Em PDF

ENGINE MECHANICAL GI
MODIFICATION NOTICE:
SECTION EM MA
LC
I Drive belt deflection of QG series engine has been modified on models produced after July 2001 (Except
for Europe). EC
I QG13DE engine with three way catalyst has been added (For the Middle East).
FE
CONTENTS
CL
QG Components...............................................................40
Removal.....................................................................41 MT
PRECAUTIONS ...............................................................5
Disassembly...............................................................43
Parts Requiring Angular Tightening.............................5
Inspection...................................................................43
Liquid Gasket Application Procedure ..........................5
CYLINDER HEAD DISTORTION ...............................43
AT
PREPARATION ...............................................................6 CAMSHAFT VISUAL CHECK ....................................43
Special Service Tools ..................................................6 CAMSHAFT RUNOUT ..............................................44
Commercial Service Tools ...........................................8 CAMSHAFT CAM HEIGHT .......................................44
AX
NOISE, VIBRATION AND HARSHNESS (NVH) CAMSHAFT JOURNAL CLEARANCE ........................44
TROUBLESHOOTING ...................................................10 CAMSHAFT END PLAY............................................45
NVH Troubleshooting - Engine Noise .......................10 CAMSHAFT SPROCKET RUNOUT ...........................45
SU
OUTER COMPONENT PARTS .....................................12 VALVE GUIDE CLEARANCE ....................................46
Removal and Installation ...........................................12 VALVE GUIDE REPLACEMENT ................................46
VALVE SEATS .........................................................47
BR
MEASUREMENT OF COMPRESSION PRESSURE ....21
REPLACING VALVE SEAT FOR SERVICE PARTS ....48
DRIVE BELTS................................................................22
VALVE DIMENSIONS ...............................................49
Checking ....................................................................22 ST
VALVE SPRING .......................................................49
AIR CLEANER...............................................................24
VALVE LIFTER AND VALVE SHIM ............................49
Cleaning and Changing .............................................24 Valve Clearance.........................................................50
VISCOUS PAPER TYPE (EXCEPT FOR THE
RS
CHECKING .............................................................50
MIDDLE EAST) ........................................................24
ADJUSTING ............................................................51
DRY PAPER TYPE (EXCEPT FOR EUROPE) ............24
SPARK PLUG................................................................25
Assembly ...................................................................53 BT
Installation..................................................................53
Checking and Changing ............................................25
ENGINE ASSEMBLY.....................................................57
OIL PAN.........................................................................26 HA
Removal and Installation ...........................................57
Components...............................................................26
REMOVAL ...............................................................58
Removal.....................................................................26 INSTALLATION........................................................60
Installation..................................................................27 Inspection after Installation........................................60 SC
TIMING CHAIN ..............................................................29 CYLINDER BLOCK .......................................................61
Components...............................................................29 Components...............................................................61
Removal.....................................................................30 EL
Removal and Installation ...........................................62
Inspection...................................................................33 Disassembly...............................................................62
Installation..................................................................34 PISTON AND CRANKSHAFT ....................................62 IDX
OIL SEAL.......................................................................38 Inspection...................................................................63
Replacement..............................................................38 PISTON AND PISTON PIN CLEARANCE ..................63
VALVE OIL SEAL .....................................................38 PISTON RING SIDE CLEARANCE ............................64
FRONT OIL SEAL ....................................................38 PISTON RING END GAP..........................................64
REAR OIL SEAL ......................................................39 CONNECTING ROD BEND AND TORSION ...............64
CYLINDER HEAD..........................................................40 CYLINDER BLOCK DISTORTION AND WEAR ...........65
CONTENTS (Cont’d)
PISTON-TO-BORE CLEARANCE ..............................65 NVH Troubleshooting - Engine Noise .......................91
CRANKSHAFT.........................................................66 MEASUREMENT OF COMPRESSION PRESSURE ....92
BEARING CLEARANCE ...........................................67 DRIVE BELTS................................................................94
CONNECTING ROD BUSHING CLEARANCE Inspection...................................................................94
(SMALL END) ..........................................................69
Adjustment .................................................................94
REPLACEMENT OF CONNECTING ROD
AIR CONDITIONER COMPRESSOR BELT ................95
BUSHING (SMALL END) ..........................................69
ALTERNATOR & WATER PUMP BELT .....................95
FLYWHEEL/DRIVE PLATE RUNOUT ........................70
Removal.....................................................................95
Assembly ...................................................................70
Installation..................................................................96
PISTON ..................................................................70
AIR CLEANER...............................................................97
CRANKSHAFT.........................................................71
SERVICE DATA AND SPECIFICATIONS (SDS) .........74 Changing Air Cleaner Filter .......................................97
VISCOUS PAPER TYPE ...........................................97
General Specifications...............................................74
OIL PAN.........................................................................98
Compression Pressure ..............................................74
Components...............................................................98
Belt Deflection............................................................75
Removal.....................................................................98
Spark Plug .................................................................75
Installation................................................................100
EXCEPT FOR EUROPE ...........................................75
FOR EUROPE .........................................................75 TIMING CHAIN ............................................................103
Cylinder Head ............................................................75 Secondary Timing Chain .........................................103
Valve ..........................................................................76 REMOVAL .............................................................103
INSPECTION .........................................................105
VALVE ....................................................................76
INSTALLATION......................................................105
VALVE SPRING .......................................................76
VALVE LIFTER ........................................................76 Primary Timing Chain ..............................................108
VALVE CLEARANCE................................................77 REMOVAL .............................................................109
VALVE GUIDE .........................................................77 INSPECTION ......................................................... 111
AVAILABLE SHIMS ..................................................77 INSTALLATION...................................................... 111
VALVE SEAT ...........................................................80 INTAKE MANIFOLD ....................................................116
VALVE SEAT RESURFACE LIMIT.............................81 Removal and Installation .........................................116
Camshaft and Camshaft Bearing ..............................81 PREPARATIVE WORK ...........................................116
Cylinder Block............................................................82 FUEL PIPING ........................................................117
Piston, Piston Ring and Piston Pin ...........................83 INTAKE MANIFOLD ...............................................117
EGR VOLUME CONTROL VALVE ...........................117
PISTON ..................................................................83
WATER HOSE .......................................................117
PISTON RING .........................................................83
PISTON PIN ............................................................84 Inspection.................................................................118
Connecting Rod .........................................................84 INTAKE MANIFOLD ...............................................118
Crankshaft..................................................................85 Removal and Installation .........................................118
PREPARATIVE WORK ...........................................119
Main Bearing..............................................................85
FUEL PIPING ........................................................119
STANDARD .............................................................85
INTAKE MANIFOLD ...............................................119
UNDERSIZE ............................................................85
EGR VOLUME CONTROL VALVE ...........................119
Connecting Rod Bearing ...........................................86
WATER HOSE .......................................................120
STANDARD SIZE ....................................................86
Inspection.................................................................120
UNDERSIZE ............................................................86
INTAKE MANIFOLD ...............................................120
Bearing Clearance .....................................................86
EXHAUST MANIFOLD (EXCEPT FOR EUROPE) .....121
Miscellaneous Components.......................................86
Removal and Installation .........................................121
YD EXHAUST MANIFOLD ...........................................121
EXHAUST MANIFOLD GASKET .............................122
PRECAUTIONS .............................................................87
Inspection.................................................................122
Parts Requiring Angular Tightening...........................87
EXHAUST MANIFOLD ...........................................122
Liquid Gasket Application Procedure ........................87
CATALYST (FOR EUROPE).......................................123
PREPARATION .............................................................88
Removal and Installation .........................................123
Special Service Tools ................................................88
Commercial Service Tools .........................................90
CATALYST ............................................................123
NOISE, VIBRATION AND HARSHNESS (NVH) GUSSET ...............................................................124
TROUBLESHOOTING ...................................................91
EM-2
CONTENTS (Cont’d)
EXHAUST MANIFOLD, TURBOCHARGER (FOR INSTALLATION......................................................152 GI
EUROPE) .....................................................................125 INSPECTION AFTER INSTALLATION .....................153
Removal and Installation .........................................125 CYLINDER BLOCK .....................................................154
PREPARATIVE WORK ...........................................125 Components.............................................................154 MA
EXHAUST MANIFOLD AND TURBOCHARGER .......125 Removal and Installation .........................................155
EXHAUST MANIFOLD GASKET .............................126 Disassembly.............................................................155
INSPECTION AFTER INSTALLATION .....................126 PISTON AND CRANKSHAFT ..................................155
Disassembly and Assembly.....................................126 Inspection.................................................................158
TURBOCHARGER .................................................126 CRANKSHAFT END PLAY .....................................158
Inspection.................................................................127 CONNECTING ROD SIDE CLEARANCE .................159
LC
EXHAUST MANIFOLD ...........................................127 PISTON AND PISTON PIN CLEARANCE ................159
TURBOCHARGER .................................................127 PISTON RING SIDE CLEARANCE ..........................159
ROCKER COVER ........................................................130 PISTON RING END GAP........................................160
EC
Removal and Installation .........................................130 CONNECTING ROD BEND AND TORSION .............161
PREPARATIVE WORK ...........................................130 CYLINDER BLOCK DISTORTION AND WEAR .........161
PISTON-TO-BORE CLEARANCE ............................162
FE
ROCKER COVER ..................................................130
CYLINDER HEAD........................................................132 CRANKSHAFT.......................................................164
MAIN BEARING HOUSING INNER DIAMETER ........164
Components.............................................................132 CL
BEARING CLEARANCE .........................................164
Removal...................................................................133
MAIN BEARING CRUSH HEIGHT ...........................169
MAIN BEARING CAP BOLT DEFORMATION ...........169 MT
CAMSHAFT ...........................................................133
CONNECTING ROD BUSHING CLEARANCE
CYLINDER HEAD ..................................................134
(SMALL END) ........................................................169
Disassembly.............................................................134
CONNECTING ROD BOLT DEFORMATION ............170 AT
Inspection.................................................................135
FLYWHEEL RUNOUT ............................................170
CYLINDER HEAD DISTORTION .............................135
OIL JET ................................................................170
CAMSHAFT VISUAL CHECK ..................................136
OIL JET RELIEF VALVE .........................................170 AX
CAMSHAFT RUNOUT ............................................136
Assembly .................................................................171
CAMSHAFT CAM HEIGHT .....................................136
PISTON ................................................................171
CAMSHAFT JOURNAL CLEARANCE ......................137
CAMSHAFT END PLAY..........................................137
CRANKSHAFT.......................................................171 SU
REPLACEMENT OF PILOT BUSHING.....................175
CAMSHAFT SPROCKET RUNOUT .........................138
SERVICE DATA AND SPECIFICATIONS (SDS) .......176
VALVE GUIDE CLEARANCE ..................................138
VALVE GUIDE REPLACEMENT ..............................138
General Specifications.............................................176 BR
VALVE SEATS .......................................................139 Compression Pressure ............................................176
REPLACING VALVE SEAT FOR SERVICE PARTS ..139 Belt Deflection..........................................................176
Cylinder Head ..........................................................176
ST
VALVE DIMENSIONS .............................................140
VALVE SPRING .....................................................140 Valve ........................................................................177
VALVE LIFTER AND VALVE SHIM ..........................141 VALVE ..................................................................177 RS
Assembly .................................................................142 VALVE CLEARANCE..............................................177
Installation................................................................142 AVAILABLE SHIMS ................................................177
CYLINDER HEAD GASKET SELECTION .................142 VALVE SPRING .....................................................178 BT
CYLINDER HEAD BOLT DEFORMATION CHECK ...144 VALVE LIFTER ......................................................179
CYLINDER HEAD-TO-BLOCK DIFFERENCE VALVE GUIDE .......................................................179
CHECK .................................................................144 Valve Seat................................................................180 HA
LIQUID GASKET APPLICATION ON REAR CHAIN Camshaft and Camshaft Bearing ............................182
CASE ....................................................................145 Cylinder Block..........................................................183
CYLINDER HEAD INSTALLATION ..........................145 Piston, Piston Ring and Piston Pin .........................184 SC
GLOW PLUG INSTALLATION .................................145 AVAILABLE PISTON ..............................................184
CAMSHAFT INSTALLATION ...................................145 PISTON RING .......................................................185
Valve Clearance.......................................................146 PISTON PIN ..........................................................185 EL
CHECKING ...........................................................146 Connecting Rod .......................................................185
ADJUSTING ..........................................................148 Crankshaft................................................................186
ENGINE ASSEMBLY...................................................150 Available Main Bearing............................................187
IDX
Removal and Installation .........................................150 EXCEPT FOR EUROPE .........................................187
REMOVAL .............................................................151 FOR EUROPE .......................................................187
EM-3
CONTENTS (Cont’d)
UNDERSIZE ..........................................................187 Miscellaneous Components.....................................188
Available Connecting Rod Bearing..........................188 BEARING CLEARANCE .........................................188
CONNECTING ROD BEARING ...............................188
UNDERSIZE ..........................................................188
EM-4
PRECAUTIONS QG
Parts Requiring Angular Tightening
Parts Requiring Angular Tightening NJEM0001

I Use an angle wrench for the final tightening of the following
engine parts: GI
a) Cylinder head bolts
b) Main bearing cap bolts MA
c) Connecting rod cap nuts
I Do not use a torque value for final tightening.
I The torque value for these parts are for a preliminary step.
I Ensure thread and seat surfaces are clean and coated with
engine oil.
LC
Liquid Gasket Application Procedure NJEM0002
1. Use a scraper to remove old liquid gasket from mating EC
surfaces and grooves. Also, completely clean any oil from
these areas.
2. Apply a continuous bead of liquid gasket to mating sur- FE
faces. (Use Genuine Liquid Gasket or equivalent.)
I For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in). CL
I For areas except oil pan, be sure liquid gasket diameter is
2.0 to 3.0 mm (0.079 to 0.118 in).
SEM164F
MT
3. Apply liquid gasket around the inner side of bolt holes
(unless otherwise specified).
4. Assembly should be done within 5 minutes after coating. AT
5. Wait at least 30 minutes before refilling engine oil and
engine coolant.
AX
SU
BR
AEM080
ST
RS
BT
HA
SC
EL
IDX
EM-5
PREPARATION QG
Special Service Tools
Special Service Tools NJEM0003
Tool number
Description
Tool name
ST0501S000 Disassembling and assembling

Engine stand assembly
(1) ST05011000
Engine stand
(2) ST05012000
Base
NT042
Engine attachment Overhauling engine

assembly
(1) KV10106500
Engine attachment
(2) KV10113300
Sub-attachment
NT029
ST10120000 Loosening and tightening cylinder head bolt

Cylinder head bolt a: 13 mm (0.51 in) dia.
wrench b: 12 mm (0.47 in)
c: 10 mm (0.39 in)
NT583
KV10116200 Disassembling valve mechanism

Valve spring compressor
(1) KV10115900
Attachment
NT022
KV10115600 Installing valve oil seal

Valve oil seal drift
NT024
KV10107902 Removing valve oil seal

Valve oil seal puller
NT011
EM-6
PREPARATION QG
Special Service Tools (Cont’d)
Tool number
Description
Tool name
GI
KV101151S0 Changing shims
Lifter stopper set
(1) KV10115110 MA
Camshaft pliers
(2) KV10115120
Lifter stopper
NT041
EM03470000 Installing piston assembly into cylinder bore

Piston ring compressor
LC
EC
NT044
KV10107400 Disassembling and assembling piston pin FE

Piston pin press stand
(1) KV10107310
Center shaft CL
(2) ST13040020
Stand
(3) ST13040030 MT
Spring
(4) KV10107320
Cap AT
(5) ST13040050
Drift
NT013
KV10111100 Removing oil pan AX

Seal cutter
SU
NT046
BR
WS39930000 Pressing the tube of liquid gasket
Tube presser
ST
NT052 RS
KV10112100 Tightening bolts for bearing cap, cylinder head,
Angle wrench etc.
BT
HA
NT014 SC
ST16610001 Removing pilot bushing
Pilot bushing puller
EL
IDX
NT045
EM-7
PREPARATION QG
Tool number
Description
Tool name
KV10117100 Loosening or tightening heated oxygen sensor

Front (heated) oxygen with 22 mm (0.87 in) hexagon nut
sensor wrench
NT379
KV101056S0* Preventing crankshaft from rotating

Rear gear stopper
(1) KV10105620
Adapter
(2) KV10105610
Plate assembly
NT773
Commercial Service Tools NJEM0004
Tool name Description
Spark plug wrench Removing and installing spark plug
NT047
Valve seat cutter set Finishing valve seat dimensions
NT048
Piston ring expander Removing and installing piston ring
NT030
Valve guide drift Removing and installing valve guide

Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
NT015
EM-8
PREPARATION QG
Commercial Service Tools (Cont’d)
Valve guide reamer Reaming valve guide 1 or hole for oversize valve GI
guide 2
Intake & Exhaust:
d1: 5.5 mm (0.217 in) dia. MA
d2: 9.685 mm (0.3813 in) dia.
NT016
Front oil seal drift Installing front oil seal

a: 52 mm (2.05 in) dia.
b: 40 mm (1.57 in) dia. LC
NT049
EC
Rear oil seal drift Installing rear oil seal
a: 103 mm (4.06 in) dia. FE
b: 84 mm (3.31 in) dia.
CL
NT049
Oxygen sensor thread Reconditioning the exhaust system threads before

cleaner installing a new heated oxygen sensor. Use with
MT
anti-seize lubricant shown below.
a: 18 mm dia. with a pitch of 1.5 mm for Zirco-
nia heated Oxygen Sensor AT
b: 12 mm dia. with a pitch of 1.25 mm for Tita-
nia heated Oxygen Sensor
AX
NT778
Anti-seize lubricant (Per- Lubricating heated oxygen sensor thread cleaning SU

matexTM 133AR or tool when reconditioning exhaust system threads
equivalent meeting MIL
specification MIL-A-907) BR
ST
NT779
RS
BT
HA
SC
EL
IDX
EM-9
NJEM0005
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING QG

NVH Troubleshooting — Engine Noise
NVH Troubleshooting — Engine Noise NJEM0005S01

Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine
Location of Type of Before After When Source of Reference
When When While Check item
noise noise warm- warm- start- noise page
idling racing driving
up up ing
Top of Ticking or C A — A B — Tappet Valve clearance EM-50

Engine click noise
Rocket
Cover Cyl- Rattle C A — A B C Camshaft Camshaft journal clear- EM-44
inder Head bearing ance
noise Camshaft runout
Crankshaft Slap or — A — B B — Piston pin Piston and piston pin EM-63, 69

Pulley knock noise clearance
Cylinder Connecting rod bushing
block (Side clearance
of Engine)
Oil pan Slap or A — — B B A Piston slap Piston-to-bore clearance EM-64, 64,
rap noise Piston ring side clearance 65
Piston ring end gap
Connecting rod bend and
torsion
Knock A B C B B B Connecting Connecting rod bearing EM-68, 69

rod-bearing clearance (Big end)
noise Connecting rod bushing
clearance (Small end)
Knock A B — A B C Main bear- Main bearing oil clear- EM-66

ing noise ance
Crankshaft runout
Front of Tapping or A A — B B B Timing Timing chain cracks and EM-33

Engine Tim- ticking chain and wear
ing Chain chain ten- Timing chain tensioner
Cover sioner noise operation
Front of Squeak or A B — B — C Drive belts Drive belts deflection EM-22

Engine fizzing (sticking or
slipping)
Creaking A B A B A B Drive belts Idler pulley bearing

(slipping) operation
Squall or A B — B A B Water pump Water pump operation LC-15

creak noise
A: Closely related B: Related C: Sometimes related —: Not related
EM-10
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING QG
NVH Troubleshooting — Engine Noise (Cont’d)
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
SEM937F
EM-11
OUTER COMPONENT PARTS QG
Removal and Installation
Removal and Installation NJEM0006
SEM843GA
EM-12
Removal and Installation (Cont’d)
1. Oil pressure switch 6. Intake manifold upper support 10. Water pump
2. EGR valve 7. Intake manifold rear supports 11. Water pump pulley
3. EGR tube 8. Oil filter 12. EGR solenoid valve GI
4. Air relief plug 9. Thermostat 13. EGR guide tube
5. Intake manifold
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-13
SEM518GA
1. Throttle position sensor 4. Fuel injector 7. Intake manifold

2. IACV-AAC valve 5. Injector tube 8. Canister purge control valve
3. Throttle body 6. Pressure regulator
EM-14
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
JEM840G
1. Gasket 8. Intake manifold support (engine 15. Air hose HA

2. Harness bracket rear) 16. Air hose
3. Intake manifold assembly 9. Harness bracket 17. Vacuum hose
4. Gasket 10. Intake manifold support (rear) 18. Canister purge control valve SC
5. Throttle body 11. Gasket 19. PCV hose
6. Fuel feed hose 12. EGR guide tube 20. Intake manifold support (engine
7. Fuel return hose 13. Harness bracket front) EL
14. Intake manifold support (front)
IDX
EM-15
JEM841G
1. Intake manifold 6. Accelerator wire bracket 10. Throttle body

2. Electric swirl control valve actuator 7. Intake manifold collector 11. Gasket
3. Gasket 8. Gasket 12. IACV-AAC valve
4. Fuel tube and fuel injector assem- 9. Throttle sensor and throttle valve 13. Purge hose bracket
bly switch
5. Vacuum hose
EM-16
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
SEM099GD
EL
1. Crankshaft pulley 5. Exhaust manifold cover 10. Converter cap
2. Engine coolant temperature sen- 6. Thermal transmitter 11. Converter cover IDX
sor 7. Water drain plug 12. Ignition coil
3. Gasket 8. Heated oxygen sensor 1 (front) 13. Spark plug
4. Exhaust manifold 9. Three way catalyst
EM-17
SEM302GA
1. Oil pressure switch 6. Intake manifold upper support 11. Water pump pulley
2. EGR valve 7. Intake manifold rear supports 12. EGR solenoid valve
3. EGR tube 8. Oil filter 13. EGR guide tube
4. Air relief plug 9. Thermostat 14. EGR gas temperature sensor
5. Intake manifold 10. Water pump
EM-18
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
SEM303GB
EL
1. Throttle position sensor 5. Injector tube 9. Throttle opener
2. IACV-AAC valve 6. Pressure regulator 10. One way valve IDX
3. Throttle body 7. Intake manifold 11. Vacuum tank
4. Fuel injector 8. Canister purge control valve 12. Swirl control solenoid valve
EM-19
SEM304GA
1. Crankshaft pulley 5. Exhaust manifold cover 10. Converter cap

2. Engine coolant temperature sen- 6. Thermal transmitter 11. Converter cover
sor 7. Water drain plug 12. Ignition coil
3. Gasket 8. Heated oxygen sensor 1 (front) 13. Spark plug
4. Exhaust manifold 9. Three way catalyst
EM-20
NJEM0007
MEASUREMENT OF COMPRESSION PRESSURE QG
1. Warm up engine.
2. Turn ignition switch OFF.
3. Release fuel pressure. GI
Refer to EC-526, “Releasing Fuel Pressure”.
4. Remove ignition coils.
5. Remove spark plugs.
MA
I Clean area around plug with compressed air before removing
the spark plug.
LC
6. Attach a compression tester to No. 1 cylinder.
7. Depress accelerator pedal fully to keep throttle valve wide
open.
EC
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown above. FE
I Always use a fully-charged battery to obtain specified
engine speed.
Compression pressure: kPa (bar, kg/cm2, psi)/rpm CL
Except for QG15DE for Europe
Standard MT
SEM973E
1,324 (13.24, 13.5, 192)/350
Minimum
1,128 (11.28, 11.5, 164)/350 AT
Maximum allowable difference between cylinders
98 (0.98, 1.0, 14)/350 AX
QG15DE for Europe
Standard
1,372 (13.720, 13.99, 198.9)/350 SU
Minimum
1,176 (11.759, 11.99, 170.5)/350 BR
AEM308 Maximum allowable difference between cylinders
98 (0.98, 1.0, 14)/350
10. If cylinder compression in one or more cylinders is low, pour a ST
small amount of engine oil into the cylinder through the spark
plug hole and retest compression.
I If adding oil improves cylinder compression, piston rings
RS
may be worn or damaged. If so, replace piston rings after
checking piston. BT
I If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. Refer
to SDS, EM-80. If valve or valve seat is damaged HA
excessively, replace them.
I If compression in any two adjacent cylinders is low and if add-
ing oil does not improve compression, there is leakage past the SC
gasket surface. If so, replace cylinder head gasket.
11. Reinstall spark plugs, ignition coils and fuel pump fuse.
12. Perform “Self-diagnosis Procedure” referring to EC-556, “How to EL
Erase DTC” if any DTC appears.
IDX
EM-21
DRIVE BELTS QG
Checking
Checking NJEM0042
SEM100GA
1. Inspect for cracks, fraying, wear or oil adhesion. If necessary,

replace with a new one.
I When replacing belt, make sure the new belt has the same
number of ribs as the old one.
2. Inspect drive belt deflections by pushing on the belt midway
between pulleys.
Adjust if belt deflections exceed the limit.
Belt deflection:
Unit: mm (in)
Used belt deflection
Applied engine Deflection Deflection

Limit after of new belt
adjustment
6-7 5.5 - 6.5

With air QG13DE 10 (0.39) (0.24 - (0.217 -
condi- 0.28) 0.256)
tioner
compres- 5.3 - 5.7 4.5 - 5.0
sor QG15·16·18DE 8.1 (0.319) (0.209 - (0.177 -
0.224) 0.197)
Alternator
7-9 6-8
Without QG13DE 11 (0.43) (0.28 - (0.24 -
air condi- 0.35) 0.31)
tioner
compres- 6.5 - 7.0 5.5 - 6.1
10.2
sor QG15·16·18DE (0.256 - (0.217 -
(0.402)
0.276) 0.240)
EM-22
DRIVE BELTS QG
Checking (Cont’d)
Applied engine Deflection Deflection GI

Limit after of new belt
adjustment
5.2 - 5.8 4.6 - 5.2 MA

QG13·15DE
8.5 (0.335) (0.205 - (0.181 -
QG16·QG18DE*1
0.228) 0.205)
Power steering pump
4.4 - 4.9 3.9 - 4.4
QG16·18DE
7.1 (0.280) (0.173 - (0.154 -
(QG15·18DE)*2
0.193) 0.173) LC
Applied pushing force 98 N (10 kg, 22 lb)
*1: For models produced after July 2001 (Except for Europe) EC
*2: For Hatchback
Inspect drive belt deflections when engine is cold.
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-23
AIR CLEANER QG
Cleaning and Changing
Cleaning and Changing NJEM0043

VISCOUS PAPER TYPE (EXCEPT FOR THE MIDDLE
EAST) NJEM0043S01
The viscous paper type filter does not need cleaning between
renewals.
SMA373C
DRY PAPER TYPE (EXCEPT FOR EUROPE) NJEM0043S02

Clean or replace filter more often under dusty driving condi-
tions.
SMA384C
EM-24
SPARK PLUG QG
Checking and Changing
Checking and Changing NJEM0044

1. Disconnect ignition coil harness connectors.
2. Remove ignition coils. GI
MA
SEM870F LC
3. Remove spark plugs with spark plug wrench.
4. Clean plugs in sand blast cleaner.
EC
5. Check insulator for cracks or chips, gasket for damage or dete-
rioration and electrode for wear and burning. If they are exces-
sively worn away, replace with new spark plugs. FE
6. Check spark plug gap.
Spark plug (Except for Europe):
CL
NGK
Standard BKR5E
SMA294A Type MT
Cold BKR6E, BKR7E
Plug gap mm (in) 0.8 - 0.9 (0.031 - 0.035)

AT
Spark plug (For Europe):

AX
NGK Champion
Standard BKR5E-11 RC10YCC4 SU

Type Hot BKR4E-11 —
Cold BKR6E-11 — BR
Plug gap mm (in) 1.0 - 1.1 (0.039 - 0.043)
ST
RS
BT
HA
7. Install spark plugs. SC

Spark plug:
: 20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)
8. Install ignition coils. EL
9. Connect ignition coil harness connectors.
IDX
SMA476
EM-25
OIL PAN QG
Components
Components NJEM0008
SEM867F
Removal NJEM0009
1. Remove front RH side cover.
2. Drain engine oil.
3. Remove front exhaust tube.
Refer to FE-15, “EXHAUST SYSTEM”.
4. Set a suitable transmission jack under transaxle and lift engine
with engine slinger.
5. Remove center member.
SEM067F
EM-26
OIL PAN QG
Removal (Cont’d)
6. Remove engine gussets.
Refer to MT-24 or AT-358, “Installation”.
7. Remove rear plate cover (A/T models). GI
MA
SEM071FA LC
EC
FE
CL
SEM110G
MT
8. Remove oil pan.
a. Insert Tool between cylinder block and oil pan. AT
1) Be careful not to damage aluminum mating face.
Do not insert screwdriver, or oil pan flange will be dam-
aged.
AX
b. Slide Tool by tapping on the side of the Tool with a hammer.
SU
BR
SEM365EB
Installation NJEM0010 ST
1. Use a scraper to remove old liquid gasket from mating surface
of oil pan.
I Also remove old liquid gasket from mating surface of cyl- RS
inder block.
BT
HA
SEM295C
2. Apply a continuous bead of liquid gasket to mating surface of SC

oil pan.
I Use Genuine Liquid Gasket or equivalent.
I Apply to groove on mating surface. EL
I Allow 7 mm (0.28 in) clearance around bolt holes.
IDX
SEM015E
EM-27
OIL PAN QG
Installation (Cont’d)
I Be sure liquid gasket diameter is 3.5 to 4.5 mm (0.138 to
0.177 in).
I Attaching should be done within 5 minutes after coating.
SEM259G
3. Install oil pan.

I Tighten oil pan nuts and bolts in the numerical order.
I Wait at least 30 minutes before refilling engine oil.
4. Install parts in reverse order of removal.
SEM072F
EM-28
TIMING CHAIN QG
Components
Components NJEM0011
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
SEM101GD
1. Chain tensioner 7. Timing chain 13. Crankshaft pulley IDX

2. Camshaft sprocket (Intake) 8. Crankshaft sprocket 14. Cylinder head front cover
3. Camshaft sprocket (Exhaust) 9. Oil pump drive spacer 15. Camshaft position sensor
4. O-ring 10. Front cover (PHASE)
5. Slack guide 11. O-ring 16. Cylinder block dowels
6. Tension guide 12. Oil seal
EM-29
TIMING CHAIN QG
Components (Cont’d)
CAUTION:
I After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
I When installing chain tensioner, oil seats, or other sliding
parts, lubricate contacting surfaces with new engine oil.
I Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprocket and crankshaft pulley.
I When removing oil pump assembly, remove camshaft
position sensor (PHASE), then remove timing chain from
engine.
I Be careful not to damage sensor edges.
Removal NJEM0105
1. Drain engine coolant from radiator and cylinder block.
Be careful not to spill coolant on drive belts.
2. Remove reservoir tank.
3. Release fuel pressure.
Refer to EC-526, “Fuel Pressure Release”.
4. Remove the following belts.
I Power steering pump drive belt
I Alternator drive belt
SEM869F
5. Remove front right-side wheel.
6. Remove front/right splash undercover.
8. Remove vacuum hoses, fuel hoses, and so on.

9. Remove ignition coils.
SEM870F
11. Remove rocker cover bolts in numerical order as shown in the

figure.
SEM102G
EM-30
TIMING CHAIN QG
Removal (Cont’d)
12. Set No. 1 piston at TDC on its compression stroke.
GI
MA
SEM872F LC
I Rotate crankshaft until mating mark on camshaft sprocket
is set at position indicated in figure at left. If not, rotate
crankshaft pulley one more turn to line up the mating EC
marks to the positions in the figure.
FE
CL
SEM873F
MT
13. Remove camshaft position sensor (PHASE).
I Do not allow any magnetic materials to contact the cam- AT
shaft position sensor (PHASE).
I Be careful not to damage sensor.
14. Remove cylinder head front cover. AX
SU
BR
SEM874F
15. Remove timing chain guide from camshaft bracket.

16. Attach a suitable stopper pin to chain tensioner.
ST
17. Remove chain tensioner.
RS
BT
HA
SEM875FA
18. Remove camshaft sprocket bolts. SC

I Apply paint to timing chain and cam sprockets for align-
ment during installation.
19. Remove camshaft sprockets. EL
IDX
SEM876F
EM-31
TIMING CHAIN QG
Removal (Cont’d)
20. Remove cylinder head bolts at engine front side.
SEM008G
21. Remove oil pan. Refer to EM-26, “Removal”.

22. Remove oil strainer.
SEM879F
23. Remove starter motor, and set ring gear stopper using mount-
ing bolt holes.
SEM880F
24. Loosen crankshaft pulley bolt.

25. Remove crankshaft pulley with a suitable puller.
SEM881F
26. Remove RH engine mounting.
SEM103G
EM-32
TIMING CHAIN QG
Removal (Cont’d)
27. Remove RH engine mounting bracket.
28. Remove idler pulley and bracket.
GI
MA
SEM104G LC
29. Remove water pump pulley and water pump. Refer to LC-14,
“Water Pump”.
30. Remove front cover bolts and front cover as shown.
EC
★1: Located on water pump
★2: Located on power steering pump adjusting bar
FE
I Inspect for oil leakage at front oil seal. Replace seal if oil leak
is present.
CL
SEM883F
MT
31. Remove timing chain.
32. Remove oil pump drive spacer. AT
33. Remove chain guides (slack guide and tension guide).
34. Remove crankshaft sprocket.
35. Remove O-rings from cylinder block and front cover.
AX
SU
BR
SEM884F
ST
RS
BT
HA
SEM897F
Inspection NJEM0106
SC
Check for cracks and excessive wear at roller links. Replace
if necessary.
EL
IDX
SEM885F
EM-33
TIMING CHAIN QG
Installation
Installation NJEM0107
1. Install crankshaft sprocket on crankshaft.
I Make sure mating marks on crankshaft sprocket face front
of engine.
SEM886F
2. Position crankshaft so that No. 1 piston is at TDC and key way

is at 12 o’clock.
SEM890F
3. Install slack guide and tension guide.
SEM891FA
4. Install timing chain on crankshaft sprocket.

I Support chain with a suitable tool to keep the mating mark
aligned.
I Set timing chain by aligning its mating mark with that on
the crankshaft sprocket.
I Make sure sprocket’s mating mark faces engine front.
SEM892F
5. Install camshaft sprocket.

I Set timing chain by aligning mating marks with those of
camshaft sprockets.
SEM905F
EM-34
TIMING CHAIN QG
6. Install camshaft sprocket bolts and tighten them to correct
torque.
I Apply new engine oil to bolt threads and seat surface. GI
MA
SEM519G LC
7. Install chain tensioner.
I Before installing chain tensioner, insert a suitable pin into
pin hole of chain tensioner.
EC
I After installing chain tensioner, remove the pin.
8. Install timing chain guide. FE
CL
SEM520GA
MT
9. Install O-rings to cylinder block.
AT
AX
SU
BR
SEM893F
10. Before installing front cover, remove all traces of liquid gasket
from mating surface using a scraper. ST
I Also remove traces of liquid gasket from mating surface of
cylinder block.
RS
BT
HA
SEM894F
11. Apply a continuous bead of liquid gasket to mating surface of SC

front cover.
I Check alignment of mating marks on chain and crankshaft
sprocket. EL
I Align oil drive spacer with oil pump.
I Place timing chain to the side of chain guide. This pre-
vents the chain from making contact with water seal area IDX
of front cover.
SEM895F
EM-35
TIMING CHAIN QG
12. Install front cover.
Bolt No. Tightening torque N·m (kg-m, in-lb) Length of “” mm (in)
a. 6.9 - 9.5 (0.70 - 0.97, 61 - 84) 20 (0.79)
b. 6.9 - 9.5 (0.70 - 0.97, 61 - 84) 40 (1.57)
c. 17 - 24 (1.7 - 2.4, 148 - 208*) 70 (2.76)
d. 6.9 - 9.5 (0.70 - 0.97, 61 - 84) 72.8 (2.866)
e. 6.9 - 9.5 (0.70 - 0.97, 61 - 84) 12 (0.47)
SEM896F *: 12 - 17 ft-lb
I Make sure two O-rings are present.
I Be careful not to damage oil seal when installing front
cover.
SEM897F
13. Install cylinder head bolts at engine front side.

I Tightening procedure
Tightening bolts (1 - 4) to 6.3 to 8.3 N·m (0.64 to 0.85 kg-m,
55.8 to 73.5 in-lb).
SEM009G
14. Install oil pump drive spacer.
SEM945F
15. Install water pump and water pump pulley.

Refer to LC-14, “Water Pump”.
16. Install idler pulley and bracket.
17. Install RH engine mounting bracket.
18. Install RH engine mounting.
19. Install oil strainer.
20. Install oil pan. Refer to EM-27, “Installation”.
21. Install crankshaft pulley.
22. Remove ring gear stopper.
SEM104G
23. Install starter motor.
EM-36
TIMING CHAIN QG
24. Install cylinder head front cover.
I Apply liquid gasket to cylinder head front cover.
I Use Genuine Liquid Gasket or equivalent. GI
MA
SEM887F LC
25. Install camshaft position sensor (PHASE).
EC
FE
CL
SEM889F
MT
26. Before installing rocker cover, apply a continuous bead of liq-
uid gasket to mating surface of cylinder head. AT
AX
SU
BR
SEM888F
27. Install rocker cover with rocker cover gasket and tighten bolts
in numerical order as shown in the figure. ST
28. Install spark plugs.
29. Install ignition coils. RS
30. Install front exhaust tube.
31. Install front/right splash undercover.
32. Install front right-side wheel. BT
33. Drive belts.
For adjusting drive belt deflection, refer to EM-22, “Checking”.
HA
34. Reinstall parts in reverse order of removal.
SEM105G
SC
EL
IDX
EM-37
OIL SEAL QG
Replacement
Replacement NJEM0015
VALVE OIL SEAL NJEM0015S01
1. Remove rocker cover.
2. Remove camshaft.
3. Remove valve spring. Refer to EM-43.
4. Remove valve oil seal with Tool.
Piston concerned should be set at TDC to prevent valve from
falling.
SEM909F
5. Apply new engine oil to new valve oil seal and install it with
Tool.
SEM910F
FRONT OIL SEAL NJEM0015S02

1. Remove the following parts:
I Engine under cover
I RH engine side cover
I Alternator and power steering drive belts
I Crankshaft pulley
2. Remove front oil seal from front cover.
I Be careful not to scratch front cover.
SEM911F
3. Apply new engine oil to new oil seal and install it using a suit-
able tool.
I Install new oil seal in the direction shown.
SEM715A
SEM912F
EM-38
OIL SEAL QG
Replacement (Cont’d)
REAR OIL SEAL =NJEM0015S03
1. Remove transaxle. Refer to MT-23 or AT-357, “REMOVAL AND
INSTALLATION”. GI
2. Remove flywheel or drive plate.
3. Remove rear oil seal.
MA
I Be careful not to scratch rear oil seal retainer.
SEM096F LC
4. Apply new engine oil to new oil seal and install it using a suit-
able tool.
I Install new oil seal in the direction shown.
EC
FE
CL
SEM715A
MT
AT
AX
SU
BR
SEM097F
ST
RS
BT
HA
SC
EL
IDX
EM-39
CYLINDER HEAD QG
Components
Components NJEM0108
SEM053H
1. Oil filler cap 7. Exhaust camshaft 15. Valve spring seat

2. Rocker cover 8. Timing chain guide 16. Valve oil seal
3. Rocker cover gasket 9. Cylinder head bolt 17. Valve guide
4. Intake valve timing control sole- 10. Shim 18. Cylinder head
noid (Models with intake valve tim- 11. Valve lifter 19. Cylinder head gasket
ing control) 12. Valve cotter 20. Valve seat
5. Camshaft bracket 13. Valve spring retainer 21. Valve
6. Intake camshaft 14. Valve spring
EM-40
CYLINDER HEAD QG
CAUTION:
I When installing camshaft and oil seal, lubricate contacting
surfaces with new engine oil. GI
I When tightening cylinder head bolts, camshaft sprocket
bolts and camshaft bracket bolts, lubricate bolt threads
and seat surfaces with new engine oil. MA
I Attach tags to valve lifters so as not to mix them up.
LC
Removal NJEM0017
1. Drain engine coolant from radiator and cylinder block. EC
Be careful not to spill coolant on drive belts.
2. Release fuel pressure.
Refer to EC-526, “Fuel Pressure Release”. FE
3. Remove drive belts.
4. Remove air duct to intake manifold collector.
5. Remove front undercovers.
CL
SEM869F
MT
7. Disconnect vacuum hoses, fuel hoses, water hoses, wires,
harness, connectors and so on. AT
8. Remove intake manifold rear supports.
9. Remove exhaust manifold.
10. Remove ignition coils. AX
SU
BR
SEM870F
12. Remove rocker cover bolts in numerical order as shown in the

figure. ST
RS
BT
HA
SEM102G
13. Set No. 1 piston at TDC on its compression stroke. SC
EL
IDX
SEM872F
EM-41
CYLINDER HEAD QG
Removal (Cont’d)
I Rotate crankshaft pulley clockwise until mating mark on
camshaft sprocket is set at position indicated in figure at
left.
SEM873F
14. Remove camshaft position sensor (PHASE).

I Do not allow any magnetic materials to contact the cam-
shaft position sensor (PHASE).
I Be careful not to damage sensor.
15. Remove cylinder head front cover.
SEM874F
16. Remove timing chain guide from camshaft bracket.

17. Attach a suitable stopper pin to chain tensioner.
I Push plunger using a flat-bladed screwdriver, then fix it
with a stopper pin, and remove mounting bolts.
SEM875FA
19. Remove camshaft sprocket bolts.

I Apply paint to timing chain and cam sprockets for align-
ment during installation.
20. Remove camshaft sprockets.
SEM876F
21. Remove camshaft brackets and camshafts.

I Apply I.D. marks to brackets to ensure correct reassembly.
I Bolts should be loosened in two or three steps.
SEM877F
EM-42
CYLINDER HEAD QG
Removal (Cont’d)
22. Remove cylinder head bolts.
23. Remove cylinder head with manifolds.
I Head warpage or cracking could result from removing in GI
incorrect order.
I Cylinder head bolts should be loosened in two or three
steps. MA
SEM878F LC
Disassembly NJEM0018
1. Remove valve components with Tool. EC
2. Remove valve oil seal with a suitable tool.
FE
CL
SEM914F
MT
Inspection NJEM0019
CYLINDER HEAD DISTORTION AT
NJEM0019S01
I Clean surface of cylinder head.
I Use a reliable straightedge and feeler gauge to check the flat- AX
ness of cylinder head mating surface.
I Check along six positions shown in figure.
Head surface flatness: SU
Standard: Less than 0.03 mm (0.0012 in)
Limit: 0.1 mm (0.004 in)
BR
SEM915F If beyond the specified limit, replace or resurface it.
Resurfacing limit:
The limit for cylinder head resurfacing is determined by the ST
amount of cylinder block resurfacing.
Amount of cylinder head resurfacing is “A”.
Amount of cylinder block resurfacing is “B”. RS
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
BT
After resurfacing cylinder head, check that camshaft rotates freely
by hand. If resistance is felt, replace cylinder head.
Nominal cylinder head height: HA
117.8 - 118.0 mm (4.638 - 4.646 in)
CAMSHAFT VISUAL CHECK NJEM0019S02 SC
Check camshaft for scratches, seizure and wear.
EL
IDX
EM-43
CYLINDER HEAD QG
Inspection (Cont’d)
CAMSHAFT RUNOUT NJEM0019S03
1. Measure camshaft runout at the center journal.
I Put V-blocks on a work bench and support camshaft at No. 2
and No. 5 journals.
I Set dial gauge vertically at No. 3 journal.
I Turn camshaft by hand in one direction and measure camshaft
runout on dial gauge (Total indicator reading).
Runout (Total indicator reading):
Standard
Less than 0.04 mm (0.0008 in)
PBIC0038E
Limit
0.1 mm (0.004 in)
2. If it exceeds the limit, replace camshaft.
CAMSHAFT CAM HEIGHT NJEM0019S04

1. Measure camshaft cam height.
Standard cam height:
Intake
QG16DE with intake valve timing control
40.220 - 40.410 mm (1.5835 - 1.5909 in)
QG18DE with intake valve timing control
40.610 - 40.800 mm (1.5988 - 1.6063 in)
Except for QG16·18DE with intake valve timing
SEM916F
control
39.880 - 40.070 mm (1.5701 - 1.5776 in)
Exhaust
40.056 - 40.246 mm (1.5770 - 1.5845 in)
Cam wear limit:
0.20 mm (0.0079 in)
2. If wear is beyond the limit, replace camshaft.
CAMSHAFT JOURNAL CLEARANCE NJEM0019S05

1. Install camshaft bracket and tighten bolts to the specified
torque.
2. Measure inner diameter of camshaft bearing.
Standard inner diameter:
No. 1 bearing
28.000 - 28.021 mm (1.1024 - 1.1032 in)
No. 2 to No. 5 bearings
24.000 - 24.021 mm (0.9449 - 0.9457 in)
SEM917F
EM-44
CYLINDER HEAD QG
3. Measure outer diameter of camshaft journal.
Standard outer diameter:
No. 1 journal GI
27.935 - 27.955 mm (1.0998 - 1.1006 in)
No. 2 to No. 5 journals MA
23.935 - 23.955 mm (0.9423 - 0.9431 in)
4. Calculate camshaft journal clearance.
(Clearance) = (inner diameter of camshaft bearing) −
(outer diameter of camshaft journal)
Camshaft journal clearance:
SEM156D
Standard LC
0.045 - 0.086 mm (0.0018 - 0.0034 in)
Limit EC
0.15 mm (0.0059 in)
5. If clearance exceeds the limit, replace camshaft and/or cylin-
der head. FE
CL
MT
CAMSHAFT END PLAY NJEM0019S06
1. Install camshaft in cylinder head. Refer to EM-53. AT
2. Measure camshaft end play.
Camshaft end play:
AX
Standard
0.115 - 0.188 mm (0.0045 - 0.0074 in)
Limit SU
0.20 mm (0.0079 in)
3. If limit is exceeded, replace camshaft and remeasure end play.
BR
SEM918F I If limit is still exceeded after replacing camshaft, replace
cylinder head.
ST
RS
BT
HA
CAMSHAFT SPROCKET RUNOUT NJEM0019S07

SC
1. Install sprocket on camshaft.
2. Measure camshaft sprocket runout.
EL
Limit 0.15 mm (0.0059 in)
3. If it exceeds the limit, replace camshaft sprocket. IDX
SEM919F
EM-45
CYLINDER HEAD QG
VALVE GUIDE CLEARANCE NJEM0019S08
1. Measure valve deflection as shown in figure. (Valve and valve
guide wear the most in this direction.)
Valve deflection limit (Dial gauge reading):
Intake & Exhaust
0.2 mm (0.008 in)
SEM345D
2. If it exceeds the limit, check valve to valve guide clearance.

a. Measure valve stem diameter and valve guide inner diameter.
b. Calculate valve to valve guide clearance.
Valve to valve guide clearance = valve guide inner diam-
eter − valve stem diameter.
c. Check that clearance is within specification.
Unit: mm (in)
Standard Limit
0.020 - 0.050
Intake 0.1 (0.004)
(0.0008 - 0.0020)
SEM938C
0.040 - 0.070
Exhaust 0.1 (0.004)
(0.0016 - 0.0028)
I If it exceeds the limit, replace valve and remeasure clearance.

I If limit is still exceeded after replacing valve, replace valve
guide.
VALVE GUIDE REPLACEMENT NJEM0019S09

1. To remove valve guide, heat cylinder head to 110 to 130°C
(230 to 266°F).
SEM008A
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2

US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.
CAUTION:
Cylinder head contains heat. When working, wear protective
equipment to avoid getting burned.
SEM931C
EM-46
CYLINDER HEAD QG
3. Ream cylinder head valve guide hole.
Valve guide hole diameter
(for service parts): GI
Intake & Exhaust
9.685 - 9.696 mm (0.3813 - 0.3817 in) MA
SEM932C LC
4. Heat cylinder head to 110 to 130°C (230 to 266°F) and press
service valve guide into cylinder head.
Projection “L”:
EC
11.5 - 11.7 mm (0.453 - 0.461 in)
CAUTION: FE
CL
MEM096A
MT
5. Ream valve guide.
Finished size: AT
Intake & Exhaust
5.500 - 5.515 mm (0.2165 - 0.2171 in)
AX
SU
BR
SEM932C
VALVE SEATS
Check valve seats for pitting at contact surface. Resurface or
NJEM0019S10 ST
replace if excessively worn.
I Before repairing valve seats, check valve and valve guide RS
for wear. If they have worn, replace them. Then correct
valve seat.
I Use both hands to cut uniformly. BT
HA
SEM934C
I Before starting this check, confirm that the dimensions of valve SC

guides and valves are as specified.
I Apply red lead primer on contacting surfaces of valve seat and
of valve face to examine the conditions of contacting surfaces. EL
I Make sure the paint on contacting surfaces is continuous along
the entire circumference.
I If there are non-standard conditions, grind the valve and check IDX
the contact again. If non-standard conditions still persist,
replace valve seat.
JEM157G
EM-47
CYLINDER HEAD QG
REPLACING VALVE SEAT FOR SERVICE PARTS NJEM0019S11
1. Bore out old seat until it collapses. Set machine depth stop so
that boring cannot contact the bottom face of seat recess in
cylinder head.
2. Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 in)]:
Refer to SDS, EM-80.
Use the valve guide center for reaming to ensure valve seat
will have the correct fit.
SEM795A
3. Heat cylinder head to 110 to 130°C (230 to 266°F).

4. Press fit valve seat until it seats on the bottom.
CAUTION:
SEM008A
5. Cut or grind valve seat using suitable tool to the specified

dimensions as shown in SDS, EM-80.
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition.
Seat face angle “α”:
44°53′ - 45°07′
Contacting width “W”:
Intake
1.06 - 1.34 mm (0.0417 - 0.0528 in)
SEM892B
Exhaust
1.20 - 1.68 mm (0.0472 - 0.0661 in)
8. Use a depth gauge to measure the distance “L” between the

mounting surface of the cylinder head spring seat and the
valve stem end. If the distance is shorter than specified, repeat
step 5 above to correct it. If the distance is longer, replace the
valve seat.
Valve seat resurface limit:
Intake
35.95 - 36.55 mm (1.4154 - 1.4390 in)
Exhaust
35.92 - 36.52 mm (1.4142 - 1.4378 in)
AEM343
EM-48
CYLINDER HEAD QG
VALVE DIMENSIONS NJEM0019S12
Check dimensions of each valve. Refer to SDS, EM-76 for dimen-
sions. GI
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or MA
less.
SEM188A LC
VALVE SPRING NJEM0019S13
Squareness NJEM0019S1301 EC
1. Measure dimension “S”.
Out-of-square “S”:
Less than 1.80 mm (0.0709 in) FE
2. If it exceeds the limit, replace spring.
CL
SEM288A
MT
Pressure NJEM0019S1302
Check valve spring pressure at specified spring height. AT
Pressure:
For Sedan
AX
Standard
344.42 N (35.12 kg, 77.44 lb) at 25.26 mm (0.9945
in) SU
Limit
More than 323.73 N (33.01 kg, 72.79 lb) at 25.26
mm (0.9945 in) BR
EM113
For Hatchback
Standard ST
370.0 N (37.73 kg, 83.19 lb) at 23.64 mm (0.9307 in)
Limit
More than 347.8 N (35.46 kg, 78.19 lb) at 23.64 mm RS
(0.9307 in)
If it exceeds the limit, replace spring. BT
HA
VALVE LIFTER AND VALVE SHIM NJEM0019S16

SC
1. Check contact and sliding surfaces for wear or scratches.
EL
IDX
SEM160D
EM-49
CYLINDER HEAD QG
2. Check diameter of valve lifter and valve lifter guide bore.
Valve lifter outside diameter:
29.960 - 29.975 mm (1.1795 - 1.1801 in)
SEM161D
Lifter guide inside diameter:

30.000 - 30.021 mm (1.1811 - 1.1819 in)
3. Calculate clearance between valve lifter and valve lifter guide.
(Clearance) = (Lifter guide inside diameter) − (Valve lifter
outside diameter)
Clearance:
0.025 - 0.065 mm (0.0010 - 0.0026 in)
If it exceeds the limit, replace valve lifter or cylinder head which
exceeds the standard diameter tolerance.
SEM920F
Valve Clearance NJEM0041

CHECKING NJEM0041S01
Check valve clearance while engine is warm and not running.
1. Remove rocker cover.
2. Remove all spark plugs.
3. Set No. 1 cylinder at TDC on its compression stroke.
I Align pointer with TDC mark on crankshaft pulley.
I Check that valve lifters on No. 1 cylinder are loose and valve
lifters on No. 4 are tight.
SEM921F I If not, turn crankshaft one revolution (360°) and align as
described above.
4. Check only those valves shown in the figure.
SEM922F
EM-50
CYLINDER HEAD QG
Valve Clearance (Cont’d)
I Using a feeler gauge, measure clearance between valve lifter
and camshaft.
I Record any valve clearance measurements which are out of GI
specification. They will be used later to determine the required
replacement adjusting shim.
Valve clearance for checking (Hot): MA
Intake
0.21 - 0.49 mm (0.008 - 0.019 in)
Exhaust
0.30 - 0.58 mm (0.012 - 0.023 in)
SEM139D LC
5. Turn crankshaft one revolution (360°) and align mark on crank-
shaft pulley with pointer.
EC
I Use the same procedure as mentioned in step 4.
7. If all valve clearances are within specification, install the fol- FE
lowing parts:
I Rocker cover
I All spark plugs CL
SEM923F
MT
ADJUSTING NJEM0041S02
Adjust valve clearance while engine is cold. AT
1. Turn crankshaft. Position cam lobe upward on camshaft for
valve that must be adjusted.
2. Place Tool (A) around camshaft as shown in figure.
AX
Before placing Tool (A), rotate notch toward center of cylinder
head. (See figure.) This will simplify shim removal later. SU
CAUTION:
Be careful not to damage cam surface with Tool (A).
BR
SEM941F
3. Rotate Tool (A) so that valve lifter is pushed down.

ST
RS
BT
HA
SEM924F
4. Place Tool (B) between camshaft and valve lifter to retain valve SC
lifter.
CAUTION:
I Tool (B) must be placed as close to camshaft bracket as EL
possible.
I Be careful not to damage cam surface with Tool (B).
5. Remove Tool (A).
IDX
SEM925F
EM-51
CYLINDER HEAD QG
6. Remove adjusting shim using a small screwdriver and a mag-
netic finger.
7. Determine replacement adjusting shim size using the following
formula.
I Use a micrometer to determine thickness of removed shim.
I Calculate thickness of new adjusting shim so valve clearance
comes within specified values.
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
SEM144D Intake:
N = R + [M − 0.37 mm (0.0146 in)]
Exhaust:
N = R + [M − 0.40 mm (0.0157 in)]
Shims are available in 50 sizes from 2.00 mm (0.0787 in) to 2.98
mm (0.1173 in), in steps of 0.02 mm (0.0008 in).
SEM145D
I Select the closest size shim to the calculated thickness. Refer

to chart in SDS, EM-77.
AEM236
8. Install new shim using a suitable tool.

I Install with the surface on which the thickness is stamped
facing down.
SEM146D
9. Place Tool (A) as explained in steps 2 and 3.

10. Remove Tool (B).
11. Remove Tool (A).
12. Recheck valve clearance.
SEM147D
EM-52
CYLINDER HEAD QG
Valve clearance:
Unit: mm (in)
For adjusting For checking GI

Cold* (reference
Hot Hot
data) MA
0.32 - 0.40 0.25 - 0.33 0.21 - 0.49
Intake
(0.013 - 0.016) (0.010 - 0.013) (0.008 - 0.019)
0.37 - 0.45 0.32 - 0.40 0.30 - 0.58

Exhaust
(0.015 - 0.018) (0.013 - 0.016) (0.012 - 0.023)
*: At a temperature of approximately 20°C (68°F)

LC
Whenever valve clearances are adjusted to cold specifications, check that
the clearances satisfy hot specifications and adjust again if necessary.
EC
FE
CL
MT
Assembly NJEM0020
1. Install valve component parts. AT
I Always use new valve oil seal. Refer to EM-38.
I Before installing valve oil seal, install valve spring seat. AX
I After installing valve components, tap valve stem tip with
a plastic hammer to assure a proper fit.
I Install valve spring (narrow pitch at both ends of spring) SU
with either end toward cylinder head.
BR
AEM293
Installation NJEM0021 ST
1. Before installing cylinder head gasket, apply a continuous
bead of liquid gasket to mating surface of cylinder block.
2. Install cylinder head gasket. RS
I When installing cylinder head with manifolds, use new
cylinder head gasket.
BT
HA
SEM899F
3. Install cylinder head with manifolds. SC

I Be sure to install washers between bolts and cylinder
head.
I Do not rotate crankshaft and camshaft separately, or EL
valves will strike piston heads.
I Apply new engine oil to cylinder head bolt threads and
seat surfaces. IDX
SEM877A
EM-53
CYLINDER HEAD QG
I Tightening procedure
a. Tighten bolts to 29 N·m (3 kg-m, 22 ft-lb).
b. Tighten bolts to 59 N·m (6 kg-m, 43 ft-lb).
c. Loosen bolts completely.
d. Tighten bolts to 29 N·m (3 kg-m, 22 ft-lb).
e. Turn bolts 50 to 55 degrees clockwise or if angle wrench
is not available, tighten bolts to 59±4.9 N·m (6±0.5 kg-m,
43±3.6 ft-lb).
f. Tightening bolts (11 - 14) to 6.3 to 8.3 N·m (0.64 to 0.85
kg-m, 55.8 to 73.5 in-lb).
SEM900F Tightening torque N·m (kg-m, ft-lb)
a b c d e, f
50 - 55
degrees or
Bolts 29 59 0 29 59±4.9
(1 - 10) (3, 22) (6, 43) (0, 0) (3, 22) (6±0.5,
43±3.6
ft-lb)
6.3 - 8.3
Bolts (0.64 -
— — — —
(11 - 14) 0.85, 55.8 -
73.5 in-lb)
SEM614EC
4. Install camshaft.
I The camshafts are distinguished by a paint mark as follows.
Intake camshaft: Other paint color than white
Exhaust camshaft: White paint or no paint
SEM901F
I Make sure camshafts are aligned as shown in figure.
SEM902F
5. Install camshaft brackets.

I Make sure camshaft brackets are aligned as marked dur-
ing disassembly.
SEM903F
EM-54
CYLINDER HEAD QG
I Apply new engine oil to bolt threads and seat surface.
I Tighten camshaft bracket bolts in the following steps.
a. Tighten bolts 9 - 12, then 1 - 8. GI
2.0 N·m (0.20 kg-m, 17.7 in-lb)
b. Tighten bolts 1 - 12.
5.9 N·m (0.60 kg-m, 52.2 in-lb) MA
c. Tighten bolts 1 - 12.
9.0 - 11.8 N·m (0.92 - 1.20 kg-m, 80 - 104 in-lb)
I If any part of valve assembly or camshaft is replaced,
check valve clearance according to reference data.
After completing assembly check valve clearance. Refer
SEM904F
to “Checking” and “Adjusting” in “VALVE CLEARANCE” LC
(EM-50).
Reference data valve clearance (Cold): EC
Intake
0.25 - 0.33 mm (0.010 - 0.013 in)
Exhaust FE
0.32 - 0.40 mm (0.013 - 0.016 in)
CL
MT
6. Install camshaft sprocket.
I Set timing chain by aligning mating marks with those of AT
camshaft sprockets.
AX
SU
BR
SEM905F
7. Install camshaft sprocket bolts to correct torque.

I Apply new engine oil to bolt threads and seat surface.
ST
RS
BT
HA
SEM906F
8. Install chain tensioner. SC

I Before installing chain tensioner, insert a suitable pin into
pin hole of chain tensioner.
I After installing chain tensioner, remove the pin. EL
9. Install timing chain guide.
IDX
SEM907FA
EM-55
CYLINDER HEAD QG
10. Install cylinder head front cover.
I Apply liquid gasket to cylinder head front cover.
SEM887F
11. Install camshaft position sensor (PHASE).
SEM889F
12. Before installing rocker cover, apply a continuous bead of liq-

uid gasket to mating surface of cylinder head.
SEM888F
13. Install rocker cover with rocker cover gasket and tighten bolts
in numerical order as shown in the figure.
14. Install spark plugs.
15. Install ignition coils.
16. Install exhaust manifold.
17. Install intake manifold rear supports.
18. Connect vacuum hoses, fuel hoses, water hose, wire, harness,
connectors and so on.
19. Install front exhaust tube.
20. Install front undercovers.
SEM105G
21. Install air duct to intake manifold collector.
22. Drive belts.
For adjusting drive belt deflection, refer to “Checking”, EM-22.
23. Reinstall parts in reverse order of removal.
EM-56
ENGINE ASSEMBLY QG
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
SEM052H
1. RH engine mounting 5. Rear engine mounting 8. Front engine mounting bracket IDX
2. RH engine mounting bracket 6. Dynamic damper (Specific models 9. Front engine mounting
3. LH engine mounting only) 10. Engine slinger
4. Rear engine mounting bracket 7. Center member
EM-57
ENGINE ASSEMBLY QG
WARNING:
I Position vehicle on a flat and solid surface.
I Place chocks at front and back of rear wheels.
I Do not remove engine until exhaust system has com-
pletely cooled off, otherwise, you may burn yourself
and/or fire may break out in fuel line.
I Before disconnecting fuel hose, release pressure.
Refer to EC-39 or EC-526, “Fuel Pressure Release”.
I Be sure to lift engine and transaxle in a safe manner.
I For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
I When lifting engine, be sure to clear surrounding parts.
Use special care near accelerator wire casing, brake lines
and brake master cylinder.
I When lifting the engine, always use engine slingers in a
safe manner.
I When removing drive shaft, be careful not to damage
grease seal of transaxle.
I Before separating engine and transaxle, remove crank-
shaft position sensor (POS) from the cylinder block
assembly.
I Always be extra careful not to damage edge of crankshaft
position sensor (POS), or signal plate teeth.
Engine cannot be removed separately from transaxle. Remove
engine with transaxle as an assembly.
REMOVAL NJEM0022S01
1. Drain coolant from radiator and cylinder block. Refer to LC-18,
“Changing Engine Coolant”.
2. Remove coolant reservoir tank and bracket.
3. Remove both battery cables.
4. Remove battery and battery tray.
5. Remove air cleaner and air duct.
6. Remove drive belts. Refer to EM-22, “DRIVE BELTS”.
7. Remove alternator and air conditioner compressor from
engine.
8. Remove power steering oil pump from engine and position
aside.
Power steering oil pump does not need to be disconnected
from power steering tubes.
EM-58
ENGINE ASSEMBLY QG
I RH and LH front wheels
I Splash covers GI
I RH and LH brake caliper assemblies
Refer to BR-26, “FRONT DISC BRAKE”.
MA
Brake hose does not need to be disconnected from brake
caliper assembly. Never depress brake pedal.
I RH & LH drive shaft. Refer to AX-10, “Drive Shaft”.
When removing drive shaft, be careful not to damage tran-
saxle side grease seal.
SEM174D LC
I Disconnect control rod and support rod from transaxle. (M/T
models.)
Refer to MT-29, “TRANSAXLE GEAR CONTROL”. EC
I Disconnect control cable from transaxle. (A/T models.)
Refer to AT-357, “Removal”.
FE
CL
SEM109G
MT
I Center member
I Front exhaust tube AT
I Stabilizer bar
I Cooling fan
I Radiator
AX
Refer to LC-17, “Radiator”.
I Disconnect wires, harness, pipes, hoses and so on. SU
10. Lift up engine slightly and disconnect or remove all engine
mountings.
When lifting engine, be sure to clear surrounding parts. Use BR
SEM108G
special care near brake tubes and brake master cylinder.
11. Remove engine with transaxle as shown.
ST
RS
BT
HA
SC
EL
IDX
SEM420D
EM-59
ENGINE ASSEMBLY QG
INSTALLATION NJEM0022S02
I Install in reverse order of removal.
Inspection after Installation NJEM0112

I Before starting engine, check the levels of coolant, lubrications
and working oils. If less than required quantity, fill to the speci-
fied level.
I Use procedure below to check for fuel leakage.
a) Turn ignition switch ON (with engine stopped). With fuel pres-
sure applied to fuel piping, check for fuel leakage at connec-
tion points.
b) Start engine. With engine speed increased, check again for
fuel leakage at connection points.
I Run engine to check for unusual noise and vibration.
I Warm up engine thoroughly to make sure there is no leakage
of coolant, lubricants, working oil, fuel and exhaust gas.
I Bleed air from passages in pipes and tubes of applicable lines,
such as in cooling system.
I After cooling down engine, again check amounts of coolant,
lubricants, oil, and fluid. Refill to specified level, if necessary.
EM-60
CYLINDER BLOCK QG
Components
Components NJEM0023
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
SEM926FC
HA
1. Oil level gauge guide 10. 2nd ring 19. Main bearing
2. Cylinder block 11. Oil ring 20. Thrust bearing SC
3. Rear oil seal retainer 12. Piston 21. Crankshaft
4. Rear oil seal 13. Snap ring 22. Main bearing cap
5. Rear plate 14. Piston pin 23. Knock sensor EL
6. Flywheel 15. Connecting rod 24. Crankshaft position sensor (POS)
7. Drain plug 16. Connecting rod bearing 25. Rear lower plate
8. Buffle plate 17. Connecting rod cap 26. Drive plate IDX
9. Top ring 18. Key 27. Signal plate
EM-61
CYLINDER BLOCK QG

CAUTION:
I When installing sliding parts such as bearings and
pistons, apply engine oil on the sliding surfaces.
I Place removed parts, such as bearings and bearing caps,
in their proper order and direction.
I When installing connecting rod nuts and main bearing cap
bolts, apply new engine oil to threads and seating sur-
faces.
I Do not allow any magnetic materials to contact the signal
plate teeth of flywheel or drive plate, and rear plate.
I Remove the crankshaft position sensor (POS).
I Be careful not to damage sensor edges and single plate
teeth.
PISTON AND CRANKSHAFT NJEM0025S01
1. Remove engine assembly from vehicle, and separate tran-
saxle from engine. Refer to EM-57, “ENGINE ASSEMBLY”.
2. Remove engine mounting bracket. Refer to EM-57, “ENGINE
ASSEMBLY”.
3. Remove exhaust manifold. Refer to EM-12, “OUTER COMPO-
NENT PARTS”.
4. Place engine on a work stand.
5. Drain coolant and oil.
SEM927F
6. Remove timing chain.
Refer to EM-30.
7. Remove pistons with connecting rod.
SEM877B
EM-62
CYLINDER BLOCK QG
Disassembly (Cont’d)
8. Remove the piston rings from the piston.
I Use a piston ring expander (commercial service tool).
CAUTION: GI
I When removing the piston rings, be careful not to damage
the piston.
I Be careful not to damage piston rings by expanding them
MA
excessively.
I When disassembling piston and connecting rod, remove snap
ring first. Then heat piston to 60 to 70°C (140 to 158°F) or use
piston pin press stand at room temperature.
PBIC0087E CAUTION: LC
I When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
I When replacing piston rings, if there is no punch mark, EC
install with either side up.
FE
CL
MT
9. Remove rear oil seal retainer. Refer to EM-61, “Components”.
10. Loosen main bearing caps in numerical order as shown in fig- AT
ure.
11. Remove bearing caps, main bearings and crankshaft.
I Before removing bearing caps, measure crankshaft end AX
play. Refer to EM-71.
I Bolts should be loosened in two or three steps. SU
BR
SEM165DB
12. Remove signal plate from crankshaft.

CAUTION:
ST
I When placing crankshaft on ground, be careful not to
damage signal plate. RS
I Never remove signal plate unless it is necessary.
NOTE:
If it is removed, positioning dowel pin (dowel pin for crankshaft and BT
signal plate are specified as a single set) must be reinstalled.
HA
SEM928F
Inspection NJEM0026
SC
PISTON AND PISTON PIN CLEARANCE NJEM0026S01
1. Measure inner diameter of piston pin hole “dp”. EL
Standard diameter “dp”:
QG18DE
18.993 - 19.005 mm (0.7478 - 0.7482 in) IDX
Except for QG18DE
18.987 - 18.999 mm (0.7475 - 0.7480 in)
AEM023
EM-63
CYLINDER BLOCK QG
2. Measure outer diameter of piston pin “Dp”.
Standard diameter “Dp”:
18.989 - 19.001 mm (0.7476 - 0.7481 in)
3. Calculate piston pin clearance.
QG18DE
dp − Dp: 0.002 - 0.006 mm (0.0001 - 0.0002 in)
Except for QG18DE
dp − Dp: −0.004 to 0 mm (−0.0002 to 0 in)
If it exceeds the above value, replace piston assembly with pin.
AEM024
PISTON RING SIDE CLEARANCE NJEM0026S02

Side clearance:
Max. limit of side clearance:
If out of specification, replace piston and/or piston ring assembly.
SEM024AA
PISTON RING END GAP NJEM0026S03

End gap:
Max. limit of end gap:
If out of specification, replace piston ring. If gap exceeds maximum
limit with a new ring, rebore cylinder and use oversized piston and
piston rings.
I When replacing the piston, check the cylinder bore surface for
AEM096
scratches or seizure. If scratches or seizure is found, hone or
replace the cylinder block.
CONNECTING ROD BEND AND TORSION NJEM0026S04

Bend:
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.3 mm (0.012 in)
If it exceeds the limit, replace connecting rod assembly.
SEM150B
EM-64
CYLINDER BLOCK QG
GI
MA
SEM003F LC
CYLINDER BLOCK DISTORTION AND WEAR NJEM0026S05
Clean upper surface of cylinder block. EC
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder block surface. Check along six positions shown in fig-
ure. FE
Block surface flatness:
Standard Less than 0.03 mm (0.0012 in)
Limit 0.10 mm (0.004 in) CL
If out of specification, resurface it.
The limit for cylinder block resurfacing is determined by the amount
SEM486C of cylinder head resurfacing.
MT
Amount of cylinder block resurfacing is “B”. AT
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height AX
from crankshaft center:
213.95 - 214.05 mm (8.4232 - 8.4271 in) SU
If necessary, replace cylinder block.
BR
SEM102F
PISTON-TO-BORE CLEARANCE
1.
NJEM0026S06
Using a bore gauge, measure cylinder bore for wear, out-of-
ST
round and taper.
Standard inner diameter: RS
Wear limit:
0.2 mm (0.008 in) BT
Out-of-round (Difference between X and Y) standard:
Less than 0.015 mm (0.0006 in) HA
SEM166D
Taper (Difference between A and B) standard:
If it exceeds the limit, rebore all cylinders. Replace cylinder SC
block if necessary.
2. Check for score and seizure. If seizure is found, hone it. EL
I If cylinder block or piston is replaced, match piston grade
with grade number on cylinder block lower surface.
IDX
SEM929F
EM-65
CYLINDER BLOCK QG
3. Measure piston skirt diameter.
Piston diameter “A”:
Measuring point “a” (Distance from the top):
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance = cylinder bore measurement
“B” − Piston diameter “A”:
SEM258C
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to SDS EM-83.
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter “A”.
Rebored size calculation:
D=A+B−C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps and tighten bolts to the specified
torque. This will prevent distortion of cylinder bores.
8. Cut cylinder bores.
I When any cylinder needs boring, all other cylinders must
also be bored.
I Do not cut too much out of cylinder bore at a time. Cut
only 0.05 mm (0.0020 in) or so at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
I Measurement should be done after cylinder bore cools
down.
CRANKSHAFT NJEM0026S07
1. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-of-
round.
Out-of-round (Difference between X and Y):
Taper (Difference between A and B):
SEM316A
3. Measure crankshaft runout.

I Place a V-block on a precise flat table to support the journals
on the both end of the crankshaft.
I Place a dial gauge straight up on the No. 3 journal.
I While rotating the crankshaft, read the movement of the
pointer on the dial gauge. (Total indicator reading)
SEM346D
EM-66
CYLINDER BLOCK QG
BEARING CLEARANCE NJEM0026S08
I Use Method A or Method B. Method A is preferred because it
is more accurate. GI
Method A (Using bore gauge and micrometer)
Main bearing NJEM0026S0801
MA
1. Set main bearings in their proper positions on cylinder block
and main bearing cap.
SEM366E LC
2. Install main bearing cap to cylinder block.
Tighten all bolts in correct order in two or three stages. Refer EC
to EM-71.
3. Measure inner diameter “A” of each main bearing.
FE
CL
AEM153
MT
4. Measure outer diameter “Dm” of each main journal in crank-
shaft. AT
5. Calculate main bearing clearance.
Main bearing clearance = A − Dm
Except for Europe AX
Standard: 0.018 - 0.042 mm (0.0007 - 0.0017 in)
Limit: 0.1 mm (0.004 in) SU
For Europe
Standard: 0.020 - 0.044 mm (0.0008 - 0.0017 in)
Limit: 0.1 mm (0.004 in) BR
AEM026
If it exceeds the limit, replace bearing.
If clearance cannot be adjusted within standard of any bearing, ST
grind crankshaft journal and use undersized bearing.
RS
BT
HA
When grinding crank pin and crank journal: SC

I Grind until clearance is within specified standard bearing
clearance.
I Fillets should be finished as shown in the figure. R: 2.3 - EL
2.5 mm (0.091 - 0.098 in)
Refer to SDS, EM-86 for standard bearing clearance and
available spare parts.
IDX
SEM588A
EM-67
CYLINDER BLOCK QG
6. If the crankshaft is replaced, select thickness of main bearings
as follows:
a. Grade number of each cylinder block main journal is punched
on the respective cylinder block. These numbers are punched
in either Arabic or Roman numerals.
SEM930F
b. Grade number of each crankshaft main journal is punched on

the respective crankshaft. These numbers are punched in
either Arabic or Roman numerals.
c. Select main bearing with suitable thickness according to the
following table.
Main bearing grade color:
Crankshaft main jour- Cylinder block main journal grade number

nal grade number 0 1 2
0 Black Brown or Red Green

AEM172
1 Brown or Red Green Yellow
2 Green Yellow Blue
For example:
Cylinder block main journal grade number: 1
Crankshaft main journal grade number: 2
Main bearing grade number = 1 + 2 = Yellow
SEM194C
Connecting rod bearing (Big end) NJEM0026S0802

1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque. Refer to EM-71, “CRANK-
SHAFT”.
3. Measure inner diameter “C” of each bearing.
AEM027
4. Measure outer diameter “Dp” of each crankshaft pin journal.

5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C − Dp
Standard: 0.014 - 0.039 mm (0.0006 - 0.0015 in)
Limit: 0.1 mm (0.004 in)
If it exceeds the limit, replace bearing.
If clearance cannot be adjusted using any standard bearing
grade, grind crankshaft journal and use undersized bearing.
Refer to step 5, EM-67.
AEM028
EM-68
CYLINDER BLOCK QG
I If a new bearing, crankshaft or connecting rod is replaced,
select connecting rod bearing according to the following table.
Connecting rod bearing grade number: GI
These numbers are punched in either Arabic or Roman numerals.
Crankshaft pin journal grade number Connecting rod bearing grade color MA
0 —
1 Brown
2 Green
SEM437CA LC
Method B (Using Plastigage)
CAUTION: EC
I Do not turn crankshaft or connecting rod while Plastigage
is being inserted.
I If incorrect bearing clearance exists, use a thicker or FE
undersized main bearing to ensure specified clearance.
CL
EM142
MT
CONNECTING ROD BUSHING CLEARANCE (SMALL
END) NJEM0026S09
AT
1. Measure inner diameter “C” of bushing.
AX
SU
BR
AEM029
2. Measure outer diameter “Dp” of piston pin.

3. Calculate connecting rod bushing clearance.
ST
Connecting rod bushing clearance = C − Dp
Standard: RS
0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit:
0.023 mm (0.0009 in)
BT
If it exceeds the limit, replace connecting rod assembly or
connecting rod bushing and/or piston pin. HA
AEM030
REPLACEMENT OF CONNECTING ROD BUSHING SC

(SMALL END) NJEM0026S10
1. Drive in small end bushing until it is flush with end surface of
rod. EL
Be sure to align the oil holes.
2. Ream the bushing so that clearance with piston pin is within IDX
specification.
Clearance between connecting rod bushing and piston
pin:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
SEM062A
EM-69
CYLINDER BLOCK QG
FLYWHEEL/DRIVE PLATE RUNOUT NJEM0026S12
Flywheel (M/T models)
Drive plate (A/T models)*
*Measuring points: Approximately 115 mm (4.53
in) from crankshaft center
CAUTION:
SEM931F
I Do not allow any magnetic materials to contact the ring
gear teeth and rear plate.
I Do not resurface flywheel. Replace as necessary.
Assembly NJEM0027
PISTON NJEM0027S01
1. Install new snap ring on one side of piston pin hole.
SEM166B
2. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston,

piston pin, connecting rod and new snap ring.
I Align the direction of piston and connecting rod.
I Numbers stamped on connecting rod and cap correspond
to each cylinder.
I After assembly, make sure connecting rod swings
smoothly.
SEM932F
3. Set piston rings as shown.

CAUTION:
I Be careful not to damage piston.
I When piston rings are not replaced, make sure that piston
rings are mounted in their original position.
I Install new piston rings either side up if there is no punch
mark.
SEM522G
EM-70
CYLINDER BLOCK QG
Assembly (Cont’d)
I Align piston rings so that end gaps are positioned as
shown.
GI
MA
SEM049H LC
1. Install signal plate to crankshaft. EC
CAUTION:
Be sure to remove dowel pin.
FE
CL
SEM934F
MT
2. Set main bearings in their proper positions on cylinder block
and main bearing cap. AT
I Confirm that correct main bearings are selected by using
Method A or Method B. Refer to EM-67.
I Apply new engine oil to bearing surfaces. AX
SU
BR
SEM366E
ST
RS
BT
HA
SEM420C
3. Install crankshaft and main bearing caps and tighten bolts to SC

the specified torque.
I Apply new engine oil to the bolt thread and seat surface.
I Prior to tightening bearing cap bolts, shift crankshaft back EL
and forth to properly seat the bearing caps.
I Tighten bearing cap bolts gradually in two or three stages.
Start with center bearing and move outward as shown in IDX
figure.
I After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
SEM933F
EM-71
CYLINDER BLOCK QG
Assembly (Cont’d)
4. Measure crankshaft end play.
Crankshaft end play:
Standard
0.060 - 0.220 mm (0.0024 - 0.0087 in)
Limit
0.3 mm (0.012 in)
If beyond the limit, replace thrust bearing with new ones.
SEM116F
5. Install connecting rod bearings in connecting rods and con-

necting rod caps.
I Confirm that correct bearings are used. Refer to EM-68.
I Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing.
I Apply new engine oil to bolt threads and bearing surfaces.
SEM168D
6. Install pistons with connecting rods.

a. Install them into corresponding cylinders with Tool.
I Make sure connecting rod does not scratch cylinder wall.
I Make sure connecting rod bolts do not scratch crankshaft
pin journals.
I Arrange so that front mark on piston head faces engine.
I Apply new engine oil to piston rings and sliding surface
of piston.
SEM942F
b. Install connecting rod caps.

Apply new engine oil to bolt threads and nut seating surfaces.
Tighten connecting rod cap nuts in the following procedure:
I Tighten to 13.72 to 15.68 N·m (1.399 to 1.599 kg-m, 10.120
to 11.566 ft-lb).
I Turn nuts to 35° to 40° degrees clockwise with an angle
wrench. If an angle wrench is not available, tighten nuts to
23 to 28 N·m (2.3 to 2.9 kg-m, 17 to 21 ft-lb).
SEM943F
7. Measure connecting rod side clearance.

Connecting rod side clearance:
Standard
0.200 - 0.470 mm (0.0079 - 0.0185 in)
Limit
0.5 mm (0.020 in)
If beyond the limit, replace connecting rod and/or crank-
shaft.
SEM935F
EM-72
CYLINDER BLOCK QG
Assembly (Cont’d)
8. Install rear oil seal retainer.
a. Before installing rear oil seal retainer, remove old liquid gasket
from cylinder block and retainer. GI
b. Apply a continuous bead of liquid gasket to rear oil seal
retainer.
I Use Genuine Liquid Gasket or equivalent. MA
I Apply around inner side of bolt holes.
9. Install crankshaft positon sensor (POS).
AEM248 LC
10. Install knock sensor.
CAUTION: EC
If any impact by dropping is applied to the knock sensor,
replace it with new one.
FE
CL
SEM936F
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-73
SERVICE DATA AND SPECIFICATIONS (SDS) QG
General Specifications
General Specifications NJEM0028
Engine QG13DE QG15DE QG16DE QG18DE
Classification Gasoline
Cylinder arrangement 4, in-line
Displacement
1,295 (79.02) 1,497 (91.35) 1,596 (97.39) 1,769 (107.94)
cm3 (cu in)
Bore × stroke 71.0 × 81.8 73.6 × 88.0 76.0 × 88.0 80.0 × 88.0
mm (in) (2.795 × 3.220) (2.898 × 3.465) (2.992 × 3.465) (3.150 × 3.465)
Valve arrangement DOHC
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1
Number of main bearings 5
Compression ratio 9.5 (9.9*)
*: For QG15DE for Europe
EM120
a b c d e f
QG16DE with intake

222° 228° −4° (16°) 52° (32°) −2° 44°
valve timing control
QG18DE with intake

222° 236° 0° (20°) 56° (36°) −2° 44°
valve timing control
Valve timing
Except for
QG16·18DE with
222° 222° 0° 42° −2° 44°
intake valve timing
control
( ): Valve timing control ON
Compression Pressure NJEM0029

Unit: kPa (bar, kg/cm2, psi)/350 rpm
1,324 (13.24, 13.5, 192)

Standard
1,372 (13.720, 13.99, 198.9)*
1,128 (11.28, 11.5, 164)

Minimum
1,176 (11.759, 11.99, 170.5)*
Difference limit between cylinders 98 (0.98, 1.0, 14)
*: For QG15DE for Europe
EM-74
Belt Deflection
Belt Deflection NJEM0045

Unit: mm (in)
GI
Applied engine Deflection after adjust- Deflection of new belt
Limit
ment MA
6-7 5.5 - 6.5
QG13DE 10 (0.39)
With air conditioner (0.24 - 0.28) (0.217 - 0.256)
compressor
5.3 - 5.7 4.5 - 5.0
QG15·16·18DE 8.1 (0.319)
(0.209 - 0.224) (0.177 - 0.197)
Alternator
7-9 6-8 LC
QG13DE 11 (0.43)
Without air conditioner (0.28 - 0.35) (0.24 - 0.31)
compressor
6.5 - 7.0 5.5 - 6.1
QG15·16·18DE 10.2 (0.402)
(0.256 - 0.276) (0.217 - 0.240)
EC
QG13·15DE 5.2 - 5.8 4.6 - 5.2
8.5 (0.335)
Power steering pump
QG16·18DE*1 (0.205 - 0.228) (0.181 - 0.205) FE
QG16·18DE 4.4 - 4.9 3.9 - 4.4
7.1 (0.280)
(QG15·18DE)*2 (0.173 - 0.193) (0.154 - 0.173)
CL
Applied pushing force 98 N (10 kg, 22 lb)
*1: For models produced after July 2001 (Except for Europe)
*2: For Hatchback for Europe MT
Spark Plug NJEM0046
EXCEPT FOR EUROPE AT
NJEM0046S01
NGK
AX
Standard BKR5E
Type
Cold BKR6E, BKR7E
SU
Plug gap mm (in) 0.8 - 0.9 (0.031 - 0.035)
FOR EUROPE NJEM0046S02 BR

NGK Champion
Standard BKR5E-11 RC10YCC4 ST

Type Hot BKR4E-11 —
Cold BKR6E-11 — RS
Plug gap mm (in) 1.0 - 1.1 (0.039 - 0.043)
BT
Cylinder Head NJEM0030
Unit: mm (in)
Standard Limit
HA
Head surface flatness Less than 0.03 (0.0012) 0.1 (0.004)
Height 117.8 - 118.0 (4.638 - 4.646) —

SC
EL
IDX
EM-75
Valve
Valve NJEM0031
VALVE NJEM0031S01
Unit: mm (in)
SEM188A
QG13DE QG15DE QG16·18DE
26.4 - 26.7 28.9 - 29.2 29.9 - 30.2

Intake
(1.039 - 1.051) (1.138 - 1.150) (1.177 - 1.189)
Valve head diameter “D”
21.4 - 21.7 23.9 - 24.2 24.9 - 25.2
Exhaust
(0.843 - 0.854) (0.941 - 0.953) (0.980 - 0.992)
Intake 92.00 - 92.50 (3.6220 - 3.6417)

Valve length “L”
Exhaust 92.37 - 92.87 (3.6366 - 3.6563)
Intake 5.465 - 5.480 (0.2152 - 0.2157)

Valve stem diameter “d”
Exhaust 5.445 - 5.460 (0.2144 - 0.2150)
Valve face angle “α” 45°15′ - 45°45′
Valve margin “T” 1 (0.04)
Valve margin “T” limit More than 0.5 (0.020 in)
Valve stem end surface grinding limit 0.2 (0.008)
Model For Sedan For Hatchback
Free height mm (in) 41.2 (1.622) 40.0 (1.575)
344.42 (35.12, 77.44) 370.0 (37.73, 83.19)

Standard
Pressure N (kg, lb) at 25.26 (0.9945) at 23.64 (0.9307)
at height mm (in)
323.73 (33.01, 72.79) 347.8 (35.46, 78.19)
Limit
at 25.26 (0.9945) at 23.64 (0.9307)
Out-of-square mm (in) Less than 1.80 (0.0709)
VALVE LIFTER NJEM0031S10

Unit: mm (in)
Valve lifter outside diameter 29.960 - 29.975 (1.1795 - 1.1801)
Lifter guide inside diameter 30.000 - 30.021 (1.1811 - 1.1819)
Clearance between valve lifter and valve lifter guide 0.025 - 0.065 (0.0010 - 0.0026)
EM-76
Valve (Cont’d)
VALVE CLEARANCE =NJEM0031S11
Unit: mm (in)
For adjusting For checking

GI
Hot Cold* (reference data) Hot
Intake 0.32 - 0.40 (0.013 - 0.016) 0.25 - 0.33 (0.010 - 0.013) 0.21 - 0.49 (0.008 - 0.019)
MA
Exhaust 0.37 - 0.45 (0.015 - 0.018) 0.32 - 0.40 (0.013 - 0.016) 0.30 - 0.58 (0.012 - 0.023)
*: At a temperature of approximately 20°C (68°F)

Whenever valve clearances are adjusted to cold specifications, check that the clearances satisfy hot specifications and adjust
again if necessary.
LC
VALVE GUIDE NJEM0031S04
Unit: mm (in)
EC
FE
CL
MT
MEM096A AT
Intake Exhaust
Standard Service Standard Service AX

9.523 - 9.534 9.723 - 9.734 9.523 - 9.534 9.723 - 9.734
Outer diameter
(0.3749 - 0.3754) (0.3828 - 0.3832) (0.3749 - 0.3754) (0.3828 - 0.3832)
Valve guide SU
Inner diameter
5.500 - 5.515 (0.2165 - 0.2171) 5.500 - 5.515 (0.2165 - 0.2171)
[Finished size]
9.475 - 9.496 9.685 - 9.696 9.475 - 9.496 9.685 - 9.696 BR

Cylinder head valve guide hole diameter
(0.3730 - 0.3739) (0.3813 - 0.3817) (0.3730 - 0.3739) (0.3813 - 0.3817)
0.027 - 0.059 0.027 - 0.049 0.027 - 0.059 0.027 - 0.049

Interference fit of valve guide
(0.0011 - 0.0023) (0.0011 - 0.0019) (0.0011 - 0.0023) (0.0011 - 0.0019)
ST
Stem to guide clearance 0.020 - 0.050 (0.0008 - 0.0020) 0.040 - 0.070 (0.0016 - 0.0028)
Valve deflection limit (Dial gauge reading) 0.2 (0.008)

RS
Projection length “L” 11.5 - 11.7 (0.453 - 0.461)
BT
AVAILABLE SHIMS NJEM0031S07
Thickness mm (in) Identification mark HA

2.00 (0.0787) 200
2.02 (0.0795) 202 SC

2.04 (0.0803) 204
2.06 (0.0811) 206 EL

2.08 (0.0819) 208
2.10 (0.0827) 210 IDX

2.12 (0.0835) 212
2.14 (0.0843) 214
2.16 (0.0850) 216
EM-77
Valve (Cont’d)
2.18 (0.0858) 218
2.20 (0.0866) 220
2.21 (0.0870) 221
2.22 (0.0874) 222
2.23 (0.0878) 223
2.24 (0.0882) 224
2.25 (0.0886) 225
2.26 (0.0890) 226
2.27 (0.0894) 227
2.28 (0.0898) 228
2.29 (0.0902) 229
2.30 (0.0906) 230
2.31 (0.0909) 231
2.32 (0.0913) 232
2.33 (0.0917) 233
2.34 (0.0921) 234
2.35 (0.0925) 235
2.36 (0.0929) 236
2.37 (0.0933) 237
2.38 (0.0937) 238
2.39 (0.0941) 239
2.40 (0.0945) 240
2.41 (0.0949) 241
2.42 (0.0953) 242
2.43 (0.0957) 243
2.44 (0.0961) 244
2.45 (0.0965) 245
2.46 (0.0969) 246
2.47 (0.0972) 247
2.48 (0.0976) 248
2.49 (0.0980) 249
2.50 (0.0984) 250
2.51 (0.0988) 251
2.52 (0.0992) 252
2.53 (0.0996) 253
2.54 (0.1000) 254
2.55 (0.1004) 255
2.56 (0.1008) 256
2.57 (0.1012) 257
2.58 (0.1016) 258
2.59 (0.1020) 259
EM-78
Valve (Cont’d)
2.60 (0.1024) 260
2.61 (0.1028) 261 GI

2.62 (0.1031) 262
2.63 (0.1035) 263 MA

2.64 (0.1039) 264
2.65 (0.1043) 265
2.66 (0.1047) 266
2.68 (0.1055) 268 LC

2.70 (0.1063) 270
2.72 (0.1071) 272 EC

2.74 (0.1079) 274
2.76 (0.1087) 276 FE

2.78 (0.1094) 278
2.80 (0.1102) 280 CL

2.82 (0.1110) 282
2.84 (0.1118) 284 MT

2.86 (0.1126) 286
2.88 (0.1134) 288 AT

2.90 (0.1142) 290
2.92 (0.1150) 292 AX

2.94 (0.1157) 294
2.96 (0.1165) 296 SU

2.98 (0.1173) 298
BR
ST
RS
BT
HA
SC
EL
IDX
EM-79
Valve (Cont’d)
AEM236
VALVE SEAT NJEM0031S05

Unit: mm (in)
SEM573DA SEM574DA
Dia. QG13DE QG15DE QG16·18DE
A 24.3 - 24.5 (0.957 - 0.965) 26.8 - 27.0 (1.055 - 1.063) 27.8 - 28.0 (1.094 - 1.102)
B 26.0 - 26.2 (1.024 - 1.031) 28.5 - 28.7 (1.122 - 1.130) 29.5 - 29.7 (1.161 - 1.169)
C 27.7 - 27.9 (1.091 - 1.098) 30.2 - 30.4 (1.189 - 1.197) 31.9 - 32.1 (1.256 - 1.264)
D 28.000 - 28.016 (1.1024 - 1.1030) 30.500 - 30.516 (1.2008 - 1.2014) 31.500 - 31.516 (1.2402 - 1.2408)
E 21.0 - 21.2 (0.827 - 0.835) 23.5 - 23.7 (0.925 - 0.933) 24.5 - 24.7 (0.9646 - 0.9724)
F 22.7 - 22.9 (0.894 - 0.902) 25.2 - 25.4 (0.992 - 1.000) 26.2 - 26.4 (1.031 - 1.039)
G 23.000 - 23.016 (0.9055 - 0.9061) 25.500 - 25.516 (1.0039 - 1.0046) 26.500 - 26.516 (1.043 - 1.0439)
EM-80
Valve (Cont’d)
VALVE SEAT RESURFACE LIMIT NJEM0031S08
Unit: mm (in)
GI
MA
LC
AEM343 EC
Intake 35.95 - 36.55 (1.4154 - 1.4390)
Depth (L)
Exhaust 35.92 - 36.52 (1.4142 - 1.4378) FE
Camshaft and Camshaft Bearing NJEM0032
Unit: mm (in) CL
QG16DE with intake valve timing QG18DE with intake valve timing Except for QG16·18DE with intake
Engine model
control control valve timing control
MT
Intake 40.220 - 40.410 (1.5835 - 1.5909) 40.610 - 40.800 (1.5988 - 1.6063) 39.880 - 40.070 (1.5701 - 1.5776)
Cam height “A”
Exhaust 40.056 - 40.246 (1.5770 - 1.5845)
AT
Cam wear limit 0.20 (0.0079)
AX
SU
BR
EM671
ST
Standard Limit
Camshaft journal to bearing clearance 0.045 - 0.086 (0.0018 - 0.0034) 0.15 (0.0059)
RS
Inner diameter of camshaft bear- No. 1 28.000 - 28.021 (1.1024 - 1.1032)
—
ing No. 2 to No. 5 24.000 - 24.021 (0.9449 - 0.9457)
BT
Outer diameter of camshaft jour- No. 1 27.935 - 27.955 (1.0998 - 1.1006)
—
nal No. 2 to No. 5 23.935 - 23.955 (0.9423 - 0.9431)
HA
Camshaft runout [TIR*] Less than 0.02 (0.0008) 0.1 (0.004)
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.20 (0.0079)

SC
*Total indicator reading
EL
IDX
EM-81
Cylinder Block
Cylinder Block NJEM0033

Unit: mm (in)
SEM171D
QG13DE QG15DE QG16DE QG18DE

Limit
Standard
Surface flatness Less than 0.03 (0.0012) 0.1 (0.004)
Height “H” (nominal) 213.95 - 214.05 (8.4232 - 8.4271) —
71.000 - 71.010 73.600 - 73.610 76.000 - 76.010 80.000 - 80.010

Grade No. 1
(2.7953 - 2.7957) (2.8976 - 2.8976) (2.9921 - 2.9925) (3.1496 - 3.1500)
Cylinder
71.010 - 71.020 73.610 - 73.620 76.010 - 76.020 80.010 - 80.020
bore inner Standard Grade No. 2 0.2 (0.008)
(2.7957 - 2.7961) (2.8980 - 2.8984) (2.7957 - 2.7961) (3.1500 - 3.1504)
diameter
71.020 - 71.030 73.620 - 73.630 76.020 - 76.030 80.020 - 80.030
Grade No. 3
(2.7961 - 2.7965) (2.8984 - 2.8988) (2.7961 - 2.9933) (3.1504 - 3.1508)
Out-of-round (Difference between X and

Less than 0.015 (0.0006) —
Y)
Taper (Difference between A and B) Less than 0.01 (0.0004) —
Difference in inner diameter between cyl-

0.05 (0.0020) 0.2 (0.008)
inders
EM-82
Piston, Piston Ring and Piston Pin
Piston, Piston Ring and Piston Pin =NJEM0034

PISTON NJEM0034S01
Unit: mm (in)
GI
MA
LC
EC
SEM882E
QG13DE QG15DE QG16DE QG18DE*1 QG18DE*2 FE

70.975 - 70.985 73.575 - 73.585 75.975 - 75.985 79.975 - 79.985 79.965 - 79.975
Grade No. 1 (2.7943 - (2.8966 - (2.9911 - (3.1486 - (3.1482 -
2.7947) 2.8970) 2.9915) 3.1490) 3.1486) CL
70.985 - 70.995 73.585 - 73.595 75.985 - 75.995 79.985 - 79.995 79.975 - 79.985
Piston skirt
Standard Grade No. 2 (2.7947 - (2.8970 - (2.9915 - (3.1490 - (3.1486 -
diameter “A”
2.7951) 2.8974) 2.9919) 3.1494) 3.1490) MT
70.995 - 71.005 73.595 - 73.605 75.995 - 76.005 79.995 - 80.005 79.985 - 79.995
Grade No. 3 (2.7951 - (2.8974 - (2.9919 - (3.1494 - (3.1490 -
2.7955) 2.8978) 2.9923) 3.1498) 3.1494)
AT
71.475 - 71.505 74.075 - 74.105 76.475 - 76.505 80.225 - 80.255 80.215 - 80.245
0.5 (0.002) oversize (service) (2.8140 - (2.9163 - (3.0108 - (3.1585 - (3.1581 - AX
2.8152) 2.9175) 3.0120) 3.1596)*3 3.1592)
71.975 - 72.005 74.575 - 74.605 76.975 - 77.005 80.475 - 80.0505 80.465 - 80.495
1.0 (0.039) oversize (service) (2.8337 - (2.9360 - (3.0305 - (3.1683 - (3.1679 - SU
2.8348) 2.9372) 3.0317) 3.1695)*4 3.1691)
“a” dimension 47 (1.850) 43.5 (1.713) 44.5 (1.7520) 45.1 (1.7756) 42.3 (1.665)
BR
Piston pin hole inner diameter 18.987 - 18.999 (0.7475 - 0.7080) 18.993 - 19.005 (0.7478 - 0.7482)
0.025 - 0.045
Piston to bore clearance 0.015 - 0.035 (0.0006 - 0.0014) (0.0010 - ST
0.0018)
*1: Except for Europe RS

*2: For Europe
*3: 0.25 (0.0098) oversize (service)
*4: 0.5 (0.002) oversize (service) BT
PISTON RING NJEM0034S02
Except for Europe NJEM0034S0201 HA
Unit: mm (in)
Except for QG18DE QG18DE

SC
Standard Limit Standard Limit
Top 0.050 - 0.085 (0.0020 - 0.0033) 0.115 (0.0045) 0.040 - 0.080 (0.0016 - 0.0031) 0.110 (0.0043)
EL
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.100 (0.0039) 0.030 - 0.070 (0.0012 - 0.0028) 0.100 (0.0039)
Oil 0.050 - 0.170 (0.0020 - 0.0067) — 0.050 - 0.170 (0.0020 - 0.0067) —

IDX
Top 0.20 - 0.35 (0.0079 - 0.0138) 0.58 (0.0228) 0.20 - 0.35 (0.0079 - 0.0138) 0.58 (0.0228)
End gap 2nd 0.37 - 0.52 (0.0146 - 0.0205) 0.72 (0.0283) 0.50 - 0.65 (0.0197 - 0.0256) 0.85 (0.0335)
Oil 0.20 - 0.60 (0.0079 - 0.0236) 0.95 (0.0374) 0.20 - 0.60 (0.0079 - 0.0236) 0.95 (0.0374)
EM-83
Piston, Piston Ring and Piston Pin (Cont’d)
For Europe NJEM0034S0202
Unit: mm (in)
QG15DE QG18DE
Limit
Standard
Top 0.045 - 0.080 (0.0018 - 0.0031) 0.040 - 0.080 (0.0016 - 0.0031) 0.110 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.100 (0.0039)
Oil 0.065 - 0.135 (0.0026 - 0.0053) 0.045 - 0.155 (0.0018 - 0.0061) —
Top 0.20 - 0.30 (0.0079 - 0.0118) 0.53 (0.0209)
End gap 2nd 0.32 - 0.47 (0.0126 - 0.0185) 0.67 (0.0264)
Oil 0.20 - 0.60 (0.0079 - 0.0236) 0.95 (0.0374)
PISTON PIN NJEM0034S03

Unit: mm (in)
Except for QG18DE QG18DE
Piston pin outer diameter 18.989 - 19.001 (0.7476 - 0.7481)
Piston pin to piston clearance −0.004 to 0 (−0.0002 to 0) 0.002 - 0.006 (0.0001 - 0.0002)
Piston pin to connecting rod bushing Standard 0.005 - 0.017 (0.0002 - 0.0007)
clearance
Limit 0.023 (0.0009)
Connecting Rod NJEM0035

Unit: mm (in)
Center distance 140.45 - 140.55 (5.5295 - 5.5335)
Bend limit [per 100 (3.94)] 0.15 (0.0059)
Torsion limit [per 100 (3.94)] 0.3 (0.012)
Connecting rod bushing inner diameter* (small end) 19.000 - 19.012 (0.7480 - 0.7485)
Connecting rod big end inner diameter 43.000 - 43.013 (1.6929 - 1.6934)
Standard 0.200 - 0.470 (0.0079 - 0.0185)

Side clearance
Limit 0.5 (0.020)
*After installing in connecting rod
EM-84
Crankshaft
Crankshaft NJEM0036
Unit: mm (in)
GI
Grade No. 0 49.956 - 49.964 (1.9668 - 1.9671)
Main journal dia. “Dm” Grade No. 1 49.948 - 49.956 (1.9665 - 1.9668)
MA
Grade No. 2 49.940 - 49.948 (1.9661 - 1.9665)
Grade No. 0 39.968 - 39.974 (1.5735 - 1.5738)
Pin journal dia. “Dp” Grade No. 1 39.962 - 39.968 (1.5733 - 1.5735)
Grade No. 2 39.956 - 39.962 (1.5731 - 1.5733)

LC
Center distance “r” 43.95 - 44.05 (1.7303 - 1.7342)
Standard Less than 0.003 (0.0001)

Out-of-round (X − Y) EC
Limit Less than 0.005 (0.0002)

Taper (A − B) FE

Runout [TIR*] CL
Standard 0.060 - 0.220 (0.0024 - 0.0087)

Free end play MT
Limit 0.3 (0.012)
*: Total indicator reading

AT
Main Bearing NJEM0037
STANDARD NJEM0037S01 AX
Except for Europe NJEM0037S0101
Grade No. Thickness “T” mm (in) Identification color

SU
0 1.827 - 1.831 (0.0719 - 0.0721) Black
1 1.831 - 1.835 (0.0721 - 0.0722) Brown

BR
2 1.835 - 1.839 (0.0722 - 0.0724) Green
3 1.839 - 1.843 (0.0724 - 0.0726) Yellow

ST
4 1.843 - 1.847 (0.0726 - 0.0727) Blue

RS
Grade No. Thickness “T” mm (in) Identification color
0 1.826 - 1.830 (0.0719 - 0.0720) Black

BT
1 1.830 - 1.834 (0.0720 - 0.0722) Brown or Red
2 1.834 - 1.838 (0.0722 - 0.0724) Green

HA
3 1.838 - 1.842 (0.0724 - 0.0725) Yellow
4 1.842 - 1.846 (0.0725 - 0.0727) Blue

SC
UNDERSIZE NJEM0037S02 EL
Unit: mm (in)
Thickness “T”
IDX
0.25 (0.0098) 1.960 - 1.964 (0.0772 - 0.0773)
0.50 (0.0197) 2.085 - 2.089 (0.0821 - 0.0822)
EM-85
Connecting Rod Bearing
Connecting Rod Bearing NJEM0038

STANDARD SIZE NJEM0038S01
Unit: mm (in)
Grade No. Thickness Identification color or number
0 1.503 - 1.506 (0.0592 - 0.0593) —
1 1.506 - 1.509 (0.0593 - 0.0594) Brown
2 1.509 - 1.512 (0.0594 - 0.0595) Green
UNDERSIZE NJEM0038S02
Unit: mm (in)
Grade No. Thickness Identification color or number
0.08 (0.0031) 1.542 - 1.546 (0.0607 - 0.0609) —
0.12 (0.0047) 1.562 - 1.566 (0.0615 - 0.0617) —
0.25 (0.0098) 1.627 - 1.631 (0.0641 - 0.0642) —
Bearing Clearance NJEM0039

Unit: mm (in)
Model Except for Europe For Europe
Standard 0.018 - 0.042 (0.0007 - 0.0017) 0.020 - 0.044 (0.0008 - 0.0017)

Main bearing clearance
Limit 0.1 (0.004)
Standard 0.014 - 0.039 (0.0006 - 0.0015)

Connecting rod bearing clearance
Limit 0.1 (0.004)
Miscellaneous Components NJEM0040

Unit: mm (in)
Flywheel runout [TIR*] Less than 0.15 (0.0059)
Drive plate runout [TIR*] Less than 0.2 (0.008)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059)
EM-86
PRECAUTIONS YD
Parts Requiring Angular Tightening
Parts Requiring Angular Tightening NJEM0047

I Use an angle wrench for the final tightening of the following
engine parts: GI
a) Cylinder head bolts
b) Main bearing cap bolts MA
c) Connecting rod cap nuts
d) Crankshaft pulley bolt
I Do not use a torque value for final tightening.
I The torque value for these parts are for a preliminary step.
I Ensure thread and seat surfaces are clean and coated with LC
engine oil.
EC
FE
CL
MT
Liquid Gasket Application Procedure NJEM0048
1. Use a scraper to remove all traces of old liquid gasket AT
from mating surfaces and grooves. Also, completely clean
any oil from these areas.
2. Apply a continuous bead of liquid gasket to mating sur-
AX
faces. (Use Genuine Liquid Gasket or equivalent.)
I Be sure liquid gasket diameter is as specified. SU
BR
SEM164F
3. Apply liquid gasket around the inner side of bolt holes

(unless otherwise specified). ST
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and RS
engine coolant.
BT
HA
AEM080
SC
EL
IDX
EM-87
PREPARATION YD
Special Service Tools
Special Service Tools NJEM0049
Tool number
Description
Tool name
ST0501S000 Disassembling and assembling

Engine stand assembly
1 ST05011000
Engine stand
2 ST05012000
Base
NT042
KV10106500
Engine stand shaft
NT028
KV11105900 KV10115900 has been replaced with

Engine sub-attachment KV10106500.
NT799
KV10115600 Installing valve oil seal

Valve oil seal drift Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
NT603 f: 5 (0.20)
Unit: mm (in)
KV10107902 Removing valve oil seal

1 KV10116100
adapter
NT605
KV11103000 Removing crankshaft pulley

Injection pump drive gear
puller
NT676
EM-88
PREPARATION YD
Tool number
Description
Tool name
GI
KV101056S0 Preventing crankshaft from rotating
Ring gear stopper a: 3 (0.12)
1 KV10105630 b: 6.4 (0.252) MA
Adapter c: 2.8 (0.110)
2 KV10105610 d: 6.6 (0.260)
Plate e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in) LC
EC
NT617
KV101151S0 Changing shims

Lifter stopper set FE
1 KV10115110
Camshaft pliers
2 KV10115120 CL
Lifter stopper
NT041
MT
EM03470000 Installing piston assembly into cylinder bore
Piston ring compressor
AT
NT044 AX
ST16610001 Removing crankshaft pilot bushing
Pilot bushing puller
SU
BR
NT045
KV10111100 Removing steel oil pan and rear timing chain

Seal cutter case ST
RS
NT046
WS39930000 Pressing the tube of liquid gasket BT

Tube presser
HA
NT052
KV10112100 Tightening bolts for bearing cap, cylinder

SC
Angle wrench head, etc.
EL
IDX
NT014
EM-89
PREPARATION YD
Tool number
Description
Tool name
KV10109300 a: 68 mm (2.68 in)

Pulley holder b: 8 mm (0.31 in) dia.
NT628
KV11106010 a: 5 mm (Face to face)

Hexagon wrench b: 20 mm
NT801
KV11106020 a: 6 mm (Face to face)

Hexagon wrench b: 20 mm
NT803
KV11106030 a: 6 mm dia.
Positioning stopper pin b: 80 mm
NT804
KV11106040 a: T70
TORX wrench b: 26 mm
NT805
Commercial Service Tools NJEM0050
Valve seat cutter set Finishing valve seat dimensions
NT048
Piston ring expander Removing and installing piston ring
NT030
EM-90
NJEM0051
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING YD

NVH Troubleshooting — Engine Noise
NVH Troubleshooting — Engine Noise NJEM0051S01

Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs. GI
2. Confirm the type of noise.
3. Specify the operating condition of engine. MA
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine
Location of Type of Source of Reference
Before After When When When While Check item
noise noise noise page LC
warm-up warm-up starting idling racing driving
Top of Ticking or Tappet

C A — A B — Valve clearance EM-148
engine clicking noise EC
Rocker
cover Camshaft Camshaft journal
EM-136,
Cylinder Rattle C A — A B C bearing clearance FE
137
head noise Camshaft runout
Piston and piston pin

Slap or Piston pin clearance EM-159, CL
— A — B B —
knock noise Connecting rod bush- 169
ing clearance
MT
Piston-to-bore clear-
ance
Piston ring side clear- EM-159,
Crankshaft Slap or A — — B B A
Piston slap
ance 160, 161,
AT
pulley rap noise
Piston ring end gap 162
Cylinder Connecting rod bend
block and torsion AX
(Side of
engine) Connecting rod bush-
Oil pan Connect- ing clearance (Small SU
ing rod end) EM-169,
Knock A B C B B B
bearing Connecting rod bear- 167
noise ing clearance (Big
end)
BR
Main bearing oil
Main bear- EM-164,
Knock A B — A B C
ing noise
clearance
164
ST
Crankshaft runout
Front of Timing
engine chain and
Timing chain cracks RS
Tapping or and wear EM-105,
Timing A A — B B B chain ten-
ticking Timing chain ten- 103
chain sioner
sioner operation BT
cover noise
Drive belts
Squeaking
A B — B — C (Sticking Drive belts deflection HA
or fizzing
or slipping) EM-94
Front of Drive belts Idler pulley bearing
Creaking A B A B A B SC
engine (Slipping) operation
Water
Squall
A B — B A B pump Water pump operation LC-43 EL
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related

IDX
EM-91
NJEM0053
MEASUREMENT OF COMPRESSION PRESSURE YD
1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated for
self-diagnosis items. Refer to EC-276, “Trouble Diagnosis —
INDEX”.
I Do not disconnect CONSULT-II until the end of this operation;
it will be used to check engine rpm and for error detection at
the end of this operation.
4. Disconnect the negative battery terminal.
5. To prevent fuel from being injected during inspection, remove
JEM111G fuel injection pump fuse [ENG CONT2 (20A)] from fuse box on
the left side of engine compartment.
6. Remove glow plugs from all the cylinders.
CAUTION:
I Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
I Carefully remove glow plugs to prevent any damage or
breakage.
I Handle with care to avoid applying any shock to glow
plugs.
7. Install adapter (SST) to installation holes of glow plugs and

connect compression gauge for diesel engine.
: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
8. Connect battery negative terminal.
9. Set the ignition switch to “START” and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
I Always use a fully-charged battery to obtain specified
engine speed.
Except for Europe
SEM112G Unit: kPa (bar, kg/cm2, psi)/rpm
Difference limit between

Standard Minimum
cylinders
2,844 (28.44, 29.0, 412)/ 2,452 (24.52, 25.0, 356)/

490 (4.90, 5.0, 71)/200
200 200
For Europe
Unit: kPa (bar, kg/cm2, psi)/rpm
Difference limit between

Standard Minimum
cylinders
3,138 (31.38, 32.0, 455)/ 2,452 (24.52, 25.0, 356)/

490 (4.90, 5.0, 71)/200
200 200
EM-92
MEASUREMENT OF COMPRESSION PRESSURE YD
I When engine rpm is out of the specified range, check the spe-
cific gravity of battery liquid. Measure again under corrected
conditions. GI
I If engine rpm exceeds the limit, check valve clearance and
combustion chamber components (valves, valve seats, cylin-
der head gaskets, piston rings, pistons, cylinder bores, cylin- MA
der block upper and lower surfaces) and measure again.
− If compression pressure becomes normal after applying oil,
piston ring may be worn or damaged. Check piston ring for
malfunction. If any, replace piston ring.
− If compression pressure is still low after applying oil, valve may
be malfunctioning. Check valve for malfunction. If contact mal-
LC
function is found, replace valve or valve seat.
I If compression pressure in adjacent two cylinders is low after EC
applying oil, pressure may be leaking from gasket. In this case,
replace cylinder head gasket.
10. Complete this operation as follows: FE
a. Turn the ignition switch to “OFF”.
b. Disconnect battery negative terminal.
CL
c. Install glow plugs.
d. Install fuel injection pump fuse [ENG CONT2 (20A)].
e. Connect battery negative terminal. MT
f. Using CONSULT-II make sure no error code is indicated for
items of self- diagnosis. Refer to EC-276, “Trouble Diagnosis —
INDEX”. AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-93
DRIVE BELTS YD
Inspection
Inspection NJEM0088
I Before inspecting the engine, make sure the engine has
cooled down; wait approximately 30 minutes after the engine
has been stopped.
I Visually inspect all belts for wear, damage, or cracks on con-
tacting surfaces and edge areas.
I When measuring deflection, apply 98 N (10 kg, 22 lb) at the H
marked point.
CAUTION:
I When checking belt deflection immediately after
JEM249G installation, first adjust it to the specified value. Then,
after turning the crankshaft two turns or more, re-adjust to
the specified value to avoid variation in deflection
between pulleys.
I Tighten idler pulley lock nut by hand and measure deflec-
tion without looseness.
Belt Deflection:
Belt deflection with 98 N (10 kg, 22 lb) force
Belt specifica- applied* mm (in)
Applied belt
tion Limit for re-
New Adjusted
tightening
Air conditioner
HA type low 4-5 6-7
compressor 8.5 (0.335)
edge belt (0.16 - 0.20) (0.24 - 0.28)
belt
Alternator & HA type low- 9.0 - 10.5 11.0 - 12.5

water pump edge wide (0.354 - (0.433 - 16.5 (0.650)
belt angle belt 0.413) 0.492)
*: When engine is cold.
Adjustment NJEM0089
I Adjust belts with the parts shown below.
Applied belt Belt tightening method for adjustment
Air conditioner compressor belt Adjusting bolt on idler pulley
Alternator & water pump belt Adjusting bolt on alternator
CAUTION:
I When a new belt is installed as a replacement, adjust it to
the value specified under “New” accommodations
because of insufficient adaptability with pulley grooves.
EM-94
DRIVE BELTS YD
Adjustment (Cont’d)
I If the belt deflection of the current belt is out of the “Limit
for re-tightening”, adjust to the “Adjusted value”.
I When checking belt deflection immediately after GI
installation, first adjust it to the specified value. Then,
after turning crankshaft two turns or more, re-adjust it to
the specified value to avoid variation in deflection MA
between pulleys.
I Make sure the belts are fully fitted into the pulley grooves
during installation.
I Handle with care to avoid smearing the belts with oil or
cooling water etc.
LC
I Do not twist or bend the belts with strong force.
EC
FE
CL
MT
AIR CONDITIONER COMPRESSOR BELT NJEM0089S01
1. Remove RH splash cover (with undercover attached). AT
2. Loosen idler pulley lock nut (A).
3. Turn adjusting bolt (B) to adjust.
AX
I Refer to EM-94, “Inspection” for adjustment values.
4. Tighten lock nut (A).
Nut A: SU
: 31 - 39 N·m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
ALTERNATOR & WATER PUMP BELT NJEM0089S02
BR
1. Loosen adjuster lock nut (C).
2. Loosen alternator fixing bolts (D) (each on front and rear).
3. Turn adjusting bolt (E) to adjust.
ST
I Refer to EM-94, “Inspection” for adjustment values.
4. Tighten nut (C) and bolt (D) in this order. RS
Nut C:
: 19 - 24 N·m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
Bolt D:
BT
: 44 - 57 N·m (4.4 - 5.9 kg-m, 32 - 42 ft-lb)
HA
JEM251G
Removal NJEM0090
SC
1. Loosen each belt. Refer to EM-94, “Adjustment”.
2. Remove air conditioner compressor belt.
EL
3. Remove alternator & water pump belt.
IDX
EM-95
DRIVE BELTS YD
Installation
1. Install each belt on pulley in reverse order of removal.
2. Adjust belt tension. Refer to EM-94, “Adjustment”.
3. Tighten nuts and bolts provided for adjustment to the specified
torque.
4. Check again that each belt tension is as specified.
EM-96
AIR CLEANER YD
Changing Air Cleaner Filter
Changing Air Cleaner Filter NJEM0092

VISCOUS PAPER TYPE
The viscous paper type filter does not need cleaning.
NJEM0092S01
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-97
OIL PAN YD
Components
Components NJEM0054
SEM492G
Removal NJEM0055
CAUTION:
When removing the upper oil pan from engine, first remove
the crankshaft position sensor (TDC sensor) from the assem-
bly.
Be careful not to damage sensor edges and signal plate teeth.
1. Remove right engine undercover.
WARNING:
To avoid the danger of being scalded, never drain the engine
oil when the engine is hot.
EM-98
OIL PAN YD
Removal (Cont’d)
3. Remove air conditioner compressor bracket.
4. Remove lower oil pan bolts.
I Loosen bolts in the reverse order of that shown in the figure. GI
MA
JEM114G LC
5. Remove lower oil pan.
a. Insert Tool between upper oil pan and lower oil pan.
EC
I Be careful not to damage aluminum mating surface.
I Do not insert screwdriver, or oil pan flange will be
deformed. FE
CL
SEM544G
MT
b. Slide Tool by tapping on the side of the Tool with a hammer.
c. Remove lower oil pan. AT
AX
SU
BR
SEM545G
6. Remove oil strainer.

7. Remove front exhaust tube and its support.
ST
Refer to FE-38, “Removal and Installation”.
RS
BT
HA
8. Set a suitable transmission jack under transaxle and hoist SC

engine with engine slinger.
I Place the jack as close to the center as possible for support.
Refer to EM-151, “REMOVAL”. EL
9. Remove front and rear engine mounting nuts and bolts.
IDX
11. Remove crankshaft position sensor (TDC sensor) from oil pan.
12. Remove oil pan cover.
JEM553G
EM-99
OIL PAN YD
Removal (Cont’d)
13. For Europe only, remove catalyst rear diffuser, EM-123, “Cata-
lyst (For Europe)”.
14. Remove upper oil pan bolts in reverse order.
JEM116G
15. Remove four engine-to-transaxle bolts using a universal

socket. (Commercial Service Tool).
16. Remove upper oil pan.
a. Insert an appropriate size tool into the notch of upper oil pan.
I Be careful not to damage aluminum mating surface.
I Do not insert screwdriver, or oil pan flange will be
deformed.
b. Pry off upper oil pan by moving the tool up and down.
c. Remove upper oil pan.
I Be careful to prevent No. 15 and 16 blots from falling into
transaxle case.
1. Install upper oil pan.
a. Use a scraper to remove old liquid gasket from mating sur-
faces.
I Also remove old liquid gasket from mating surface of cyl-
inder block, front cover and lower oil pan.
I Remove old liquid gasket from the bolt hole and thread.
JEM117G
b. Apply a continuous bead of liquid gasket to mating surface of

aluminum oil pan.
SEM159F
c. Apply liquid gasket, to areas shown in the figure.

I At the 8 bolt holes marked ★, liquid gasket should be
applied on the rims of the holes.
I Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
or 4.5 to 5.5 mm (0.177 to 0.217 in) wide. (Be careful that
the diameter of the silicon bead is different around the
front.)
JEM118G
EM-100
OIL PAN YD
d. Install upper oil pan.
I Tighten bolts in numerical order.
I Bolt dimensions vary depending on the installation location. GI
Refer to the following and use appropriate bolts.
M6 x 30 mm: Bolt No. 15, 16
M8 x 25 mm: Bolt No. 3, 4, 9, 10
MA
M8 x 60 mm: Bolt No. 1, 2, 5, 6, 7, 8, 11, 12, 13, 14
I The shank length under the bolt neck above is the length of the
threaded part (pilot portion not included).
JEM116G LC
2. Install the four engine-to-transaxle bolts. For tightening torque,
refer to MT-24, “Installation”.
3. Install oil pan cover.
EC
4. Install air conditioner compressor bracket.
: 57 - 65 N·m (5.8 - 6.7 kg-m, 42 - 48 ft-lb) FE
5. Install center member.
6. Install front and rear engine mounting insulator nuts and bolts.
CL
MT
7. Install crankshaft position sensor (TDC sensor).
I Tighten bolt while positioning and setting the side surface of AT
the crankshaft position sensor (TDC sensor) sleeve against
the arc of the upper oil pan.
8. Install front exhaust tube and its support. AX
9. Install oil strainer.
SU
BR
JEM119G
10. Install lower oil pan.

a. Use a scraper to remove old liquid gasket from mating sur-
ST
faces.
I Also remove old liquid gasket from mating surface of RS
upper oil pan.
BT
HA
SEM493G
b. Apply a continuous bead of liquid gasket to mating surface of SC

lower oil pan.
EL
IDX
SEM159F
EM-101
OIL PAN YD
I Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
SEM494G
c. Install lower oil pan.

I Tighten in numerical order shown in the figure.
11. Install in the reverse order of removal.
JEM114G
EM-102
TIMING CHAIN YD
Secondary Timing Chain
Secondary Timing Chain NJEM0093

CAUTION:
I After removing timing chain, do not turn crankshaft and GI
camshaft separately, or valves will strike piston heads.
I When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
MA
engine oil.
I Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprockets, crankshaft pulley,
and camshaft brackets.
I When removing the oil pans, oil pump assembly and tim- LC
ing chain from engine, first remove the crankshaft posi-
tion sensor (TDC sensor).
Be careful not to damage sensor edges. EC
I Do not spill engine coolant on drive belts.
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
JEM055H
SC
REMOVAL NJEM0093S01
I For preparative work for removing/installing secondary timing
chain to remove/install fuel injection pump, refer to EC-299,
EL
“Electronic control fuel injection pump”.
I To prepare for removing/installing secondary timing chain to IDX
remove/install camshaft, refer to EM-133, “CAMSHAFT”.
2. Drain coolant by removing cylinder block drain plugs. Refer to
LC-47, “Changing Engine Coolant”.
EM-103
TIMING CHAIN YD
Secondary Timing Chain (Cont’d)
3. Remove front chain case.
I Move power steering fluid reservoir tank from the bracket.
I Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
I Remove No. 6, 10, and 11 bolts with the rubber washer as
space is limited for pulling them out.
JEM121G
CAUTION:
I While front chain case is removed, cover openings to pre-
vent entry of foreign material into engine.
I Do not remove two mass dampers on the back of cover.
SEM514G
4. Set the No. 1 piston to TDC on its compression stroke.

I Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
shown in the figure.
I No position indicator is provided on the crankshaft pulley.
I When installing, color coded links on the secondary tim-
ing chain can be used as alignment marks. Marking may
not be necessary for removal; however, make alignment
marks as required because the alignment mark on fuel
injection pump sprocket may not be easy to see.
SEM515G

a. Push the plunger of chain tensioner and keep it pressed with
a push pin.
JEM124G
b. Using a hexagon-head wrench (face to face: 5 mm, SST),

remove bolts to remove chain tensioner.
JEM125G
EM-104
TIMING CHAIN YD
6. Remove slack guide.
I Using a hexagon-head wrench (face to face: 6 mm, SST),
remove bolt to remove slack guide. GI
MA
JEM126G LC
7. Remove tension guide.
8. Remove secondary timing chain.
EC
I Timing chain alone can be removed without removing sprock-
ets.
FE
CL
JEM127G
MT
INSPECTION NJEM0093S02
Check for cracks and excessive wear at roller links. Replace AT
chain if necessary.
AX
SU
BR
SEM885F
INSTALLATION
1. Install secondary timing chain.
NJEM0093S03 ST
I When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the chain. RS
2. Install tension guide.
I The upper bolt has a longer shank than the lower bolt.
BT
HA
SC
EL
IDX
JEM128G
EM-105
TIMING CHAIN YD
3. Using a hexagon-head wrench (face to face: 6 mm, SST),
install slack guide.
JEM126G

a. Push the plunger of the chain tensioner. While holding it with
a push pin, install the chain tensioner.
b. Using a hexagon-head wrench (face to face: 5 mm, SST),
tighten bolts.
c. Pull out the push pin, etc. holding the plunger.
I Check again that the alignment marks on the sprockets
and the colored alignment marks on the timing chain are
aligned.
JEM125G
5. Install front chain case.

a. Install tension guide on the back surface of front chain case.
I Hold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.
SEM514G
b. Apply specified liquid gasket (Refer to EM-87, “Liquid Gasket

Application Procedure”.) on both ends of arched area (loca-
tions where rear chain case is adjoined) as shown in the fig-
ure.
c. Install front chain case.
I When installing, align dowel pin on oil pump case with the pin
hole.
JEM129G
I Install No. 6, 10, and 11 bolts with the rubber washer to the
front chain case.
d. Tighten fixing bolts in the numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order.
JEM121G
EM-106
TIMING CHAIN YD
6. Hereafter, install in the reverse order of removal.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-107
TIMING CHAIN YD
Primary Timing Chain
Primary Timing Chain NJEM0094
JEM056H
EM-108
TIMING CHAIN YD
Primary Timing Chain (Cont’d)
REMOVAL NJEM0094S01
1. Remove lower and upper oil pans. Refer to EM-98, “OIL PAN”.
2. Install center member, and front and rear engine mounting GI
parts to support engine temporarily. Refer to EM-150,
“ENGINE ASSEMBLY”.
3. Remove drive belts. Refer to EM-95, “Drive Belts”.
MA
4. Remove water pump pulley.
5. Remove RH engine mounting parts. Refer to EM-150,
“ENGINE ASSEMBLY”.
6. Remove secondary timing chain and associated parts. Refer to
EM-103, “Secondary Timing Chain”. LC
7. Remove oil filter bracket. Refer to LC-33, “Oil Filter Bracket”.
EC
FE
CL
MT
8. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (SST). AT
b. Loosen crankshaft pulley fixing bolt and pull out the bolt
approximately 10 mm (0.39 in).
AX
SU
BR
JEM131G
c. Using pulley puller (SST), remove crankshaft pulley.

I Use two M6 bolts with approx. 60 mm (2.36 in) shank length
ST
for securing crankshaft pulley.
RS
BT
HA
JEM132G
9. Remove oil pump. SC

I Loosen bolts in the reverse order of that shown in the figure
and remove them.
I Use seal cutter (SST) etc. for removal. EL
10. Remove front oil seal from oil pump.
I Punch out the seal off from the back surface of the oil pump IDX
using a flat-bladed screwdriver.
I Be careful not to damage the oil pump.
JEM133G
EM-109
TIMING CHAIN YD
I When removing chain tensioner, push the sleeve of chain ten-
sioner and keep it pressed with a push pin, etc.
12. Remove timing chain slack guide.
JEM134G
13. Hold fuel injection pump sprocket and remove bolt.

a. Insert positioning stopper pin (SST) into the hole 6 mm (0.24
in) in the diameter on the fuel injection pump sprocket.
b. Using a TORX wrench (SST), turn pump shaft little by little to
adjust the position of fuel injection pump sprocket so that the
holes align.
c. Push positioning stopper pin (SST) through pump sprocket to
fuel injection pump body to hold pump sprocket, and remove
bolt.
JEM135G
14. Remove primary timing chain with fuel injection pump sprocket
and crankshaft sprocket.
15. When removing rear chain case, perform the following steps.
16. Remove camshaft sprockets. Refer to EM-133, “CAMSHAFT”.
JEM136G
17. Remove chain guide and tension guides.

18. Remove fuel injection pump. Refer to EC-299, “Electronic Con-
trol Fuel Injection Pump”.
19. Remove power steering pump.
JEM137G
EM-110
TIMING CHAIN YD
20. Remove rear chain case.
I Loosen fixing bolts in the reverse order of that shown in the
figure and remove them. GI
I Use seal cutter (SST) for removal.
MA
LC
EC
FE
CL
JEM138G
MT
INSPECTION NJEM0094S02
Check for cracks and excessive wear at roller links. Replace AT
chain if necessary.
INSTALLATION NJEM0094S03 AX
SU
BR
ST
RS
BT
HA
JEM139G SC
EL
IDX
EM-111
TIMING CHAIN YD
1. When rear chain case is removed, perform the following steps
from 2 to 6.
2. Install rear chain case.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-87, “Liquid Gasket Application Procedure”.) on locations
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by start and end
areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protrud-
ing from the case surface.
JEM140G
b. Install four O-rings to the grooves of the cylinder block, fuel

injection pump bracket.
JEM141G
c. Install rear chain case.

I When installing, align the dowel pin with the pin hole.
d. Tighten bolts in the numerical order shown in the figure.
I Install the following four types of bolts, referring to the figure.
16 mm (0.63 in): Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22
20 mm (0.79 in): Bolt No. 3, 4, 6, 9, 10, 11, 13, 14
25 mm (0.98 in): Bolt No. 12, 15
35 mm (1.38 in): Bolt No. 5, 7, 8
I The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.
JEM138G
EM-112
TIMING CHAIN YD
3. Install power steering pump.
4. Install fuel injection pump. Refer to “Electronic Control Fuel
Injection Pump” in EC section. GI
I Before installing, make sure the notch on the fuel injection
pump flange and the hole 6 mm (0.24 in) in diameter on the
pump body are aligned. MA
5. Install chain guide and tension guides.
6. Install camshaft sprockets. Refer to EM-145, “Camshaft”.
7. Install crankshaft sprocket, aligning it with the crankshaft key
on the far side.
JEM137G LC
8. Install primary timing chain with fuel injection pump sprocket.
I When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the chain.
EC
I Install fuel injection pump sprocket washer with the surface
marked “F” (front mark) facing the front of the engine. FE
9. Install timing chain onto power steering pump sprocket and
through chain guide.
CL
JEM136G
MT
10. Use the positioning stopper pin (SST) to hold the fuel injection
pump sprocket and install the bolt. AT
I Using a TORX wrench (SST), turn the pump shaft little by little
to adjust the position of the pump flange. Insert positioning
stopper pin (SST) into the hole 6 mm (0.24 in) in diameter on AX
the fuel injection pump sprocket so that the stopper pin goes
through the pump flange to the pump body. While the stopper
pin is in place, install the bolt. SU
BR
JEM135G
11. Install timing chain slack guide.

ST
I Push the plunger of the chain tensioner. While keeping plunger
pressed down with a push pin, etc., install the chain tensioner. RS
I After installation, pull out the push pin holding the plunger.
I Check again that the alignment marks on the sprockets
and the colored alignment marks on timing chain are BT
aligned.
HA
JEM134G
13. Install front oil seal to oil pump. SC

I Using a suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
I Do not touch lips of oil seal. Make sure seal surfaces are EL
free of foreign materials.
IDX
JEM142G
EM-113
TIMING CHAIN YD
14. Install chain case cover (for opening for power steering pump
removal/installation) to oil pump.
I Apply a continuous bead of specified liquid gasket (Refer to
EM-87, “Liquid Gasket Application Procedure”.) as shown in
the figure.
I Apply liquid gasket on oil pump-side surface.
JEM143G
15. Install oil pump.

a. Apply a continuous bead of specified liquid gasket (Refer to
A: Leave the start and end areas of the bead slightly protrud-
ing from the surface.
B: Apply liquid gasket along upper end surface of oil pump.
JEM144G
b. Install oil pump drive spacer to crankshaft.

I Install with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
JEM145G
d. Install oil pump.

I When installing, align the inner rotor in the direction of the two
facing flats of the oil pump drive spacer.
I When installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in the numerical order shown in the figure.
f. After tightening all the bolts, re-tighten in the same order.
JEM133G
16. Check gaps on upper oil pan mounting surface.

I Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
Standard:
Oil pump and rear chain case
–0.14 to 0.14 mm (–0.0055 to 0.0055 in)
Rear chain case and cylinder block
–0.25 to 0.13 mm (–0.0098 to 0.0051 in)
I If the measured value is out of the above range, install again.
JEM146G
EM-114
TIMING CHAIN YD
17. Install crankshaft pulley.
a. Install crankshaft pulley to crankshaft.
b. Hold crankshaft pulley with the pulley holder (SST). GI
c. Tighten bolt to 20 to 29 N·m (2.0 to 3.0 kg-m, 15 to 21 ft-lb).
d. Put an alignment mark on crankshaft pulley that aligns with MA
one of the punched marks on the bolt.
e. Tighten fixing bolt another 60° - 66° [target: 60° (turn by one
notch)].
18. Install oil filter bracket. Refer to LC-33, “Oil Filter Bracket”.
19. Install secondary timing chain and the associated parts.
JEM147G
Refer to EM-103, “Secondary Timing Chain”, EM-105, LC
“INSTALLATION”.
20. Install in the reverse order of removal hereafter.
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-115
INTAKE MANIFOLD YD
SEM486GA
PREPARATIVE WORK NJEM0095S01

1. Drain engine coolant. Refer to LC-47, “Changing engine cool-
ant”.
2. Remove engine cover. Refer to the figure at left.
3. Remove injection tube.
4. Remove blow-by hose (on rocker cover side).
5. Remove or relocate fuel pipes.
6. Remove or relocate wires/harnesses and tubes/pipes.
JEM050H
EM-116
INTAKE MANIFOLD YD
FUEL PIPING NJEM0095S02
Removal
I
NJEM0095S0201
To prevent fuel from flowing out, plug the opening of the hose GI
with a blind plug after disconnection.
I Be careful not to spill fuel in the engine compartment. MA
Installation NJEM0095S0202
After repairing, bleed air in pipes by shifting priming pump up and
down until the touch is heavy.
For further air bleeding, idle at least 1 minute or more.
JEM238G LC
INTAKE MANIFOLD NJEM0095S03
Removal NJEM0095S0301 EC
I Loosen bolts and nuts in the reverse order of that shown in the
figure.
Installation FE
NJEM0095S0302
I When stud bolts come off, install with the following torque:
: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb) CL
I Tighten fixing bolts in the numerical order shown in the figure.
EGR VOLUME CONTROL VALVE NJEM0095S04 MT
SEM511G
I Handle with care avoiding any shocks.
I Do not disassemble or adjust.
AT
AX
SU
BR
WATER HOSE NJEM0095S05 ST

I Install water hose by referring to identification marks; avoiding
twisting. RS
I When an insert stopper is not provided with the pipe, insert the
hose up to dimension A. When the pipe is shorter than dimen-
sion A, insert hose fully until it reaches the end. BT
Dimension A: 25 - 30 mm (0.984 - 1.181 in)
I When an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
HA
I When marking is provided on the pipe, insert hose until it cov-
ers half of the marking. SC
EL
IDX
JEM240G
EM-117
INTAKE MANIFOLD YD
Inspection
Inspection NJEM0096
Check distortion on the mounting surface with a straightedge and
feeler gauge.
Limit: 0.1 mm (0.004 in)
SEM495G
SEM487GA
EM-118
INTAKE MANIFOLD YD
For Europe
1.
NJEM0109S0101
Drain engine coolant. Refer to LC-47, “Changing engine cool- GI
ant”.
2. Remove engine cover. Refer to the figure at left. MA
3. Remove injection tube.
4. Remove blow-by hose (on rocker cover side).
5. Remove or relocate fuel pipes.
6. Remove or relocate wires/harnesses and tubes/pipes.
LC
EC
FE
CL
SEM565G
MT
FUEL PIPING NJEM0109S02
Removal NJEM0109S0201
AT
I To prevent fuel from flowing out, plug the opening of the hose
with a blind plug after disconnection.
I Be careful not to spill fuel in the engine compartment.
AX
Installation
I
NJEM0109S0202
After repairing, bleed air in pipes by shifting priming pump up SU
and down until the touch is heavy.
I For further air bleeding, idle at least 1 minute or more. BR
JEM238G
INTAKE MANIFOLD NJEM0109S03 ST

I Loosen bolts and nuts in the reverse order of that shown in the
figure. RS
I When stud bolts come off, install with the following torque: BT
: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)
I Tighten fixing bolts in the numerical order shown in the figure.
HA
EGR VOLUME CONTROL VALVE NJEM0109S04
SEM489G
I Handle with care avoiding any shocks.
I Do not disassemble or adjust. SC
EL
IDX
EM-119
INTAKE MANIFOLD YD
WATER HOSE NJEM0109S05
I Install water hose by referring to identification marks; avoiding
twisting.
I When an insert stopper is not provided with the pipe, insert the
hose up to dimension A. When the pipe is shorter than dimen-
sion A, insert hose fully until it reaches the end.
Dimension A: 25 - 30 mm (0.984 - 1.181 in)
I When an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
I When marking is provided on the pipe, insert hose until it cov-
ers half of the marking.
SEM490G
Inspection NJEM0110
Check distortion on the mounting surface with a straightedge and
feeler gauge.
Limit: 0.1 mm (0.004 in)
SEM491G
EM-120
EXHAUST MANIFOLD (EXCEPT FOR EUROPE) YD
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
JEM243G
BR
1. Remove engine cover.
2. Remove air cleaner case (upper), and air duct.
ST
3. Remove glow plate. Refer to EM-132, “Components”.
4. Remove exhaust front tube manifold nuts. Refer to FE-38, RS
“Removal and Installation”.
BT
HA
EXHAUST MANIFOLD NJEM0097S02

SC
1. Remove all the bolts holding the exhaust manifold cover and
bring the cover toward the front of the vehicle. EL
2. Loosen nuts holding the exhaust manifold in the reverse order
of that shown in the figure. IDX
3. Remove exhaust manifold with exhaust manifold cover.
I When stud bolts come off, install with the following torque:
JEM244G : 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
EM-121
EXHAUST MANIFOLD (EXCEPT FOR EUROPE) YD
I Tighten exhaust manifold holding nuts in the numerical order
shown in the figure above.
I Tighten only 1 to 4 nuts to the specified torque again.
EXHAUST MANIFOLD GASKET NJEM0097S03
Install gasket so that the protruding tab (mark for correct installa-
tion) is positioned on the side of No. 4 port (rear side). Refer to
component structure diagram on the previous page.
Inspection NJEM0098
Check distortion on mounting surface with straightedge and feeler
gauge.
Limit: 0.3 mm (0.012 in)
JEM245G
EM-122
CATALYST (FOR EUROPE) YD
GI
MA
LC
EC
FE
CL
MT
AT
JEM264G
AX
PREPARATIVE WORK NJEM0101S01 SU

Remove the following parts.
I Undercover
I Engine coolant (drain) BR
Refer to LC-47, “Changing Engine Coolant”.
I Radiator upper hose ST
I Cooling fan
Refer to LC-46, “Radiator”.
I Radiator mount bracket RS
I Water inlet pipe
I Exhaust front tube (disconnect)
Refer to FE-38, “Removal and Installation”, “EXHAUST SYS- BT
TEM”.
CATALYST NJEM0101S02
HA
CAUTION: SC
Do not disassemble.
Install two locking pins into both sides of the catalytic converter. Be EL
careful not to confuse locking pins with insulator mounting bolts.
Catalytic converter locking pin: IDX
Flange bolt (black)
Insulator mounting bolt:
Washer bolt (silver or yellow)
EM-123
CATALYST (FOR EUROPE) YD
GUSSET NJEM0101S03
Pushing gussets against the oil pan and the catalytic converter,
temporarily tighten the mounting bolt. And then tighten it to the
specified torque.
EM-124
EXHAUST MANIFOLD, TURBOCHARGER (FOR EUROPE) YD
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
JEM265G
BR
Remove the following parts.
I Engine coolant (drain)
ST
Refer to LC-47, “Changing Engine Coolant”.
I Air duct, air inlet pipe RS
I Water inlet pipe
I Catalytic converter
I Exhaust manifold cover BT
I Insulator
I A/T fluid charging pipe mounting bolt HA
I Each wiring and piping (disconnect/move)
EXHAUST MANIFOLD AND TURBOCHARGER NJEM0102S02

SC
I Loosen exhaust manifold mounting nuts in the reverse order
specified in the figure. EL
I Rotate the exhaust manifold and turbocharger assembly so
that the rear side (EGR tube mounting side) faces upward. And IDX
then pull out the assembly from between the engine and the
air conditioning piping.
CAUTION:
Be careful not to deform each turbocharger piping when pull-
JEM266G ing out the assembly.
EM-125
I When a stud bolt is pulled out, tighten it to the following torque:
: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
I Tighten the exhaust manifold mounting nuts in the following
procedure:
a) Tighten the nuts in the order specified in the figure.
b) Re-tighten the nuts 1 to 4.
EXHAUST MANIFOLD GASKET NJEM0102S03
Install the gasket so that the alignment protrusion faces the No. 4
port.
INSPECTION AFTER INSTALLATION NJEM0102S05
Start engine and raise engine speed to check no exhaust emission
leaks.
Disassembly and Assembly NJEM0103
SEM051H
TURBOCHARGER NJEM0103S01
Disassembly NJEM0103S0101
After applying penetration lubricant (Lucen, etc.) to the mounting
nuts, check for the penetration of the lubricant, and then loosen the
nuts to remove.
EM-126
Disassembly and Assembly (Cont’d)
CAUTION:
Do not disassemble or adjust the turbocharger body.
Assembly GI
NJEM0103S0102
When a stud bolt is pulled out, tighten it to the following torque:
: 24 - 27 N·m (2.4 - 2.8 kg-m, 18 - 20 ft-lb) MA
LC
Inspection NJEM0104
EC
Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.
Limit: 0.3 mm (0.012 in) FE
CL
JEM267G
MT
TURBOCHARGER NJEM0104S02
AT
AX
SU
BR
ST
RS
BT
SEM269G
HA
CAUTION:
When the compressor wheel, turbine wheel, or rotor shaft is
damaged, remove all the fragments and foreign matter left in SC
the following passages in order to prevent a secondary failure:
Suction side: Between turbocharger and air cleaner
EL
Exhaust side: Between turbocharger and catalytic con-
verter
IDX
EM-127
Rotor Shaft NJEM0104S0201
I Make sure the rotor shaft rotates smoothly without any resis-
tance when it is rotated by your fingertips.
I Make sure the rotor shaft is not loose when it is moved verti-
cally or horizontally.
Standard value for rotor shaft oil clearance:
0.086 - 0.117 mm (0.0034 - 0.0046 in)
SEM270G
Rotor Shaft End Play NJEM0104S0202

Place a dial gauge at the rotor shaft end in the axial direction to
measure the end play.
Standard: 0.036 - 0.090 mm (0.0014 - 0.0035 in)
SEM271G
Turbine Wheel NJEM0104S0203

I Make sure there is no oil adhesion.
I Make sure there is no carbon accumulation.
I Make sure blades of the turbine wheel are not bent or broken.
I Make sure the turbine wheel does not interfere with the turbine
housing.
SEM272G
Compressor Wheel NJEM0104S0204

I Make sure there is no oil adhesion inside the air inlet.
I Make sure the compressor wheel does not interfere with the
compressor housing.
I Make sure the wheel is not bent or broken.
SEM273G
Wastegate Valve Actuator NJEM0104S0205

I Connect the handy pump to the actuator, and check that the
rod strokes smoothly in compliance with the following pres-
sure.
I Pressure to be applied at actuator part to move rod end as
follows:
Standard (Pressure/rod stroke amount):
115.44 - 120.76 kPa (1,154 - 1,208 mbar, 866.0 - 906.0
mmHg, 34.1 - 35.7 inHg)/0.38 mm (0.0150 in)
140.54 - 149.86 kPa (1,405 - 1,498 mbar, 1,054.3 -
SEM274G 1,124.2 mmHg, 41.5 - 44.3 inHg)/4.0 mm (0.157 in)
EM-128
Trouble Diagnosis of Turbocharger =NJEM0104S0206
Preliminary check:
I Make sure the engine oil level is between MIN and MAX of the GI
dipstick. (When the engine oil amount is more than MAX, the
oil flows into the inlet duct through the blow-by gas passage,
and the turbocharger is misjudged failure.) MA
I Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
I Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
I If no malfunction is found after the unit inspections, judge that LC
the turbocharger body has no failure. Check the other parts
again.
EC
Symptom (when each inspection
item meets each inspection result)
Insuffi- FE
Inspection item Inspection result cient
Oil power/
Smoke Noise
leakage accel- CL
eration
failure
Oil leaks. g g g
MT
Carbon is accumulated. g q q
Turbine wheel
Friction with housing. g q q
AT
Blades are bent or broken.
AX
Inside the air inlet is seriously contami-
q q
nated by oil.
Compressor wheel
Friction with housing. g q q SU
Blades are bent or broken.
There is resistance when the rotor shaft BR

g g q
is rotated by your fingertips.
After checking both turbine and compressor,
inspect rotor shaft end play.
The rotor shaft sometimes does not ST
rotate by your fingertips.
There is too much play in the bearing. g g q g

RS
Carbon or sludge is accumulated in the
Oil return port g g g
waste oil hole.
: Large possibility
BT
q: Medium possibility
g: Small possibility
HA
SC
EL
IDX
EM-129
ROCKER COVER YD
SEM503G

Remove engine cover.
ROCKER COVER NJEM0099S02

Loosen holding bolts in the reverse order of that shown in the fig-
ure and remove.
CAUTION:
Do not remove mass damper on top. If damper must be
removed, remove all traces of old locking sealant from threads
of bolts and holes, and apply new locking sealant on the bolts
before tightening.
JEM247G
I Tighten holding bolts in the numerical order shown in the fig-
ure.
I Re-tighten to the same torque in the same order as above.
EM-130
ROCKER COVER YD
I Apply 3.0 mm (0.118 in) dia. of specified liquid gasket (Refer
to EM-87, “Liquid Gasket Application Procedure”.) on locac-
tions shown in the figure. GI
MA
JEM248G LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-131
CYLINDER HEAD YD
Components
Components NJEM0062
SEM504G
EM-132
CYLINDER HEAD YD
CAUTION:
I When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new GI
engine oil.
I Apply new engine oil to threads and seat surfaces when
installing cylinder head, camshaft sprocket, crankshaft MA
pulley, and camshaft bracket.
I Attach tags to valve lifters so as not to mix them up.
LC
Removal NJEM0063
EC
1. Drain engine coolant. Refer to LC-47, “Changing Engine Cool-
ant”.
2. Remove exhaust manifold. Refer to EM-121, “Removal”. FE
3. Remove intake manifold. Refer to EM-117, “Removal”.
I Apply paint to camshaft sprockets for alignment during CL
installation.
MT
CAMSHAFT NJEM0063S02
1. Remove the following parts: AT
I Rocker cover
Refer to EM-130, “ROCKER COVER”.
I Vacuum pump and cylinder head rear cover assembly
AX
I Spill tube
Refer to EC-294 and EC-1010, “Injection Tube and Injection SU
Nozzle”.
I High pressure injection nozzle assembly
Refer to EC-294 and EC-1010, “Injection Tube and Injection BR
JEM152G Nozzle”.
I Secondary timing chain and associated parts
Refer to EM-103, “Secondary Timing Chain”. ST
RS
BT
HA
2. Remove camshaft sprockets. SC

I Holding the hexagonal part of the camshaft with a wrench
having 21 mm (0.83 in) width between facing flats, loosen the
bolt holding the camshaft sprocket. EL
IDX
JEM159G
EM-133
CYLINDER HEAD YD
Removal (Cont’d)
3. Remove camshafts.
I Loosen bolts holding the camshaft bracket in several stages in
the reverse order of that shown in the figure, and remove them.
4. Remove adjusting shims and valve lifters.
I Confirm the correct location of each part removed. Store them
so they do not get mixed up.
I For re-installation, be sure to put mark on camshaft
bracket before removal.
JEM160G
CYLINDER HEAD NJEM0063S03

I Loosen bolts in the reverse order of that shown in the figure
and remove them.
I Be careful not to damage the tips of glow plugs project-
ing out of the bottom surface of the cylinder head. To
avoid damage to glow plugs, either remove them
beforehand, or support cylinder head with wooden blocks
to create a space below the bottom surface.
JEM149G
JEM150G
1. Remove adjusting shims and valve lifters. Confirm the correct

location of each part removed. Store them in order to avoid
mixing them up.
EM-134
CYLINDER HEAD YD
2. Remove valve collets.
쐌 Compress valve spring with a valve spring compressor, and
remove valve collet with a magnet hand. GI
3. Remove valve spring retainers, and valve springs.
4. Push valve stem toward combustion chamber and remove
valve. MA
쐌 Before removing valves, check valve guide clearance. Refer to
EM-138, “VALVE GUIDE CLEARANCE”.
쐌 Confirm the correct location of each valve. Store them so they
do not get mixed up.
JEM151G LC
쐌 For the locations and arrangement of intake and exhaust
valves, refer to the figure.
EC
FE
CL
JEM152G
MT
5. Remove valve oil seals.
쐌 Use a valve oil seal puller (SST) for removal. AT
6. Remove valve spring seats.
7. When removing valve seats, check valve seat contact. Refer
to EM-139. AX
8. Before removing valve guides, check valve guide clearance.
Refer to EM-138, “VALVE GUIDE CLEARANCE”. SU
9. Remove glow plugs.
쐌 To avoid damage, glow plugs should be removed only
when required. BR
JEM153G
쐌 Handle with care to avoid applying shock. (When dropped
from approx. 100 mm (3.94 in) or higher, always replace
with a new one.) ST
RS
BT
HA
Inspection NJEM0065
SC
CYLINDER HEAD DISTORTION NJEM0065S01
Clean surface of cylinder head. EL
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder head surface.
Check along six positions shown in the figure. IDX
Head surface flatness: Limit 0.1 mm (0.004 in)
If beyond the specified limit, resurface or replace it.
The limit for cylinder head resurfacing is determined by the
cylinder block resurfacing.
SEM496G
Resurfacing limit:
EM-135
CYLINDER HEAD YD
Amount of cylinder block resurfacing is “B”.
The maximum limit: A + B = 0.07 mm (0.0028 in)
After resurfacing cylinder head, check that camshaft rotates freely
by hand. If resistance is felt, cylinder head must be replaced.
Nominal cylinder head height:
153.9 - 154.1 mm (6.059 - 6.067 in)
CAMSHAFT VISUAL CHECK NJEM0065S02

Check camshaft for scratches, seizure and wear.
CAMSHAFT RUNOUT NJEM0065S03

1. Place V-blocks on a work bench and support camshaft at No.
2 and No. 5 journals.
2. Set dial gauge perpendicularly at camshaft No. 3 journal.
3. Turn camshaft by hand in one direction and read runout on dial
gauge.
Limit 0.04 mm (0.0016 in)
4. If it exceeds the limit, replace camshaft.
JEM161G
CAMSHAFT CAM HEIGHT NJEM0065S04

1. Measure camshaft cam height.
Standard cam height:
Except for Europe
Intake and Exhaust
39.905 - 40.095 mm (1.5711 - 1.5785 in)
for Europe
Intake
39.505 - 39.695 mm (1.5553 - 1.5628)
SEM549A Exhaust
39.905 - 40.095 (1.5711 - 1.5785)
Cam wear limit:
0.2 mm (0.008 in)
2. If wear is beyond the limit, replace camshaft.
EM-136
CYLINDER HEAD YD
CAMSHAFT JOURNAL CLEARANCE NJEM0065S05
1. Install camshaft bracket and tighten bolts to the specified
torque. GI
2. Measure inner diameter of camshaft bearing.
Standard inner diameter:
MA
No. 1: 30.500 - 30.521 mm (1.2008 - 1.2016 in)
No. 2, 3, 4, 5: 24.000 - 24.021 mm (0.9449 - 0.9457 in)
JEM162G LC
3. Measure outer diameter of camshaft journal.
Standard outer diameter:
EC
No. 1: 30.435 - 30.455 mm (1.1982 - 1.1990 in)
No. 2, 3, 4, 5: 23.935 - 23.955 mm (0.9423 - 0.9431 in)
4. Calculate camshaft journal clearance. FE
(Clearance) = (inner diameter of camshaft bearing) −
(outer diameter of camshaft journal)
Camshaft journal clearance: CL
Standard
No. 1 - 5: 0.045 - 0.086 mm (0.0018 - 0.0034 in) MT
SEM012A
Limit
0.15 mm (0.0059 in)
5. If clearance exceeds the limit, replace camshaft and/or cylin- AT
der head.
AX
SU
BR
CAMSHAFT END PLAY

1. Install camshaft in cylinder head.
NJEM0065S06 ST
2. Measure camshaft end play.
Camshaft end play: RS
Standard
0.070 - 0.148 mm (0.0028 - 0.0058 in)
Limit
BT
0.24 mm (0.0094 in)
I If the value exceeds the limit, replace camshaft and measure HA
JEM163G
again.
I If the measurement exceeds the limit again, replace cylinder
head. SC
EL
IDX
EM-137
CYLINDER HEAD YD
CAMSHAFT SPROCKET RUNOUT NJEM0065S07
1. Install sprocket on camshaft.
2. Measure camshaft sprocket runout.
3. If it exceeds the limit, replace camshaft sprocket.
JEM164G
VALVE GUIDE CLEARANCE NJEM0065S08

1. Make sure valve stem diameter is within the specified range.
2. Push out valve approx. 25 mm (0.98 in) toward combustion
chamber. Swing valve in the direction of the dial gauge to
measure the runout.
I This inspection should be performed before removing valve
guides.
I Half of the runout reading on the dial gauge is the valve guide
clearance.
Standard:
JEM155G Intake 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust 0.040 - 0.073 mm (0.0016 - 0.0029 in)
3. If it exceeds the limit, check valve to valve guide clearance.
a. Measure valve stem diameter and valve guide inner diameter.
b. Make sure clearance is within specification.
Valve to valve guide clearance limit:
Intake 0.08 mm (0.0031 in)
Exhaust 0.1 mm (0.004 in)
c. If it exceeds the limit, replace valve or valve guide.
VALVE GUIDE REPLACEMENT NJEM0065S09

I When a valve guide is removed, replace with an oversized [0.2
mm (0.008 in)] valve guide.
1. To remove valve guide, heat cylinder head to 110 to 130°C
(230 to 266°F) by soaking in heated oil.
SEM008A
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2

US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.
CAUTION:
SEM931C
EM-138
CYLINDER HEAD YD
3. Ream cylinder head valve guide hole.
Valve guide hole diameter (for service parts):
10.175 - 10.196 mm (0.4006 - 0.4014 in) GI
MA
SEM932C LC
4. Heat cylinder head to 110 to 130°C (230 to 266°F) and press
service valve guide onto cylinder head.
Projection “L”:
EC
10.4 - 10.6 mm (0.409 - 0.417 in)
CAUTION: FE
5. Ream valve guide. CL
Finished size:
6.000 - 6.018 mm (0.2362 - 0.2369 in) MT
JEM156G
VALVE SEATS NJEM0065S10

Check valve seats for pitting at contact surface. Resurface or AT
replace if excessively worn.
I Before repairing valve seats, check valve and valve guide
for wear. If they have worn, replace them. Then correct AX
valve seat.
I Use both hands to cut uniformly.
SU
BR
SEM934C
I Before starting this check, confirm that the dimensions of valve

guides and valves are as specified. ST
I Apply red lead primer on contacting surfaces of valve seat and
of valve face to examine the conditions of contacting surfaces.
RS
I Make sure the paint on contacting surfaces is continuous along
the entire circumference.
I If there are non-standard conditions, grind the valve and check BT
the contact again. If non-standard conditions still persist,
replace valve seat.
HA
JEM157G
REPLACING VALVE SEAT FOR SERVICE PARTS NJEM0065S11

SC
1. Bore out old seat until it collapses. Boring should not continue
beyond the bottom face of the seat recess in cylinder head. Set
the machine depth stop to ensure this. EL
2. Ream cylinder head recess for service valve seat.
Oversize [0.5 mm (0.020 in)]:
IDX
Intake 30.500 - 30.516 mm (1.2008 - 1.2014 in)
Exhaust 29.500 - 29.516 mm (1.1614 - 1.1620 in)
Be sure to ream in circles concentric to the valve guide
center.
SEM795A
This will enable valve seat to fit correctly.
EM-139
CYLINDER HEAD YD
3. Heat cylinder head to 110 to 120°C (230 to 248°F) by soaking
in heated oil.
4. Sufficiently cool valve seat with dry ice. Force fit valve seat into
cylinder head.
WARNING:
Do not touch cold valve seat with your bare hands.
CAUTION:
5. Cut or grind valve seat using suitable tool to the specified
dimensions as shown in SDS (EM-180).
CAUTION:
Use the valve seat cutter properly. Securely gripping the cut-
ter handle with both hands, press the cutter down onto the
entire circumference of the contacting surface and finish cut-
ting at one time. Improper pressing of the cutter or cutting in
several steps may result in staged surface on the valve seat.
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. Refer to EM-139, “Valve Seats”.
8. Use a depth gauge to measure the distance between the

mounting surface of the cylinder head spring seat and the
valve stem end. If the distance is shorter than specified, repeat
step 5 above to adjust it. If it is longer, replace the valve seat
with a new one.
Valve seat resurface limit “L”:
Intake 36.53 - 36.98 mm (1.4382 - 1.4559 in)
Exhaust 36.53 - 37.01 mm (1.4382 - 1.4571 in)
JEM253G
VALVE DIMENSIONS NJEM0065S12

Check dimensions of each valve. For dimensions, refer to SDS
(EM-177).
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.
SEM188A

Squareness NJEM0065S1301
1. Measure dimension “S”.
Out-of-square “S”:
For Sedan
Limit 2.1 mm (0.083 in)
For Hatchback
Limit 1.5 mm (0.059 in)
2. If it exceeds the limit, replace spring.
SEM288A
EM-140
CYLINDER HEAD YD
Pressure NJEM0065S1302
Check valve spring pressure at specified spring height.
For Sedan GI
Standard:
Installation height 32.82 mm (1.2921 in) MA
Installation load 166 - 188 N (16.93 - 19.17 kg, 37.3
- 42.2 lb)
Height during valve open 24.82 mm (0.9772 in)
Load with valve open 345 - 376 N (35.18 - 38.34 kg,
77.5 - 84.5 lb)
EM113
For Hatchback LC
Standard:
Installation height 32.82 mm (1.2921 in) EC
Installation load 168 - 186 N (17.13 - 18.97 kg, 37.8
- 41.8 lb)
Height during valve open 24.82 mm (0.9772 in) FE
Load with valve open 350 - 382 N (35.7 - 37.9 kg,
78.7 - 83.6 lb)
CL
If it exceeds the standard, replace spring.
MT
VALVE LIFTER AND VALVE SHIM NJEM0065S14
1. Check contact and sliding surfaces for wear or scratches. AT
AX
SU
BR
SEM960E
2. Check diameter of valve lifter and valve lifter guide bore.

Valve lifter outer diameter:
ST
29.960 - 29.975 mm (1.1795 - 1.1801 in)
RS
BT
HA
SEM961E
Lifter guide bore diameter: SC

30.000 - 30.021 mm (1.1811 - 1.1819 in)
Clearance:
Standard 0.025 - 0.061 mm (0.0010 - 0.0024 in) EL
I If the value is out of the range, replace valve lifter and/or cyl-
inder head, referring to the specified values for the outer diam- IDX
eter and bore diameter.
SEM867E
EM-141
CYLINDER HEAD YD
Assembly
Assembly NJEM0066
1. Install valve oil seal.
I Using valve oil seal drift (SST), install so that the dimension
shown in the figure is obtained. The dimension in the figure
shows the dimension before the valve spring seat is installed.
I Different parts should be used depending on the valve oil seal
location. Identify by the rubber color.
For intake: Black
For exhaust: Brown
I Always use new valve oil seal.
JEM165G
I Before installing valve oil seal, install valve spring seat.
2. Install other valve component parts. Refer to “Disassembly”,
EM-134.
I For uneven pitch type models only, install valve spring
with its narrow pitch side toward cylinder head side (paint
mark).
I After installing valve collets, tap valve stem tip with plastic
hammer to assure a proper fit.
SEM523G
I Before installation, remove old liquid gasket from mating
surface of all liquid gasket applied parts.
CYLINDER HEAD GASKET SELECTION NJEM0067S01

I Select and install cylinder head gasket with appropriate thick-
ness according to the following procedure:
When replacing gasket alone:
I Install a gasket with the same thickness as that of the one
removed.
I Identify the thickness of gasket by the number of cut-outs and
holes on the rear RH side.
JEM168G Gasket thickness*
Number of cut-outs Number of holes
mm (in)
0.900 (0.0354) 1 2
0.925 (0.0364) 2 2
0.950 (0.0374) 3 2
0.975 (0.0384) 1 3
1.000 (0.0394) 2 3
1.025 (0.0404) 3 3
*: Measured with head bolts tightened
EM-142
CYLINDER HEAD YD
I Gasket thickness can be identified at the location shown in the
figure by the numbers of cut-outs and holes before removal.
When the following parts have been repaired/replaced: GI
I With cylinder block upper surface and/or crankshaft pin journal
ground
I With cylinder block, pistons, connecting rods, and/or crank-
MA
shaft replaced
1. Set piston at a point close to TDC.
2. Set a dial gauge at the location as shown in the figure. Turn-
ing crankshaft gradually, set the gauge scale to “0” where the
JEM169G piston protrusion is maximized. LC
3. Move the dial gauge stand so that the tip of dial gauge can
contact the cylinder block. Read the difference.
4. Measure at two locations per cylinder, that is eight locations for EC
four cylinders. Select gasket based on the maximum protru-
sion of eight measurements.
FE
Gasket thickness* Identification
Piston protrusion mm (in)
mm (in) Number of holes
CL
Less than 0.255 (0.0100) 0.900 (0.0354) 1
JEM170G
Less than 0.255 - 0.280
0.925 (0.0364) 2 MT
(0.0100 - 0.0110)
Less than 0.280 - 0.305

(0.0110 - 0.0120)
0.950 (0.0374) 3 AT
Less than 0.305 - 0.330
0.975 (0.0384) 4
(0.0120 - 0.0130) AX
Less than 0.330 - 0.355
1.000 (0.0394) 5
(0.0130 - 0.0140)
SU
More than 0.355 (0.0140) 1.025 (0.0404) 6

BR
For Europe
I Select and install cylinder head gasket with appropriate thick-
NJEM0067S0102 ST
ness according to the following procedure:
When replacing gasket alone: RS
I Install a gasket with the same thickness as that of the one
removed.
I Identify the thickness of gasket by the number of holes on the BT
RH side.
Gasket thickness*
Number of holes
HA
mm (in)
SEM505G
0.900 (0.0354) 1
SC
0.925 (0.0364) 2
0.950 (0.0374) 3 EL
0.975 (0.0384) 4
1.000 (0.0394) 5 IDX

1.025 (0.0404) 6
EM-143
CYLINDER HEAD YD
When the following parts have been repaired/replaced:
I With cylinder block upper surface and/or crankshaft pin journal
ground
I With cylinder block, pistons, connecting rods, and/or crank-
shaft replaced
1. Set piston at a point close to TDC.
2. Set a dial gauge at the location as shown in the figure. Turn-
ing crankshaft gradually, set the gauge scale to “0” where the
piston protrusion is maximized.
3. Move the dial gauge stand so that the tip of dial gauge can
SEM507G contact the cylinder block. Read the difference.
4. Measure at two locations per cylinder, that is eight locations for
four cylinders. Select gasket based on the maximum protru-
sion of eight measurements.
Gasket thickness* Identification

Piston protrusion mm (in)
mm (in) Number of holes
Less than 0.255 (0.0100) 0.900 (0.0354) 1
Less than 0.255 - 0.280

0.925 (0.0364) 2
(0.0100 - 0.0110)
Less than 0.280 - 0.305

0.950 (0.0374) 3
(0.0110 - 0.0120)
Less than 0.305 - 0.330

0.975 (0.0384) 4
(0.0120 - 0.0130)
Less than 0.330 - 0.355

1.000 (0.0394) 5
(0.0130 - 0.0140)
More than 0.355 (0.0140) 1.025 (0.0404) 6
CYLINDER HEAD BOLT DEFORMATION CHECK NJEM0067S02

I Measure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.
I When the necked point is identified at a point other than speci-
fied points, measure at the point as d1.
I Calculate the difference between d1 and d2. If the value
exceeds the limit, replace with new ones.
Limit: 0.15 mm (0.0059 in)
JEM171G
CYLINDER HEAD-TO-BLOCK DIFFERENCE CHECK

NJEM0067S03
I After installing cylinder head, measure dimension from the
front end surface of cylinder block to that of cylinder head.
Standard: 23.53 - 24.07 mm (0.9264 - 0.9476 in)
I If the difference is out of the range, check fitting of dowel pins
and cylinder head.
JEM172G
EM-144
CYLINDER HEAD YD
LIQUID GASKET APPLICATION ON REAR CHAIN CASE
NJEM0067S04
Apply a continuous bead of specified liquid gasket (Refer to EM-87,
“Liquid Gasket Application Procedure”.) on the surface shown in GI
the figure.
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end MA
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external location
but cannot be viewed externally after engine is assembled.
JEM057H LC
CYLINDER HEAD INSTALLATION NJEM0067S05
I Tighten bolts in numerical order as shown in the figure accord- EC
ing to the following procedure:
1. Apply engine oil to bolt threads and seat surfaces.
2. Tighten bolts to 29 to 38 N·m (2.9 to 3.9 kg-m, 21 to 28 ft-lb). FE
3. Tighten 180° to 185° [target: 180°] (angular tightening).
4. Loosen completely to 0 N·m (0 kg-m, 0 in-lb) in the reverse
order of that shown in the figure. CL
5. Tighten bolts to 35 to 44 N·m (3.5 to 4.5 kg-m, 26 to 32 ft-lb).
6. Tighten 90° to 95° [target: 90°] (angular tightening). MT
JEM149G
7. Tighten another 90° to 95° [target: 90°] (angular tightening).
I When an angle wrench is not used, paint an alignment
mark on the head of cylinder head bolt and cylinder head AT
surface before tightening. Check the angle with a protrac-
tor.
AX
SU
BR
JEM166G
GLOW PLUG INSTALLATION

I To avoid damage, glow plugs should be removed only
NJEM0067S06 ST
when required.
I Handle with care to avoid applying shock. (When dropped RS
from approx. 100 mm (3.94 in) or higher, always replace
with a new one.)
I Before installing, remove carbon depositing on mounting hole BT
of glow plug with a reamer.
HA
CAMSHAFT INSTALLATION NJEM0067S07

SC
1. Install valve lifters and adjusting shims.
I Install in the correct locations (the same places as before
removal). EL
2. Install camshafts.
I Identify camshafts by the paint position and screw hole at the IDX
rear end.
Camshaft RH: Paint is at position A without screw hole.
Camshaft LH: Paint is at position B with screw hole.
JEM173G
EM-145
CYLINDER HEAD YD
I Install so that knock pins are positioned in the directions shown
in the figure.
SEM516G
3. Install camshaft brackets.

I Install correctly, identifying brackets by the journal No. and
front mark on top surface.
JEM175G
4. Tighten bolts in the order shown in the figure according to the

following procedure:
a. Tighten to 2.0 N·m (0.2 kg-m, 17 in-lb).
I Make sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten to 6 N·m (0.6 kg-m, 52 in-lb).
c. Tighten to 12 to 13 N·m (1.2 to 1.4 kg-m, 9 to 10 ft-lb).
5. Install camshaft sprockets.
I Camshaft sprockets are commonly used for RH and LH.
I Align camshaft sprocket and dowel pin on camshaft, and
JEM160G
install.
I Holding the hexagonal part of camshaft with a wrench, tighten
bolt securing camshaft sprocket.
6. Before installing spill tube after installing secondary timing
chain, check and adjust valve clearance. Refer to EM-146,
“Valve Clearance”.
7. Hereafter, install in the reverse order of removal.
Valve Clearance NJEM0068

CHECKING NJEM0068S01
I Inspect and adjust when the engine is cool (at normal tempera-
ture).
I Be careful of the intake and exhaust valve arrangement. The
valve arrangement is different from that in a normal engine.
NOTE:
The camshafts have, alternately, either an intake valve or an
exhaust valve. (Refer to illustration)
SBIA0178E
EM-146
CYLINDER HEAD YD
Check valve clearance while engine is cold and not running.
1. Set the No. 1 piston to TDC on its compression stroke.
I Turn crankshaft pulley clockwise so that the knock pin on cam- GI
shaft LH faces straight above. (No position indicator, etc. is
provided on the crankshaft pulley.)
MA
JEM176G LC
2. Put an alignment mark with paint, etc. on the crankshaft pul-
ley and on the oil pump as an angle indicator.
EC
FE
CL
JEM177G
MT
Valve
AT
No. 1 No. 2 No. 3 No. 4
AX
Crank position INT EXH INT EXH INT EXH INT EXH
No. 1 TDC
(Compression q q q q SU
stroke)
BR
JEM178G
I Using a feeler gauge, measure clearance between valve lifter

and camshaft. ST
I Record any valve clearance measurements which are out of
specification. They will be used later to determine the required
replacement adjusting shim.
RS
Valve clearance for checking (Cold):
Intake BT
0.24 - 0.32 mm (0.0094 - 0.0126 in)
Exhaust
0.26 - 0.34 mm (0.0102 - 0.0134 in)
HA
JEM179G
4. Rotate crankshaft clockwise by one turn to set the No. 4 pis- SC

ton to TDC on the compression stroke.
EL
Valve
No. 1 No. 2 No. 3 No. 4

IDX
Crank position INT EXH INT EXH INT EXH INT EXH
No. 4 TDC
(Compression q q q q
stroke)
JEM180G
EM-147
CYLINDER HEAD YD
ADJUSTING NJEM0068S02
Adjust valve clearance while engine is cold.
1. Turn crankshaft, to position cam lobe on camshaft of valve that
must be adjusted upward.
2. Place Tool (A) around camshaft as shown in figure.
Before placing Tool (A) (SST), rotate notch toward center
of cylinder head (See figure.), to simplify shim removal
later.
CAUTION:
Be careful not to damage cam surface with Tool (A).
JEM181G
3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down.
SEM497G
4. Place Tool (B) (SST) between camshaft and the edge of the
valve lifter to retain valve lifter.
CAUTION:
I Tool (B) must be placed as close to camshaft bracket as
possible.
I Be careful not to damage cam surface with Tool (B).
5. Remove Tool (A).
SEM498G
6. Blow air into the hole to separate adjusting shim from valve
lifter.
I To avoid engine oil spills, wipe off oil fully beforehand.
Wear safety goggles, etc. during work if necessary.
JEM555G
7. Remove adjusting shim using a small screwdriver and a mag-

netic finger.
JEM556G
EM-148
CYLINDER HEAD YD
8. Determine replacement adjusting shim size following formula.
I Using a micrometer determine thickness of removed shim.
I Calculate thickness of new adjusting shim so valve clearance GI
comes within specified values.
R = Thickness of removed shim
N = Thickness of new shim MA
M = Measured valve clearance
Intake:
N = R + [M − 0.28 mm (0.0110 in)]
Exhaust:
SEM145D N = R + [M − 0.30 mm (0.0118 in)] LC
Shims are available in 33 sizes from 2.10 mm (0.0827 in)
to 2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in).
I Select new shim with thickness as close as possible to calcu-
EC
lated value. Refer to EM-177, “AVAILABLE SHIMS”.
FE
CL
JEM184G
MT
9. Install new shim using a suitable tool.
I Install with the surface on which the thickness is stamped AT
facing down.
AX
SU
BR
SEM552G
10. Place Tool (A) as mentioned in steps 2 and 3.

11. Remove Tool (B).
ST
12. Remove Tool (A).
13. Recheck valve clearance. RS
Valve clearance:
Unit: mm (in)
BT
Cold Hot* (reference data)
Intake 0.24 - 0.32 (0.009 - 0.013) 0.274 - 0.386 (0.011 - 0.015)

HA
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)

SC
EL
IDX
EM-149
ENGINE ASSEMBLY YD
SEM554G
WARNING:
I Situate vehicle on a flat and solid surface.
I Place chocks at front and back of rear wheels.
I Do not remove engine until exhaust system has com-
pletely cooled off. Otherwise, you may burn yourself
and/or fire may break out in fuel line.
I For safety during subsequent steps, the tension of wires
should be slackened against the engine.
I Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI-49, “Garage Jack and Safety Stand”.
I Be sure to hoist engine and transaxle in a safe manner.
I For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
I When lifting engine, be careful not to strike adjacent parts,
especially the following: Accelerator wire casing, brake
lines, and brake master cylinder.
I In hoisting the engine, always use engine slingers in a
safe manner.
I In removing drive shaft, be careful not to damage grease
seal of transaxle.
I Before separating engine and transaxle, remove the
EM-150
ENGINE ASSEMBLY YD
crankshaft position sensor (TDC sensor) from the assem-
bly.
I Always pay extra attention not to damage edge of crank- GI
shaft position sensor (TDC sensor) or ring gear teeth.
REMOVAL NJEM0069S01 MA
1. Remove engine undercover, and hood for hoisting.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-47, “Changing Engine Coolant”.
I Battery
LC
I RH and LH front wheels
I RH and LH splash covers (combined with undercover)
I Drive belts EC
Refer to EM-94, “DRIVE BELTS”.
I Alternator
I Alternator brackets
FE
I Radiator and cooling fan
Refer to LC-45, “Radiator”. CL
I Engine cover
I Air ducts and air cleaner case
LH side of engine room: MT
4. Disconnect all harnesses and grounds that are connected to
components on vehicle. AT
5. Disconnect vacuum hose on vacuum pump side.
6. Disconnect fuel feed and fuel return hoses on engine side.
I Immediately put blind plugs into the openings to prevent AX
fuel from flowing out.
7. Disconnect heater hose. Plug opening of hose to prevent cool-
ant from flowing out. SU
RH side of engine room:
8. Remove air conditioner compressor from brackets and move BR
it toward vehicle side. Secure compressor on vehicle side with
rope.
Vehicle underside: ST
9. Remove exhaust front tube.
10. Disconnect two hoses from power steering pump and plug to RS
stop fluid.
11. Remove M/T control rod and support rod.
12. Remove ABS wheel sensor, and temporarily hang brake cali- BT
per with rope on vehicle side.
13. Remove RH and LH drive shafts.
HA
14. Install engine slingers to cylinder head. SC

: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
I Use engine slingers and securing bolts of the specified
service parts. EL
IDX
JEM551G
EM-151
ENGINE ASSEMBLY YD
15. Lift up vehicle to appropriate level where work can be per-
formed efficiently. Using two transmission jacks, securely sup-
port engine oil pan and bottom surface of transaxle.
SEM566G
I Make sure that support is stable with the use of safety

blocks.
16. Install hooks of lifting chain into engine slingers and tighten
chain so that engine still remains on transmission jacks with-
out being lifted up.
17. Remove engine mount insulator RH.
18. Remove through-bolt of engine mount insulator LH.
19. Remove bolts securing center member at front and rear.
SEM189G
20. Carefully lower transmission jacks in accordance with the low-

ering pace of the hoist, and remove engine and transaxle
assembly from vehicle.
I While working, check that no parts of engine assembly
interfere with adjacent parts on the vehicle.
I While working, make sure that parts requiring disconnec-
tion are not left connected, and that no parts interfere with
vehicle.
I To prevent vehicle from falling down, perform operation
carefully so that the center of gravity of the vehicle will not
JEM190G
shift.
I Before starting removal operation, first place the assem-
bly on a level surface and securely support the bottom
surface with wood blocks. Using a hoist, lift engine
slingers, and make sure the assembly is stable.
22. Separate engine and transaxle.
INSTALLATION NJEM0069S02
Install in the reverse order of removal, observing the following:
I While installing, be careful to keep mount insulators free of oil
smear and damage.
I When parts require specified installation directions/positions,
install by using the identifying marks indicating up or front.
I While keeping the mount insulators free of twists or distortions,
start tightening from the through-bolt on the engine mount
insulator LH. This mount is used as the reference position.
EM-152
ENGINE ASSEMBLY YD
INSPECTION AFTER INSTALLATION NJEM0069S03
I Before starting engine check the levels of coolant, lubrications
and working oils. If less than required quantity, fill to the speci- GI
fied level.
I Before starting engine, bleed air from fuel piping. Refer to
FE-27, “Bleeding Fuel Filter”. MA
I Run engine to check for unusual noise and vibration.
I Warm up engine thoroughly to make sure there is no leakage
of coolant, lubricants, working oil, fuel and exhaust gas.
I Bleed air from passages in pipes and tubes of applicable lines.
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-153
CYLINDER BLOCK YD
Components
Components NJEM0070
SEM510GB
EM-154
CYLINDER BLOCK YD

CAUTION:
I When installing bearings, pistons, or other sliding parts, GI
lubricate contacting surfaces with new engine oil.
I Place removed parts such as bearings and bearing caps
in their proper order and direction.
MA
I When installing connecting rod nuts, and main bearing
cap bolts, apply new engine oil to threads and seating
surfaces.
plate of flywheel. LC
I Do not remove the signal plate at back.
I Do not place the signal plate side facing under.
I Handle with care so as not to damage the signal plate
EC
[especially four places on protrusions for signal of crank
position sensor (TDC sensor)]. FE
CL
MT
PISTON AND CRANKSHAFT AT
NJEM0072S01
1. Remove engine. Refer to “ENGINE ASSEMBLY”, “Removal
and Installation”, EM-150. AX
2. Place engine on a work stand.
a. Remove flywheel.
I Hold ring gear with ring gear stopper (KV10105630, SU
KV10105610). Then, loosen securing bolts with TORX socket
(size: Q8 E20, Commercial Service Tool) and remove them.
As an alternative method, hold the crankshaft pulley with a BR
pulley holder (SST) to remove the flywheel.
b. Install engine sub-attachment (SST) to rear surface of cylinder
block. ST
I To install, align the hole on the sub-attachment with the knock
pin on the cylinder block.
RS
I The engine sub-attachment has five bolts.
c. Install engine attachment (SST).
I The four sets of bolts and nuts are multi-purpose products. BT
HA
JEM192G
SC
EL
IDX
EM-155
CYLINDER BLOCK YD
d. Hoist up engine and install it on the engine stand (SST).
I Another method is to set engine sub-attachment and engine
attachment on engine stand beforehand, and then, install
engine.
3. Drain engine oil and coolant from engine.
4. Remove the following and the associated parts:
I Exhaust manifold
Refer to FE-38, “Removal and Installation”.
I Turbocharger assembly (For Europe)
Refer to EM-125, “Removal and Installation”.
I Fuel injection tube
RefertoEC-1010andEC-294,“REMOVALANDINSTALLATION”.
I Intake manifold
Refer to EM-118 and EM-116, “INTAKE MANIFOLD”.
I Oil pan (upper and lower)
Refer to EM-98, “OIL PAN”.
I Secondary timing chain
Refer to EM-103, “Secondary Timing Chain”.
I Fuel injection pump
Refer to EC-1010 and EC-294, “Electoric Control Fuel Injection
Pump”.
JEM193G I Primary timing chain
Refer to EM-108, “Primary timing chain”.
I Rocker cover
Refer to EM-130, “ROCKER COVER”.
I High pressure fuel injection nozzle assembly
RefertoEC-1010andEC-294,“REMOVALANDINSTALLATION”.
I Camshaft
Refer to EM-133, “CAMSHAFT”.
I Cylinder head
Refer to EM-132, “CYLINDER HEAD”.
I Thermostat, water pipes
Refer to LC-43, “Thermostat”.
I Oil cooler
Refer to LC-35, “Oil Cooler”.
I Auxiliary component brackets
5. Remove fuel injection pump bracket.
6. If the replacement of pilot bushing is necessary, remove it with

pilot bushing puller (SST).
7. Remove rear oil seal retainer.
I Insert a flat-bladed screwdriver between main bearing cap and
rear oil seal retainer to remove retainer.
8. Remove rear oil seal from rear oil seal retainer.
I Punch out with a flat-bladed screwdriver.
I Be careful not to damage rear oil seal retainer.
SEM500G
EM-156
CYLINDER BLOCK YD
9. Remove piston and connecting rod assembly.
a. Set crankshaft pin of the removal location at a position close
to BDC. GI
b. Remove connecting rod cap.
c. Push piston and connecting rod assembly toward cylinder
head using a hammer handle. MA
I Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-159, “CONNECT-
ING ROD SIDE CLEARANCE”.
10. Remove connecting rod bearings from connecting rod and
JEM195G connecting rod cap. LC
I Store the removed parts in sets by the cylinder No. to avoid
mixing them up.
EC
FE
CL
MT
11.Remove piston rings from pistons.
I Use piston ring expander (Commercial Service Tool). AT
I Avoid scratching pistons during removal.
I Be careful not to damage piston rings by expanding
excessively. AX
CAUTION:
I When piston rings are not replaced, make sure that piston SU
rings are mounted in their original positions.
BR
JEM196G
12. Remove piston from connecting rod.

a. Remove snap rings using snap ring pliers.
ST
RS
BT
HA
JEM197G
b. With an industrial drier, heat pistons to 60 to 70°C (140 to SC

158°F).
EL
IDX
JEM198G
EM-157
CYLINDER BLOCK YD
c. Push out piston pin with a rod approx. 26 mm (1.02 in) in
diameter.
JEM199G
13. Remove main bearing cap bolts.

I With a TORX socket (size: E-14, Commercial Service Tool),
loosen main bearing cap bolts in several stages in the reverse
order of that shown in the figure and remove them.
I Before loosening main bearing cap bolts, measure crankshaft
end play. Refer to EM-158, “CRANKSHAFT END PLAY”.
JEM200G
14. Remove main bearing caps.

I Using main bearing cap bolts, remove by rocking bearing cap
back and forth.
JEM201G
15. Remove crankshaft.

16. Remove main bearings and thrust bearings from cylinder block
and main bearing caps.
I Check the correct installation locations of removed parts.
Store them so they do not get mixed up.
17. Remove oil jet.
18. Remove oil jet check valve.
Inspection NJEM0073
CRANKSHAFT END PLAY NJEM0073S13
I Measure the moving distance of the crankshaft with the dial
gauge when the crankshaft is moved fully forward or back-
ward.
Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit: 0.30 mm (0.0118 in)
I If the value exceeds the limit, replace thrust bearings with new
ones and measure again. If the measurement exceeds the limit
again, replace crankshaft with a new one.
JEM202G
EM-158
CYLINDER BLOCK YD
CONNECTING ROD SIDE CLEARANCE NJEM0073S14
I Measure the side clearance between connecting rod and crank
arm with feeler gauge. GI
Standard: 0.200 - 0.350 mm (0.0079 - 0.0138 in)
Limit: 0.4 mm (0.0157 in)
MA
I If the value exceeds the limit, replace connecting rod and mea-
sure again. If the measurement exceeds the limit again,
replace the crankshaft.
JEM203G LC
PISTON AND PISTON PIN CLEARANCE NJEM0073S01
1. Measure inner diameter of piston pin hole “dp”. EC
Standard diameter “dp”:
27.997 - 28.005 mm (1.1022 - 1.1026 in)
FE
CL
AEM023
MT
2. Measure outer diameter of piston pin “Dp”.
Standard diameter “Dp”: AT
27.994 - 28.000 mm (1.1021 - 1.1024 in)
3. Calculate interference fit of piston pin to piston.
Dp − dp = 0.002 - 0.006 mm (0.0001 - 0.0002 in)
AX
If it exceeds the above value, replace piston assembly with pin.
SU
BR
AEM024
PISTON RING SIDE CLEARANCE NJEM0073S02 ST

Side clearance:
Top ring RS
0.050 - 0.090 mm (0.0020 - 0.0035 in)
2nd ring
BT
0.050 - 0.090 mm (0.0020 - 0.0035 in)
Oil ring
0.030 - 0.070 mm (0.0012 - 0.0028 in) HA
SEM024AA Max. limit of side clearance:
Top ring 0.1 mm (0.004 in)
SC
2nd ring 0.1 mm (0.004 in)
For Europe
Side clearance:
NJEM0073S0202
EL
Top ring
0.120 - 0.180 mm (0.0047 - 0.0071 in) IDX
2nd ring
0.050 - 0.090 mm (0.0020 - 0.0035 in)
Oil ring
0.030 - 0.070 mm (0.0012 - 0.0028 in)
EM-159
CYLINDER BLOCK YD
Max. limit of side clearance:
2nd ring 0.1 mm (0.004 in)
I To measure top ring side clearance, align the outer circumfer-

ences of the ring and piston while pressing ring upward against
the upper surface of the ring groove. Under this condition,
measure the clearance between ring and bottom surface of the
ring groove.
I If out of specification, replace piston ring. If clearance exceeds
maximum limit with new ring, replace piston.
JEM205G
PISTON RING END GAP NJEM0073S03

End gap:
Except for Europe
Top ring 0.21 - 0.31 mm (0.0083 - 0.0122 in)
2nd ring 0.37 - 0.52 mm (0.0146 - 0.0205 in)
Oil ring 0.30 - 0.55 mm (0.0118 - 0.0217 in)
For Europe
Top ring 0.20 - 0.35 mm (0.0079 - 0.0138 in)
2nd ring 0.39 - 0.54 mm (0.0154 - 0.0213 in)
SEM599A Oil ring 0.25 - 0.50 mm (0.0098 - 0.0197 in)
Max. limit of ring gap:
2nd ring 1.0 mm (0.039 in)
Oil ring 1.0 mm (0.039 in)
If out of specification, replace piston ring. If gap still exceeds the
limit even with a new ring, do the following. Rebore cylinder and
use oversized piston and piston rings.
Refer to SDS (EM-184).
I When replacing the piston, check the cylinder block surface for
scratches or seizure. If scratches or seizure is found, hone or
replace the cylinder block.
EM-160
CYLINDER BLOCK YD
CONNECTING ROD BEND AND TORSION NJEM0073S04
Bend:
Limit 0.12 mm (0.0047 in) GI
Torsion: MA
Limit 0.12 mm (0.0047 in)
If it exceeds the limit, replace connecting rod assembly.
SEM038F LC
EC
FE
CL
SEM003F
MT
CYLINDER BLOCK DISTORTION AND WEAR NJEM0073S05
I Clean upper surface of cylinder block. AT
Use a reliable straightedge and feeler gauge to check the flat-
ness of cylinder block surface.
Check along six positions shown in the figure. AX
Distortion limit: 0.1 mm (0.004 in)
I If out of specification, resurface it. The limit for cylinder block
resurfacing is determined by cylinder head resurfacing in
SU
engine.
Resurfacing limit: BR
SEM501G Amount of cylinder head resurfacing is “A”.
Amount of cylinder block resurfacing is “B”.
The maximum limit is as follows: ST
A + B = 0.07mm (0.0028 in)
Nominal cylinder block height from crankshaft center:
252.95 - 253.05 mm (9.9586 - 9.9626 in) RS
I If necessary, replace cylinder block.
BT
HA
SC
EL
IDX
EM-161
CYLINDER BLOCK YD
PISTON-TO-BORE CLEARANCE NJEM0073S06
1. Using a bore gauge, measure cylinder bore in X and Y direc-
tions at A, B and C for wear, out-of-round and taper.
Cylinder bore inner diameter:
Standard
86.000 - 86.030 mm (3.3858 - 3.3870 in)
Wear limit
0.07 mm (0.0028 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
JEM206G
block if necessary.
Limit 0.015 mm (0.0006 in)
Taper (Difference between A and C):
Limit 0.010 mm (0.0004 in)
2. Check for scratches and seizure. If seizure is found, hone it.
JEM207G
3. Measure piston skirt diameter.

Piston diameter “A”:
Except for Europe (Standard)
85.940 - 85.970 mm (3.3835 - 3.3846 in)
For Europe (Standard)
85.920 - 85.950 mm (3.3827 - 3.3839 in)
Measuring point “a” (Distance from the top):
48.83 mm (1.9224 in)
4. Make sure piston-to-bore clearance is within specification.
SEM258C I Calculate the clearance by using outer diameter at piston skirt
and inner diameter of cylinder (direction of X, point B):
Piston-to-bore clearance = Cylinder bore – Piston
diameter “A”
Standard [at room temperature 20°C (68°F)]:
Except for Europe
0.050 - 0.070 mm (0.0020 - 0.0028 in)
For Europe
0.070 - 0.090 mm (0.0028 - 0.0035 in)
I If the value is out of the specified range, replace piston and
piston pin assembly.
I If cylinder block or pistons are replaced with new ones, select

piston as follows:
When using a new cylinder block:
I Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface
at the rear of cylinder block and select a piston of the same
grade.
I The part No. of piston is specified together with the piston pin
as an assembly.
JEM208G
EM-162
CYLINDER BLOCK YD
When re-using a removed cylinder block:
I Measure the inner diameter of the cylinder block bore.
I Determine the bore grade by comparing the measurement with GI
the values under “Cylinder bore inner diameter” of the table
below. Choose a piston of the same grade.
Selective fitting for piston (Except for Europe):
MA
Unit: mm (in)
Grade (punched) 1 2 3
Cylinder bore 86.000 - 86.010 86.010 - 86.020 86.020 - 86.030

inner diameter (3.3858 - 3.3862) (3.3862 - 3.3866) (3.3866 - 3.3870)
SEM508G LC
Piston outer diam- 85.940 - 85.950 85.950 - 85.960 85.960 - 85.970
eter (3.3835 - 3.3839) (3.3839 - 3.3842) (3.3842 - 3.3846)
EC
Selective fitting for piston (For Europe):
Unit: mm (in) FE
Grade (punched) 1 2 3
Cylinder bore 86.000 - 86.010 86.010 - 86.020 86.020 - 86.030 CL

inner diameter (3.3858 - 3.3862) (3.3862 - 3.3866) (3.3866 - 3.3870)
Piston outer diam- 85.920 - 85.930 85.930 - 85.940 85.940 - 85.950

SEM509G eter (3.3827 - 3.3831) (3.3831 - 3.3835) (3.3835 - 3.3839)
MT
5. Determine piston oversize according to amount of cylinder

wear. AT
I For oversize pistons, 0.25 and 0.5OS [0.25 mm (0.0098 in),
0.5 mm (0.0197 in) oversize] are available as service parts. AX
Refer to SDS, EM-184. When using an oversize piston,
hone cylinder so that the clearance between piston and
cylinder becomes the specified value. Be sure to use SU
appropriate oversize piston ring for the oversize piston.
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter “A”. BR
Rebored size calculation: D = A + B − C
where,
D: Bored diameter
ST
A: Piston diameter as measured
B: Piston-to-bore clearance RS
C: Honing allowance 0.02 mm (0.0008 in)
7. Cut cylinder bores.
I When any cylinder needs boring, all other cylinders must
BT
also be bored.
I Do not cut too much out of cylinder bore at a time. Cut HA
only 0.05 mm (0.0020 in) or so in diameter at a time.
8. Hone cylinders to obtain specified piston-to-bore clearance.
9. Measure finished cylinder bore for out-of-round and taper. SC
I Measurement should be done after cylinder bore cools
down.
EL
IDX
EM-163
CYLINDER BLOCK YD
1. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-of-
round.
Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
SEM316A
Taper (Difference between A and B):
Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
3. Measure crankshaft runout at No. 3 (center) journal.

Standard 0.05 mm (0.0020 in)
Limit 0.10 mm (0.0039 in)
JEM212G
MAIN BEARING HOUSING INNER DIAMETER NJEM0073S15

I Without installing main bearings, install main bearing caps,
and tighten bolts to the specified torque. Refer to EM-171,
“CRANKSHAFT”.
I Measure the inner diameter of main bearing housing with a
bore gauge.
Standard:
66.654 - 66.681 mm (2.6242 - 2.6252 in) dia.
I If the measurement is out of the specified range, replace cyl-
inder block and main bearing caps.
JEM214G

I Use either of the following two methods, however, method “A”
gives more reliable results and is preferable.
Method A (Using bore gauge & micrometer)
Main bearing NJEM0073S0801
1. Install main bearings to the cylinder block and bearing cap, and
tighten the bolts to the specified torque. Then, measure the
inner diameter of the main bearings. Refer to EM-171,
“CRANKSHAFT”.
JEM213G
EM-164
CYLINDER BLOCK YD
Oil clearance = Bearing inner diameter – Crankshaft
journal outer diameter
Standard: 0.039 - 0.066 mm (0.0015 - 0.0026 in) GI
2. If the value is out of the specified range, select main bearings
to obtain the specified oil clearance, based on the measure-
ments of the main bearing housing inner diameter and crank- MA
shaft journal outer diameter.
LC
When using a new cylinder block and crankshaft:
1) Identify the bearing housing grade (No. 0, 1, or 2) on LH sur-
face at the rear of the cylinder block, and locate the applicable
EC
grade on the “Grade” row in the table below.
2) Identify the journal grade (No. 0, 1, or 2) on the front surface FE
of the crankshaft, and locate the applicable grade under the
“Grade” column on the table.
3) The main bearing to be used (STD 0 to STD 4) can be located CL
in the cell where the row and column cross.
JEM208G
MT
When re-using removed cylinder block and crankshaft:
1) Measure the inner diameter of cylinder block main bearing AT
housing.
2) Locate the applicable cell where the measurement falls, on
“Cylinder block main bearing housing inner diameter” row on AX
the table.
3) Measure the outer diameter of the crankshaft journal.
SU
4) Locate the applicable cell where the measurement falls, under
“Crankshaft journal outer diameter” column on the table.
5) The main bearing to be used (STD 0 to STD 4) can be located BR
JEM215G in the cell where the row and column cross.
Selective fitting for main bearing ST
Except for Europe
Unit: mm (in)
66.654 - 66.663 66.663 - 66.672 66.672 - 66.681 RS

Cylinder block main bearing housing inner diameter
(2.6242 - 2.6245) (2.6245 - 2.6249) (2.6249 - 2.6252)
Crankshaft journal Grade

0 1 2 BT
outer diameter (punched)
STD 0 STD 1 STD 2

I Bearing grade No. 1.816 - 1.820 1.820 - 1.824 1.824 - 1.828 HA
62.967 - 62.975 I Bearing thickness (0.0715 - 0.0717) (0.0717 - 0.0718) (0.0718 - 0.0720)
0
(2.4790 - 2.4793) I Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
I Identification color (0.0015 - 0.0026) (0.0015 - 0.0026) (0.0015 - 0.0026) SC
Black Brown Green
STD 1 STD 2 STD 3

I Bearing grade No. 1.820 - 1.824 1.824 - 1.828 1.828 - 1.832
EL
1
(2.4787 - 2.6790) I Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
I Identification color (0.0015 - 0.0026) (0.0015 - 0.0026) (0.0015 - 0.0026) IDX
Brown Green Yellow
EM-165
CYLINDER BLOCK YD
STD 2 STD 3 STD 4

2
(2.4784 - 2.4787) I Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
I Identification color (0.0015 - 0.0026) (0.0015 - 0.0026) (0.0015 - 0.0026)
Green Yellow Blue
Selective fitting for main bearing

For Europe
Unit: mm (in)
66.654 - 66.663 66.663 - 66.672 66.672 - 66.681

Cylinder block main bearing housing inner diameter
(2.6242 - 2.6245) (2.6245 - 2.6249) (2.6249 - 2.6252)
Crankshaft journal Grade

0 1 2
outer diameter (punched)
STD 0 STD 1 STD 2

0
(2.4790 - 2.4793) I Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
Black Red or Brown Green
STD 1 STD 2 STD 3

1
(2.4787 - 2.6790) I Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
Red or Brown Green Yellow
STD 2 STD 3 STD 4

2
(2.4784 - 2.4787) I Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
Green Yellow Blue
3. When the specified oil clearance is not obtained with standard

size main bearings, use undersized bearings.
I When an undersized bearing is used, measure the inner diam-
eter of the bearing while the bearing is installed. Grind crank-
shaft journal so that the specified oil clearance is obtained.
Undersize bearing
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
CAUTION:
When grinding the crankshaft journal to use an undersize
bearing, avoid damaging the fillet R.
JEM216G
EM-166
CYLINDER BLOCK YD
Connecting Rod Bearing (Big end) NJEM0073S0802
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod. GI
Tighten bolts to the specified torque. Refer to EM-171,
“CRANKSHAFT”.
3. Measure inner diameter “C” of connecting rod.
MA
Inner diameter:
Standard 55.000 - 55.013 mm (2.1654 - 2.1659 in)
AEM027 LC
4. Measure outer diameter “Dp” of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C − Dp
EC
Standard: 0.031 - 0.061 mm (0.0012 - 0.0024 in)
6. If it exceeds the standard, replace bearing. FE
CL
AEM034
MT
When using a new crankshaft and connecting rods:
I Identify the pin diameter grade (No. 0, 1, or 2) on front surface AT
of crankshaft and select the connecting rod bearings of the
same grade.
I There is no grading for the inner diameter of the big end of the AX
connecting rod.
When re-using the removed crankshaft and connecting rods:
SU
I Measure the inner diameter of the big end of the connecting
rod and make sure it is within the specified range.
I Measure the outer diameter of the crankshaft pin. BR
JEM215G I Determine the crankshaft pin grade by comparing the mea-
surement with the values under the column “Crankshaft pin
outer diameter” of the table below. Choose the bearings of the ST
same grade.
RS
BT
HA
SC
EL
IDX
EM-167
CYLINDER BLOCK YD
Selective fitting for connecting rod bearing
Unit: mm (in)
Crankshaft pin outer diameter Grade (punched) 0 (no punching)
STD 0
I Bearing grade No. 1.492 - 1.496
51.968 - 51.974 I Bearing thickness (0.0587 - 0.0589)
0
(2.0460 - 2.0462) I Oil clearance 0.031 - 0.061
I Identification color (0.0012 - 0.0024)
Black
STD 1
1
(2.0457 - 2.0460) I Oil clearance 0.031 - 0.061
Brown
STD 2
2
(2.0454 - 2.0457) I Oil clearance 0.031 - 0.061
Green
7. If clearance cannot be adjusted within the standard of any

bearing, grind crankshaft journal and use undersized bearing.
I When an undersized bearing is used, measure the inner diam-
eter of the bearing while the bearing is installed. Grind the pins
so that the specified oil clearance is obtained.
Undersize bearing
Unit: mm (in)
Size Thickness
US 0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
US 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
US 0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
CAUTION:
When grinding the crankshaft journal to use an undersize
JEM216G bearing, avoid damaging the fillet R.
Standard dimension R:
1.5 - 1.7 mm (0.0591 - 0.0669 in)
EM-168
CYLINDER BLOCK YD
Method B (Using plastigage)
CAUTION:
I Do not turn crankshaft or connecting rod while plastigage GI
is being inserted.
I When bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. If incor- MA
rect bearing clearance exists, use a thicker or undersized
main bearing to ensure specified clearance.
EM142 LC
MAIN BEARING CRUSH HEIGHT NJEM0073S16
I When the bearing cap is removed after being tightened to the EC
specified torque with main bearings installed, the tip end of
bearing must protrude.
Standard: There must be crush height. FE
I If the standard is not met, replace main bearings.
CL
SEM502G
MT
MAIN BEARING CAP BOLT DEFORMATION NJEM0073S17
I Measure the outer diameter of threaded area, d1 and d2, at the AT
points specified in the figure.
I When the necked point is identified at a point other than where
specified, measure at the point as d2. AX
I Calculate the difference between d1 and d2.
Limit: 0.13 mm (0.0051 in) SU
BR
JEM219G
CONNECTING ROD BUSHING CLEARANCE (SMALL

END) ST
NJEM0073S09
1. Measure inner diameter “C” of bushing.
Inner diameter “C”: RS
Standard 28.026 - 28.038 mm (1.1034 - 1.1039 in)
2. Measure outer diameter “Dp” of piston pin.
Outer diameter “Dp”:
BT
Standard 27.994 - 28.000 mm (1.1021 - 1.1024 in)
3. Calculate connecting rod bushing clearance. HA
SEM673E
Connecting rod bushing clearance = C − Dp
Standard: 0.026 - 0.044 mm (0.0010 - 0.0017 in)
Limit: 0.057 mm (0.0022 in) SC
If it exceeds the limit, replace connecting rod assembly and/or
piston set with pin. EL
IDX
EM-169
CYLINDER BLOCK YD
CONNECTING ROD BOLT DEFORMATION NJEM0073S18
I Install nuts to connecting rod bolts. Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread
on the bolt.
I If the nut does not screw in smoothly, measure the outer diam-
eter of the bolt thread at the point specified in the figure.
I If a necked point is identified, measure at that point.
Standard: 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.
Limit: 8.75 mm (0. 3445 in) dia.
I If the measurement exceeds the limit, replace connecting rod
JEM220G bolts and nuts.
FLYWHEEL RUNOUT NJEM0073S11
Flywheel★
CAUTION:
I The signal plate is built into the flywheel assembly. Be
careful not to damage the signal plate, especially the
teeth.
I Check the signal plate for deformation or cracks.
I Never place the flywheel assembly with the signal plate
AEM100
facing down.
I Keep any magnetized objects away from the signal plate.
plate teeth.
OIL JET NJEM0073S19

I Check nozzle for deformation or damage.
I Check oil passage for obstruction by blowing in air on nozzle
side.
I If abnormality is found, clean or replace.
JEM221G
OIL JET RELIEF VALVE NJEM0073S20

Using a clean resin rod, press down on the check valve inside relief
valve. Check for appropriate bounce/repulsion and smooth
operation.
JEM222G
EM-170
CYLINDER BLOCK YD
Assembly
Assembly NJEM0074
PISTON
1.
NJEM0074S01
With using snap ring pliers, install snap rings to grooves at the
GI
rear side of the piston.
I Install securely to fully fit into the groove. MA
2. Install piston to the connecting rod.
I Heat the piston with an industrial drier to 60 to 70°C (140 to
158°F) so that the piston pin can be easily inserted by finger.
Then, insert the piston pin from the front of the piston into the
piston and into the connecting rod.
LC
I Assemble so that the front mark on the piston top surface and
cylinder No. stamped on connecting rod are positioned as
shown in the figure. EC
3. Install new snap ring on piston front.
I Refer to step 1. above for notes for installation. FE
I After installing, check that the connecting rod moves smoothly.
4. Install piston rings using piston ring expander (Commercial
Service Tool). CL
I Be extremely careful to avoid any damage to the piston.
JEM227G
MT
I Install top ring and second ring with the punched surface fac-
ing upward. AT
Identification mark:
Except for Europe
Top ring R AX
Second ring 2R
For Europe SU
Top ring AE
Second ring AE2
I Install rings so that three closed gap position 120° apart one BR
JEM228G
another.
I Closed gaps do not need to face in a specific directions, as ST
long as each are positioned 120° apart.
RS
BT
HA
SC
1. Blow air sufficiently into the coolant passage, oil passage in the
cylinder block, inside of crankshaft case, and inside of cylinder
bores to remove any foreign materials. EL
2. Install oil jet relief valves.
3. Install oil jets.
IDX
JEM223G
EM-171
CYLINDER BLOCK YD
Assembly (Cont’d)
4. Install main bearings and thrust bearings.
a. Remove debris, dust, and oil from the locations on the cylin-
der block and main bearing caps where bearings are installed.
b. Install thrust bearing on each side of cylinder block No. 3
housing.
I Install thrust bearings with oil groove facing in the direction of
the crankshaft arm (outside).
JEM224G
c. Be sure to install main bearings in the correct direction.

I Make sure those with oil holes or oil grooves are mounted on
the cylinder block side, and those without oil holes or oil
grooves are on the main cap side.
I Before installing, apply engine oil on the front (inner) surfaces
of bearings. Do not apply oil to the back surfaces, but thor-
oughly clean them.
I Align stopper notches on bearings and install.
I Check the oil holes on cylinder block and those on bearings
are aligned.
JEM213G
5. Install crankshaft to cylinder block.

I Make sure crankshaft rotates smoothly by hand.
6. Install main bearing caps.
I Identify main bearing caps by the punched mark. Install
correctly, matching the journal No. on the bearing cap and the
journal, with the front mark facing forward.
I Main bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
JEM225G
7. Check the main bearing cap bolts for deformation.

Refer to EM-169, “MAIN BEARING CAP BOLT DEFORMA-
TION”.
8. Tighten the main bearing cap bolts according to the following
procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten to 25 to 30 N·m (2.5 to 3.1 kg-m, 18 to 22 ft-lb) in the
numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main
JEM200G bearing cap, all in the same direction. (when using a protrac-
tor)
d. Then, tighten 90° to 95° [target: 90°].
I Always use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
I After tightening bolts to specified torque, make sure that crank-
shaft rotates smoothly.
I Check crankshaft end play. Refer to EM-158, “CRANKSHAFT
END PLAY”.
9. Check the outer diameter of connecting rod bolts. Refer to
EM-170, “CONNECTING ROD BOLT DEFORMATION”.
JEM226G
EM-172
CYLINDER BLOCK YD
Assembly (Cont’d)
10. Install piston to connecting rod.
GI
MA
LC
11. Install connecting rod bearing to connecting rod and connect-
ing rod cap.
I Before installing, apply engine oil on the front (inner) surface
EC
of bearing. Do not apply oil to the back surface, but thoroughly
clean it.
FE
I Align stopper notches on connecting rod and protrusions on
bearing and install.
CL
JEM229G
MT
12. Install piston and connecting rod assembly to crankshaft.
I Set crankshaft pin of the installation location at BDC. AT
I Match the cylinder No. of connecting rod to the location of cyl-
inder.
I Using piston ring compressor (Commercial Service Tool), AX
install so that the front mark on the piston top surface faces in
the direction of engine front.
SU
BR
JEM230G
13. Install connecting rod caps.

I Match the cylinder No. punched on connecting rod and that on
ST
cap.
I Make sure that the front mark on connecting rod cap faces RS
towards the front of the engine.
BT
HA
JEM227G
SC
EL
IDX
EM-173
CYLINDER BLOCK YD
Assembly (Cont’d)
14. Tighten connecting rod nuts according to the following proce-
dure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten to 29 to 30 N·m (2.9 to 3.1 kg-m, 21 to 22 ft-lb).
c. Loosen completely to 0 N·m (0 kg-m, 0 in-lb).
d. Tighten to 19 to 20 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).
e. Tighten 120° to 125° [target: 120°]. (angular tightening)
I Always use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
JEM231G
I After tightening nuts, check that crankshaft rotates smoothly.
I Check connecting rod side clearance. Refer to EM-159, “CON-
NECTING ROD SIDE CLEARANCE”.
15. Force fit new rear oil seal into rear oil seal retainer.
I Using a drift [105 mm (4.13 in) dia.], force fit so that the dimen-
sion is as specified in the figure.
I Avoid inclined fitting. Force fit perpendicularly.
JEM232G
16. Install rear oil seal retainer.

I Apply a continuous bead of specified liquid gasket (Refer to
JEM233G
17. Install pilot bushing.

I Force fit with the drift [approx. 19 mm (0.75 in) dia.].
JEM234G
18. Install fuel injection pump bracket.

I Install insulator according to the shape of the block, and secure
by placing the bracket against the insulator. (Not installed on
some models)
I Align the bracket with the dowel pins on the block to install.
I The two bolts used for dowel pins have a longer shanks than
the other two.
I Check the protruding distance of the dowel pin for fuel injec-
tion pump.
Standard: 13.0 - 15.0 mm (0.512 - 0.591 in)
SEM513G
EM-174
CYLINDER BLOCK YD
Assembly (Cont’d)
19. Install parts to the engine in the reverse order of disassembly.
I Tighten bolts securing brackets of auxiliary components (A/C
compressor, alternator) to the specified torque. GI
: 57 - 65 N·m (5.8 - 6.7 kg-m, 42 - 48 ft-lb)
20. Remove engine from engine stand in the reverse order of
assembly. MA
21. Install flywheel.
I Holding ring gear with ring stopper (SST), tighten securing
bolts with TORX-socket (size: Q8 E20, Commercial Service
Tool).
I Tighten bolts uniformly in a crisscross manner. LC
REPLACEMENT OF PILOT BUSHING NJEM0074S03
1. Remove pilot bushing using tool or suitable tool. EC
FE
CL
SEM500G
MT
2. Install pilot bushing as shown.
AT
AX
SU
BR
SEM275GA
ST
RS
BT
HA
SC
EL
IDX
EM-175
SERVICE DATA AND SPECIFICATIONS (SDS) YD
General Specifications
General Specifications NJEM0075
Cylinder arrangement In-line 4
Displacement cm3 (cu in) 2,184 (133.27)
Bore and stroke mm (in) 86 x 94 (3.39 x 3.70)
Valve arrangement DOHC
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1
Number of main bearings 5
Compression ratio 18.0
Compression Pressure NJEM0076

Unit: kPa (bar, kg/cm2, psi)/200 rpm
Except for Europe 2,844 (28.4, 29.0, 412)

Standard
For Europe 3,138 (31.4, 32.0, 455)
Compression pressure
Minimum 2,452 (24.5, 25.0, 356)
Differential limit between cylinders 490 (4.9, 5.0, 71)
Belt Deflection NJEM0111
Belt deflection with 98 N (10 kg, 22 lb) force applied*

mm (in)
Applied belt Belt specification
Limit for re-tighten-
New Adjusted
ing
4-5 6-7
Air conditioner compressor belt HA type low edge belt 8.5 (0.335)
(0.16 - 0.20) (0.24 - 0.28)
HA type low-edge wide angle 9.0 - 10.5 11.0 - 12.5

Alternator & water pump belt 16.5 (0.650)
belt (0.354 - 0.413) (0.433 - 0.492)
*: When engine is cold.
Cylinder Head NJEM0077

Unit: mm (in)
Standard Limit
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
JEM204G
EM-176
Valve
Valve NJEM0078
VALVE NJEM0078S01
Unit: mm (in)
GI
MA
LC
SEM188
EC
Intake 28.0 - 28.3 (1.102 - 1.114)
Valve head diameter “D” FE
Exhaust 26.0 - 26.3 (1.024 - 1.035)
Intake 106.72 (4.2016)

Valve length “L” CL
Exhaust 106.36 (4.1874)
Intake 5.965 - 5.980 (0.2348 - 0.2354)

Valve stem diameter “d” MT
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
Intake
Valve seat angle “α” 45°15′ - 45°45′ AT
Exhaust
Intake 1.38 (0.0543)

Valve margin “T” AX
Exhaust 1.48 (0.0583)
Valve margin “T” limit More than 1.0 (0.039)

SU
Valve stem end surface grinding limit Less than 0.2 (0.008)
VALVE CLEARANCE NJEM0078S02

BR
Unit: mm (in)
Cold Hot* (reference data)

ST
Intake 0.24 - 0.32 (0.009 - 0.013) 0.274 - 0.386 (0.011 - 0.015)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)

RS
*: Approximately 80°C (176°F)
AVAILABLE SHIMS NJEM0078S03 BT

Thickness mm (in) Identification mark
2.10 (0.0827) 2.10 HA

2.12 (0.0835) 2.12
2.14 (0.0843) 2.14 SC

2.16 (0.0850) 2.16
2.18 (0.0858) 2.18 EL

2.20 (0.0866) 2.20
2.22 (0.0874) 2.22 IDX

2.24 (0.0882) 2.24
2.26 (0.0890) 2.26
2.28 (0.0898) 2.28
EM-177
Valve (Cont’d)
Thickness mm (in) Identification mark
2.30 (0.0906) 2.30
2.32 (0.0913) 2.32
2.34 (0.0921) 2.34
2.36 (0.0929) 2.36
2.38 (0.0937) 2.38
2.40 (0.0945) 2.40
2.42 (0.0953) 2.42
2.44 (0.0961) 2.44
2.46 (0.0969) 2.46
2.48 (0.0976) 2.48
2.50 (0.0984) 2.50
2.52 (0.0992) 2.52
2.54 (0.1000) 2.54
2.56 (0.1008) 2.56
2.58 (0.1016) 2.58
2.60 (0.1024) 2.60
2.62 (0.1031) 2.62
2.64 (0.1039) 2.64
2.66 (0.1047) 2.66
2.68 (0.1055) 2.68
2.70 (0.1063) 2.70
2.72 (0.1071) 2.72
2.74 (0.1079) 2.74
SEM512G
Free height mm (in) Outer 42.3 (1.6654)
For Sedan 360 (36.8, 81.2) at 24.82 (0.9772)

Pressure N (kg, lb) at height mm (in) Outer
For Hatchback 366 (37.3, 82.2) at 24.82 (0.9772)
For Sedan Limit 2.1 (0.083)

Out-of-square mm (in) Outer
For Hatchback Limit 1.5 (0.059)
EM-178
Valve (Cont’d)
VALVE LIFTER =NJEM0078S05
Unit: mm (in)
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801)

GI
Lifter guide inner diameter 30.000 - 30.021 (1.1181 - 1.1819)
Clearance between lifter and lifter guide 0.025 - 0.061 (0.0010 - 0.0024)
MA
VALVE GUIDE NJEM0078S06

Unit: mm (in)
LC
EC
FE
CL
JEM156G
Standard Service MT
Valve guide 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) AT
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023) AX

Standard Limit
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031) SU

Stem to guide clearance
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.1 (0.004)
Valve deflection limit 0.15 (0.0059) BR

Projection length 10.4 - 10.6 (0.4094 - 0.4173)
ST
RS
BT
HA
SC
EL
IDX
EM-179
Valve Seat
Valve Seat NJEM0079

Unit: mm (in)
SEM546G
JEM253G
Standard Service
Intake 30.000 - 30.016 (1.1181 - 1.1817) 30.500 - 30.516 (1.2008 - 1.2014)

Cylinder head seat recess diameter (D)
Exhaust 29.000 - 29.016 (1.1417 - 1.1424) 29.500 - 29.516 (1.1614 - 1.1620)
Intake 0.064 - 0.100 (0.0025 - 0.0039)

Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038)
Intake 30.080 - 30.100 (1.1842 - 1.1850) 30.580 - 30.600 (1.2039 - 1.2047)

Valve seat outer diameter (d)
Exhaust 29.080 - 29.096 (1.1449 - 1.1455) 29.580 - 29.596 (1.1646 - 1.1652)
EM-180
Valve Seat (Cont’d)
Intake 7.0 - 7.1 (0.276 - 0.280) 6.60 - 6.70 (0.2598 - 0.2638)

Height (h)
Exhaust 6.7 - 6.8 (0.264 - 0.268) 6.3 - 6.4 (0.248 - 0.252) GI
Intake 8.83 - 9.13 (0.3476 - 0.3594)
Depth (H)
Exhaust 9.06 - 9.36 (0.3567 - 0.3685) MA
Intake 36.53 - 36.98 (1.4382 - 1.4559)
Depth (L)
Exhaust 36.53 - 37.01 (1.4382 - 1.4571)
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-181
Camshaft and Camshaft Bearing
Camshaft and Camshaft Bearing =NJEM0080

Unit: mm (in)
Standard Limit
Camshaft journal to bearing clearance 0.045 - 0.086 (0.0018 - 0.0034) 0.15 (0.0059)
No. 1
30.500 - 30.521 (1.2008 - 1.2016)
Inner diameter of camshaft bearing —
No. 2, 3, 4, 5
24.000 - 24.021 (0.9449 - 0.9457)
No. 1
30.435 - 30.455 (1.1982 - 1.1990)
Outer diameter of camshaft journal —
No. 2, 3, 4, 5
23.935 - 23.955 (0.9423 - 0.9431)
Camshaft runout [TIR*] — 0.04 (0.0016)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059) —
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.24 (0.0094)
EM671
Except for Europe 39.905 - 40.095 (1.5711 - 1.5785)

Intake
Cam height “A” For Europe 39.505 - 39.695 (1.5553 - 1.5628)
Exhaust 39.905 - 40.095 (1.5711 - 1.5785)
Wear limit of cam height 0.15 (0.0059)
Valve timing
EM120
Unit: degree
a b c d e f
Except for Europe 220 224 2 42 –6 46
For Europe 224 212 2 30 –2 46
EM-182
Cylinder Block
Cylinder Block NJEM0081

Unit: mm (in)
GI
MA
LC
JEM207G EC
Surface flatness
Limit 0.1 (0.004) FE
Grade No. 1 86.000 - 86.010 (3.3858 - 3.3862)
Standard Grade No. 2 86.010 - 86.020 (3.3862 - 3.3866) CL

Cylinder bore Inner diameter
Grade No. 3 86.020 - 86.030 (3.3866 - 3.3870)
Wear limit 0.07 (0.0028) MT

Out-of-round (Difference between X and Y) Less than 0.015 (0.0006)
Taper (Difference between A and B) Less than 0.010 (0.0004) AT

Main journal inner Grade No. 0 66.654 - 66.663 (2.6242 - 2.6245)
diameter grade Grade No. 1 66.663 - 66.672 (2.6245 - 2.6249)
(Without bearing) Grade No. 2 66.672 - 66.681 (2.6249 - 2.6252)
AX
Difference in inner
diameter between
cylinders
Limit Less than 0.05 (0.0020) SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-183
Piston, Piston Ring and Piston Pin
Piston, Piston Ring and Piston Pin =NJEM0082

AVAILABLE PISTON NJEM0082S01
Unit: mm (in)
SEM882E
Grade No. 1 85.940 - 85.950 (3.3835 - 3.3839)
Grade No. 2 85.950 - 85.960 (3.3839 - 3.3842)
Piston skirt diameter “A” Standard Grade No. 3 85.960 - 85.970 (3.3842 - 3.3846)
0.25 (0.0098) oversize (Service) 86.190 - 86.220 (3.3933 - 3.3945)
“a” dimension 48.83 (1.9224)
Piston pin hole diameter 27.997 - 28.005 (1.1022 - 1.1026)
Piston clearance to cylinder block 0.050 - 0.070 (0.0020 - 0.0028)

Unit: mm (in)
SEM882E
Grade No. 1 85.920 - 85.930 (3.3827 - 3.3831)
Grade No. 2 85.930 - 85.940 (3.3831 - 3.3835)
Piston skirt diameter “A” Standard Grade No. 3 85.940 - 85.950 (3.3835 - 3.3839)
“a” dimension 48.83 (1.9224)
Piston pin hole diameter 27.997 - 28.005 (1.1022 - 1.1026)
Piston clearance to cylinder block 0.070 -0.090 (0.0028 - 0.0035)
EM-184
Piston, Piston Ring and Piston Pin (Cont’d)
PISTON RING =NJEM0082S02
Unit: mm (in) GI
Standard Limit
Top 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004) MA

Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
Top 0.21 - 0.31 (0.0083 - 0.0122) 1.0 (0.039)
End gap 2nd 0.37 - 0.52 (0.0146 - 0.0205) 1.0 (0.039) LC

Oil (rail ring) 0.30 - 0.55 (0.0118 - 0.0217) 1.0 (0.039)
EC
Unit: mm (in)
Standard Limit
FE
Top 0.120 - 0.180 (0.0047 - 0.0071) 0.2 (0.008)

CL
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
Top 0.20 - 0.35 (0.0079 - 0.0138) 1.0 (0.039)

MT
End gap 2nd 0.39 - 0.54 (0.0154 - 0.0213) 1.0 (0.039)
Oil (rail ring) 0.25 - 0.50 (0.0098 - 0.0197) 1.0 (0.039)

AT
PISTON PIN NJEM0082S03 AX

Unit: mm (in)
Piston pin outer diameter 27.994 - 28.000 (1.1021 - 1.1024)

SU
Interference fit of piston pin to piston 0.002 - 0.006 (0.0001 - 0.0002)
Standard 0.026 - 0.044 (0.0010 - 0.0017)

Piston pin to connecting rod bushing clearance BR
Limit 0.057 (0.0022)
*: Values measured at ambient temperature of 20°C (68°F)

ST
Connecting Rod NJEM0083
Unit: mm (in)
RS
Center distance 157.5 (6.201)
Bend [per 100 (3.94)] Limit 0.12 (0.0047)

BT
Torsion [per 100 (3.94)] Limit 0.12 (0.0047)
Connecting rod small end inner diameter 30.080 - 31.000 (1.1842 - 1.2205)
HA
Piston pin bushing inner diameter* 28.026 - 28.038 (1.1034 - 1.1039)
SC
Standard 0.200 - 0.350 (0.0079 - 0.0138)
Side clearance
Limit 0.4 (0.016)
EL
*: After installing in connecting rod
IDX
EM-185
Crankshaft
Crankshaft =NJEM0084
Unit: mm (in)
Grade No. 0 62.967 - 62.975 (2.4790 - 2.4793)

Main journal dia. “Dm” grade Grade No. 1 62.959 - 62.967 (2.4787 - 2.4790)
Grade No. 2 62.951 - 62.959 (2.4784 - 2.4787)
Grade No. 0 51.968 - 51.974 (2.0460 - 2.0462)
Pin journal dia. “Dp” Grade No. 1 51.961 - 51.968 (2.0457 - 2.0460)
Grade No. 2 51.954 - 51.961 (2.0454 - 2.0457)
Center distance “r” 46.97 - 47.03 (1.8492 - 1.8516)
Out-of-round (Difference between X

Standard/Limit Less than 0.003 (0.0001)/Less than 0.005 (0.0002)
and Y)
Taper (Difference between A and B) Standard/Limit Less than 0.003 (0.0001)/Less than 0.005 (0.0002)

Runout [TIR*]
Standard 0.10 - 0.25 (0.0039 - 0.0098)

Free end play
Limit 0.30 (0.0118)
SEM645 SEM054H
EM-186
Available Main Bearing
Available Main Bearing =NJEM0085

EXCEPT FOR EUROPE NJEM0085S05
GI
MA
LC
SEM255G EC
Grade number Thickness “T” mm (in) Width “W” mm (in) Identification color
0 1.816 - 1.820 (0.0715 - 0.0717) Black FE

1 1.820 - 1.824 (0.0717 - 0.0718) Brown
2 1.824 - 1.828 (0.0718 - 0.0720) 19.9 - 20.1 (0.783 - 0.791) Green CL

3 1.828 - 1.832 (0.0720 - 0.0721) Yellow
4 1.832 - 1.836 (0.0721 - 0.0723) Blue MT
FOR EUROPE NJEM0085S06 AT
AX
SU
BR
SEM255G ST
Grade number Thickness “T” mm (in) Width “W” mm (in) Identification color
0 1.816 - 1.820 (0.0715 - 0.0717) Black

RS
1 1.820 - 1.824 (0.0717 - 0.0718) Red or Brown
2 1.824 - 1.828 (0.0718 - 0.0720) 19.9 - 20.1 (0.783 - 0.791) Green

BT
3 1.828 - 1.832 (0.0720 - 0.0721) Yellow
4 1.832 - 1.836 (0.0721 - 0.0723) Blue

HA
Unit: mm (in)
SC
Thickness Main journal diameter “Dm”
EL
Grind so that bearing clearance is the specified
0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
value.
IDX
EM-187
Available Connecting Rod Bearing
Available Connecting Rod Bearing =NJEM0086

CONNECTING ROD BEARING NJEM0086S01
Grade number Thickness “T” mm (in) Width “W” mm (in) Identification color (mark)
0 1.492 - 1.496 (0.0587 - 0.0589) Black

22.9 - 23.1
1 1.496 - 1.500 (0.0589 - 0.0591) Brown
(0.902 - 0.909)
2 1.500 - 1.504 (0.0591 - 0.0592) Green
Unit: mm (in)
Thickness Crank pin journal diameter “Dp”
0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)

Grind so that bearing clearance is the specified
0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
value.
0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
Miscellaneous Components NJEM0087

Unit: mm (in)
Flywheel runout [TIR]* Less than 0.15 (0.0059)

Unit: mm (in)
Standard 0.039 - 0.066 (0.0015 - 0.0026)

Main bearing clearance
Limit 0.10 (0.0039)
Standard 0.031 - 0.061 (0.0012 - 0.0024)

Connecting rod bearing clearance
Limit 0.09 (0.0035)
EM-188

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ENGINE MECHANICAL GI

Parts Requiring Angular Tightening NJEM0001

Special Service Tools NJEM0003

ST0501S000 Disassembling and assembling

Engine attachment Overhauling engine

ST10120000 Loosening and tightening cylinder head bolt

KV10116200 Disassembling valve mechanism

KV10115600 Installing valve oil seal

KV10107902 Removing valve oil seal

EM03470000 Installing piston assembly into cylinder bore

KV10107400 Disassembling and assembling piston pin FE

KV10111100 Removing oil pan AX

KV10117100 Loosening or tightening heated oxygen sensor

KV101056S0* Preventing crankshaft from rotating

Commercial Service Tools NJEM0004

Tool name Description

Spark plug wrench Removing and installing spark plug

Valve seat cutter set Finishing valve seat dimensions

Piston ring expander Removing and installing piston ring

Valve guide drift Removing and installing valve guide

Tool name Description

Front oil seal drift Installing front oil seal

Oxygen sensor thread Reconditioning the exhaust system threads before

Anti-seize lubricant (Per- Lubricating heated oxygen sensor thread cleaning SU

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING QG

NVH Troubleshooting — Engine Noise NJEM0005S01

Top of Ticking or C A — A B — Tappet Valve clearance EM-50

Crankshaft Slap or — A — B B — Piston pin Piston and piston pin EM-63, 69

Knock A B C B B B Connecting Connecting rod bearing EM-68, 69

Knock A B — A B C Main bear- Main bearing oil clear- EM-66

Front of Tapping or A A — B B B Timing Timing chain cracks and EM-33

Front of Squeak or A B — B — C Drive belts Drive belts deflection EM-22

Creaking A B A B A B Drive belts Idler pulley bearing

Squall or A B — B A B Water pump Water pump operation LC-15

A: Closely related B: Related C: Sometimes related —: Not related

Removal and Installation NJEM0006

1. Throttle position sensor 4. Fuel injector 7. Intake manifold

1. Gasket 8. Intake manifold support (engine 15. Air hose HA

1. Intake manifold 6. Accelerator wire bracket 10. Throttle body

1. Crankshaft pulley 5. Exhaust manifold cover 10. Converter cap

MEASUREMENT OF COMPRESSION PRESSURE QG

1. Inspect for cracks, fraying, wear or oil adhesion. If necessary,

Used belt deflection

Applied engine Deflection Deflection

6-7 5.5 - 6.5

Used belt deflection

Applied engine Deflection Deflection GI

5.2 - 5.8 4.6 - 5.2 MA

Cleaning and Changing NJEM0043

DRY PAPER TYPE (EXCEPT FOR EUROPE) NJEM0043S02

Checking and Changing NJEM0044

Plug gap mm (in) 0.8 - 0.9 (0.031 - 0.035)

Spark plug (For Europe):

Standard BKR5E-11 RC10YCC4 SU

7. Install spark plugs. SC

2. Apply a continuous bead of liquid gasket to mating surface of SC

3. Install oil pan.

1. Chain tensioner 7. Timing chain 13. Crankshaft pulley IDX

8. Remove vacuum hoses, fuel hoses, and so on.