limit : Refer to EM-132, "Cam- G
shaft".
2. If wear exceeds the limit, replace camshaft.
H

EMQ0072D

Camshaft Journal Oil Clearance I

CAMSHAFT JOURNAL DIAMETER
• Measure the outer diameter of camshaft journal with a micrometer
(A). J

Standard and limit : Refer to EM-132, "Camshaft".

K

JPBIA0122ZZ
M
CAMSHAFT BRACKET INNER DIAMETER
• Tighten camshaft bracket bolt with the specified torque. Refer to EM-84, "Removal and Installation" for the
tightening procedure. N
• Measure inner diameter (A) of camshaft bracket with a bore gauge.

Standard : Refer to EM-132, "Camshaft".

O

PBIC1645E

CAMSHAFT JOURNAL OIL CLEARANCE

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

Revision: 2008 October EM-89 Z51

 CAMSHAFT
< DISASSEMBLY AND ASSEMBLY >

Standard and limit : Refer to EM-132, "Camshaft".

• If the calculated value exceeds the limit, replace either or both camshaft and cylinder head.
NOTE:
Camshaft brackets cannot be replaced as single parts, because there are machined together with cylinder
head. Replace whole cylinder head assembly.
Camshaft End Play
• Install a dial indicator in thrust direction on front end of camshaft.
Measure the end play of a dial indicator when camshaft is moved
forward/backward (in direction to axis).

Standard and limit : Refer to EM-132, "Camshaft".

SEM864E

• Measure the following parts if out of the limit.

- Dimension (A) for camshaft No. 1 journal

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

- Dimension (B) for cylinder head No. 1 journal bearing

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

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

Camshaft Sprocket Runout

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

Limit : Refer to EM-132, "Camshaft".

• If it exceeds the limit, replace camshaft sprocket.

PBIC0930E

Valve Lifter

Revision: 2008 October EM-90 Z51

 CAMSHAFT
< DISASSEMBLY AND ASSEMBLY >
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-132, A
"Camshaft".

EM

KBIA0182E

D
Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER

• Measure the outer diameter at 1/2 height of valve lifter with a E
micrometer (A) since valve lifter is in barrel shape.

Standard
: Refer to EM-132, "Camshaft". F
(Intake and exhaust)

JPBIA0125ZZ H

VALVE LIFTER HOLE DIAMETER

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

Standard
: Refer to EM-132, "Camshaft". J
(Intake and exhaust)

SEM867E
L

VALVE LIFTER CLEARANCE

• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
M
Standard
: Refer to EM-132, "Camshaft".
(Intake and exhaust)
N
• If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and
valve lifter hole diameter, replace either or both valve lifter and cylinder head.
INSPECTION AFTER INSTALLATION O
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III P
and it is directed according to inspection procedure of EC section. Refer to EC-141, "Diagnosis Pro-
cedure" (TYPE 1) or EC-543, "Diagnosis Procedure" (TYPE 2).
• Check when engine is cold so as to prevent burns from the splashing engine oil.
1. Check engine oil level. Refer to LU-7, "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-418, "Inspection" (TYPE 1) or EC-783, "Inspection" (TYPE 2).

Revision: 2008 October EM-91 Z51

 CAMSHAFT
< DISASSEMBLY AND ASSEMBLY >
b. Disconnect ignition coil and injector harness connectors. Refer to EM-50, "Exploded View" and EM-45,
"Exploded View".
3. Remove intake valve timing control solenoid valve. Refer to EM-53, "Exploded View".
4. Crank engine, and then check that engine oil comes out from
intake valve timing control solenoid valve hole (A). End crank
after checking.

1 : Valve timing control cover (bank 2)

: Engine front

WARNING:
Be careful not to touch rotating parts. (drive belt, idler pul-
ley, and crankshaft pulley, etc.)
CAUTION:
JPBIA1783ZZ
• 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.
• Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful no to apply engine oil to rubber parts of drive belt,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
• Remove oil filter, and then clean it. Refer to LU-10, "Removal and Installation".
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-2,
"Engine Lubrication System".
6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-2, "Engine Lubrication System".
7. After inspection, install removed parts in the reverse order.
Inspection for Leakage

The following are procedures for checking fluids leakage, lubricates 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-8, "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.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
• Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

Revision: 2008 October EM-92 Z51

 OIL SEAL
< DISASSEMBLY AND ASSEMBLY >
OIL SEAL
A
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation INFOID:0000000004556086
EM
REMOVAL
1. Remove camshaft relating to valve oil seal to be removed. Refer to EM-84, "Exploded View".
C
2. Remove valve lifters. Refer to EM-84, "Exploded View".
3. Turn crankshaft until the cylinder requiring new oil seals is at TDC. This will prevent valve from dropping
into cylinder.
D
4. Remove valve collet.
• Compress valve spring with the valve spring compressor [SST:
KV10116200] (A), the attachment [SST: KV10115900] (C), and
the adapter [SST: KV10109220] (B). Remove valve collet with E
a magnet hand.
CAUTION:
When working, take care not to damage valve lifter holes. F

JPBIA0180ZZ

5. Remove valve spring retainer and valve spring. H

6. Remove valve oil seal using the valve oil seal puller [SST:
KV10107902] (A).
I

K
JPBIA0177ZZ

L
INSTALLATION
1. Apply new engine oil on new valve oil seal joint and seal lip.
2. Using the valve oil seal drift [SST: KV10115600] (A), press fit M
valve seal to height (b) shown in the figure.
NOTE:
Dimension: Height measured before valve spring seat installa-
tion N

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

O

JPBIA0178ZZ
P
3. Install in the reverse order of removal after this step.
FRONT OIL SEAL
FRONT OIL SEAL : Removal and Installation INFOID:0000000004556087

REMOVAL

Revision: 2008 October EM-93 Z51

 OIL SEAL
< DISASSEMBLY AND ASSEMBLY >
1. Remove the following parts:
• Road wheel and tire (RH)
• Splash guard (RH): Refer to EXT-25, "FENDER PROTECTOR : Exploded View".
• Drive belt: Refer to EM-13, "Removal and Installation".
• Crankshaft pulley: Refer to EM-53, "Exploded View".
2. Remove front oil seal using a suitable tool.
CAUTION:
Be careful not to damage front timing chain case and crank-
shaft.

SEM829E

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

A : Oil seal lip

B : Dust seal lip
: Engine inside
: Engine outside

JPBIA0054ZZ

• Using a suitable drift, press-fit until the height of front oil seal is
level with the mounting surface.
- Suitable drift: outer diameter 60 mm (2.36 in), inner diameter
50 mm (1.97 in).
• Check the garter spring is in position and seal lips not inverted.
CAUTION:
• Be careful not to damage front timing chain case and
crankshaft.
• Press-fit straight and avoid causing burrs or tilting oil
seal.
3. Install in the reverse order of removal after this step. SEM829E

REAR OIL SEAL

REAR OIL SEAL : Removal and Installation INFOID:0000000004556088

REMOVAL
1. Remove transaxle assembly. Refer to TM-189, "Exploded View".
2. Remove drive plate. Refer to EM-107, "Exploded View".
3. Remove oil pan (upper). Refer to EM-39, "Exploded View".

Revision: 2008 October EM-94 Z51

 OIL SEAL
< DISASSEMBLY AND ASSEMBLY >
4. Use a seal cutter (SST) to cut away liquid gasket and remove
rear oil seal retainer. A
CAUTION:
Be careful not to damage mating surfaces.
NOTE:
EM
Regard both rear oil seal and retainer an assembly.

PBIC1612E

D
INSTALLATION
1. Remove old liquid gasket on mating surfaces of cylinder block and oil pan (upper) using scraper.
2. Apply new engine oil to both oil seal lip and dust seal lip of new oil seal retainer. E
3. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to rear oil seal retainer as shown in the
figure.
F
a : φ2.0 - 3.0 mm (0.079 - 0.118 in)
Use Genuine Liquid Gasket or equivalent.
G
CAUTION:
Attaching should be done within 5 minutes after coating.

H
JPBIA0542ZZ

4. Install rear oil seal retainer to cylinder block. Refer to EM-107, "Exploded View". I
• Check the garter spring is in position and seal lips not inverted.
5. Install in the reverse order of removal after this step.
J

Revision: 2008 October EM-95 Z51

 CYLINDER HEAD
< DISASSEMBLY AND ASSEMBLY >
CYLINDER HEAD
Exploded View INFOID:0000000004556089

REMOVAL

JPBIA1748ZZ

1. Oil level gauge 2. Cylinder head assembly (bank 2) 3. Cylinder head bolt
4. Cylinder head assembly (bank 1) 5. Cylinder head gasket (bank 1) 6. Cylinder head gasket (bank 2)
A. Refer to EM-97
Refer to GI-4, "Components" for symbols in the figure.

DISASSEMBLY

Revision: 2008 October EM-96 Z51

 CYLINDER HEAD
< DISASSEMBLY AND ASSEMBLY >

EM

H
JPBIA1728GB

1. Valve lifter 2. Valve collet 3. Valve spring retainer

4. Valve spring 5. Valve oil seal 6. Valve spring seat I
7. Valve guide (EXH) 8. Spark plug 9. Spark plug tube
10. Cylinder head (bank 1) 11. Valve seat (EXH) 12. Valve (EXH)
13. Valve (INT) 14. Valve seat (INT) 15. Valve guide (INT) J
16. Cylinder head (bank 2)
: Apply genuine high strength thread locking sealant or equivalent.
K
Refer to GI-4, "Components" for symbols not described on the above.

Removal and Installation INFOID:0000000004556090

L
REMOVAL
1. Remove the following parts:
• Oil level gauge M
• Intake manifold collector: Refer to EM-29, "Exploded View".
• Rocker cover: Refer to EM-50, "Exploded View".
• Fuel tube and fuel injector assembly: Refer to EM-45, "Exploded View". N
• Intake manifold: Refer to EM-32, "Exploded View".
• Exhaust manifold: Refer to EM-34, "Exploded View".
• Water inlet and thermostat assembly: Refer to CO-23, "Exploded View".
• Water outlet, water connector, water bypass pipe, and heater pipe: Refer to CO-25, "Exploded View". O
• Timing chain and rear timing chain case: Refer to EM-53, "Exploded View" and EM-79, "Exploded
View".
• Camshaft: Refer to EM-84, "Exploded View". P

Revision: 2008 October EM-97 Z51

 CYLINDER HEAD
< DISASSEMBLY AND ASSEMBLY >
2. Remove cylinder head bolts in the reverse order as shown in the
figure with cylinder head bolt wrench (commercial service tool)
and power tool to remove cylinder heads (bank 1 and bank 2).

A : Bank 1
B : Bank 2
: Engine front

JPBIA0172ZZ

3. Remove cylinder head gaskets.

INSTALLATION
1. Install new cylinder head gaskets.
2. Turn crankshaft until No. 1 piston is set at TDC.
• Crankshaft key should line up with the bank 1 cylinder center
line as shown in the figure.

1 : Crankshaft key
: Bank 1 side

JPBIA1752ZZ

Revision: 2008 October EM-98 Z51

 CYLINDER HEAD
< DISASSEMBLY AND ASSEMBLY >
3. Install cylinder head follow the steps below to tighten cylinder
head bolts in numerical order as shown in the figure with cylin- A
der head bolts wrench (commercial service tool).

A : Bank 1
EM
B : Bank 2
: Engine front

CAUTION: C
• If cylinder head bolts reused, check their outer diameters
before installation. Refer to EM-104, "Inspection".
• Before installing cylinder head, inspect cylinder head dis- D
tortion. Refer to EM-104, "Inspection".
a. Apply new engine oil to threads and seat surfaces of cylinder
head bolts.
E
b. Tighten all cylinder head bolts.

: 98.1 N·m (10 kg-m, 72 ft-lb) F

c. Completely loosen all cylinder head bolts.

: 0 N·m (0 kg-m, 0 ft-lb) G

JPBIA0172ZZ

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

: 39.2 N·m (4.0 kg-m, 29 ft-lb)

I
e. Turn all cylinder head bolts 103 degrees clockwise (angle tightening).
CAUTION:
Check the tightening angle by using the angle wrench [SST: J
KV10112100] (A). Avoid judgment by visual inspection with-
out.
• Check tightening angle indicated on the angle wrench indica-
tor plate. K
f. Turn all cylinder head bolts 103 degrees clockwise again (angle
tightening).
L

JPBIA0175ZZ M

4. After installing cylinder head, measure distance between front

end faces of cylinder block and cylinder head (bank 1 and bank
2). N

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

O
• If measured value is out of the standard, reinstall cylinder
head.

EMQ0662D

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

Revision: 2008 October EM-99 Z51

 CYLINDER HEAD
< DISASSEMBLY AND ASSEMBLY >
Disassembly and Assembly INFOID:0000000004556091

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.
3. Remove valve collet.
• Compress valve spring with the valve spring compressor [SST:
KV10116200] (A), the attachment [SST: KV10115900] (C), and
the adapter [SST: KV10109220] (B). Remove valve collet with
a magnet hand.
CAUTION:
When working, take care not to damage valve lifter holes.

JPBIA0180ZZ

4. Remove valve spring retainer, valve spring, and valve spring seat.
5. Push valve stem to combustion chamber side, and remove valve.
• Identify installation positions, and store them without mixing them up.
6. Remove valve oil seal with the valve oil seal puller [SST:
KV10107902] (A).

JPBIA0177ZZ

7. Remove valve seat, if 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-134, "Cylinder Head".
CAUTION:
Prevent to scratch cylinder head by excessive boring.
8. Remove valve guide, if 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).

JPBIA0184ZZ

Revision: 2008 October EM-100 Z51

 CYLINDER HEAD
< DISASSEMBLY AND ASSEMBLY >
b. Drive out valve guide with a press [under a 20 kN (2 ton, 2.0 lmp
ton) pressure] or a hammer and the valve guide drift (commer- A
cial service tool).
WARNING:
Cylinder head contains heat. When working, wear protec- EM
tive equipment to avoid getting burned.

SEM931C

D
9. Remove spark plug tube, if necessary.
• Using a pliers, pull spark plug tube out of cylinder head.
CAUTION:
E
• Take care not to damage cylinder head.
• Once removed, spark plug tube will be deformed and cannot be reused. Never remove it unless
absolutely necessary.
F
ASSEMBLY
1. If valve guide is removed in step 8 (DISASSEMBLY), install it.
Replace with oversized [0.2 mm (0.008 in)] valve guide.
G
a. Using the valve guide reamer (commercial service tool) (A),
ream cylinder head valve guide hole.
H
Valve guide hole diameter (for service parts):
Intake and exhaust
: Refer to EM-134, "Cylinder Head". I

J
JPBIA0185ZZ

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

heated oil (A). K

JPBIA0184ZZ
N
c. Using the valve guide drift (commercial service tool), press valve
guide from camshaft side to the dimensions as shown in the fig-
ure. O

Projection (A)
Intake and exhaust P
: Refer to EM-134, "Cylinder Head".
WARNING:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned. JPBIA0186ZZ

Revision: 2008 October EM-101 Z51

 CYLINDER HEAD
< DISASSEMBLY AND ASSEMBLY >
d. Using the valve guide reamer (commercial service tool) (A),
apply reamer finish to valve guide.

Standard : Refer to EM-134,

(Intake and exhaust) "Cylinder Head".

JPBIA0185ZZ

2. If valve seat is removed in step 7 (DISASSEMBLY), install it.

Replace with oversize [0.5 mm (0.020 in)] valve seat.
a. Ream cylinder head recess diameter (a) for service valve seat.

Oversize : Refer to EM-134,

(Intake and exhaust) "Cylinder Head".
• Be sure to ream in circles concentric to valve guide center.
This will enable valve to fit correctly.

JPBIA0188ZZ

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

heated oil (A).

JPBIA0184ZZ

c. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head.
WARNING:
Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
CAUTION:
Avoid directly touching cold valve seats.
d. Using the valve seat cutter set (commercial service tool) or valve
seat grinder, finish seat to the specified dimensions. Refer to
EM-134, "Cylinder Head".
CAUTION:
When using the valve seat cutter, firmly grip cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with cutter or cutting many different times may
result in stage valve seat.

SEM934C

e. Using compound, grind to adjust valve fitting.

f. Check again for normal contact. Refer to EM-104, "Inspection".
3. Install new valve oil seals as follows:

Revision: 2008 October EM-102 Z51

 CYLINDER HEAD
< DISASSEMBLY AND ASSEMBLY >
a. Apply new engine oil on valve oil seal joint and seal lip.
b. Install with the valve oil seal drift [SST: KV10115600] (A) press fit A
valve seal to height (b) shown in the figure.
NOTE:
Dimension: Height measured before valve spring seat installa- EM
tion.

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

C

JPBIA0178ZZ
D

4. Install valve spring seat.

5. Install valve. E
• Install it in the original position.
NOTE:
Larger diameter valves are for intake side.
F
6. Install valve spring (uneven pitch type).
• Install narrow pitch end (paint mark) to cylinder head side
(valve spring seat side).
G
A : Wide pitch
B : Narrow pitch
C : Paint mark H
: Cylinder head side

I
JPBIA0179ZZ

7. Install valve spring retainer. J

8. Install valve collet.
• Compress valve spring with the valve spring compressor [SST:
KV10116200] (A), the attachment [SST: KV10115900] (C), and K
the adapter [SST: KV10109220] (B). Install valve collet with a
magnet hand.
CAUTION:
When working, take care not to damage valve lifter holes. L
• Tap valve stem edge lightly with plastic hammer after installa-
tion to check its installed condition.
M

JPBIA0180ZZ

N
9. Install valve lifter.
• Install it in the original position.
10. Install spark plug tube.
O
• Press-fit spark plug tube as follows:
a. Remove old liquid gasket adhering to cylinder head mounting hole.
b. Apply sealant to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side.
P
Use genuine high strength thread locking sealant or equivalent.

Revision: 2008 October EM-103 Z51

 CYLINDER HEAD
< DISASSEMBLY AND ASSEMBLY >
c. Using a drift, press-fit spark plug tube so that its height (A) is as
specified in the figure.

B : Genuine high strength thread locking sealant application area

Standard press-fit height: 37.7 - 38.7 mm (1.484 - 1.524 in)

CAUTION:
• When press-fitting, take care not to deform spark plug
tube.
• After press-fitting, wipe off liquid gasket protruding onto
JPBIA0181ZZ
cylinder-head upper face.

11. Install spark plug with the spark plug wrench (commercial service tool).
Inspection INFOID:0000000004556092

INSPECTION AFTER REMOVAL

Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between (C) and (B)
exceeds the limit, replace them with new one.

Limit [(C) - (B)] : 0.11 mm (0.0043 in)

A : Measuring point
d : 11 mm (0.43 in)
e : 48 mm (1.89 in)
• If reduction of outer diameter appears in a position other than (B), JPBIA0173ZZ
use it as (B) point.
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-137,
"Cylinder Block".
1. Using a scraper, wipe off oil, scale, gasket, sealant, and carbon deposits from surface of cylinder head.
CAUTION:
Never allow gasket fragments to enter engine oil or engine coolant passages.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions (A), (B), (C), (D), (E), and
(F).

Limit : Refer to EM-134, "Cylinder Head".

• If it exceeds the limit, replace cylinder head.

JPBIA0176ZZ

INSPECTION AFTER DISASSEMBLY

Valve Dimensions
• Check the dimensions of each valve. For the dimensions, refer to EM-134, "Cylinder Head".
• If dimensions are out of the standard, replace valve and check valve seat contact. Refer to "Valve Seat Con-
tact".
Valve Guide Clearance

Valve Stem Diameter

Revision: 2008 October EM-104 Z51

 CYLINDER HEAD
< DISASSEMBLY AND ASSEMBLY >
• Measure the diameter of valve stem with micrometer (A).
A
Standard : Refer to EM-134,
(Intake and exhaust) "Cylinder Head".
EM
Valve Guide Inner Diameter
• Measure the inner diameter of valve guide with bore gauge.

Standard C
: Refer to EM-134,
(Intake and exhaust) "Cylinder Head".
JPBIA0183ZZ

Valve Guide Clearance D

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter)

Valve guide clearance E

: Refer to EM-134, "Cylinder Head".
Standard and limit (Intake and exhaust)
• If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be
replaced, refer to EM-100, "Disassembly and Assembly". F
Valve Seat Contact
• After confirming that the dimensions of valve guides and valves are within the specifications, perform this
procedure. G
• 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 circumference. H
• 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-100, "Disassembly and Assem-
bly". I

A : OK
J

K
JPBIA0187ZZ

Valve Spring Squareness

L
• Set a try square (A) along the side of valve spring and rotate
spring. Measure the maximum clearance between the top of spring
and try square.
M
B : Contact

Limit : Refer to EM-134, "Cylinder Head". N

• If it exceeds the limit, replace valve spring.

O
JPBIA0189ZZ

Valve Spring Dimensions and Valve Spring Pressure Load

P

Revision: 2008 October EM-105 Z51

 CYLINDER HEAD
< DISASSEMBLY AND ASSEMBLY >
• Check the valve spring pressure at specified spring height.

Standard (Intake and exhaust)

Free height
Installation height : Refer to EM-134,
Installation load "Cylinder Head".
Height during valve open
Load with valve open
• If the installation load or load with valve open is out of the stan- SEM113

dard, replace valve spring.

INSPECTION AFTER INSTALLATION
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-8, "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.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

Revision: 2008 October EM-106 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
A
Exploded View INFOID:0000000004556093

EM

JPBIA2237GB

1. Reinforcement plate 2. Drive plate 3. Rear oil seal retainer

4. Sub harness 5. Knock sensor 6. Cylinder block
7. Thrust bearing (upper) 8. Main bearing (upper) 9. Crankshaft

Revision: 2008 October EM-107 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
10. Crankshaft key 11. Thrust bearing (lower) 12. Main bearing (lower)
13. Main bearing cap 14. Main bearing cap bolt 15. Main bearing beam
16. Baffle plate 17. Connecting rod bolt 18. Connecting rod bearing cap
19. Connecting rod bearing 20. Connecting rod 21. Snap ring
22. Piston pin 23. Piston 24. Oil ring
25. Second ring 26. Top ring 27. Pilot converter
28. Oil jet
A. Crankshaft side B. Chamfered C. Refer to EM-108
D. Front mark
Refer to GI-4, "Components" for symbols in the figure.

Disassembly and Assembly INFOID:0000000004556094

DISASSEMBLY
1. Remove the following parts:
• Intake manifold collector: Refer to EM-29, "Exploded View".
• Intake manifold: Refer to EM-32, "Exploded View".
• Oil pans (lower and upper): Refer to EM-39, "Exploded View".
• Front and rear timing chain case: Refer to EM-53, "Exploded View" and EM-79, "Exploded View".
• Cylinder head: Refer to EM-96, "Exploded View".
2. Remove knock sensor.
CAUTION:
Carefully handle sensor avoiding shocks.
3. Remove rear oil seal retainer.
• Remove by inserting screwdriver between main bearing cap and rear oil seal retainer.
CAUTION:
If rear oil seal retainer is removed, replace it with new one.
NOTE:
Regard both rear oil seal and retainer as an assembly.
4. Remove baffle plate from main bearing beam.
5. 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-116, "Inspection".
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod bearing cap.
c. Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.

EMQ0191D

6. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
• Be careful not to drop connecting rod bearing, and to scratch the surface.
• Identify installation positions, and store them without mixing them up.
7. Remove piston rings form piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-116, "Inspection".

Revision: 2008 October EM-108 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
• Use a piston ring expander (commercial service tool) (A).
CAUTION: A
• When removing piston rings, be careful not to damage
piston.
• Be careful not to damage piston rings by expanding them
EM
excessively.

JPBIA0194ZZ

D
8. Remove piston from connecting rod as follows:
a. Using a snap ring pliers (A), remove snap rings.
E

JPBIA0195ZZ

H
b. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use
drier (A) or equivalent.
I

K
JPBIA0196ZZ

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

mm (0.79 in). L

PBIC0262E
O
9. Remove main bearing cap bolts.
NOTE:
• Before loosening main bearing cap bolts, measure the crankshaft end play. Refer to EM-116, "Inspec- P
tion".

Revision: 2008 October EM-109 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
• Loosen main bearing cap bolts in the reverse order shown in
the figure in several different steps.

: Engine front

JPBIA0439ZZ

10. Remove main bearing beam.

PBIC0881E

11. Remove main bearing caps.

CAUTION:
Be careful not to drop main bearing, and to scratch the sur-
face.
• Using main bearing cap bolts, remove main bearing cap while
shaking it back-and-forth.

EMQ0195D

12. Remove crankshaft.

13. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION:
• Be careful not to drop main bearing, and to scratch the surface.
• Identify installation positions, and store them without mixing them up.
14. Remove oil jet.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.

Revision: 2008 October EM-110 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
2. Install each plug to cylinder block as shown in the figure.
A
B : Water drain plug
• Apply sealant to the thread of water drain plug (A).
Use Genuine Liquid Gasket or equivalent. EM
• Apply sealant to the thread of connector bolt (D).
Use Genuine Liquid Gasket or equivalent.
• Apply sealant to the thread of plug (C).
C
Use genuine high strength thread locking sealant or
equivalent.
• Replace washers with new one.
D

G
PBIC2487E

• Tighten each plug and connector bolt as specified below. H

Part Washer Tightening torque

A Yes 62.0 N·m (6.3 kg-m, 46 ft-lb)
I
B No 9.8 N·m (1.0 kg-m, 87 in-lb)
C Yes 62.0 N·m (6.3 kg-m, 46 ft-lb)
D No 39.2 N·m (4.0 kg-m, 29 ft-lb) J

3. Install oil jet.

• Insert oil jet dowel pin (A) into cylinder block dowel pin hole, K
and tighten mounting bolts.

: Engine front
L

JPBIA0198ZZ N
4. Install main bearings and thrust bearings as follows:
CAUTION:
Be careful not to drop main bearing, and to scratch the surface. O
a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.

Revision: 2008 October EM-111 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
b. Install thrust bearings (1) to the both sides of the No. 3 journal
housing on cylinder block and main bearing cap.

A : No. 1
B : No. 2
C : No. 3
D : No. 4
F : Thrust bearing installation position
: Engine front

• Install thrust bearings with the oil groove (E) facing crankshaft JPBIA0199ZZ

arm (outside).
• Install thrust bearing with a projection on one end on cylinder block, and thrust bearing with a projection
at center on main bearing cap. Align each projection with mating notch.

c. Install main bearings paying attention to the direction.

• Main bearing with oil hole (B) and groove (C) goes on cylinder
block. The one without them goes on main bearing cap.

A : Cylinder block side

D : Main bearing cap side
: Engine front

• Before installing main bearings, apply engine oil to the bearing

surface (inside). Do not apply engine oil to the back surface,
but thoroughly clean it.
• When installing, align main bearing stopper protrusion to cut- JPBIA0200ZZ
out of cylinder block and main bearing caps.
• Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.

5. Install crankshaft to cylinder block.

• While turning crankshaft by hand, check that it turns smoothly.
6. Install main bearing caps.
• Main bearing caps are identified by identification mark cast on
them. For installation, face front mark (E) to front side.

A : No. 1
B : No. 2
C : No. 3
D : No. 4
: Engine front

NOTE:
Main bearing cap cannot be replaced as a single part, because it JPBIA0440ZZ

is machined together with cylinder block.

7. Install main bearing beam.

• Install main bearing beam with front mark facing downward (oil pan side).
• Install main bearing beam with front mark facing front of the
engine.

PBIC0881E

Revision: 2008 October EM-112 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
8. Install main bearing cap bolts in numerical order as shown in the
figure as follows: A

: Engine front

a. Inspect the outer diameter of main bearing cap bolt. Refer to EM

EM-116, "Inspection".
b. Apply new engine oil to threads and seat surfaces of main bear-
ing cap bolts. C
c. Tighten main bearing cap bolts in several different steps.
JPBIA0439ZZ

: 35.3 N·m (3.6 kg-m, 26 ft-lb) D

d. Turn all main bearing cap bolts 90 degrees clockwise (angle tightening).
CAUTION: E
Use the angle wrench [SST: KV10112100] to check tighten-
ing angle. Never make judgment by visual inspection.
• After installing main bearing cap bolts, check that crankshaft
can be rotated smoothly by hand. F
• Check the crankshaft end play. Refer to EM-116, "Inspection".

H
PBIC0921E

9. Install piston to connecting rod as follows:

a. Using snap ring pliers, install new snap ring to the groove of piston rear side. I
• Insert it fully into groove to install.
b. Install piston to connecting rod.
• Using an industrial drier or similar tool, heat piston until piston pin can be pushed in by hand without J
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 on the piston crown and the K
cylinder number on connecting rod are positioned as shown in
the figure.
c. Install new snap ring to the groove of the piston front side. L
• Insert it fully into groove to install.
• After installing, check that connecting rod moves smoothly.

SEM838F N

10. Using a piston ring expander (commercial service tool) (A),

install piston rings.
CAUTION: O
• When installing piston rings, be careful not to damage
piston.
• Be careful not to damage piston rings by expending them P
excessively.

JPBIA0194ZZ

Revision: 2008 October EM-113 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
• If there is stamped mark on ring, mount it with marked side up.
NOTE:
If there is no stamp on ring, no specific orientation is required
for installation.

Stamped mark:
Top ring (A) :—
Second ring (B) :2R

JPBIA0263ZZ

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

C : Top ring gap

E : Oil ring upper or lower rail gap (either of then)
F : Second ring and oil ring spacer gap
a : 90 degrees
b : 45 degrees

JPBIA0205ZZ

• Check the piston rings side clearance. Refer to EM-116, "Inspection".

11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
• Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply
engine oil to the back surface, but thoroughly clean it.
• When installing, align connecting rod bearing stopper protru-
sion (B) with cutout (C) of connecting rod and connecting rod
bearing cap to install.
• Ensure the oil hole (A) on connecting rod and that on the cor-
responding bearing are aligned.

JPBIA0206ZZ

12. Install piston and connecting rod assembly to crankshaft.

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

JPBIA0207ZZ

Revision: 2008 October EM-114 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
13. Install connecting rod bearing cap.
• Match the stamped cylinder number marks on connecting rod A
with those on connecting rod bearing cap to install.

A : Sample codes
EM
B : Bearing stopper groove
C : Small-end diameter grade
D : Standard stamp
C
E : Weight grade
F : Cylinder No.
G : Management code
JPBIA0208ZZ D
I : Management code
• Be sure that front mark (H) on connecting rod bearing cap is facing front of the engine.
E
14. Tighten connecting rod bolt as follows:
a. Inspect the outer diameter of connecting rod bolt. Refer to EM-116, "Inspection".
b. Apply engine oil to the threads and seats of connecting rod bolts. F
c. Tighten connecting rod bolts.

: 19.6 N·m (2.0 kg-m, 14 ft-lb) G

d. Then tighten all connecting rod bolts 90 degrees clockwise (angle tightening).
CAUTION:
Always use the angle wrench [SST: KV10112100]. Avoid H
tightening based on visual check alone.
• After tightening connecting rod bolts, check that crankshaft
rotates smoothly. I
• Check the connecting rod side clearance. Refer to EM-116,
"Inspection".
J

SEM953E
K

15. Install baffle plate to main bearing beam.

16. Install new rear oil seal retainer to cylinder block. Refer to EM-94, "REAR OIL SEAL : Removal and Instal- L
lation".
17. Install pilot converter.
• With drift [outer diameter: approximately 33 mm (1.30 in)], M
press-fit as far as it will go.

PBIC0899E P

Revision: 2008 October EM-115 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
• Press-fit pilot converter with its chamfer facing crankshaft as
shown in the figure.

: Crankshaft side

JPBIA0210ZZ

18. Install knock sensors.

• Install knock sensor so that connector faces the rear of the
engine.

A : Bank 1
B : Bank 2
: Engine front

• After installing knock sensor, connect harness connector, and

lay it out to rear of engine.
CAUTION:
• Never tighten mounting bolts while holding connector.
• If any impact by dropping is applied to knock sensor,
replace it with new one.
NOTE:
• 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.

JPBIA0211ZZ

19. Note the following, assemble in the reverse order of disassembly after this step.
Drive plate
• When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive
plate side dowel pin hole.
- If these are not aligned correctly, engine runs roughly and “MIL” turns on.
• Install drive plate (2) and reinforcement plate (3) as shown in
the figure.

1 : Ring gear
4 : Pilot converter
5 : Crankshaft
A : Rounded
: Engine front

• Holding ring gear with the pulley holder (commercial service

tool). JPBIA0212ZZ

• Tighten mounting bolts crosswise over several times.

Inspection INFOID:0000000004556095

CRANKSHAFT END PLAY

Revision: 2008 October EM-116 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial A
indicator.

Standard and limit : Refer to EM-137, EM

"Cylinder Block".
• If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft C
also.
EMQ0196D

D
CONNECTING ROD SIDE CLEARANCE
• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A).
E
Standard and limit : Refer to EM-137,
"Cylinder Block".
F
• If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the limit, replace crankshaft
also.
G

JPBIA0536ZZ

PISTON TO PISTON PIN OIL CLEARANCE H

Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer (A). I

Standard : Refer to EM-137, "Cylinder Block".

J

JPBIA0217ZZ
L
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer (A).
M
Standard : Refer to EM-137, "Cylinder Block".

JPBIA0218ZZ

Piston to Piston Pin Oil Clearance P

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

Standard : Refer to EM-137, "Cylinder Block".

• If the calculated value is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly, refer to EM-126, "Description".
NOTE:
• Piston is available together with piston pin as assembly.

Revision: 2008 October EM-117 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
piston pin grades can be selected. (Only “0” grade is available.)
PISTON RING SIDE CLEARANCE
• Measure the side clearance of piston ring (1) and piston ring
groove with a feeler gauge (C).

A : NG
B : OK

Standard and limit : Refer to EM-137,

"Cylinder Block".
• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also. JPBIA0219ZZ

PISTON RING END GAP

• Check that the cylinder bore inner diameter is within the specification. Refer to EM-137, "Cylinder Block".
• Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert piston ring until middle of cylinder with piston, and mea-
sure the piston ring end gap with a feeler gauge (B).

A : Press-fit
C : Measuring point

Standard and limit : Refer to EM-137, "Cylinder Block".

• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, rebore cylinder and use JPBIA0220ZZ
oversize piston and piston rings.
CONNECTING ROD BEND AND TORSION
• Check with a connecting rod aligner.

A : Bend
B : Torsion
C : Feeler gauge

Bend limit
: Refer to EM-137, "Cylinder Block".
Torsion limit
• If it exceeds the limit, replace connecting rod assembly.

JPBIA0221ZZ

CONNECTING ROD BIG END DIAMETER

Revision: 2008 October EM-118 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
• Install connecting rod bearing cap without installing connecting rod
bearing, and tightening connecting rod bolts to the specified A
torque. Refer to EM-108, "Disassembly and Assembly" for the
tightening procedure.
EM
1 : Connecting rod
• Measure the inner diameter of connecting rod big end with an
inside micrometer.
C
Standard : Refer to EM-137, "Cylinder Block".
JPBIA0222ZZ
• If out of the standard, replace connecting rod assembly. D
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
E
Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).

Standard : Refer to EM-137, "Cylinder Block". F

H
JPBIA0223ZZ

Piston Pin Outer Diameter

Measure the outer diameter of piston pin with a micrometer (A). I

Standard : Refer to EM-137, "Cylinder Block".

J

JPBIA0218ZZ L
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter) M

Standard and limit : Refer to EM-137, "Cylinder Block".

• If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin N
assembly.
• If replacing piston and piston pin assembly, refer to EM-126, "Description".
• If replacing connecting rod assembly, refer to EM-127, O
"Connecting Rod Bearing" to select the connecting rod bearing.

A : Sample codes
P
B : Bearing stopper groove
C : Small-end diameter grade
D : Standard stamp
E : Weight grade
F : Cylinder No.
G : Management code
JPBIA0208ZZ

Revision: 2008 October EM-119 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
H : Front mark
I : Management code

Factory installed parts grading:

• Service parts apply only to grade “0”.

A : Piston grade number

B : Front mark
C : Piston pin grade number
D : Identification code

JPBIA2199ZZ

Unit: mm (in)

Grade 0 1
Connecting rod bushing inner diameter * 22.000 - 22.006 (0.8661 - 0.8664) 22.006 - 22.012 (0.8664 - 0.8666)
Piston pin hole diameter 21.993 - 21.999 (0.8659 - 0.8661) 21.999 - 22.005 (0.8661 - 0.8663)
Piston pin outer diameter 21.989 - 21.995 (0.8657 - 0.8659) 21.995 - 22.001 (0.8659 - 0.8662)
*: After installing in connecting rod

CYLINDER BLOCK DISTORTION

• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
• Measure the distortion on the cylinder block upper face at some
different points in six directions (C), (D), (E), (F), (G), and (H) with a
straightedge (A) and a feeler gauge (B).

Limit : Refer to EM-137, "Cylinder Block".

• If it exceeds the limit, replace cylinder block.

JPBIA0224ZZ

MAIN BEARING HOUSING INNER DIAMETER

• Install main bearing caps (2) and main bearing beam without
installing main bearings, and tighten main bearing cap bolts to the
specified torque. Refer to EM-108, "Disassembly and Assembly"
for the tightening procedure.
• Measure the inner diameter of main bearing housing with a bore
gauge.

Standard : Refer to EM-137, "Cylinder Block".

• If out of the standard, replace cylinder block (1) and main bearing
caps as assembly.
NOTE: JPBIA0225ZZ

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

machined together with main bearing caps.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore inner Diameter

Revision: 2008 October EM-120 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
• Using a bore gauge, measure cylinder bore for wear, out-of-round
and taper at six different points on each cylinder. [(A) and (B) direc- A
tions at (C), (D), and (E)] is in longitudinal direction of engine.

f : 10 mm (0.39 in) EM
g : 60 mm (2.36 in)
h : 120 mm (4.72 in)
C
Standard and limit : Refer to EM-137, "Cylinder Block".
JPBIA0226ZZ

D
• If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or rebore the inner
wall. E
• Oversize piston is provided. When using oversize piston, rebore
cylinder so that the clearance of the piston to cylinder bore satis-
fies the standard.
CAUTION: F
When using oversize piston, use oversize pistons for all cylin-
ders with oversize piston rings.
G
Oversize (O/S) : 0.2 mm (0.008 in) SEM843E

Piston Skirt Diameter

Measure the outer diameter of piston skirt with a micrometer (A). H

Measure point
: Refer to EM-137, "Cylinder Block". I
Standard

K
JPBIA0227ZZ

Piston-to-Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter L
[direction (B), position (D)].

A : Direction A
C : Position C
M
E : Position E
f : 10 mm (0.39 in)
N
g : 60 mm (2.36 in)
h : 120 mm (4.72 in)
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diame- JPBIA0226ZZ
O
ter).

Standard and limit : Refer to EM-137, "Cylinder Block".

P
• If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to EM-126, "Piston".
Reboring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.

Rebored size calculation: D = A + B – C

where,

Revision: 2008 October EM-121 Z51

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

Standard : Refer to EM-137, "Cylinder Block".

• If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to EM-
128, "Main Bearing".
CRANKSHAFT PIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft pin journal with a
micrometer (A).

Standard : Refer to EM-137, "Cylinder Block".

• If out of the standard, measure the connecting rod bearing oil
clearance. Then use undersize bearing. Refer to EM-127,
"Connecting Rod Bearing".

JPBIA0228ZZ

CRANKSHAFT OUT-OF-ROUND AND TAPER

• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in the dimensions
between (d) and (c) at (a) and (b).
• Taper is indicated by the difference in the dimensions between.

Limit : Refer to EM-137, "Cylinder Block".

• If the measured value exceeds the limit, correct or replace crank-
shaft.
• If corrected, measure the bearing oil clearance of the corrected
main journal and/or pin journal. Then select the main bearing and/ JPBIA0229ZZ

or connecting rod bearing. Refer to EM-128, "Main Bearing" and/

or EM-127, "Connecting Rod Bearing".
CRANKSHAFT RUNOUT
• Place V-block on precise flat table, and support the journals on the both end of crankshaft.

Revision: 2008 October EM-122 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
• Place a dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on a A
dial indicator. (Total indicator reading)

Standard and limit : Refer to EM-137, EM

"Cylinder Block".
• If it exceeds the limit, replace crankshaft.
C

SEM346D

D
CONNECTING ROD BEARING OIL CLEARANCE
Method by Calculation
• Install connecting rod bearings (1) to connecting rod (2) and con- E
necting rod cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-108, "Disassembly and Assembly" for the
tightening procedure.
• Measure the inner diameter of connecting rod bearing with an F
inside micrometer.
(Oil clearance) = (Connecting rod bearing inner diameter) – (Crank-
shaft pin journal diameter) G

Standard and limit : Refer to EM-140,

"Connecting Rod Bearing". JPBIA0230ZZ H
• If the calculated value exceeds the limit, select proper connecting
rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the
specified bearing oil clearance. Refer to EM-127, "Connecting Rod Bearing". I
Method of Using Plastigage
• Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil J
holes.
• Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting
rod bolts to the specified torque. Refer to EM-108, "Disassembly and Assembly" for the tightening proce-
dure. K
CAUTION:
Never rotate crankshaft.
• Remove connecting rod bearing cap and bearings, and using the L
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
M
same as that described in the “Method by Calculation”.

JPBIA0231ZZ O
MAIN BEARING OIL CLEARANCE
Method by Calculation P

Revision: 2008 October EM-123 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
• Install main bearings (3) to cylinder block (1) and main bearing
caps (2), and main bearing cap bolts with main bearing beam to
the specified torque. Refer to EM-108, "Disassembly and Assem-
bly" for the tightening procedure.
• Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main
journal diameter)

Standard and limit : Refer to EM-139, "Main Bearing".

• If the calculated value exceeds the limit, select proper main bear-
ing according to main bearing inner diameter and crankshaft main JPBIA0232ZZ

journal diameter to obtain the specified bearing oil clearance.

Refer to EM-128, "Main Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install main bearing to cylinder block and main bearing caps, and tighten main bearing cap bolts with main
bearing beam to the specified torque. Refer to EM-108, "Disassembly and Assembly" for the tightening pro-
cedure.
CAUTION:
Never rotate crankshaft.
• Remove main bearing caps and bearings, and using the scale 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”.

JPBIA0231ZZ

MAIN BEARING CRUSH HEIGHT

• When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of
bearing must protrude. Refer to EM-108, "Disassembly and
Assembly" for the tightening procedure.

A : Crush height

Standard : There must be crush height.

• If the standard is not met, replace main bearings.
JPBIA0233ZZ

CONNECTING ROD BEARING CRUSH HEIGHT

• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings (1) installed,
the tip end of bearing must protrude. Refer to EM-108, "Disassem-
bly and Assembly" for the tightening procedure.

A : Crush height

Standard : There must be crush height.

• If the standard is not met, replace connecting rod bearings.
JPBIA0233ZZ

Revision: 2008 October EM-124 Z51

 CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
MAIN BEARING CAP BOLT OUTER DIAMETER
• Measure the outer diameters (c), (d) at two positions as shown in A
the figure.

a : 20 mm (0.79 in) EM
b : 30 mm (1.18 in)
e : 10 mm (0.39 in)
• If reduction appears in (a) range, regard it (c). C

Limit [(d) – (c)] : 0.11 mm (0.0043 in)

• If it exceeds the limit (large difference in dimensions), replace main JPBIA0234ZZ D
bearing cap bolt with new one.
CONNECTING ROD BOLT OUTER DIAMETER
E
• Measure the outer diameter (d) at position shown in the figure.
• If the reduction appears in a position other than (d), regard it as (d).

Standard : 7.90 - 8.00 mm (0.3110 - 0.3150 in) F

Limit : 7.75 mm (0.3051 in)
• When (d) exceeds the limit (when it becomes thinner), replace
G
connecting rod bolt with new one.

H
PBIC0912E

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

JPBIA0192ZZ L
OIL JET
• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs. M
• If it is not satisfied, clean or replace oil jet.
OIL JET RELIEF VALVE
• Using a clean plastic stick, press check valve in oil jet relief valve. N
Check that valve moves smoothly with proper reaction force.
• If it is not satisfied, replace oil jet relief valve.
O

EMU0468D

Revision: 2008 October EM-125 Z51

 HOW TO SELECT PISTON AND BEARING
< DISASSEMBLY AND ASSEMBLY >
HOW TO SELECT PISTON AND BEARING
Description INFOID:0000000004556096

Selection points Selection parts Selection items Selection methods

Determined by match of cylin-
der block bearing housing
Between cylinder block and Main bearing grade grade (inner diameter of hous-
Main bearing
crankshaft (bearing thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block and pis- Piston grade Piston grade = cylinder bore
(Piston is available together
ton (piston skirt diameter) grade (inner diameter of bore)
with piston pin as assembly.)
Between piston and connecting
— — —
rod*
*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is available.) The
information at the shipment from the plant is described as a reference.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
Piston INFOID:0000000004556097

WHEN NEW CYLINDER BLOCK IS USED

Check the cylinder bore grade (“1”, “2” or “3”) on rear side of cylinder
block, and select piston of the same grade.
NOTE:
Piston is available with piston pin as a set for the service part. (Only
“0” grade piston pin is available.)

SEM756G

WHEN NEW CYLINDER BLOCK IS REUSED

1. Measure the cylinder bore inner diameter. Refer to EM-116, "Inspection".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “PISTON SELECTION TABLE”.

Revision: 2008 October EM-126 Z51

 HOW TO SELECT PISTON AND BEARING
< DISASSEMBLY AND ASSEMBLY >
3. Select piston of the same grade.
A
A : Piston grade number
B : Front mark
C : Piston pin grade number EM
D : Identification code

JPBIA2199ZZ

D
PISTON SELECTION TABLE
Unit: mm (in)

Grade 1 2 3 E
95.500 - 95.510 95.510 - 95.520 95.520 - 95.530
Cylinder bore inner diameter
(3.7598 - 3.7602) (3.7602 - 3.7606) (3.7606 - 3.7610)
95.480 - 95.490 95.490 - 95.500 95.500 - 95.510 F
Piston skirt diameter
(3.7590 - 3.7594) (3.7594 - 3.7598) (3.7598 - 3.7602)
NOTE:
• Piston is available together with piston pin as assembly. G
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no pis-
ton pin grades can be selected. (Only “0” grade is available.)
• No second grade mark is available on piston.
H
Connecting Rod Bearing INFOID:0000000004556098

WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED I

• Check pin diameter grade (“0”, “1” or “2”) on front of crankshaft,
and select connecting rod bearing of the same grade.
J
A : Journal diameter grade No. 1
B : Journal diameter grade No. 2
C : Journal diameter grade No. 3
K
D : Journal diameter grade No. 4
E : Pin diameter grade No. 1
F : Pin diameter grade No. 2
L
G : Pin diameter grade No. 3
JPBIA0269ZZ
H : Pin diameter grade No. 4
I : Pin diameter grade No. 5
M
J : Pin diameter grade No. 6
K : Identification
NOTE: N
There is no grading for connecting rod big end diameter.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
O
1. Measure the connecting rod big end diameter. Refer to EM-116, "Inspection".
2. Check that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to EM-116, "Inspection".
P
4. Determine the grade of crankshaft pin diameter grade by corresponding to the measured dimension in
“Crankshaft pin journal diameter” column of “CONNECTING ROD BEARING SELECTION TABLE”.
5. Select connecting rod bearing of the same grade.
CONNECTING ROD BEARING SELECTION TABLE
Unit: mm (in)

Connecting rod big end diameter 55.000 - 55.013 (2.1654 - 2.1659)

Revision: 2008 October EM-127 Z51

 HOW TO SELECT PISTON AND BEARING
< DISASSEMBLY AND ASSEMBLY >
Unit: mm (in)

Crankshaft Connecting rod bearing

Crankshaft pin journal diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
51.968 - 51.974 (2.0460 - 2.0462) 0 1.500 - 1.503 (0.0591 - 0.0592) STD A Black
51.962 - 51.968 (2.0457 - 2.0460) 1 1.503 - 1.506 (0.0592 - 0.0593) STD B Brown
51.956 - 51.962 (2.0455 - 2.0457) 2 1.506 - 1.509 (0.0593 - 0.0594) STD C Green

CONNECTING ROD BEARING GRADE TABLE

Connecting rod bearing grade table : Refer to EM-140, "Connecting Rod Bearing".

UNDERSIZE BEARING USAGE GUIDE

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

Bearing under- : Refer to EM-140,

size table "Connecting Rod Bearing".

JPBIA0216ZZ

Main Bearing INFOID:0000000004556099

WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED

1. “MAIN BEARING SELECTION TABLE” rows correspond to
bearing housing grade on rear left side of cylinder block.

SEM756G

2. “MAIN BEARING SELECTION TABLE” columns correspond to

journal diameter grade on front side of crankshaft.

A : Journal diameter grade No. 1

B : Journal diameter grade No. 2
C : Journal diameter grade No. 3
D : Journal diameter grade No. 4
E : Pin diameter grade No. 1
F : Pin diameter grade No. 2
G : Pin diameter grade No. 3
JPBIA0269ZZ
H : Pin diameter grade No. 4
I : Pin diameter grade No. 5

Revision: 2008 October EM-128 Z51

 HOW TO SELECT PISTON AND BEARING
< DISASSEMBLY AND ASSEMBLY >
J : Pin diameter grade No. 6
K : Identification code A

3. Select main bearing grade at the point where selected row and column meet in “MAIN BEARING SELEC-
TION TABLE”. EM
4. Apply sign at crossing in above step 3 to “MAIN BEARING GRADE TABLE”.
NOTE:
• “MAIN BEARING GRADE TABLE” applies to all journals.
• Service parts is available as a set of both upper and lower. C

WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED

1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer D
to EM-116, "Inspection".
2. Correspond the measured dimension in “Cylinder block main bearing housing inner diameter” row of
“MAIN BEARING SELECTION TABLE”. E
3. Correspond the measured dimension in “Crankshaft main journal diameter” column of “MAIN BEARING
SELECTION TABLE”.
4. Follow step 3 and later in “When New Cylinder Block and Crankshaft are Used”. F
MAIN BEARING SELECTION TABLE

PBIC5332E

MAIN BEARING GRADE TABLE (ALL JOURNALS)

Main bearing grade table (All journals) : Refer to EM-139, "Main Bearing".

Revision: 2008 October EM-129 Z51

 HOW TO SELECT PISTON AND BEARING
< DISASSEMBLY AND ASSEMBLY >
UNDERSIZE BEARING USAGE GUIDE
• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-
size (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)].

Bearing undersize : Refer to EM-139,

table "Main Bearing".

JPBIA0216ZZ

Revision: 2008 October EM-130 Z51

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000004556100
EM

GENERAL SPECIFICATIONS
C
Cylinder arrangement V-6

Displacement cm3 (cu in) 3,498 (213.45)

Bore and stroke mm (in) 95.5 x 81.4 (3.760 x 3.205) D
Valve arrangement DOHC
Firing order 1-2-3-4-5-6
E
Compression 2
Number of piston rings
Oil 1
Number of main bearings 4 F
Compression ratio 10.3
Standard 1,275 (12.8, 13.0, 185)
Compression pressure G
Minimum 981 (9.8, 10.0, 142)
kPa (bar, kg/cm2, psi)/300 rpm
Differential limit between cylinders 98 (1.0, 1.0, 14)
H

Cylinder number
J

K
SEM713A

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

PBIC0187E
O
Unit: degree
a b c d e f
10 70 P
240 240 10 50
ATDC ATDC

Drive Belt INFOID:0000000004556101

DRIVE BELT

Revision: 2008 October EM-131 Z51

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)

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

Spark Plug INFOID:0000000004556102

SPARK PLUG
Unit: mm (in)

Make DENSO
Standard type FXE22HR11
Standard 1.1 (0.043)
Gap
Limit 1.4 (0.055)

Intake Manifold INFOID:0000000004556103

INTAKE MANIFOLD
Unit: mm (in)

Items Limit
Surface distortion Intake manifold 0.1 (0.004)

Exhaust Manifold INFOID:0000000004556104

EXHAUST MANIFOLD
Unit: mm (in)

Items Limit
Surface distortion Exhaust manifold 0.3 (0.012)

Camshaft INFOID:0000000004556105

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 0.035 - 0.076 (0.0014 - 0.0030)
No. 1 26.000 - 26.021 (1.0236 - 1.0244) —
Camshaft bracket inner diameter
No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) —
No. 1 25.935 - 25.955 (1.0211 - 1.0218) —
Camshaft journal diameter
No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) —
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)
Intake 45.465 - 45.655 (1.7900 - 1.7974) 0.2 (0.008)*1
Camshaft cam height “A”
Exhaust 45.475 - 45.665 (1.7904 - 1.7978) 0.2 (0.008)*1

Camshaft runout [TIR*2] Less than 0.02 (0.0008) 0.05 (0.0020)

Revision: 2008 October EM-132 Z51

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Camshaft sprocket runout [TIR*2] — 0.15 (0.0059)
A

EM

D
SEM671

*1: Cam wear limit E

*2: Total indicator reading

VALVE LIFTER
Unit: mm (in)
F

Items Standard
Valve lifter outer diameter 33.980 - 33.990 (1.3378 - 1.3382) G
Valve lifter hole diameter 34.000 - 34.016 (1.3386 - 1.3392)
Valve lifter clearance 0.010 - 0.036 (0.0004 - 0.0014)
H
VALVE CLEARANCE
Unit: mm (in)

Items Cold Hot* (reference data) I

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)
J
*: Approximately 80°C (176°F)

AVAILABLE VALVE LIFTER

Unit: mm (in) K
Identification (stamped) mark Thickness
788 7.88 (0.3102)
L
790 7.90 (0.3110)
792 7.92 (0.3118)
794 7.94 (0.3126) M
796 7.96 (0.3134)
798 7.98 (0.3142)
800 8.00 (0.3150) N
802 8.02 (0.3157)
804 8.04 (0.3165)
O
806 8.06 (0.3173)
808 8.08 (0.3181)
810 8.10 (0.3189) P
812 8.12 (0.3197)
814 8.14 (0.3205)
816 8.16 (0.3213)
818 8.18 (0.3220)
820 8.20 (0.3228)

Revision: 2008 October EM-133 Z51

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Identification (stamped) mark Thickness
822 8.22 (0.3236)
824 8.24 (0.3244)
826 8.26 (0.3252)
828 8.28 (0.3260)
830 8.30 (0.3268)
832 8.32 (0.3276)
834 8.34 (0.3283)
836 8.36 (0.3291)
838 8.38 (0.3299)
840 8.40 (0.3307)

SEM758G

Cylinder Head INFOID:0000000004556106

CYLINDER HEAD
Unit: mm (in)

Items Standard Limit

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

PBIC0924E

VALVE DIMENSIONS

Revision: 2008 October EM-134 Z51

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)
A

EM

D
SEM188

Intake 36.6 - 36.9 (1.441 - 1.453)

Valve head diameter “D” E
Exhaust 30.2 - 30.5 (1.189 - 1.201)
Intake 97.13 (3.8240)
Valve length “L”
Exhaust 94.67 (3.7272)
F
Intake 5.965 - 5.980 (0.2348 - 0.2354)
Valve stem diameter “d”
Exhaust 5.962 - 5.970 (0.2347 - 0.2350)
Intake G
Valve seat angle “α” 45°15′ - 45°45′
Exhaust
Intake 1.1 (0.043)
Valve margin “T” H
Exhaust 1.3 (0.051)
Valve margin “T” limit 0.5 (0.020)
Valve stem end surface grinding limit 0.2 (0.008) I

VALVE GUIDE
Unit: mm (in)
J

SEM950E

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

Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014) O
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Items Standard Limit
P
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Valve guide clearance
Exhaust 0.030 - 0.056 (0.0012 - 0.0022) 0.09 (0.0035)
Projection length “L” 12.6 - 12.8 (0.496 - 0.504)

VALVE SEAT

Revision: 2008 October EM-135 Z51

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)

PBIC2745E

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

Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164)
Cylinder head seat recess diameter “D”
Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)
Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202)
Valve seat outer diameter “d”
Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676)
Intake 0.081 - 0.113 (0.0032 - 0.0044)
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038)
Intake 34.6 (1.362)
Diameter “d1”*1
Exhaust 27.7 (1.091)
Intake 35.9 - 36.4 (1.413 - 1.433)
Diameter “d2”*2
Exhaust 29.3 - 29.8 (1.154 - 1.173)
Intake 60°
Angle “α1”
Exhaust 60°
Intake 88°45′ - 90°15′
Angle “α2”
Exhaust 88°45′ - 90°15′
Intake 120°
Angle “α3”
Exhaust 120°
Intake 1.0 - 1.4 (0.039 - 0.055)
Contacting width “W”*3
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Intake 5.9 - 6.0 (0.232 - 0.236) 5.0 - 5.1 (0.197 - 0.201)
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.9 - 5.0 (0.193 - 0.197)
Depth “H” 6.0 (0.236)

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

VALVE SPRING

Items Standard
Free height 47.07 mm (1.8531 in)
Installation height 37.00 mm (1.4567 in)
Installation load 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)
Height during valve open 27.20 mm (1.0709 in)
Load with valve open 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb)

Revision: 2008 October EM-136 Z51

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)

Items Limit A
Squareness 2.1 (0.083)

Cylinder Block INFOID:0000000004556107 EM

CYLINDER BLOCK
Unit: mm (in) C

JPBIA2238GB

Standard Less than 0.03 (0.0012) G

Surface flatness
Limit 0.1 (0.004)
Main bearing housing inner diameter Standard 63.993 - 64.017 (2.5194 - 2.5203) H
Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602)
Standard Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606)
Cylinder bore Inner diameter
Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610) I
Wear limit 0.2 (0.008)
Out-of-round 0.015 (0.0006)
Limit J
Taper 0.010 (0.0004)
Grade No. A 63.993 - 63.994 (2.5194 - 2.5194)
Grade No. B 63.994 - 63.995 (2.5194 - 2.5195)
K
Grade No. C 63.995 - 63.996 (2.5195 - 2.5195)
Grade No. D 63.996 - 63.997 (2.5195 - 2.5196)
Grade No. E 63.997 - 63.998 (2.5196 - 2.5196)
Grade No. F 63.998 - 63.999 (2.5196 - 2.5196) L
Grade No. G 63.999 - 64.000 (2.5196 - 2.5197)
Grade No. H 64.000 - 64.001 (2.5197 - 2.5197)
Grade No. J 64.001 - 64.002 (2.5197 - 2.5198)
Grade No. K 64.002 - 64.003 (2.5198 - 2.5198) M
Grade No. L 64.003 - 64.004 (2.5198 - 2.5198)
Grade No. M 64.004 - 64.005 (2.5198 - 2.5199)
Main bearing housing inner diameter grade (Without bearing)
Grade No. N 64.005 - 64.006 (2.5199 - 2.5199)
Grade No. P 64.006 - 64.007 (2.5199 - 2.5200) N
Grade No. R 64.007 - 64.008 (2.5200 - 2.5200)
Grade No. S 64.008 - 64.009 (2.5200 - 2.5200)
Grade No. T 64.009 - 64.010 (2.5200 - 2.5201)
Grade No. U 64.010 - 64.011 (2.5201 - 2.5201) O
Grade No. V 64.011 - 64.012 (2.5201 - 2.5202)
Grade No. W 64.012 - 64.013 (2.5202 - 2.5202)
Grade No. X 64.013 - 64.014 (2.5202 - 2.5202)
P
Grade No. Y 64.014 - 64.015 (2.5202 - 2.5203)
Grade No. 4 64.015 - 64.016 (2.5203 - 2.5203)
Grade No. 7 64.016 - 64.017 (2.5203 - 2.5203)
Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)

AVAILABLE PISTON

Revision: 2008 October EM-137 Z51

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)

SEM882E

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

Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) —
Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) —
Piston skirt diameter “A”
Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602) —
Service — 95.680 - 95.710 (3.7669 - 3.7681)
Items Standard Limit
“a” dimension 38.0 (1.496) —
Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) —
Piston pin hole diameter
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) —
Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)

PISTON RING
Unit: mm (in)
Items Standard Limit
Top 0.045 - 0.080 (0.0018 - 0.0031) 0.11 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.065 - 0.125 (0.0026 - 0.0049) —
Top 0.23 - 0.28 (0.0091 - 0.0110) 0.49 (0.0139)
End gap 2nd 0.33 - 0.43 (0.0130 - 0.0169) 0.90 (0.0354)
Oil (rail ring) 0.20 - 0.45 (0.0079 - 0.0177) 0.95 (0.0374)

PISTON PIN
Unit: mm (in)

Items Standard Limit

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

CONNECTING ROD
Unit: mm (in)

Items Standard Limit

Center distance 144.15 - 144.25 (5.68 - 5.68) —
Bend [per 100 (3.94)] — 0.15 (0.0059)
Torsion [per 100 (3.94)] — 0.30 (0.0118)
Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664) —
Connecting rod bushing inner diameter*
Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666) —

Revision: 2008 October EM-138 Z51

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Connecting rod big end diameter (Without bearing) 55.000 - 55.013 (2.1654 - 2.1659) —
A
Side clearance 0.20 - 0.35 (0.0079 - 0.0138) 0.40 (0.0157)
*: After installing in connecting rod

CRANKSHAFT EM
Unit: mm (in)

SEM645 SBIA0535E F
Grade No. A 59.975 - 59.974 (2.3612 - 2.3612)
Grade No. B 59.974 - 59.973 (2.3612 - 2.3611)
Grade No. C 59.973 - 59.972 (2.3611 - 2.3611) G
Grade No. D 59.972 - 59.971 (2.3611 - 2.3611)
Grade No. E 59.971 - 59.970 (2.3611 - 2.3610)
Grade No. F 59.970 - 59.969 (2.3610 - 2.3610)
Grade No. G 59.969 - 59.968 (2.3610 - 2.3609) H
Grade No. H 59.968 - 59.967 (2.3609 - 2.3609)
Grade No. J 59.967 - 59.966 (2.3609 - 2.3609)
Grade No. K 59.966 - 59.965 (2.3609 - 2.3608)
Grade No. L 59.965 - 59.964 (2.3608 - 2.3608) I
Grade No. M 59.964 - 59.963 (2.3608 - 2.3607)
Main journal diameter. “Dm” grade Standard
Grade No. N 59.963 - 59.962 (2.3607 - 2.3607)
Grade No. P 59.962 - 59.961 (2.3607 - 2.3607)
J
Grade No. R 59.961 - 59.960 (2.3607 - 2.3606)
Grade No. S 59.960 - 59.959 (2.3606 - 2.3606)
Grade No. T 59.959 - 59.958 (2.3606 - 2.3605)
Grade No. U 59.958 - 59.957 (2.3605 - 2.3605) K
Grade No. V 59.957 - 59.956 (2.3605 - 2.3605)
Grade No. W 59.956 - 59.955 (2.3605 - 2.3604)
Grade No. X 59.955 - 59.954 (2.3604 - 2.3604)
Grade No. Y 59.954 - 59.953 (2.3604 - 2.3603) L
Grade No. 4 59.953 - 59.952 (2.3603 - 2.3603)
Grade No. 7 59.952 - 59.951 (2.3603 - 2.3603)
Grade No. 0 51.968 - 51.974 (2.0460 - 2.0462) M
Pin journal diameter. “Dp” grade Standard Grade No. 1 51.962 - 51.968 (2.0457 - 2.0460)
Grade No. 2 51.956 - 51.962 (2.0445 - 2.0457)
Center distance “r” 40.66 - 40.74 (1.6008 - 1.6039) N
Taper (Difference between “A” and “B”) 0.002 (0.0001)
Limit
Out-of-round (Difference between “X” and “Y”) 0.002 (0.0001)
O
Standard Less than 0.05 (0.0020)
Crankshaft runout [TIR*]
Limit 0.10 (0.0039)
Standard 0.10 - 0.25 (0.0039 - 0.0098) P
Crankshaft end play
Limit 0.30 (0.0118)
*: Total indicator reading

Main Bearing INFOID:0000000004556108

MAIN BEARING

Revision: 2008 October EM-139 Z51

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)

PBIC2619E

Grade number Thickness Width Identification color Remarks

0 2.000 - 2.003 (0.0787 - 0.0789) Black
1 2.003 - 2.006 (0.0789 - 0.0790) Brown
2 2.006 - 2.009 (0.0790 - 0.0791) Green
3 2.009 - 2.012 (0.0791 - 0.0792) Yellow Grade is the same
for upper and lower
4 2.012 - 2.015 (0.0792 - 0.0793) Blue bearings.
5 2.015 - 2.018 (0.0793 - 0.0794) Pink
6 2.018 - 2.021 (0.0794 - 0.0796) Purple
7 2.021 - 2.024 (0.0796 - 0.0797) White
UPR 2.003 - 2.006 (0.0789 - 0.0790) Brown
01
LWR 2.000 - 2.003 (0.0787 - 0.0789) Black
UPR 2.006 - 2.009 (0.0790 - 0.0791) 19.9 - 20.1 Green
12
LWR 2.003 - 2.006 (0.0789 - 0.0790) (0.783 - 0.791) Brown
UPR 2.009 - 2.012 (0.0791 - 0.0792) Yellow
23
LWR 2.006 - 2.009 (0.0790 - 0.0791) Green
UPR 2.012 - 2.015 (0.0792 - 0.0793) Blue Grade and color are
34 different for upper
LWR 2.009 - 2.012 (0.0791 - 0.0792) Yellow and lower bearings.
UPR 2.015 - 2.018 (0.0793 - 0.0794) Pink
45
LWR 2.012 - 2.015 (0.0792 - 0.0793) Blue
UPR 2.018 - 2.021 (0.0794 - 0.0796) Purple
56
LWR 2.015 - 2.018 (0.0793 - 0.0794) Pink
UPR 2.021 - 2.024 (0.0796 - 0.0797) White
67
LWR 2.018 - 2.021 (0.0794 - 0.0796) Purple

UNDERSIZE
Unit: mm (in)

Items Thickness Main journal diameter

0.25 (0.0098) 2.132 - 2.140 (0.0839 - 0.0843) Grind so that bearing clearance is the specified value.

MAIN BEARING OIL CLEARANCE

Unit: mm (in)

Items Standard Limit

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

Connecting Rod Bearing INFOID:0000000004556109

CONNECTING ROD BEARING

Revision: 2008 October EM-140 Z51

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)

Grade number Thickness Identification color (mark) A

A 1.500 - 1.503 (0.0591 - 0.0592) Black
B 1.503 - 1.506 (0.0592 - 0.0593) Brown
EM
C 1.506 - 1.509 (0.0593 - 0.0594) Green

UNDERSIZE
Unit: mm (in) C
Items Thickness Crank pin journal diameter
0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643) Grind so that bearing clearance is the specified value.
D
CONNECTING ROD BEARING OIL CLEARANCE
Unit: mm (in)

Items Standard Limit E

Connecting rod bearing oil clearance 0.020 - 0.045 (0.0008 - 0.0018)* 0.070 (0.0028)
*: Actual clearance
F

Revision: 2008 October EM-141 Z51