NISSAN Pathfinder R51 EM (ENGINE MECHANICAL)

ENGINE MECHANICAL
B ENGINE
EM
SECTION
ENGINE MECHANICAL C
E
CONTENTS
VQ INSTALLATION ................................................... 17 F
Changing Air Cleaner Filter .................................... 17
PRECAUTIONS .......................................................... 6 REMOVAL ........................................................... 17
PrecautionsforProcedureswithoutCowlTopCover..... 6 INSTALLATION ................................................... 17 G
PrecautionsNecessaryforSteeringWheelRotation INTAKE MANIFOLD COLLECTOR .......................... 18
After Battery Disconnect .......................................... 6 Components ........................................................... 18
OPERATION PROCEDURE ................................. 6 Removal and Installation ........................................ 18
Precautions for Drain Engine Coolant ...................... 6 H
REMOVAL ........................................................... 18
Precautions for Disconnecting Fuel Piping .............. 6 INSTALLATION ................................................... 19
Precautions for Removal and Disassembly ............. 6 INTAKE MANIFOLD ................................................. 21
Precautions for Inspection, Repair and Replace- Components ........................................................... 21 I
ment ......................................................................... 7 Removal and Installation ........................................ 21
Precautions for Assembly and Installation ............... 7 REMOVAL ........................................................... 21
Parts Requiring Angle Tightening ............................. 7 INSPECTION AFTER REMOVAL ....................... 22 J
Precautions for Liquid Gasket .................................. 7 INSTALLATION ................................................... 22
REMOVAL OF LIQUID GASKET SEALING .......... 7 EXHAUST MANIFOLD AND THREE WAY CATA-
LIQUID GASKET APPLICATION PROCEDURE..... 8 LYST .......................................................................... 23
PREPARATION ........................................................... 9 K
Components ........................................................... 23
Special Service Tools ............................................... 9 Removal and Installation ........................................ 23
Commercial Service Tools ...................................... 10 REMOVAL (LEFT BANK) .................................... 23
NOISE, VIBRATION AND HARSHNESS (NVH) INSPECTION AFTER REMOVAL (LEFT BANK)... 25 L
TROUBLESHOOTING .............................................. 12 INSTALLATION (LEFT BANK) ............................ 25
NVH Troubleshooting —Engine Noise ................... 12 REMOVAL (RIGHT BANK) .................................. 26
Use the Chart Below to Help You Find the Cause INSPECTION AFTER REMOVAL (RIGHT M
of the Symptom. ..................................................... 13 BANK) ................................................................. 26
DRIVE BELTS ........................................................... 14 INSTALLATION (RIGHT BANK) .......................... 26
Checking Drive Belts .............................................. 14 OIL PAN AND OIL STRAINER ................................. 28
Tension Adjustment ................................................ 14 Components ........................................................... 28
Removal and Installation ........................................ 14 Removal and Installation ........................................ 28
REMOVAL ........................................................... 14 REMOVAL ........................................................... 28
INSTALLATION ................................................... 15 INSPECTION AFTER REMOVAL ....................... 30
Drive Belt Auto Tensioner and Idler Pulley ............. 16 INSTALLATION ................................................... 30
REMOVAL ........................................................... 16 INSPECTION AFTER INSTALLATION ................ 32
INSTALLATION ................................................... 16 IGNITION COIL ......................................................... 33
AIR CLEANER AND AIR DUCT ............................... 17 Components ........................................................... 33
Components ........................................................... 17 Removal and Installation ........................................ 33
Removal and Installation ........................................ 17 REMOVAL (LEFT BANK) .................................... 33
REMOVAL ........................................................... 17 INSTALLATION (LEFT BANK) ............................ 33
INSPECTION AFTER REMOVAL ....................... 17 REMOVAL (RIGHT BANK) .................................. 33
INSTALLATION (RIGHT BANK) .......................... 33
EM-1
SPARK PLUG (PLATINUM-TIPPED TYPE) ............. 34 Disassembly and Assembly ....................................97
Components ........................................................... 34 DISASSEMBLY ....................................................97
Removal and Installation ........................................ 34 ASSEMBLY ..........................................................97
REMOVAL ........................................................... 34 Inspection After Disassembly ..................................99
INSPECTION AFTER REMOVAL ........................ 34 VALVE DIMENSIONS ..........................................99
INSTALLATION .................................................... 35 VALVE GUIDE CLEARANCE ..............................99
FUEL INJECTOR AND FUEL TUBE ........................ 36 VALVE GUIDE REPLACEMENT .........................99
Components ........................................................... 36 VALVE SEAT CONTACT .................................... 101
Removal and Installation ........................................ 36 VALVE SEAT REPLACEMENT .......................... 101
REMOVAL ........................................................... 36 VALVE SPRING SQUARENESS ....................... 102
INSTALLATION .................................................... 39 VALVE SPRING DIMENSIONS AND VALVE
INSPECTION AFTER INSTALLATION ................ 40 SPRING PRESSURE LOAD .............................. 102
ROCKER COVER ..................................................... 41 ENGINE ASSEMBLY ............................................... 103
Components ........................................................... 41 Components .......................................................... 103
Removal and Installation ........................................ 41 Removal and Installation ....................................... 104
REMOVAL ........................................................... 41 REMOVAL .......................................................... 104
INSTALLATION .................................................... 42 INSTALLATION .................................................. 105
FRONT TIMING CHAIN CASE ................................. 44 INSPECTION AFTER INSTALLATION .............. 105
Removal and Installation ........................................ 44 CYLINDER BLOCK ................................................. 106
REMOVAL ........................................................... 44 Components .......................................................... 106
INSTALLATION .................................................... 48 Disassembly and Assembly .................................. 107
INSPECTION AFTER INSTALLATION ................ 52 DISASSEMBLY .................................................. 107
TIMING CHAIN .......................................................... 53 ASSEMBLY ........................................................ 110
Components ........................................................... 53 How to Select Piston and Bearing ........................ 117
Removal and Installation ........................................ 54 DESCRIPTION .................................................. 117
REMOVAL ........................................................... 54 HOW TO SELECT PISTON ............................... 117
INSPECTION AFTER REMOVAL ........................ 61 HOW TO SELECT CONNECTING ROD BEAR-
INSTALLATION .................................................... 62 ING ..................................................................... 118
INSPECTION AFTER INSTALLATION ................ 72 HOW TO SELECT MAIN BEARING .................. 119
CAMSHAFT ............................................................... 73 Inspection After Disassembly ................................ 122
Components ........................................................... 73 CRANKSHAFT END PLAY ................................ 122
Removal and Installation ........................................ 74 CONNECTING ROD SIDE CLEARANCE ......... 122
REMOVAL ........................................................... 74 PISTON TO PISTON PIN OIL CLEARANCE ..... 122
INSPECTION AFTER REMOVAL ........................ 75 PISTON RING SIDE CLEARANCE ................... 123
INSTALLATION .................................................... 78 PISTON RING END GAP .................................. 123
INSPECTION AFTER INSTALLATION ................ 82 CONNECTING ROD BEND AND TORSION ..... 124
Valve Clearance ...................................................... 83 CONNECTING ROD BIG END DIAMETER ...... 124
INSPECTION ....................................................... 83 CONNECTING ROD BUSHING OIL CLEAR-
ADJUSTMENT .................................................... 86 ANCE ................................................................. 124
OIL SEAL .................................................................. 88 CYLINDER BLOCK DISTORTION .................... 125
Removal and Installation of Valve Oil Seal ............. 88 MAIN BEARING HOUSING INNER DIAMETER.126
REMOVAL ........................................................... 88 PISTON TO CYLINDER BORE CLEARANCE . 126
INSTALLATION .................................................... 88 CRANKSHAFT MAIN JOURNAL DIAMETER ... 127
Removal and Installation of Front Oil Seal ............. 89 CRANKSHAFT PIN JOURNAL DIAMETER ...... 128
REMOVAL ........................................................... 89 CRANKSHAFT OUT-OF-ROUND AND TAPER.128
INSTALLATION .................................................... 89 CRANKSHAFT RUNOUT .................................. 128
Removal and Installation of Rear Oil Seal .............. 89 CONNECTING ROD BEARING OIL CLEAR-
REMOVAL ........................................................... 89 ANCE ................................................................. 128
INSTALLATION .................................................... 90 MAIN BEARING OIL CLEARANCE ................... 129
CYLINDER HEAD ..................................................... 91 CRUSH HEIGHT OF MAIN BEARING .............. 130
On-Vehicle Service ................................................. 91 CRUSH HEIGHT OF CONNECTING ROD
CHECKING COMPRESSION PRESSURE ......... 91 BEARING ........................................................... 130
Components ........................................................... 92 LOWER CYLINDER BLOCK BOLT OUTER
Removal and Installation ........................................ 92 DIAMETER ........................................................ 130
REMOVAL ........................................................... 92 CONNECTING ROD BOLT OUTER DIAMETER.131
INSPECTION AFTER REMOVAL ........................ 93 DRIVE PLATE .................................................... 131
INSTALLATION .................................................... 94 OIL JET .............................................................. 131
INSPECTION AFTER INSTALLATION ................ 96 OIL JET RELIEF VALVE .................................... 131
Components ........................................................... 96
EM-2
SERVICE DATA AND SPECIFICATIONS (SDS) .... 132 CHARGE AIR COOLER ......................................... 164
Standard and Limit ............................................... 132 Components ......................................................... 164 A
GENERAL SPECIFICATIONS .......................... 132 Removal and Installation ...................................... 164
DRIVE BELT ..................................................... 133 REMOVAL ......................................................... 164
INTAKE MANIFOLD COLLECTOR, INTAKE INSPECTION AFTER REMOVAL ..................... 165 EM
MANIFOLD AND EXHAUST MANIFOLD ......... 133 INSTALLATION ................................................. 165
SPARK PLUG ................................................... 133 INTAKE MANIFOLD ............................................... 166
CAMSHAFT AND CAMSHAFT BEARING ........ 134 Components (EURO 3) ........................................ 166
CYLINDER HEAD ............................................. 136 Components (EURO 4) ........................................ 168 C
CYLINDER BLOCK ........................................... 139 Removal and Installation ...................................... 169
PISTON, PISTON RING AND PISTON PIN ...... 140 REMOVAL ......................................................... 169
CONNECTING ROD ......................................... 141 INSPECTION AFTER REMOVAL ..................... 170 D
CRANKSHAFT .................................................. 142 INSTALLATION ................................................. 170
MAIN BEARING ................................................ 143 INSPECTION AFTER INSTALLATION .............. 176
CONNECTING ROD BEARING ........................ 144 CATALYST .............................................................. 177 E
Components (EURO 3) ........................................ 177
YD Components (EURO 4) ........................................ 178
Removal and Installation ...................................... 178
APPLICATION NOTICE .......................................... 145 REMOVAL ......................................................... 178 F
How to Check Engine Type .................................. 145 INSTALLATION ................................................. 179
PRECAUTIONS ...................................................... 146 TURBO CHARGER ................................................. 180
PrecautionsforProcedureswithoutCowlTopCover. 146 Components (EURO 3) ........................................ 180 G
PrecautionsNecessaryforSteeringWheelRotation Components (EURO 4) ........................................ 181
After Battery Disconnect ...................................... 146 Removal and Installation ...................................... 182
OPERATION PROCEDURE ............................. 146 REMOVAL ......................................................... 182 H
Precautions for Draining Engine Coolant ............. 146 INSPECTION AFTER REMOVAL (EURO 3) ..... 182
Precautions for Disconnecting Fuel Piping .......... 146 INSPECTION AFTER REMOVAL (EURO 4) ..... 184
Precautions for Removal and Disassembly ......... 146 TROUBLE DIAGNOSIS OF TURBOCHARGER. 186
Precautions for Inspection, Repair and Replace- I
INSTALLATION ................................................. 186
ment ..................................................................... 147 EXHAUST MANIFOLD ........................................... 187
Precautions for Assembly and Installation ........... 147 Components (EURO 3) ........................................ 187
Parts Requiring Angle Tightening ......................... 147 Components (EURO 4) ........................................ 188 J
Precautions For Liquid Gasket ............................. 147 Removal and Installation ...................................... 188
REMOVAL OF LIQUID GASKET ...................... 147 REMOVAL ......................................................... 188
LIQUID GASKET APPLICATION PROCEDURE. 148 INSPECTION AFTER REMOVAL ..................... 189 K
PREPARATION ....................................................... 149 INSTALLATION ................................................. 189
Special Service Tools ........................................... 149 INSPECTION AFTER INSTALLATION .............. 189
Commercial Service Tools .................................... 151 OIL PAN AND OIL STRAINER ............................... 190 L
NOISE, VIBRATION AND HARSHNESS (NVH) Components ......................................................... 190
TROUBLESHOOTING ............................................ 153 Removal and Installation ...................................... 190
NVH Troubleshooting — Engine Noise ................ 153 REMOVAL ......................................................... 190
Use the Chart Below to Help You Find the Cause INSPECTION AFTER REMOVAL ..................... 192 M
of the Symptom. ................................................... 154 INSTALLATION ................................................. 192
DRIVE BELTS ......................................................... 155 INSPECTION AFTER INSTALLATION .............. 194
Checking Drive Belts ............................................ 155 GLOW PLUG .......................................................... 195
Deflection Adjustment .......................................... 156 Components ......................................................... 195
POWER STEERING OIL PUMP BELT ............. 156 Removal and Installation ...................................... 195
A/C COMPRESSOR, ALTERNATOR AND REMOVAL ......................................................... 195
WATER PUMP BELT ........................................ 157 INSTALLATION ................................................. 195
Removal and Installation ...................................... 157 VACUUM PUMP ...................................................... 196
REMOVAL ......................................................... 157 Components ......................................................... 196
INSTALLATION ................................................. 157 Removal and Installation ...................................... 196
AIR CLEANER AND AIR DUCT ............................. 158 INSPECTION BEFORE REMOVAL .................. 196
Components (EURO 3) ........................................ 158 REMOVAL ......................................................... 196
Components (EURO 4) ........................................ 159 INSTALLATION ................................................. 197
Removal and Installation ...................................... 159
REMOVAL ......................................................... 159
INSTALLATION ................................................. 161
CHANGING AIR CLEANER FILTER ................. 163
EM-3
INJECTION TUBE AND FUEL INJECTOR ............ 198 Removal and Installation ....................................... 253
Components ......................................................... 198 REMOVAL .......................................................... 253
Removal and Installation ...................................... 198 INSPECTION AFTER REMOVAL ...................... 253
REMOVAL ......................................................... 198 INSTALLATION .................................................. 255
INSTALLATION .................................................. 200 INSPECTION AFTER INSTALLATION .............. 257
INSPECTION AFTER INSTALLATION .............. 202 Components .......................................................... 258
FUEL PUMP ............................................................ 204 Disassembly and Assembly .................................. 258
Components ......................................................... 204 DISASSEMBLY .................................................. 258
Removal and Installation ...................................... 204 ASSEMBLY ........................................................ 259
REMOVAL ......................................................... 204 INSPECTION AFTER DISASSEMBLY .............. 260
INSPECTION AFTER REMOVAL ...................... 207 ENGINE ASSEMBLY ............................................... 265
INSTALLATION .................................................. 207 Components .......................................................... 265
ROCKER COVER ................................................... 211 Removal and Installation ....................................... 266
Components (EURO 3) ......................................... 211 REMOVAL .......................................................... 266
Components (EURO 4) ......................................... 212 INSTALLATION .................................................. 267
Removal and Installation ...................................... 212 INSPECTION AFTER INSTALLATION .............. 267
REMOVAL ......................................................... 212 CYLINDER BLOCK ................................................. 269
INSTALLATION .................................................. 213 Components .......................................................... 269
INSPECTION AFTER INSTALLATION .............. 214 Disassembly and Assembly .................................. 270
CAMSHAFT ............................................................. 215 DISASSEMBLY .................................................. 270
Components ......................................................... 215 ASSEMBLY ........................................................ 273
Removal and Installation ...................................... 215 How to Select Piston and Bearing ........................ 280
REMOVAL ......................................................... 215 DESCRIPTION .................................................. 280
INSPECTION AFTER REMOVAL ...................... 216 HOW TO SELECT PISTON ............................... 280
INSTALLATION .................................................. 219 HOW TO SELECT CONNECTING ROD BEAR-
INSPECTION AFTER INSTALLATION .............. 221 ING ..................................................................... 281
Valve Clearance .................................................... 222 HOW TO SELECT MAIN BEARING .................. 282
INSPECTION ..................................................... 222 Inspection After Disassembly ................................ 283
ADJUSTMENTS ................................................ 223 CRANKSHAFT END PLAY ................................ 283
OIL SEAL ................................................................ 226 CONNECTING ROD SIDE CLEARANCE ......... 284
Removal and Installation of Valve Oil Seal ........... 226 PISTON TO PISTON PIN CLEARANCE ........... 284
REMOVAL ......................................................... 226 PISTON RING SIDE CLEARANCE ................... 285
INSTALLATION .................................................. 226 PISTON RING END GAP .................................. 285
Removal and Installation of Front Oil Seal ........... 227 CONNECTING ROD BEND AND TORSION ..... 286
REMOVAL ......................................................... 227 CONNECTING ROD BIG END INNER DIAME-
INSTALLATION .................................................. 227 TER .................................................................... 286
Removal and Installation of Rear Oil Seal ............ 228 CONNECTING ROD BUSHING OIL CLEAR-
REMOVAL ......................................................... 228 ANCE ................................................................. 286
INSTALLATION .................................................. 228 CYLINDER BLOCK TOP SURFACE DISTOR-
SECONDARY TIMING CHAIN ................................ 229 TION .................................................................. 287
Components (EURO 3) ......................................... 229 MAIN BEARING HOUSING INNER DIAMETER.287
Components (EURO 4) ......................................... 230 PISTON TO CYLINDER BORE CLEARANCE . 288
Removal and Installation ...................................... 230 CRANKSHAFT MAIN JOURNAL DIAMETER ... 289
REMOVAL ......................................................... 230 CRANKSHAFT PIN JOURNAL DIAMETER ...... 289
INSPECTION AFTER REMOVAL ...................... 232 CRANKSHAFT OUT-OF-ROUND AND TAPER.289
INSTALLATION .................................................. 232 CRANKSHAFT RUNOUT .................................. 290
INSPECTION AFTER INSTALLATION .............. 234 CONNECTING ROD BEARING OIL CLEAR-
PRIMARY TIMING CHAIN ...................................... 236 ANCE ................................................................. 290
Components (EURO 3) ......................................... 236 MAIN BEARING OIL CLEARANCE ................... 291
Components (EURO 4) ......................................... 238 CRUSH HEIGHT OF MAIN BEARING .............. 291
Removal and Installation ...................................... 239 CRUSH HEIGHT OF CONNECTING ROD
REMOVAL ......................................................... 239 BEARING ........................................................... 291
INSPECTION AFTER REMOVAL ...................... 243 MAIN BEARING CAP BOLT DEFORMATION ... 292
INSTALLATION .................................................. 244 CONNECTING ROD BOLT DEFORMATION .... 292
INSPECTION AFTER INSTALLATION .............. 250 OIL JET .............................................................. 292
CYLINDER HEAD ................................................... 251 OIL JET RELIEF VALVE .................................... 292
On-Vehicle Service ............................................... 251 FLYWHEEL DEFLECTION ................................ 293
CHECKING COMPRESSION PRESSURE ....... 251 MOVEMENT AMOUNT OF FLYWHEEL ........... 293
Components ......................................................... 252 DRIVE PLATE .................................................... 293
EM-4
SERVICE DATA AND SPECIFICATIONS (SDS) .... 294 FOLD ................................................................. 294
Standard and Limit ............................................... 294 DRIVE BELTS ................................................... 294 A
GENERAL SPECIFICATIONS .......................... 294 CYLINDER HEAD ............................................. 295
INTAKE MANIFOLD AND EXHAUST MANI- VALVE ............................................................... 295
CAMSHAFT ....................................................... 299 EM
CYLINDER BLOCK ........................................... 300
PISTON, PISTON RING AND PISTON PIN ...... 300
CONNECTING ROD ......................................... 302
CRANKSHAFT .................................................. 302 C
AVAILABLE MAIN BEARING ............................ 303
AVAILABLE CONNECTING ROD BEARING .... 303
MISCELLANEOUS COMPONENTS ................. 303 D
EM-5
PRECAUTIONS
[VQ]
PRECAUTIONS
[VQ] PFP:00001
Precautions for Procedures without Cowl Top Cover BBS00BG2
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
PIIB3706J
Precautions Necessary for Steering Wheel Rotation After Battery Disconnect

BBS00BG3
NOTE:
● This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT
SYSTEM).
● Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
● Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
Precautions for Drain Engine Coolant BBS00BG4
Drain engine coolant when engine is cooled.

Precautions for Disconnecting Fuel Piping BBS00BG5
● Before starting work, make sure no fire or spark producing items are in the work area.
● Release fuel pressure before disconnecting and disassembly.
● After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly BBS00BG6
● When instructed to use SST, use the specified tools. Always be careful to work safely, avoid forceful or
uninstructed operations.
● Exercise maximum care to avoid damage to mating or sliding surfaces.
● Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
EM-6
PRECAUTIONS
[VQ]
● Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
● When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally A
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and Replacement BBS00BG7
EM
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and Installation BBS00BG8 C
● Use torque wrench to tighten bolts or nuts to specification.
● When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
D
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
● Replace with new gasket, packing, oil seal or O-ring.
E
● Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
make sure that dowel pins are installed in the original position.
● Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage. F
● Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
● Release air within route when refilling after draining engine coolant. G
● After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gasses for leakage.
H
Parts Requiring Angle Tightening BBS00BG9
● Use angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
– Cylinder head bolts I
– Lower cylinder block bolts
– Connecting rod cap bolts
J
● Do not use a torque value for final tightening.
● The torque value for these parts are for a preliminary step.
● Ensure thread and seat surfaces are clean and coated with engine oil. K
Precautions for Liquid Gasket BBS00BGA
REMOVAL OF LIQUID GASKET SEALING

● After removing mounting nuts and bolts, separate the mating L
surface using the seal cutter (SST) and remove the old liquid
gasket sealing.
CAUTION: M
Be careful not to damage the mating surfaces.
● Tap seal cutter to insert it, and then slide it by tapping on the
side as shown in the figure.
● In areas where seal cutter (SST) is difficult to use, use plastic
hammer to lightly tap the parts, to remove it.
CAUTION: PBIC0275E
If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces.
EM-7
PRECAUTIONS
[VQ]
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
● Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts, and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0003E
3. Attach liquid gasket tube to tube presser (SST).

Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
● If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.
PBIC2160E
● As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes.
Make sure to read the text of this manual.
● Within five minutes of liquid gasket application, install the mat-
ing component.
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten mounting bolts or nuts after the installation.
● After 30 minutes or more have passed from the installation, fill

engine oil and engine coolant.
CAUTION: SEM159F
If there are specific instructions in this manual, observe
them.
EM-8
PREPARATION
[VQ]
PREPARATION PFP:00002
A
Special Service Tools BBS00008
Tool number
Description
Tool name EM
KV10116200 Disassembling valve mechanism
Valve spring compressor Part (1) is a component of KV10116200, but
1. KV10115900 Part (2) is not so. C
Attachment
2.KV10109220
Adapter
D
PBIC1650E
KV10107902 Replacing valve oil seal

Valve oil seal puller E
NT011
KV10115600 Installing valve oil seal G

Valve oil seal drift
ZZA0996D
I
EM03470000 Installing piston assembly into cylinder bore
Piston ring compressor
NT044 K
ST16610001 Removing pilot converter
Pilot bushing puller
L
M
NT045
KV10111100 Removing oil pan (lower and upper), front

Seal cutter and rear timing chain case, etc.
NT046
WS39930000 Pressing the tube of liquid gasket

Tube presser
NT052
EM-9
PREPARATION
[VQ]
Tool number
Description
Tool name
KV10112100 Tightening bolts for bearing cap, cylinder

Angle wrench head, etc. in angle
NT014
KV991- J0050 Loosening or tightening air fuel ratio sensor 1

Heated oxygen sensor wrench a: 22 mm (0.87 in)
LBIA0444E
KV10114400 Loosening or tightening heated oxygen

Heated oxygen sensor wrench sensor 2
a: 22 mm (0.87 in)
NT636
KV10117700 Removing and installing crankshaft pulley

Ring gear stopper
NT822
— Removing fuel tube quick connectors in

Quick connector release engine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)
PBIC0198E
Commercial Service Tools BBS00009
Tool name Description
TORX socket Removing and installing flywheel

Size: T55
PBIC1113E
Cylinder head bolt wrench Loosening and tightening cylinder head bolt,
and used with angle wrench [SST:
KV10112100]
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
NT583
EM-10
PREPARATION
[VQ]
A
Spark plug wrench Removing and installing spark plug
EM
NT047
C
Valve seat cutter set Finishing valve seat dimensions
E
NT048
Piston ring expander Removing and installing piston ring

F
NT030
Valve guide drift Removing and installing valve guide H

Intake and Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
I
NT015
J
Valve guide reamer (1): Reaming valve guide inner hole
(2): Reaming hole for oversize valve guide
Intake and Exhaust:
d1 : 6.0 mm (0.236 in) dia. K
d2 : 10.2 mm (0.402 in) dia.
NT016 L
Oxygen sensor thread cleaner Reconditioning the exhaust system threads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.) M
a: 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor
b: 12 mm (0.47 in) dia. for titania heated
oxygen sensor
AEM488
Anti-seize lubricant (Permatex 133AR Lubricating oxygen sensor thread cleaning

or equivalent meeting MIL tool when reconditioning exhaust system
specification MIL-A-907) threads
AEM489
EM-11
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[VQ]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting —Engine Noise BBS0000A
PBIC2873E
EM-12
[VQ]
Use the Chart Below to Help You Find the Cause of the Symptom. BBS0000B
A
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine. EM
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine C
Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing D
Top of Ticking or Tappet
C A — A B — Valve clearance EM-83
engine clicking noise
Rocker
cover Camshaft Camshaft runout E
EM-75
Cylinder Rattle C A — A B C bearing Camshaft journal oil
EM-76
head noise clearance
Piston to piston pin oil F

Slap or Piston pin clearance EM-122
— A — B B —
knock noise Connecting rod bush- EM-124
ing oil clearance
G
Piston to cylinder bore
clearance
Crank- EM-126
Piston ring side clear-
shaft pul- Slap or Piston EM-123
A — — B B A ance H
ley rap slap noise EM-123
Piston ring end gap
Cylinder EM-124
Connecting rod bend
block and torsion
(Side of I
engine) Connecting rod bush-
Connect-
Oil pan ing oil clearance
ing rod EM-124
Knock A B C B B B Connecting rod bear-
bearing EM-128
noise
ing oil clearance (Big J
end
Main Main bearing oil clear-
EM-129
Knock A B — A B C bearing ance
EM-128 K
noise Crankshaft runout
Front of Timing
Timing chain cracks
engine chain and
Tapping or and wear EM-53 L
Timing A A — B B B chain
ticking Timing chain tensioner EM-53
chain tensioner
operation
case noise
Squeak-
Drive belts M
(Sticking
ing or fizz- A B — B — C Drive belts deflection
or slip-
ing EM-14
ping)
Front of
Drive belts Idler pulley bearing
engine Creaking A B A B A B
(Slipping) operation
Water CO-22,
Squall
A B — B A B pump Water pump operation "WATER
Creak
noise PUMP"
A: Closely related B: Related C: Sometimes related —: Not related
EM-13
DRIVE BELTS
[VQ]
DRIVE BELTS PFP:02117
Checking Drive Belts BBS0000C
LBIA0427E
1. Drive belt 2. Power steering oil pump pulley 3. Alternator pulley

4. Crankshaft pulley 5. A/C compressor pulley 6. Cooling fan pulley
7. Idler pulley 8. Drive belt auto tensioner
WARNING:
Be sure to perform when engine is stopped.
● Remove engine undercover front and air-duct-and-resonator-assembly when inspecting drive belt. Refer
to EI-15, "FRONT BUMPER" and EM-17, "AIR CLEANER AND AIR DUCT" .
● Make sure that indicator (A) of auto tensioner is within the allow-
able working range (between three line notches “B”).
:Engine front
NOTE:
● Check auto tensioner indication when engine is cold.
● When new drive belt is installed, the range should be (C).
● The indicator notch is located on the moving side of auto

tensioner for alternator, water pump and A/C compressor belt,
while it is found on the fixed side for power steering oil pump
belt. PBIC3875E
● Visually check drive belt for wear, damage or cracks.

● If the indicator is out of allowable working range or belt is damaged, replace drive belt.
Tension Adjustment BBS0000D
Belt tensioning is not necessary, as it is automatically adjusted by auto tensioner.

Removal and Installation BBS0000E
REMOVAL
1. Remove engine undercover front and air-duct-and-resonator-assembly when inspecting drive belt. Refer
EM-14
DRIVE BELTS
[VQ]
2. While securely holding the square hole in pulley center of auto
tensioner (1) with a spinner handle (A), move spinner handle in A
the direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur EM
if the holding tool accidentally comes off.
3. Under the above condition, insert a metal bar (B) of approxi-
mately 6 mm (0.24 in) in diameter (hexagonal bar wrench shown
C
as example in the figure) through the holding boss to lock auto
tensioner (1) pulley arm.
● Leave auto tensioner pulley arm locked until drive belt is PBIC3876E
installed again. D
4. Remove drive belt.
INSTALLATION E
Note the following, and install in the reverse order of removal.
CAUTION:
● Make sure drive belt is securely installed around all pulleys. F
● Make sure drive belt is correctly engaged with the pulley groove.
● Check for engine oil and engine coolant are not adhered drive belt and pulley groove.
● Check that drive belt tension is within the allowable working range, using indicator notch on auto G
tensioner. Refer to EM-14, "Checking Drive Belts" .
EM-15
DRIVE BELTS
[VQ]
Drive Belt Auto Tensioner and Idler Pulley BBS0000F
LBIA0429E
1. Idler pulley 2. Drive belt auto tensioner
REMOVAL
1. Remove engine undercover front and air-duct-and-resonator-assembly when inspecting drive belt. Refer
2. Remove drive belt. Refer to EM-14, "Removal and Installation" .
● Keep auto tensioner pulley arm locked after belt is removed.
3. Remove auto tensioner and idler pulley.

● Keep auto tensioner pulley arm locked to install or remove auto tensioner.
INSTALLATION
Installation is the reverse order of removal.
EM-16
AIR CLEANER AND AIR DUCT
[VQ]
AIR CLEANER AND AIR DUCT PFP:16500
A
Components BBS0000G
EM
G
WBIA0623E
1. Air duct and resonator 2. Air cleaner case (upper) 3. Air cleaner filter
4. Air cleaner case (lower) H
Removal and Installation BBS0000H
REMOVAL
1. Disconnect harness connector from mass air flow sensor. I
2. Disconnect PCV hose.
3. Remove air cleaner case/mass air flow sensor assembly and air duct assembly disconnecting their joints.
J
● Add marks as necessary for easier installation.
CAUTION:
Handle mass air flow sensor with care.
K
● Do not shock it.
● Do not disassemble it.
● Do not touch its sensor. L

INSPECTION AFTER REMOVAL
Inspect air duct for crack or tear.
● If anything found, replace air duct. M
INSTALLATION
● Align marks. Attach each joint. Screw clamps firmly.
Changing Air Cleaner Filter BBS0000I
REMOVAL
1. Unhook clips, and lift air cleaner case (upper).
2. Remove air cleaner filter.
INSTALLATION
EM-17
INTAKE MANIFOLD COLLECTOR
[VQ]
INTAKE MANIFOLD COLLECTOR PFP:14003
Components BBS0000J
PBIC2874E
1. Vacuum tank 2. VIAS control solenoid valve 3. Vacuum hose

4. Intake manifold collector support 5. Water hose 6. Electric throttle control actuator
7. Water hose 8. EVAP hose 9. Bracket
EVAP canister purge volume control
10. EVAP hose 11. 12. Gasket
solenoid valve
13. Gasket 14. Intake manifold collector 15. Clip
16. PCV hose 17. Connector 18. PCV hose
Removal and Installation BBS0000K
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Remove engine cover.
CAUTION:
Be careful not to damage or scratch engine cover.
a. Loosen mounting bolts.
b. Lift up on engine cover firmly to dislodge snap fit mounts.
WBIA0622E
2. Remove air cleaner case (upper) with mass air flow sensor and air duct assembly. Refer to EM-17, "AIR
CLEANER AND AIR DUCT" .
3. Remove electric throttle control actuator as follows:
EM-18
[VQ]
a. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-10, "Changing Engine Coolant" . A
CAUTION:
● Perform when engine is cold.
● Do not spill engine coolant on drive belt. EM

b. Disconnect water hoses from electric throttle control actuator.
● When engine coolant is not drained from radiator, attach plug to water hoses to prevent engine coolant
leakage. C
c. Disconnect harness connector.
d. Loosen mounting bolts in reverse order as shown in the figure.
CAUTION: D
● Handle carefully to avoid any shock to electric throttle
control actuator.
● Do not disassemble. E
PBIC2875E
G
4. Remove the following parts:
● Vacuum hose (to brake booster)
● PCV hose H
5. Loosen mounting bolts in reverse order as shown in the figure to
remove intake manifold collector support.
I
K
PBIC2876E
6. Disconnect EVAP hoses and harness connector from EVAP canister purge volume control solenoid valve. L
7. Remove EVAP canister purge volume control solenoid valve.
8. Remove VIAS control solenoid valve and vacuum tank.
● Add mating marks as necessary for easier installation.
M
9. Loosen mounting nuts and bolts in reverse order as shown in
the figure, and remove intake manifold collector.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
PBIC2877E
INSTALLATION
Intake Manifold Collector
● If stud bolts were removed from intake manifold, install them and tighten to the specified torque below.
EM-19
[VQ]
: 6.9 N·m (0.70 kg-m, 61 in-lb)

● Tighten mounting nuts and bolts in numerical order as shown in
the figure.
PBIC2877E
Electric Throttle Control Actuator

● Tighten mounting bolts in numerical order as shown in the fig-
ure.
● Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is discon-
nected. Refer to EC-78, "Throttle Valve Closed Position
Learning" (WITH EURO-OBD) or EC-607, "Throttle Valve
Closed Position Learning" (WITHOUT EURO-OBD).
● Perform the “Idle Air Volume Learning” and “Throttle Valve
Closed Position Learning” when electric throttle control actuator
is replaced. Refer to EC-79, "Idle Air Volume Learning" (WITH
EURO-OBD) or EC-608, "Idle Air Volume Learning" (WITHOUT PBIC2875E
EURO-OBD).
EM-20
INTAKE MANIFOLD
[VQ]
INTAKE MANIFOLD PFP:14003
A
Components BBS0000L
EM
G
PBIC2878E
1. Intake manifold 2. Gasket
Removal and Installation BBS0000M

H
REMOVAL
1. Release fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-610,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD). I
2. Remove intake manifold collector. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .
3. Remove fuel tube and fuel injector assembly. Refer to EM-36, "FUEL INJECTOR AND FUEL TUBE" .
4. Loosen mounting nuts and bolts with power tool in reverse order J
as shown in the figure to remove intake manifold.
M
PBIC2879E
5. Remove gaskets.
CAUTION:
EM-21
INTAKE MANIFOLD
[VQ]
Surface Distortion
● Check the surface distortion of the intake manifold mating sur-
face with straightedge and feeler gauge.
Limit : 0.1 mm (0.004 in)
● If it exceeds the limit, replace intake manifold.
PBIC0870E
INSTALLATION
Intake Manifold
● If stud bolts were removed from cylinder head, install them and tighten to the specified torque below.
: 10.8 N·m (1.1 kg-m, 8 ft-lb)

● Tighten all mounting nuts and bolts to the specified torque in two
or more steps in numerical order shown in the figure.
1st step
: 7.4 N·m (0.75 kg-m, 5 ft-lb)
2nd step and after
: 29.0 N·m (3.0 kg-m, 21 ft-lb)
PBIC2879E
EM-22
EXHAUST MANIFOLD AND THREE WAY CATALYST
[VQ]
EXHAUST MANIFOLD AND THREE WAY CATALYST PFP:14004
A
Components BBS0000N
EM
PBIC4063E
K
1. Air fuel ratio sensor 1 (bank 1) 2. Ring gasket 3. Exhaust manifold cover (right bank)
4. Exhaust manifold (right bank) 5. Gasket 6. Exhaust manifold (left bank)
Three way catalyst (manifold) (left L
7. Exhaust manifold cover (left bank) 8. Air fuel ratio sensor 1 (bank 2) 9.
bank)
Three way catalyst (manifold) (right
10.
bank)
M
● Refer to GI-11, "Components" for symbol marks in the figure.
Removal and Installation BBS0000O
REMOVAL (LEFT BANK)

1. Remove air cleaner case and air duct. Refer to EM-17, "AIR CLEANER AND AIR DUCT" .
2. Remove engine undercover front and engine undercover middle. Refer to EI-15, "FRONT BUMPER" .
3. Disconnect harness connector and remove heated oxygen sen-
sor 2 on both banks using heated oxygen sensor wrench (C)
[SST: KV10114400].
A : Right bank
B : Left bank
: Vehicle front
CAUTION:
● Be careful not to damage heated oxygen sensor 2.
PBIC3882E
EM-23
[VQ]
● Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a
concrete floor; replace with a new sensor.
4. Fasten main muffler temporarily to the vehicle, and remove exhaust front tube (left bank). Refer to EX-3,
"EXHAUST SYSTEM" .
5. Remove exhaust manifold cover (left bank).
6. Disconnect harness connector and remove air fuel ratio sensor
1 on both banks using heated oxygen sensor wrench (C) [SST:
KV991- J0050].
A : Left bank
B : Right bank
: Vehicle front
CAUTION:
● Be careful not to damage air fuel ratio sensor 1.
● Discard any air fuel ratio sensor 1 which has been
dropped onto a hard surface such as a concrete floor; PBIC3883E
replace with a new sensor.
7. Remove three way catalyst (manifold) (left bank).

8. Loosen mounting nuts in reverse order as shown in the figure to
remove exhaust manifold.
NOTE:
Disregard the numerical order No. 7 and 8 in removal.
PBIC2881E
9. Remove gaskets.
CAUTION:
EM-24
[VQ]
INSPECTION AFTER REMOVAL (LEFT BANK)
Surface Distortion A
● Check the surface distortion of the exhaust manifold mating sur-
EM
Limit : 0.3 mm (0.012 in)
● If it exceeds the limit, replace exhaust manifold.
C
D
PBIC1096E
INSTALLATION (LEFT BANK) E

Exhaust Manifold Gasket
Install in direction shown in the figure. F
I
PBIC2882E
Exhaust Manifold
● If stud bolts (between engine and exhaust manifold) were removed, install them and tighten to the speci- J
fied torque below.
: 14.7 N·m (1.5 kg-m, 11 ft-lb)

K
● Install exhaust manifold and tighten mounting nuts in numerical
order as shown in the figure.
NOTE: L
Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7
and 8 shows second step.
PBIC2881E
EM-25
[VQ]
Three Way Catalyst
● If stud bolts were removed, install them and tighten to the specified torque below.
: 25.4 N·m (2.6 kg-m, 19 ft-lb)

Heated Oxygen Sensor
CAUTION:
● Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system
threads using oxygen sensor thread cleaner (commercial service tool) and apply anti-seize lubri-
cant (commercial service tool).
● Do not over torque air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause dam-
age to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the “MI” coming on.
REMOVAL (RIGHT BANK)
1. Remove engine assembly. Refer to EM-103, "ENGINE ASSEMBLY" .
2. Loosen nuts in reverse order as shown.
NOTE:
Disregard the numerical order No. 7 and 8 in removal.
PBIC2881E
3. Remove gasket.
CAUTION:
INSPECTION AFTER REMOVAL (RIGHT BANK)
Surface Distortion
● Check the surface distortion of the exhaust manifold mating sur-
Limit : 0.3 mm (0.012 in)
PBIC1096E
INSTALLATION (RIGHT BANK)

EM-26
[VQ]
Exhaust Manifold Gasket
Install in direction shown in the figure. A
EM
PBIC2882E
D
Exhaust Manifold
● If stud bolts were removed, install them and tighten to the specified torque below. E
: 14.7 N·m (1.5 kg-m, 11 ft-lb)
● Install exhaust manifold and tighten mounting nuts in numerical F
NOTE:
Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7
and 8 shows second step. G
L
PBIC2881E
Three Way Catalyst M

● If stud bolts were removed, install them and tighten to the specified torque below.
: 25.4 N·m (2.6 kg-m, 19 ft-lb)

Heated Oxygen Sensor
CAUTION:
● Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system
threads using oxygen sensor thread cleaner (commercial service tool) and apply anti-seize lubri-
cant (commercial service tool).
● Do not over torque air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause dam-
age to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the “MI” coming on.
EM-27
OIL PAN AND OIL STRAINER
[VQ]
OIL PAN AND OIL STRAINER PFP:11110
Components BBS0000P
PBIC4067E
1. Oil pan (upper) 2. Oil pressure switch 3. O-ring

4. Relief valve 5. O-ring 6. Oil cooler
7. Connector bolt 8. Oil filter 9. Drain plug
10. Drain plug washer 11. Oil pan (lower) 12. Rear cover plate
13. Oil strainer 14 O-ring 15. Oil level gauge guide
16. Oil level gauge 17. Crankshaft position sensor (POS)
A. Oil pan side B. Refer to LU-11 C. Refer to LU-10

Removal and Installation BBS0000Q
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
NOTE:
To remove oil pan (lower) only, take step 3 and step 4, then step 14. Step 1 to 2, 5 to 13 and 15 to 19 are
unnecessary.
1. Remove engine cover. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .
2. Remove air duct. Refer to EM-17, "AIR CLEANER AND AIR DUCT" .
4. Drain engine oil. Refer to LU-8, "Changing Engine Oil" .
CAUTION:
● Perform this step when engine is cold.
EM-28
[VQ]
● Do not spill engine oil on drive belts.
5. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant" . A

CAUTION:
● Do not spill engine coolant on drive belts. EM

6. Remove front final drive assembly. Refer to FFD-15, "FRONT FINAL DRIVE ASSEMBLY" .
7. Disconnect steering gear lower joint shaft bolt and steering gear nuts and bolts, position out of the way.
Refer to PS-16, "POWER STEERING GEAR AND LINKAGE" . C
8. Remove starter motor. Refer to SC-35, "Removal and Installation" .
9. Disconnect A/T fluid cooler tube brackets and position out of the way. Refer to AT-245, "A/T FLUID
COOLER" . D
10. Install engine slinger to sling engine assembly for positioning. Refer to EM-103, "ENGINE ASSEMBLY" .
11. Disconnect oil cooler water hoses, and remove oil cooler water pipe mounting bolt. Refer to LU-11, "OIL
E
COOLER" .
12. Remove oil filter. Refer to LU-10, "OIL FILTER" .
13. Remove oil cooler. Refer to LU-11, "OIL COOLER" .
F
14. Remove oil pan (lower) as follows:
a. Loosen mounting bolts in reverse order as shown in the figure to
remove. G
PBIC2890E
J
b. Insert seal cutter (SST) between oil pan (upper) and oil pan
(lower).
CAUTION:
● Be careful not to damage the mating surfaces.
K
● Do not insert screwdriver, this will damage the mating
surfaces.
L
M
SEM365ED
c. Slide seal cutter by tapping on the side of the tool with hammer. Remove oil pan (lower).
15. Remove oil strainer.
16. Remove transmission joint bolts which pierce oil pan (upper). Refer to AT-248, "TRANSMISSION ASSEM-
BLY" .
17. Remove rear cover plate.
EM-29
[VQ]
18. Loosen mounting bolts in reverse order as shown in the figure to
remove.
● Insert seal cutter [SST: KV10111100] between oil pan (upper)
and lower cylinder block. Slide seal cutter by tapping on the
side of tool with hammer. Remove oil pan (upper).
CAUTION:
Be careful not to damage mating surfaces.
PBIC2887E
19. Remove O-rings from bottom of lower cylinder block and oil
pump.
PBIC2885E

Clean oil strainer if any object attached.
INSTALLATION
1. Install oil pan (upper) as follows:
a. Use scraper to remove old liquid gasket from mating surfaces.
● Also remove the old liquid gasket from mating surface of
lower cylinder block.
● Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
PBIC2884E
b. Install new O-rings on the bottom of lower cylinder block and oil
pump.
PBIC2885E
EM-30
[VQ]
c. Apply a continuous bead of liquid gasket with tube presser [SST:
WS39930000] to the lower cylinder block mating surfaces of oil A
pan (upper) to a limited portion as shown in the figure.
CAUTION: EM
● For bolt holes with mark, apply liquid gasket outside
the hole.
● Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 in) in diame-
C
ter to area “A”.
● Attaching should be done within 5 minutes after coating.
PBIC2886E
D
d. Install oil pan (upper).
CAUTION:
Install avoiding misalignment of both oil pan gaskets and O-rings. E
ure.
● There are two types of mounting bolts. Refer to the following F
for locating bolts.
M8 × 100 mm (3.97 in) : 7, 11, 12, 13
M8 × 25 mm (0.98 in) : Except the above G
H
PBIC2887E
e. Tighten transmission joint bolts. Refer to AT-248, "TRANSMISSION ASSEMBLY" .

I
2. Install oil strainer to oil pan (upper).
3. Install oil pan (lower) as follows:
a. Use scraper to remove old liquid gasket from mating surfaces. J
● Also remove old liquid gasket from mating surface of oil pan
(upper).
● Remove old liquid gasket from the bolt holes and thread. K
CAUTION:
Do not scratch or damage the mating surfaces when clean-
ing off old liquid gasket. L
PBIC2888E
M
b. Apply a continuous bead of liquid gasket with tube presser [SST:
WS39930000] to the oil pan (lower) as shown in the figure.
CAUTION:
Attaching should be done within 5 minutes after coating.
PBIC2889E
c. Install oil pan (lower).
EM-31
[VQ]
ure.
PBIC2890E
4. Install oil pan drain plug.

● Refer to the figure of components of former page for installation direction of drain plug washer. Refer to
EM-28, "Removal and Installation" .
5. Installation is the reverse order of removal after this step.
NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.
INSPECTION AFTER INSTALLATION
1. Check engine oil level and adjust engine oil. Refer to LU-7, "ENGINE OIL" .
2. Start engine, and check there is no leak of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-7, "ENGINE OIL" .
EM-32
IGNITION COIL
[VQ]
IGNITION COIL PFP:22448
A
Components BBS0000R
EM
G
PBIC2901E
1. Ignition coil 2. Spark plug
Removal and Installation BBS0000S

H
REMOVAL (LEFT BANK)
2. Remove air cleaner case and air duct. (At the left bank side, remove ignition coil) Refer to EM-17, "AIR I
CLEANER AND AIR DUCT" .
3. Move aside harness, harness bracket, and hoses located above ignition coil.
4. Disconnect harness connector from ignition coil. J
5. Remove ignition coil.
CAUTION:
K
Do not shock it.
INSTALLATION (LEFT BANK)
Installation is the reverse order of removal. L
REMOVAL (RIGHT BANK)
2. Move aside harness, harness bracket, and hoses located above ignition coil. M
3. Disconnect harness connector from ignition coil.
4. Remove ignition coil.
CAUTION:
Do not shock it.
INSTALLATION (RIGHT BANK)
EM-33
SPARK PLUG (PLATINUM-TIPPED TYPE)
[VQ]
SPARK PLUG (PLATINUM-TIPPED TYPE) PFP:22401
Components BBS0000T
PBIC2901E
1. Ignition coil 2. Spark plug
Removal and Installation BBS0000U
REMOVAL
1. Remove ignition coil. Refer to EM-33, "IGNITION COIL" .
2. Remove spark plug using spark plug wrench (commercial ser-
vice tool).
CAUTION:
Do not drop or shock it.
SEM294A

Use standard type spark plug for normal condition.
Hot type spark plug is suitable when fouling occurs with standard type spark plug under conditions such as:
● Frequent engine starts
● Low ambient temperatures
Cold type spark plug is suitable when spark plug knock occurs with standard type spark plug under conditions
such as:
● Extended highway driving
● Frequent high engine revolution
Make NGK
Standard type PLFR5A-11
Hot type PLFR4A-11
Cold type PLFR6A-11
Gap (Nominal) : 1.1 mm (0.043 in)
EM-34
SPARK PLUG (PLATINUM-TIPPED TYPE)
[VQ]
CAUTION:
● Do not drop or shock spark plug. A
● Do not use wire brush for cleaning.
● If plug tip is covered with carbon, spark plug cleaner may

be used. EM
Cleaner air pressure:
Less than 588 kPa (6 kg/cm2 , 85 psi)
C
Cleaning time:
Less than 20 seconds
D
SMA773C
● Checking and adjusting plug gap is not required between

E
change intervals.
SMA806CA
H
INSTALLATION
I
EM-35
FUEL INJECTOR AND FUEL TUBE
[VQ]
FUEL INJECTOR AND FUEL TUBE PFP:16600
Components BBS0000V
PBIC4062E
1. Fuel tube 2. Fuel feed hose 3. Quick connector cap

4. Clip 5. O-ring (blue) 6. Fuel injector
7. O-ring (brown) 8. O-ring 9. Spacer
10. Fuel damper 11. Fuel damper cap
A. Refer to EM-39 B. Do not loosen these bolts.

Removal and Installation BBS0000W
REMOVAL
WARNING:
● Put a “CAUTION: FLAMMABLE” sign in the workshop.
● Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher.
● Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
● To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
3. Disconnect quick connector on the engine side as follows:
EM-36
[VQ]
a. Remove quick connector cap.
A
EM
LBIA0090E
D
b. Disconnect quick connector as follows:
CAUTION:
Disconnect quick connector by using quick connector release (A) (SST), not by picking out E
retainer tabs.
i. With the sleeve side (B) of quick connector release (A) facing to quick connector (1), install quick connec-
tor release (A) onto fuel tube (2).
F
ii. Insert quick connector release (A) into quick connector (1) until
sleeve (B) contacts and goes no further (D). Hold quick connec-
tor release (A) on that position.
G
CAUTION:
Inserting quick connector release (A) hard will not discon-
nect quick connector (1). Hold quick connector release (A)
where it contacts and goes no further (D). H
iii. Draw and pull out (E) quick connector (1) straight from fuel tube
(2).
CAUTION: I
● Pull quick connector holding (C) position as shown in the PBIC3886E
figure.
● Do not pull with lateral force applied. O-ring inside quick connector (1) may be damaged. J
● Prepare container and cloth beforehand as fuel will leak out.
● Avoid fire and sparks.
● Keep parts away from heat source. Especially, be careful when welding is performed around
K
them.
● Do not expose parts to battery electrolyte or other acids.
L
● Do not bend or twist connection between quick connector and fuel tube during installation/
removal.
● To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with M
plastic bags or something similar.
PBIC1899E
4. Remove PCV hose between rocker covers (right and left banks).
5. Disconnect harness connector from fuel injector.
EM-37
[VQ]
6. Loosen mounting bolts in reverse order as shown in the figure,
and remove fuel tube and fuel injector assembly.
CAUTION:
● Do not tilt it, or remaining fuel in pipes may flow out from
pipes.
● Do not disassemble fuel tube.
PBIC2902E
7. Remove fuel injector from fuel tube as follows:

a. Open and remove clip.
b. Remove fuel injector from fuel tube by pulling straight.
CAUTION:
● Be careful with remaining fuel that may go out from fuel
tube.
● Be careful not to damage injector nozzles during
removal.
● Do not bump or drop fuel injector.
● Do not disassemble fuel injector and fuel tube.
SBIA0364E
8. Loosen mounting bolts, to remove fuel damper cap and fuel damper, if necessary.
EM-38
[VQ]
INSTALLATION
1. Install fuel damper as follows: A
a. Install new O-ring to fuel tube as shown in the figure.
● When handling new O-rings, be careful of the following cau-
tion: EM
CAUTION:
● Handle O-ring with bare hands. Do not wear gloves.
● Lubricate O-ring with new engine oil. C

● Do not clean O-ring with solvent.
● Make sure that O-ring and its mating part are free of
foreign material. D
● When installing O-ring, be careful not to scratch it with
tool or fingernails. Also be careful not to twist or
stretch O-ring. If O-ring was stretched while it was E
being attached, do not insert it quickly into fuel tube.
● Insert new O-ring straight into fuel tube. Do not
decenter or twist it. F
b. Install spacer to fuel damper.
c. Insert fuel damper straight into fuel tube.
● Insert fuel damper until “B” is hit “A” of fuel tube. G
d. Tighten mounting bolts evenly in turn. PBIC2903E
● After tightening mounting bolts, make sure that there is no
gap between fuel damper cap and fuel tube. H
2. Install new O-rings to fuel injector, paying attention to the following.
CAUTION:
● Upper and lower O-ring are different. Be careful not to confuse them.
I
Fuel tube side : Blue

Nozzle side : Brown J
● Handle O-ring with bare hands. Do not wear gloves.
● Lubricate O-ring with new engine oil.
K
● Do not clean O-ring with solvent.
● Make sure that O-ring and its mating part are free of foreign material.
● When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to L
twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it
quickly into fuel tube.
● Insert O-ring straight into fuel injector. Do not decenter or twist it.
M
EM-39
[VQ]
3. Install fuel injector to fuel tube as follows:
a. Insert clip into clip mounting groove on fuel injector.
● Insert clip so that protrusion “A” of fuel injector matches cutout
“A” of clip.
CAUTION:
● Do not reuse clip. Replace it with a new one.
● Be careful to keep clip from interfering with O-ring. If

interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube with clip attached.
● Insert it while matching it to the axial center.
● Insert fuel injector so that protrusion “B” of fuel tube matches

cutout “B” of clip.
● Make sure that fuel tube flange is securely fixed in flange fix-
ing groove on clip.
c. Make sure that installation is complete by checking that fuel
injector does not rotate or come off.
● Make sure that protrusions of fuel injectors are aligned with
cutouts of clips after installation.
PBIC2545E
4. Install fuel tube and fuel injector assembly to intake manifold.

CAUTION:
Be careful not to let tip of injector nozzle come in contact with other parts.
● Tighten mounting bolts in two steps in numerical order as
shown in the figure.
1st step
: 10.1 N·m (1.0 kg-m, 7 ft-lb)
2nd step
: 22.0 N·m (2.2 kg-m, 16 ft-lb)
PBIC2902E
5. Connect fuel injector harness connector.

6. Install intake manifold collector. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .
7. Install in the reverse order of removal after this step.
Check on Fuel Leakage
1. Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.
2. Start engine. With engine speed increased, check again for fuel leakage at connection points.
CAUTION:
Do not touch engine immediately after stopped, as engine becomes extremely hot.
EM-40
ROCKER COVER
[VQ]
ROCKER COVER PFP:13264
A
Components BBS0000X
EM
PBIC4061E
1. Oil filler cap 2. PCV hose 3. PCV valve J

4. O-ring 5. Rocker cover (right bank) 6. PCV hose
7. Rocker cover gasket (right bank) 8. Rocker cover gasket (left bank) 9. Rocker cover (left bank)
10. PCV hose K
A. To intake manifold collector B. To air duct C. Refer to EM-42
D. Camshaft bracket side
L
Removal and Installation BBS0000Y
REMOVAL M
2. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-10, "Changing Engine Coolant" and EM-18, "INTAKE MANIFOLD COLLECTOR" .
CAUTION:
Perform this step when engine is cold.
4. Separate engine harness removing their brackets from rocker covers.
5. Remove harness bracket from cylinder head (right bank). Refer to EM-91, "CYLINDER HEAD" .
6. Remove ignition coil. Refer to EM-33, "IGNITION COIL" .
7. Remove PCV hoses from rocker covers.
8. Remove PCV valve and O-ring from rocker cover (right bank), if necessary.
9. Remove oil filler cap from rocker cover (left bank), if necessary.
EM-41
ROCKER COVER
[VQ]
10. Loosen mounting bolts with power tool in reverse order as
PBIC2906E
11. Remove rocker cover gaskets from rocker covers.

12. Use scraper to remove all trances of liquid gasket from cylinder head and camshaft bracket (No. 1).
CAUTION:
Do not scratch or damage the mating surface when cleaning off old liquid gasket.
INSTALLATION
1. Apply liquid gasket with tube presser [SST: WS39930000] to
joint part among rocker cover, cylinder head and camshaft
bracket (No. 1) as follows:
NOTE:
The figure shows an example of left bank side [zoomed in
shows camshaft bracket (No. 1)].
a. Refer to the figure “a” to apply liquid gasket to joint part of cam-
shaft bracket (No. 1) and cylinder head.
b. Refer to the figure “b” to apply liquid gasket to the figure “a”
squarely.
PBIC2474E
2. Install new rocker cover gasket to rocker cover.

3. Install rocker cover.
● Check if rocker cover gasket is not dropped from installation groove of rocker cover.
EM-42
ROCKER COVER
[VQ]
4. Tighten bolts in two steps separately in numerical order as
shown in the figure. A
1st step
: 1.96 N·m (0.20 kg-m, 17 in-lb)
EM
2nd step
: 8.33 N·m (0.85 kg-m, 74 in-lb)
C
G
PBIC2906E
5. Install oil filer cap to rocker cover (left bank), if removed.

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

J
EM-43
FRONT TIMING CHAIN CASE
[VQ]
FRONT TIMING CHAIN CASE PFP:13599
Removal and Installation BBS0000Z
NOTE:
● This section describes removal/installation procedure of front timing chain case and timing chain related
parts without removing oil pan (upper) on vehicle.
● When oil pan (upper) needs to be removed or installed, or when rear timing chain case is removed or
installed, remove oil pans (upper and lower) first. Then remove front timing chain case, timing chain
related parts, and rear timing chain case in this order, and install in the reverse order of removal. Refer to
EM-53, "TIMING CHAIN" .
● Refer to EM-53, "TIMING CHAIN" for component parts location.
REMOVAL
3. Release the fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-
610, "FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
CAUTION:
5. Drain engine coolant from radiator. Refer to CO-10, "Changing Engine Coolant" .
CAUTION:
● Do not spill engine coolant on drive belts.
6. Remove radiator cooling fan assembly. Refer to CO-21, "COOLING FAN" .

7. Separate engine harnesses removing their brackets from front timing chain case.
8. Remove drive belt. Refer to EM-14, "DRIVE BELTS" .
9. Remove power steering oil pump from bracket with piping connected, and temporarily secure it to aside.
Refer to PS-35, "POWER STEERING OIL PUMP" .
10. Remove power steering oil pump bracket. Refer to PS-35, "POWER STEERING OIL PUMP" .
11. Remove alternator. Refer to SC-14, "CHARGING SYSTEM" .
12. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
13. Remove right and left intake valve timing control covers.
● Loosen mounting bolts in reverse order as shown in the fig-
ure.
● Use seal cutter [SST: KV10111100] to cut liquid gasket for
removal.
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) cen-
ter hole. When removing, keep it horizontal until it is com-
pletely disconnected.
SEM728G
EM-44
[VQ]
14. Remove collared O-rings from front timing chain case (left and
right side). A
EM
PBIC2631E
D
15. Remove rocker covers (right and left banks). Refer to EM-41, "ROCKER COVER" .
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed. E
16. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
NOTE:
When timing chain is not removed/installed, this step is not required. F
a. Rotate crankshaft pulley clockwise to align timing mark (grooved
line without color) with timing indicator.
G
I
KBIA1717J
b. Make sure that intake and exhaust cam noses on No. 1 cylinder J
(engine front side of right bank) are located as shown in the fig-
ure.
● If not, turn crankshaft one revolution (360 degrees) and align
K
as shown in the figure.
NOTE:
When only timing chain (primary) is removed, rocker cover does
not need to be removed. To make sure that No. 1 cylinder is at L
its compression TDC, remove front timing chain case first. Then
check mating marks on camshaft sprockets. Refer to EM-62,
"INSTALLATION" . SEM418G
M
17. Remove crankshaft pulley as follows:

a. Remove starter motor and set ring gear stopper (A) [SST:
KV10117700] as shown in the figure. Refer to SC-31, "START-
ING SYSTEM" .
1 : Transmission
2 : Oil pan (upper)
PBIC3889E
EM-45
[VQ]
b. Loosen crankshaft pulley bolt and locate bolt seating surface as
10 mm (0.39 in) from its original position.
CAUTION:
Do not remove crankshaft pulley bolt. Keep loosened
crankshaft pulley bolt in place to protect removed crank-
shaft pulley from dropping.
PBIC2918E
c. Pull crankshaft pulley with both hands to remove it.

18. Loosen two mounting bolts in front of oil pan (upper) in reverse
PBIC2907E
19. Remove front timing chain case as follows:

a. Loosen mounting bolts in reverse order as shown in the figure.
PBIC2908E
b. Insert suitable tool into the notch at the top of the front timing
chain case as shown (1).
c. Pry off case by moving tool as shown (2).
removal.
CAUTION:
● Do not use screwdriver or something similar.
● After removal, handle front timing chain case carefully so

it does not tilt, cant, or warp under a load.
SEM156F
EM-46
[VQ]
20. Remove O-rings from rear timing chain case.
A
EM
PBIC2548E
D
21. Remove water pump cover and chain tensioner cover from front timing chain case, if necessary.
● Use seal cutter [SST: KV10111100] to cut liquid gasket for removal.
22. Remove front oil seal from front timing chain case using suitable E
tool.
● Use screwdriver for removal.
CAUTION: F
Be careful not to damage front timing chain case.
PBIC2909E H
23. Remove timing chain and related parts. Refer to EM-53, "TIMING CHAIN" .
24. Use a scraper to remove all traces of old liquid gasket from front I
and rear timing chain cases and oil pan (upper), and liquid gas-
ket mating surfaces.
CAUTION: J
Be careful not to allow gasket fragments to enter oil pan.
PBIC2910E L
● Remove old liquid gasket from bolt hole and thread.

M
PBIC2084E
EM-47
[VQ]
25. Use a scraper to remove all traces of old liquid gasket from
water pump cover, chain tensioner cover and intake valve timing
control covers.
SEM926E
INSTALLATION
1. Install timing chain and related parts. Refer to EM-53, "TIMING CHAIN" .
2. Hammer dowel pins (right and left) into front timing chain case
up to a point close to taper in order to shorten protrusion length.
PBIC2615E
3. Install new front oil seal on the front timing chain case.
● Apply new engine oil to both oil seal lip and dust seal lip.
● Install it so that each seal lip is oriented as shown in the fig-

ure.
SEM715A
● Using suitable drift [outer diameter: 60 mm (2.36 in)], press-fit

oil seal until it becomes flush with front timing chain case end
face.
● Make sure the garter spring is in position and seal lip is not
inverted.
PBIC2911E
4. Install water pump cover and chain tensioner cover to front timing chain case, if removed.
EM-48
[VQ]
● Apply a continuous bead of liquid gasket with tube presser
[SST: WS39930000] to front timing chain case as shown in A
the figure.
EM
PBIC2912E
D
5. Install front timing chain case as follows:
a. Apply a continuous bead of liquid gasket with tube presser [SST:
WS39930000] to front timing chain case back side as shown in E
the figure.
B : Protrusion
C : Both permissible F
D : Bolt hole

G
K
PBIC3887E
b. Apply liquid gasket with tube presser [SST: WS39930000] to top

surface of oil pan (upper) as shown in the figure. L
PBIC2914E
EM-49
[VQ]
c. Install new O-rings on rear timing chain case.
PBIC2548E
d. Assemble front timing chain case as follows:

i. Fit lower end of front timing chain case tightly onto top face of oil
pan (upper). From the fitting point, make entire front timing chain
case contact rear timing chain case completely.
CAUTION:
Be careful that oil pan gasket is in place.
PBIC1100E
ii. Since front timing chain case is offset for difference of bolt holes,
tighten bolts temporarily with holding front timing chain case
from front and top as shown in the figure.
iii. Same as the step ii, insert dowel pin with holding front timing
chain case from front and top completely.
PBIC2915E
e. Tighten mounting bolts to the specified torque in numerical order

● There are four types of mounting bolts. Refer to the following
for locating bolts.
M10 × 70 mm (2.76 in) :5
: 55.0 N·m (5.6 kg-m, 41 ft-lb)
M10 × 90 mm (3.54 in) : 1, 2, 3, 4
: 55.0 N·m (5.6 kg-m, 41 ft-lb)
M6 × 40 mm (1.57 in) : 24, 25 PBIC2908E
: 12.7 N·m (1.3 kg-m, 9 ft-lb)

M6 × 25 mm (0.98 in) : Except above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
f. After all bolts tightened, retighten them to the specified torque in numerical order as shown in the figure.
EM-50
[VQ]
6. Install two mounting bolts in front of oil pan (upper) in numerical
order as shown in the figure. A
: 22.0 N·m (2.2 kg-m, 16 ft-lb)
EM
PBIC2907E
D
7. Install right and left intake valve timing control covers as follows:
a. Install new seal rings in shaft grooves.
b. Apply a continuous bead of liquid gasket with tube presser [SST: E
WS39930000] to intake valve timing control covers as shown in
the figure.
F
SBIA0492E H
c. Install new collared O-rings in front timing chain case oil hole
(left and right sides).
I
PBIC2631E
d. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain L
case with the holes to install intake valve timing control covers.
e. Tighten mounting bolts in numerical order as shown in the fig-
ure. M
PBIC0918E
8. Install crankshaft pulley as follows:

a. Fix crankshaft using ring gear stopper [SST: KV10117700].
b. Install crankshaft pulley, taking care not to damage front oil seal.
● When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference).
c. Tighten crankshaft pulley bolt.
EM-51
[VQ]
: 44.1 N·m (4.5 kg-m, 33 ft-lb)

d. Place a paint mark (A) on crankshaft pulley (1) aligning with the
angle mark (B) on crankshaft pulley bolt (2). Tighten the bolt 90
degrees (Angle tightening).
PBIC4627J
9. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns
smoothly.
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
● Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-18, "RECOMMENDED FLUIDS AND LUBRICANTS" .
● Use procedure below to check for fuel leakage.
– Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
– Start engine. With engine speed increased, check again for fuel leakage at connection points.
● Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
● Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
● Bleed air from lines and hoses of applicable lines, such as in cooling system.
● After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
* Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc.
EM-52
TIMING CHAIN
[VQ]
TIMING CHAIN PFP:13028
A
Components BBS00010
EM
PBIC3888E
EM-53
TIMING CHAIN
[VQ]
Timing chain tensioner (secondary) Timing chain tensioner (secondary)
1. 2. Internal chain guide 3.
(left bank) (right bank)
4. Camshaft sprocket (EXH) 5. Timing chain (secondary) 6. Timing chain (primary)
7. Camshaft sprocket (INT) 8. Camshaft sprocket (INT) 9. Slack guide
10. Timing chain tensioner (primary) 11. Crankshaft sprocket 12. Collared O-ring
13. O-ring 14. Intake valve timing control cover 15. Idler pulley
16. Drive belt auto tensioner 17. Cooling fan bracket 18. Crankshaft pulley
19. Front oil seal 20. Water pump cover 21. Chain tensioner cover
22. Front timing chain case 23. Rear timing chain case 24. Water drain plug (front)
25. Tension guide 26. O-ring
A. Refer to EM-62

NOTE:
● This section describes procedures for removing/installing front timing chain case and timing chain related
parts, and rear timing chain case, when oil pan (upper) needs to be removed/installed for engine overhaul,
etc.
● To remove/install front timing chain case, timing chain, and its related parts without removing oil pan
(upper), refer to EM-44, "FRONT TIMING CHAIN CASE" .
Removal and Installation BBS00011
REMOVAL
2. Remove air duct and resonator. Refer to EM-17, "AIR CLEANER AND AIR DUCT" .
4. Release the fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-
610, "FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
CAUTION:

CAUTION:
7. Remove radiator cooling fan assembly. Refer to CO-21, "COOLING FAN" .

8. Separate engine harnesses removing their brackets from front timing chain case.
9. Remove drive belt. Refer to EM-14, "DRIVE BELTS" .
10. Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to
avoid putting load on its piping. Refer to ATC-185, "Removal and Installation for Compressor" .
11. Remove power steering oil pump from bracket with piping connected from engine. Temporarily secure it
on body with a rope to avoid putting load on its piping. Refer to PS-35, "POWER STEERING OIL PUMP" .
12. Remove power steering oil pump bracket. Refer to PS-35, "POWER STEERING OIL PUMP" .
13. Remove alternator. Refer to SC-14, "CHARGING SYSTEM" .
14. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
15. Remove right and left intake valve timing control covers.
EM-54
TIMING CHAIN
[VQ]
● Loosen mounting bolts in reverse order as shown in the fig-
ure. A
removal.
CAUTION: EM
Shaft is internally jointed with camshaft sprocket (INT) cen-
ter hole. When removing, keep it horizontal until it is com-
pletely disconnected.
C
SEM728G
D
16. Remove collared O-rings from front timing chain case (left and
right side).
E
G
PBIC2631E
17. Remove rocker covers (right and left banks). Refer to EM-41, "ROCKER COVER" . H
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed.
18. Obtain No. 1 cylinder at TDC of its compression stroke as follows: I
NOTE:
When timing chain is not removed/installed, this step is not required.
a. Rotate crankshaft pulley clockwise to align timing mark (grooved J
line without color) with timing indicator.
KBIA1717J
M
b. Make sure that intake and exhaust cam noses on No. 1 cylinder
(engine front side of right bank) are located as shown in the fig-
ure.
● If not, turn crankshaft one revolution (360 degrees) and align
SEM418G
19. Remove crankshaft pulley as follows:
EM-55
TIMING CHAIN
[VQ]
a. Remove starter motor and set ring gear stopper (A) [SST:
KV10117700] as shown in the figure. Refer to SC-31, "START-
ING SYSTEM" .
1 : Transmission
2 : Oil pan (upper)
PBIC3889E
b. Loosen crankshaft pulley bolt and locate bolt seating surface as

10 mm (0.39 in) from its original position.
CAUTION:
Do not remove crankshaft pulley bolt. Keep loosened
crankshaft pulley bolt in place to protect removed crank-
shaft pulley from dropping.
PBIC2918E
c. Pull crankshaft pulley with both hands to remove it.

20. Remove oil pans (upper and lower). Refer to EM-28, "OIL PAN AND OIL STRAINER" .
21. Remove front timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
PBIC2908E
b. Insert suitable tool into the notch at the top of the front timing
chain case as shown (1).
c. Pry off case by moving the tool as shown (2).
removal.
CAUTION:
● Do not use screwdriver or something similar.
● After removal, handle front timing chain case carefully so

SEM156F
EM-56
TIMING CHAIN
[VQ]
22. Remove O-rings from rear timing chain case.
A
EM
PBIC2548E
D
23. Remove water pump cover and chain tensioner cover from front timing chain case.
● Use seal cutter [SST: KV10111100] to cut liquid gasket for removal.
24. Remove front oil seal from front timing chain case using suitable E
tool.
● Use screwdriver for removal.
CAUTION: F
Be careful not to damage front timing chain case.
PBIC2909E H
25. Remove timing chain tensioner (primary) as follows:

a. Loosen clip of timing chain tensioner (primary), and release I
plunger stopper. (1)
b. Insert plunger into tensioner body by pressing slack guide. (2)
c. Keep slack guide pressed and hold plunger in by pushing stop- J
per pin through the tensioner body hole and plunger groove. (3)
PBIC2919E L
d. Remove mounting bolts and remove timing chain tensioner (primary).

M
EM-57
TIMING CHAIN
[VQ]
26. Remove internal chain guide, tension guide and slack guide.
NOTE:
Tension guide can be removed after removing timing chain (pri-
mary).
PBIC2266E
27. Remove timing chain (primary) and crankshaft sprocket.

CAUTION:
After removing timing chain (primary), do not turn crankshaft and camshaft separately, or valves
will strike the piston heads.
28. Remove timing chain (secondary) and camshaft sprockets as follows:
a. Attach suitable stopper pin to the right and left timing chain
tensioners (secondary).
NOTE:
● Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a
stopper pin.
● For removal of timing chain tensioner (secondary), refer to
EM-73, "CAMSHAFT" . [Removing camshaft bracket (No. 1)
is required.]
PBIC2047E
b. Remove camshaft sprocket (INT and EXH) bolts.

● Secure the hexagonal portion of camshaft using wrench to
loosen mounting bolts.
CAUTION:
Do not loosen mounting bolts with securing anything
other than the camshaft hexagonal portion or with ten-
sioning the timing chain.
KBIA1698J
c. Remove timing chain (secondary) together with camshaft sprockets.

● Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.
EM-58
TIMING CHAIN
[VQ]
● Insert 0.5 mm (0.020 in)-thick metal or resin plate between
timing chain and timing chain tensioner plunger (guide). A
Remove timing chain (secondary) together with camshaft
sprockets with timing chain loose from guide groove.
CAUTION: EM
Be careful of plunger coming-off when removing timing
chain (secondary). This is because plunger of timing
chain tensioner (secondary) moves during operation,
leading to coming-off of fixed stopper pin. C
NOTE:
Camshaft sprocket (INT) is two-for-one structure of sprockets PBIC1978E
for timing chain (primary) and for timing chain (secondary). D

● When handling camshaft sprocket (INT), be careful of the fol-
lowing caution:
CAUTION: E
● Handle carefully to avoid any shock to camshaft
sprocket.
● Do not disassemble. (Do not loosen bolts “A” as F
shown in the figure).
G
PBIC2920E
29. Remove water pump. Refer to CO-22, "WATER PUMP" . H

30. Remove rear timing chain case as follows:
a. Loosen and remove mounting bolts in reverse order as shown in
the figure. I
b. Cut liquid gasket using seal cutter [SST: KV10111100] and
remove rear timing chain case.
J
PBIC2921E
L
CAUTION:
● Do not remove plate metal cover of oil passage.
● After removal, handle rear timing chain case carefully so M

PBIC2922E
EM-59
TIMING CHAIN
[VQ]
31. Remove O-rings from cylinder head and camshaft bracket
(No. 1).
SBIA0496E
32. Remove O-rings from cylinder block.
PBIC0788E
33. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a. Remove camshaft brackets (No. 1). Refer to EM-74, "REMOVAL" .
b. Remove timing chain tensioners (secondary) with stopper pin attached.
34. Use scraper to remove all traces of old liquid gasket from front
and rear timing chain cases, and opposite mating surfaces.
PBIC2910E
PBIC2084E
EM-60
TIMING CHAIN
[VQ]
35. Use scraper to remove all traces of liquid gasket from water
pump cover, chain tensioner cover and intake valve timing con- A
trol covers.
EM
SEM926E
D
Timing Chain
Check for cracks and any excessive wear at link plates and roller E
links of timing chain. Replace timing chain as necessary.
PBIC0282E H
EM-61
TIMING CHAIN
[VQ]
INSTALLATION
NOTE:
The below figure shows the relationship between the mating mark on each timing chain and that on the corre-
sponding sprocket, with the components installed.
PBIC4214E
1. Camshaft sprocket (INT) 2. Timing chain (secondary) 3. Camshaft sprocket (EXH)

4. Timing chain tensioner (primary) 5. Slack guide 6. Timing chain (primary)
7. Crankshaft sprocket 8. Water pump 9. Tension guide
10. Timing chain tensioner (secondary) 11. Internal chain guide 12. Timing chain tensioner (secondary)
13. Crankshaft key
A. Mating mark (copper color link) B. Mating mark (punched) C. Mating mark (notched)
D. Mating mark (yellow paint) E. Mating mark (back side)
1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Refer to EM-78,
"INSTALLATION" .
a. Install timing chain tensioners (secondary) with stopper pin attached and new O-ring.
b. Install camshaft brackets (No. 1). Refer to EM-78, "INSTALLATION" .
2. Install rear timing chain case as follows:
a. Install new O-rings onto cylinder block.
PBIC0788E
EM-62
TIMING CHAIN
[VQ]
b. Install new O-rings to cylinder head and camshaft bracket
(No. 1). A
EM
SBIA0496E
D
c. Apply liquid gasket with tube presser [SST: WS39930000] to rear timing chain case back side as shown in
the figure.
E
CAUTION:
● For “A” in the figure, completely wipe out liquid gasket extended on a portion touching at
engine coolant.
F
● Apply liquid gasket on installation position of water pump and cylinder head very completely.
PBIC3890E
d. Align rear timing chain case with dowel pins (right and left) on cylinder block and install rear timing chain
case.
● Make sure O-rings stay in place during installation to cylinder block, cylinder head and camshaft
bracket (No. 1).
EM-63
TIMING CHAIN
[VQ]
ure.
● There are two types of mounting bolts. Refer to the following
for locating bolts.
Bolt length: Bolt position
20 mm (0.79 in) : 1, 2, 3, 6, 7, 8, 9, 10
16 mm (0.63 in) : Except the above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)

PBIC2921E
f. After all bolts are tightened, retighten them to the specified
torque in numerical order as shown in the figure.
● If liquid gasket protrudes, wipe it off immediately.
g. After installing rear timing chain case, check the surface height
difference between following parts on oil pan (upper) mounting
surface.
Standard
Rear timing chain case to lower cylinder block:
–0.24 to 0.14 mm (–0.0094 to 0.0055 in)
● If not within the standard, repeat the installation procedure.
PBIC2925E
3. Install water pump with new O-rings. Refer to CO-22, "WATER PUMP" .
4. Make sure that dowel pin hole, dowel pin of camshaft and crank-
shaft key are located as shown in the figure. (No. 1 cylinder at
compression TDC)
● NOTE:
Though camshaft does not stop at the position as shown in
the figure, for the placement of cam nose, it is generally
accepted camshaft is placed for the same direction of the fig-
ure.
Camshaft dowel pin hole (intake side)
: At cylinder head upper face side in each bank. KBIA1073E
Camshaft dowel pin (exhaust side)

: At cylinder head upper face side in each bank.
Crankshaft key
: At cylinder head side of right bank.
CAUTION:
Hole on small dia. side must be used for intake side dowel pin hole. Do not misidentify (ignore big
dia. side).
5. Install timing chains (secondary) and camshaft sprockets as follows:
CAUTION:
Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions
repeatedly during the installation process.
EM-64
TIMING CHAIN
[VQ]
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with stopper pin. A
EM
SEM430G
D
b. Install timing chains (secondary) and camshaft sprockets (INT
and EXH).
● Align the mating marks on timing chain (secondary) (copper E
color link) with the ones on camshaft sprockets (INT and
EXH) (punched), and install them.
NOTE:
F
● Mating marks for camshaft sprocket (INT) are on the back
side of camshaft sprocket (secondary).
● There are two types of mating marks, circle and oval types.
They should be used for the right and left banks, respec- G
tively.
Right bank : Use circle type. H
Left bank : Use oval type.
● Align dowel pin and pin hole on camshafts with the groove
and dowel pin on sprockets, and install them. I
● On the intake side, align pin hole on the small diameter side of
the camshaft front end with dowel pin on the back side of
camshaft sprocket, and install them. J
● On the exhaust side, align dowel pin on camshaft front end
with pin groove on camshaft sprocket, and install them.
PBIC2926E
● In case that positions of each mating mark and each dowel K
pin are not fit on mating parts, make fine adjustment to the position holding the hexagonal portion on
camshaft with wrench or equivalent.
● Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is L
enough to prevent the dislocation of dowel pins.
● It may be difficult to visually check the dislocation of mating
marks during and after installation. To make the matching
M
easier, make a mating mark on the top of sprocket teeth and
its extended line in advance with paint.
PBIC2927E
EM-65
TIMING CHAIN
[VQ]
c. After confirming the mating marks are aligned, tighten camshaft
sprocket mounting bolts.
● Secure camshaft using wrench at the hexagonal portion to
tighten mounting bolts.
KBIA1698J
d. Pull stopper pins out from timing chain tensioners (secondary).
PBIC2110E
6. Install tension guide.

7. Install timing chain (primary) as follows:
a. Install crankshaft sprocket.
● Make sure the mating marks on crankshaft sprocket face the
front of engine.
SEM929E
b. Install timing chain (primary).
EM-66
TIMING CHAIN
[VQ]
● Install timing chain (primary) so the mating mark (punched)
(B) on camshaft sprocket (1) is aligned with the copper color A
link (A) on timing chain, while the mating mark (notched) (D)
on crankshaft sprocket (2) is aligned with the yellow paint (C)
on timing chain, as shown in the figure.
EM
3 : Water pump
● When it is difficult to align mating marks of timing chain (pri-

mary) with each sprocket, gradually turn camshaft using C
wrench on the hexagonal portion to align it with the mating
marks.
● During alignment, be careful to prevent dislocation of mating D
mark alignments of timing chains (secondary).
G
PBIC4215E
8. Install internal chain guide, slack guide and timing chain

tensioner (primary). H
PBIC2109E
EM-67
TIMING CHAIN
[VQ]
CAUTION:
Do not overtighten slack guide mounting bolts. It is normal
for a gap to exist under the bolt seats when mounting bolt
are tightened to specification.
PBIC2633E
● When installing timing chain tensioner (primary), push in plunger and keep it pressed in with stopper
pin.
● Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing
chain tensioner (primary).
● After installation, pull out stopper pin by pressing slack guide.
9. Make sure again that the mating marks on camshaft sprockets and timing chain have not slipped out of
alignment.
10. Install new front oil seal on front timing chain case.
● Apply new engine oil to both oil seal lip and dust seal lip.
● Install it so that each seal lip is oriented as shown in the fig-

ure.
SEM715A
● Using suitable drift [outer diameter: 60 mm (2.36 in)], press-fit

oil seal until it becomes flush with front timing chain case end
face.
● Make sure the garter spring is in position and seal lip is not
inverted.
PBIC2911E
11. Install water pump cover and chain tensioner cover to front timing chain case.
EM-68
TIMING CHAIN
[VQ]
● Apply a continuous bead of liquid gasket with tube presser
[SST: WS39930000] to front timing chain case as shown in A
the figure.
EM
PBIC2912E
D
12. Install front timing chain case as follows:
WS39930000] to front timing chain case back side as shown in E
the figure.
B : Protrusion
C : Both permissible F
D : Bolt hole

G
K
PBIC3887E
b. Install new O-rings on rear timing chain case.

L
PBIC2548E
c. Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
EM-69
TIMING CHAIN
[VQ]
d. Tighten mounting bolts to the specified torque in numerical order
● There are four types of mounting bolts. Refer to the following
for locating bolts.
M10 × 70 mm (2.76 in) :5
: 55.0 N·m (5.6 kg-m, 41 ft-lb)
M10 × 90 mm (3.54 in) : 1, 2, 3, 4
: 55.0 N·m (5.6 kg-m, 41 ft-lb)
M6 × 40 mm (1.57 in) : 24, 25 PBIC2908E
: 12.7 N·m (1.3 kg-m, 9 ft-lb)

M6 × 25 mm (0.98 in) : Except above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
e. After all bolts are tightened, retighten them to the specified torque in numerical order as shown in the fig-
ure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).
f. After installing front timing chain case, check surface height dif-
ference between the following parts on the oil pan (upper)
mounting surface.
Standard
Front timing chain case to rear timing chain case:
–0.14 to 0.14 mm (–0.005 to 0.0055 in)
● If not within the standard, repeat the installation procedure.
PBIC2929E
13. Install right and left intake valve timing control covers as follows:
a. Install new seal rings in shaft grooves.
b. Apply a continuous bead of liquid gasket with tube presser [SST:
WS39930000] to intake valve timing control covers as shown in
the figure.
SBIA0492E
c. Install new collared O-rings in front timing chain case oil hole
(left and right sides).
PBIC2631E
EM-70
TIMING CHAIN
[VQ]
d. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain
case with holes to install intake valve timing control covers. A
ure.
EM
D
PBIC0918E
14. Install oil pans (upper and lower). Refer to EM-28, "OIL PAN AND OIL STRAINER" . E
15. Install rocker covers (right and left banks). Refer to EM-41, "ROCKER COVER" .
16. Install crankshaft pulley as follows:
a. Fix crankshaft using ring gear stopper [SST: KV10117700]. F
b. Install crankshaft pulley, taking care not to damage front oil seal.
● When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference).
c. Tighten crankshaft pulley bolt. G
: 44.1 N·m (4.5 kg-m, 33 ft-lb)

d. Place a paint mark (A) on crankshaft pulley (1) aligning with the H
angle mark (B) on crankshaft pulley bolt (2). Tighten the bolt 90
degrees (Angle tightening).
I
K
PBIC4627J
17. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns
smoothly. L
EM-71
TIMING CHAIN
[VQ]
The following are procedures for checking fluids leak, lubricant leak and exhaust gases leak.
NOTE:
EM-72
CAMSHAFT
[VQ]
CAMSHAFT PFP:13001
A
Components BBS00012
EM
PBIC3891E
Intake valve timing control solenoid

1. 2. Gasket 3. Camshaft bracket (No. 2 to 4)
valve (right bank)
4. Camshaft (EXH) 5. Camshaft (INT) 6. Camshaft bracket (No. 1)
7. Dowel pin 8. Valve lifter 9. O-ring
Timing chain tensioner (secondary)
10. 11. Spring 12. Plunger
(right bank)
Timing chain tensioner (secondary)
13. 14. Cylinder head (right bank) 15. Cylinder head (left bank)
(left bank)
Camshaft position sensor (PHASE) Camshaft position sensor (PHASE)
16. O-ring 17. 18.
(right bank) (left bank)
EM-73
CAMSHAFT
[VQ]
Intake valve timing control solenoid
19.
valve (left bank)
A. Refer to EM-78

Removal and Installation BBS00013
REMOVAL
1. Remove front timing chain case, camshaft sprocket, timing chain and rear timing chain case. Refer to EM-
53, "TIMING CHAIN" .
2. Remove camshaft position sensor (PHASE) (right and left
banks) from cylinder head back side.
CAUTION:
● Handle carefully to avoid dropping and shocks.
● Do not disassemble.
● Do not allow metal powder to adhere to magnetic part at

sensor tip.
● Do not place sensors in a location where they are
exposed to magnetism.
KBIA1046E
3. Remove intake valve timing control solenoid valves.

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

● Mark camshafts, camshaft brackets and bolts so they are placed in the same position and direction for
installation.
EM-74
CAMSHAFT
[VQ]
● Equally loosen camshaft bracket bolts in several steps in
reverse order as shown in the figure. A
EM
G
PBIC2050E
5. Remove camshafts.
H
6. Remove valve lifters.
● Identify installation positions, and store them without mixing them up.
7. Remove timing chain tensioner (secondary) from cylinder head.

I
● Remove timing chain tensioner (secondary) with its stopper
pin attached.
NOTE: J
Stopper pin was attached when timing chain (secondary) was
removed.
PBIC2111E
L

Camshaft Runout M
1. Put V-block on precise flat table, and support No. 2 and 4 journal
of camshaft.
CAUTION:
Do not support journal No. 1 (on the side of camshaft
sprocket) because it has a different diameter from the other
three locations.
2. Set dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on dial indicator. (Total indicator reading)
Standard : Less than 0.02 mm (0.001 in) PBIC0929E
Limit : 0.05 mm (0.002 in)

4. If it exceeds the limit, replace camshaft.
EM-75
CAMSHAFT
[VQ]
Camshaft Cam Height
1. Measure the camshaft cam height with micrometer.
Standard:
Intake : 45.465 - 45.655 mm (1.7900 - 1.7974 in)
Exhaust : 45.075 - 45.265 mm (1.7746 - 1.7821 in)
Limit:
Intake : 45.265 mm (1.7821 in)
Exhaust : 44.875 mm (1.7667 in)
2. If wear exceeds the limit, replace camshaft.
EMQ0072D
Camshaft Journal Oil Clearance

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

● Tighten camshaft bracket bolt with the specified torque. Refer to EM-78, "INSTALLATION" for the tighten-
ing procedure.
● Measure the inner diameter “A” of camshaft bracket with bore
gauge.
Standard:
No. 1 : 26.000 - 26.021 mm (1.0236 - 1.0244 in)
No. 2, 3, 4 : 23.500 - 23.521 mm (0.9252 - 0.9260 in)
PBIC1645E
CAMSHAFT JOURNAL OIL CLEARANCE

● (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter).
Standard:
No. 1 : 0.045 - 0.086 mm (0.0018 - 0.0034 in)
No. 2, 3, 4 : 0.035 - 0.076 mm (0.0014 - 0.0030 in)
Limit : 0.15 mm (0.0059 in)
● If the calculated value exceeds the limit, replace either or both camshaft and cylinder head.
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
EM-76
CAMSHAFT
[VQ]
Camshaft End Play
● Install dial indicator in thrust direction on front end of camshaft. A
Measure the end play of dial indicator when camshaft is moved
forward/backward (in direction to axis).
Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in) EM
Limit : 0.24 mm (0.0094 in)
SEM864E
D
● Measure the following parts if out of the limit.

– Dimension “A” for camshaft No. 1 journal E
Standard : 27.500 - 27.548 mm (1.0827 - 1.0846 in)
– Dimension “B” for cylinder head No. 1 journal bearing
F
Standard : 27.360 - 27.385 mm (1.0772 - 1.0781 in)
● Refer to the standards above, and then replace camshaft and/or
cylinder head. G
KBIA2404J
Camshaft Sprocket Runout H

1. Put V-block on precise flat table, and support No. 2 and 4 journal of camshaft.
CAUTION:
Do not support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter I
from the other three locations.
2. Measure the camshaft sprocket runout with dial indicator. (Total
indicator reading) J
Limit : 0.15 mm (0.0059 in)
● If it exceeds the limit, replace camshaft sprocket. K
PBIC0930E
M
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
● If anything above is found, replace valve lifter. Refer to EM-135,
"Available Valve Lifter" .
KBIA0182E
EM-77
CAMSHAFT
[VQ]
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
● Measure the outer diameter at 1/2 height of valve lifter with
micrometer since valve lifter is in barrel shape.
Standard (Intake and exhaust)
: 33.977 - 33.987 mm (1.3377 - 1.3381 in)
JEM798G
VALVE LIFTER HOLE DIAMETER

● Measure the inner diameter of valve lifter hole of cylinder head
with inside micrometer.
: 34.000 - 34.016 mm (1.3386 - 1.3392 in)
SEM867E
VALVE LIFTER CLEARANCE

● (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
: 0.013 - 0.039 mm (0.0005 - 0.0015 in)
● If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and
valve lifter hole diameter, replace either or both valve lifter and cylinder head.
INSTALLATION
1. Install timing chain tensioners (secondary) on both sides of cyl-
inder head.
● Install timing chain tensioner with its stopper pin attached.
● Install timing chain tensioner with sliding part facing down-

ward on right-side cylinder head, and with sliding part facing
upward on left-side cylinder head.
● Install new O-rings as shown in the figure.
PBIC2111E
2. Install valve lifters.

● Install it in the original position.
3. Install camshafts.
EM-78
CAMSHAFT
[VQ]
● Install camshaft with dowel pin attached to its front end face
on the exhaust side. A
EM
KBIA1071E
D
● Follow your identification marks made during removal, or fol-
low the identification marks that are present on new cam-
shafts for proper placement and direction.
E
Paint marks Identification
Bank INT/EXH Dowel pin
M1 M2 mark
F
INT No Green No RE
RH
EXH Yes No White RE
INT No Green No LH G
LH
EXH Yes No White LH KBIA1009E
● Install camshaft so that dowel pin hole and dowel pin on front
end face are positioned as shown in the figure. (No. 1 cylinder H
TDC on its compression stroke)
NOTE:
● Large and small pin holes are located on front end face of I
camshaft (INT), at intervals of 180 degrees. Face small dia.
side pin hole upward (in cylinder head upper face direc-
tion). J
● Though camshaft does not stop at the portion as shown in
the figure, for the placement of cam nose, it is generally
accepted camshaft is placed for the same direction of the PBIC2478E
K
figure.
4. Install camshaft brackets.

● Remove foreign material completely from camshaft bracket
L
backside and from cylinder head installation face.
● Install camshaft bracket in original position and direction as
shown in the figure. M
PBIC2051E
EM-79
CAMSHAFT
[VQ]
● Install camshaft brackets (No. 2 to 4) aligning the stamp
marks as shown in the figure.
NOTE:
There are no identification marks indicating left and right for
camshaft bracket (No. 1).
PBIC2052E
● Apply liquid gasket to mating surface of camshaft bracket (No.

1) as shown on right and left banks.
PBIC2617E
5. Tighten camshaft bracket bolts in the following steps, in numeri-

cal order as shown in the figure.
a. Tighten No. 7 to 10 in order as shown.
: 1.96 N·m (0.2 kg-m, 1 ft-lb)

b. Tighten No. 1 to 6 in order as shown.
: 1.96 N·m (0.2 kg-m, 1 ft-lb)

c. Tighten No. 1 to 10 in numerical order as shown.
: 5.88 N·m (0.6 kg-m, 4 ft-lb)

d. Tighten No. 1 to 10 in numerical order as shown.
: 10.4 N·m (1.1 kg-m, 8 ft-lb)
CAUTION:
After tightening mounting bolts of camshaft brackets (No.
1), be sure to wipe off excessive liquid gasket from the
parts list below.
● Mating surface of rocker cover
● Mating surface of rear timing chain case
PBIC2050E
EM-80
CAMSHAFT
[VQ]
6. Measure the difference in levels between front end faces of
camshaft bracket (No. 1) and cylinder head. A
Standard : –0.14 to 0.14 mm (–0.0055 to 0.0055 in)
● Measure two positions (both intake and exhaust side) for a
single bank. EM
● If the measured value is out of the standard, re-install cam-
shaft bracket (No. 1).
C
EMQ0044D
D
7. Check and adjust the valve clearance. Refer to EM-134, "Valve Clearance" .
E
EM-81
CAMSHAFT
[VQ]
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
● Perform this inspection only when DTC P0011 or P0021 are detected in self-diagnostic results of
CONSULT-II and it is directed according to inspection procedure of EC section. Refer to EC-117,
"SELF-DIAG RESULTS MODE" (WITH EURO-OBD) or EC-646, "SELF-DIAG RESULTS MODE"
(WITHOUT EURO-OBD).
● Check when engine is cold so as to prevent burns from any splashing engine oil.
1. Check the engine oil level. Refer to LU-7, "ENGINE OIL" .
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-610,
b. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to EM-73, "CAMSHAFT" .
4. Crank the engine, and then make sure that engine oil comes out
from camshaft bracket (No. 1) oil hole. End crank after checking.
WARNING:
Be careful not to touch rotating parts (drive belts, idler pul-
ley, and crankshaft pulley, etc.).
CAUTION:
Engine oil may squirt from intake valve timing control sole-
noid valve installation hole during cranking. Use a shop
cloth to prevent the engine components and the vehicle. Do
not allow engine oil to get on rubber components such as
drive belt or engine mount insulators. Immediately wipe off PBIC2869E
any splashed engine oil.

● Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not
come out from camshaft bracket (No. 1) oil hole. Refer to LU-5, "LUBRICATION SYSTEM" .
5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
● Clean oil groove if necessary. Refer to LU-5, "LUBRICATION SYSTEM" .
6. After inspection, install removed parts.

NOTE:
EM-82
CAMSHAFT
[VQ]
A
EM
* Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc. C
Valve Clearance BBS00014
INSPECTION D
In cases of removing/installing or replacing camshaft and valve-
related parts, or of unusual engine conditions due to changes in
valve clearance (found malfunctions during stating, idling or causing
noise), perform inspection as follows: E
G
SEM713A
1. Remove rocker covers (right and left banks). Refer to EM-41, "ROCKER COVER" . H
2. Measure the valve clearance as follows:
a. Set No. 1 cylinder at TDC of its compression stroke.
● Rotate crankshaft pulley clockwise to align timing mark I
(grooved line without color) with timing indicator.
KBIA1717J
L
● Make sure that intake and exhaust cam noses on No. 1 cylin-
der (engine front side of right bank) are located as shown in M
the figure.
● If not, rotate crankshaft one revolution (360 degrees) and
align as shown in the figure.
SEM418G
EM-83
CAMSHAFT
[VQ]
b. Use feeler gauge, measure the clearance between valve lifter
and camshaft.
SEM139D
Valve clearance:
Unit: mm (in)
Items Cold Hot * (reference data)
Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)
● By referring to the figure, measure the valve clearances at

locations marked “×” as shown in the table below (locations
indicated in the figure) with feeler gauge.
● No. 1 cylinder at compression TDC
Measuring position (right bank) No. 1 CYL. No. 3 CYL. No. 5 CYL.
No. 1 cylinder at EXH ×

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

compression TDC EXH ×
PBIC2054E
c. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 3 cylinder at
TDC of its compression stroke.
NOTE:
●To align cylinder No.3 with the compression top dead center,
place matching marks (A) on the crankshaft pulley (1) side
and on the cylinder block side at a point 240°counterclock-
wise from the compression top dead center using the hex
head of the crankshaft pulley bolt as a guide.
PBIC4628J
EM-84
CAMSHAFT
[VQ]
locations marked “×” as shown in the table below (locations A
EM

C

compression TDC EXH × D
G
PBIC2055E
d. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 5 cylinder at
TDC of compression stroke. H
NOTE:
● To align cylinder No.5 with the compression top dead center, I
place matching marks (A) on the crankshaft pulley (1) side
and on the cylinder block side at a point 240°counterclock-
wise from the compression top dead center using the hex
J
head of the crankshaft pulley bolt as a guide.
PBIC4628J L
EM-85
CAMSHAFT
[VQ]
locations marked “×” as shown in the table below (locations


compression TDC EXH ×
PBIC2056E
3. Perform adjustment if the measured value is out of the standard. Refer to EM-86, "ADJUSTMENT" .
ADJUSTMENT
● Perform adjustment depending on selected head thickness of valve lifter.
1. Measure the valve clearance. Refer to EM-83, "INSPECTION" .
2. Remove camshaft. Refer to EM-74, "REMOVAL" .
3. Remove valve lifters at the locations that are out of the standard.
4. Measure the center thickness of removed valve lifters with
micrometer.
KBIA0057E
5. Use the equation below to calculate valve lifter thickness for replacement.
Valve lifter thickness calculation: t = t1 + (C1 – C2 )
t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.30 mm (0.012 in)*
Exhaust : 0.33 mm (0.013 in)*
EM-86
CAMSHAFT
[VQ]
● Thickness of new valve lifter can be identified by stamp marks
on the reverse side (inside the cylinder). A
EM
KBIA0119E
D
Intake
Stamp mark Thickness
788U 7.88 mm (0.3102 in) E
790U 7.90 mm (0.3110 in)
· ·
· ·
F
840U 8.40 mm (0.3307 in)
Available thickness of valve lifter: 27 sizes with range 7.88 to 8.40 mm (0.3102 to 0.3307 in) in steps of G
0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-135, "Available Valve Lifter" .
Exhaust
H
Stamp mark Thickness
N788 7.88 mm (0.3102 in)
N790 7.90 mm (0.3110 in) I
· ·
· ·
J
N836 8.36 mm (0.3291 in)
Available thickness of valve lifter: 25 sizes with range 7.88 to 8.36 mm (0.3102 to 0.3291 in) in steps of
0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-135, "Available Valve Lifter" . K
CAUTION:
Install identification letter at the end and top, “U” and “N”, at each of proper positions. (Be care-
ful of mis-installation between intake and exhaust) L
6. Install selected valve lifter.
7. Install camshaft. Refer to EM-78, "INSTALLATION" .
8. Manually turn crankshaft pulley a few turns. M
9. Make sure that the valve clearances for cold engine are within the specifications by referring to the speci-
fied values.
10. Installation of all removed parts is in the reverse order of removal. Refer to EM-78, "INSTALLATION" .
11. Start the engine, and check for unusual noise and vibration.
EM-87
OIL SEAL
[VQ]
OIL SEAL PFP:00100
Removal and Installation of Valve Oil Seal BBS00015
REMOVAL
1. Turn crankshaft until the cylinder requiring new valve oil seals is at TDC. This will prevent valve from drop-
ping into cylinder.
2. Remove camshaft relating to valve oil seal to be removed. Refer to EM-73, "CAMSHAFT" .
3. Remove valve lifters. Refer to EM-73, "CAMSHAFT" .
4. Remove valve collet.
● Compress valve spring with valve spring compressor, attach-
ment, adapter (SST). Remove valve collet with magnet hand.
CAUTION:
When working, take care not to damage valve lifter holes.
PBIC1791E
5. Remove valve spring retainer and valve spring.

6. Remove valve oil seal using valve oil seal puller (SST).
PBIC1610E
INSTALLATION
1. Apply new engine oil on new valve oil seal joint and seal lip.
2. Using valve oil seal drift (SST), press fit valve seal to height “H”
NOTE:
Dimension “H”: Height measured before valve spring seat instal-
lation
Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
PBIC1611E
EM-88
OIL SEAL
[VQ]
Removal and Installation of Front Oil Seal BBS00016
REMOVAL A
● Engine undercover front, engine undercover middle: Refer to EI-15, "FRONT BUMPER" .
● Drive belts: Refer to EM-14, "DRIVE BELTS" .

EM
● Radiator cooling fan assembly: Refer to CO-21, "COOLING FAN" .
● Crankshaft pulley: Refer to EM-53, "TIMING CHAIN" .

C
2. Remove front oil seal using suitable tool.
CAUTION:
Be careful not to damage front timing chain case and crank-
D
shaft.
F
PBIC2931E
INSTALLATION
1. Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal. G
2. Install front oil seal.
● Install front oil seal so that each seal lip is oriented as shown
in the figure. H
SEM715A
K
● Using suitable drift, press-fit until the height of front oil seal is
level with the mounting surface.
– Suitable drift: outer diameter 60 mm (2.36 in), inner diameter L
50 mm (1.97 in).
CAUTION:
● Be careful not to damage front timing chain case and M
crankshaft.
● Press-fit straight and avoid causing burrs or tilting oil
seal.
PBIC2931E

Removal and Installation of Rear Oil Seal BBS00017
REMOVAL
1. Remove transmission assembly. Refer to AT-248, "TRANSMISSION ASSEMBLY" .
2. Remove drive plate. Refer to EM-106, "CYLINDER BLOCK" .
EM-89
OIL SEAL
[VQ]
3. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
PBIC2932E
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.
SEM715A
● Press in rear oil seal to the position as shown in the figure.
SBIA0281E
● Press-fit rear oil seal with a suitable drift [outside diameter

104 mm (4.09 in), inside diameter 88 mm (3.46 in)].
CAUTION:
● Be careful not to damage crankshaft and cylinder
block.
● Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
● Do not touch grease applied onto oil seal lip.
PBIC2933E
3. Installation of the remaining parts is the reverse order of removal.
EM-90
CYLINDER HEAD
[VQ]
CYLINDER HEAD PFP:11041
A
On-Vehicle Service BBS00018
CHECKING COMPRESSION PRESSURE

1. Warm up engine thoroughly. Then, stop it.
EM
3. Disconnect fuel pump fuse to avoid fuel injection during mea-
C
surement.
BBIA0534E
F
5. Remove ignition coil and spark plug from each cylinder. Refer to EM-33, "IGNITION COIL" and EM-34,
"SPARK PLUG (PLATINUM-TIPPED TYPE)" . G
6. Connect engine tachometer (not required in use of CONSULT-ll).
7. Install compression tester with adapter onto spark plug hole.
H
PBIC0900E
K
● Use compression gauge whose picking up end inserted to

spark plug hole is smaller than 20 mm (0.79 in) in diameter.
L
Otherwise, it may be caught by cylinder head during removal.
SBIA0533E
8. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and engine rpm. Perform these steps to check each cyl-
inder.
Compression pressure:
Unit: kPa (kg/cm2 , psi)/rpm
Standard Minimum Differential limit between cylinders
1,275 (13.0, 185)/300 981 (10.0, 142)/300 98 (1.0, 14)/300
CAUTION:
Always use a fully changed battery to obtain specified engine speed.
EM-91
CYLINDER HEAD
[VQ]
If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine
●
speed again with normal battery gravity.
● If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again.
● If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug
hole of the cylinder to re-check it for compression.
– If the added engine oil improves the compression, piston rings may be worn out or damaged. Check the
piston rings and replace if necessary.
– If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
● If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
9. After inspection is completed, install removed parts.
10. Start engine, and make sure that engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-84, "TROUBLE DIAGNOSIS" (WITH
EURO-OBD) or EC-613, "TROUBLE DIAGNOSIS" (WITHOUT EURO-OBD).
Components BBS00019
PBIC2934E
1. Rubber plug 2. Cylinder head (left bank) 3. Cylinder head bolt

4. Cylinder head (right bank) 5. Harness bracket 6. Cylinder head gasket (right bank)
7. Cylinder head gasket (left bank)
Removal and Installation BBS0001A
REMOVAL
1. Remove camshaft. Refer to EM-73, "CAMSHAFT" .
2. Release the hoist from hanging, then remove the engine slingers.
EM-92
CYLINDER HEAD
[VQ]
● Intake manifold: Refer to EM-21, "INTAKE MANIFOLD" .
● Exhaust manifold: Refer to EM-23, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . A
● Water inlet and thermostat assembly: Refer to CO-26, "WATER INLET AND THERMOSTAT ASSEM-
BLY" .
● Water outlet, water pipe and heater pipe: Refer to CO-28, "WATER OUTLET AND WATER PIPING" . EM
4. Remove cylinder head bolts in reverse order as shown in the fig-
ure with cylinder head bolt wrench (commercial service tool) and
power tool to remove cylinder heads (right and left banks). C
PBIC2057E I
5. Remove cylinder head gaskets.

INSPECTION AFTER REMOVAL J
Cylinder Head Bolts Outer Diameter
● Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “d1” and “d2” K
exceeds the limit, replace them with new one.
Limit (“d1” – “d2”) : 0.11 mm (0.0043 in)
L
● If reduction of outer diameter appears in a position other than
“d2”, use it as “d2” point.
M
PBIC2480E
Cylinder Head Distortion

NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-125, "CYLIN-
DER BLOCK DISTORTION" .
1. Using scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.
CAUTION:
Do not allow gasket fragments to enter engine oil or engine coolant passages.
EM-93
CYLINDER HEAD
[VQ]
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions.
Limit : 0.1 mm (0.004 in)
● If it exceeds the limit, replace cylinder head.
SEM861E
INSTALLATION
1. Install new cylinder head gasket.
2. Turn crankshaft until No. 1 piston is set at TDC.
● Crankshaft key should line up with the right bank cylinder cen-
ter line as shown in the figure.
SEM532G
3. Install cylinder head follow the steps below to tighten cylinder

head bolts in numerical order as shown in the figure.
CAUTION:
If cylinder head bolts re-used, check their outer diameters
before installation. Refer to EM-93, "Cylinder Head Bolts
Outer Diameter" .
a. Apply new engine oil to threads and seat surface of cylinder
head bolts.
b. Tighten all cylinder head bolts.
: 98.1 N·m (10 kg-m, 72 ft-lb)

c. Completely loosen all cylinder head bolts.
: 0 N·m (0 kg-m, 0 ft-lb)
CAUTION:
In step “c”, loosen cylinder head bolts in reverse order of
that indicated in the figure.
d. Tighten all cylinder head bolts.
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
PBIC2057E
EM-94
CYLINDER HEAD
[VQ]
e. Turn all cylinder head bolts 90 degrees clockwise (angle tighten-
ing). A
CAUTION:
Check the tightening angle by using angle wrench (SST).
Avoid judgment by visual inspection without tool. EM
● Check tightening angle indicated on angle wrench (SST) indi-
cator plate.
f. Turn all cylinder head bolts 90 degrees clockwise again. C
PBIC1613E
D
4. After installing cylinder head, measure distance between front
end faces of cylinder block and cylinder head (left and right
banks).
E
Standard : 14.1 - 14.9 mm (0.555 - 0.587 in)
● If the measured value is out of the standard, re-install cylinder
head. F
G
EMQ0662D
5. Install in the reverse order of removal after this step. H
EM-95
CYLINDER HEAD
[VQ]
Exhaust gases — Leakage —
Components BBS0001B
PBIC2481E
EM-96
CYLINDER HEAD
[VQ]
1. Valve lifter 2. Valve collet 3. Valve spring retainer
4. Valve spring 5. Valve oil seal 6. Valve spring seat
A
7. Valve guide 8. Spark plug 9. Spark plug tube
10. Cylinder head (right bank) 11. Valve seat 12. Valve (EXH)
EM
13. Valve (INT) 14. Cylinder head (left bank)
Disassembly and Assembly BBS0001C
DISASSEMBLY C
1. Remove spark plug with spark plug wrench (commercial service tool).
2. Remove valve lifter.
● Identify installation positions, and store them without mixing them up. D
ment and adapter (SST). Remove valve collet with magnet E
hand.
CAUTION:
When working, take care not to damage valve lifter holes. F
G
PBIC1791E
4. Remove valve spring retainer, valve spring and valve spring seat. H
5. Push valve stem to combustion chamber side, and remove valve.
6. Remove valve oil seals using valve oil seal puller (SST). I
PBIC1610E
L
7. If valve seat must be replaced, refer to EM-101, "VALVE SEAT REPLACEMENT" .

8. If valve guide must be replaced, refer to EM-99, "VALVE GUIDE REPLACEMENT" . M
9. Remove spark plug tube, as necessary.
● Using pair of pliers, pull spark plug tube out of cylinder head.
CAUTION:
● Take care not to damage cylinder head.
● Once removed, spark plug tube will be deformed and cannot be reused. Do not remove it unless
absolutely necessary.
ASSEMBLY
1. When valve guide is removed, install it. Refer to EM-99, "VALVE GUIDE REPLACEMENT" .
2. When valve seat is removed, install it. Refer to EM-101, "VALVE SEAT REPLACEMENT" .
EM-97
CYLINDER HEAD
[VQ]
3. Install valve oil seals.
● Install with valve oil seal drift (SST) to match dimension in the
figure.
Height “H” (Without valve spring seat installed)
Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
PBIC0802E
4. Install valve spring seat.

5. Install valves.
NOTE:
Larger diameter valves are for intake side.
6. Install valve spring (uneven pitch type).
● Install narrow pitch end (paint mark) to cylinder head side
(valve spring seat side).
● Intake side and exhaust side valve springs are different.
Install them referring to the following paint mark collar.
SEM085D
7. Install valve spring retainer.

8. Install valve collet.
ment and adapter (SST). Install valve collet with magnet
hand.
CAUTION:
When working, take care not to damage valve lifter holes.
● Tap valve stem edge lightly with plastic hammer after installa-
tion to check its installed condition.
PBIC1791E
9. Install valve lifter.

10. Install spark plug tube.

● Press-fit spark plug tube as follows:
a. Remove old liquid gasket adhering to cylinder head mounting hole.

b. Apply sealant to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side.
Use Genuine High Strength Locking Sealant or equivalent.
EM-98
CYLINDER HEAD
[VQ]
c. Using drift, press-fit spark plug tube so that its height “H” is as
specified in the figure. A
Standard press-fit height “H”:
: 38.1 - 39.1 mm (1.500 - 1.539 in)
EM
CAUTION:
● When press-fitting, take care not to deform spark plug
tube.
C
● After press-fitting, wipe off liquid gasket protruding onto
cylinder-head upper face.
11. Install spark plug with spark plug wrench (commercial service PBIC2634E
tool). D
Inspection After Disassembly BBS0001D
VALVE DIMENSIONS E
● Check dimensions of each valve. For dimensions, refer to EM-136, "Valve Dimensions" .
● If dimensions are out of the standard, replace valve and check the valve seat contact. Refer to EM-101,
"VALVE SEAT CONTACT" . F
VALVE GUIDE CLEARANCE
Valve Stem Diameter
Measure the diameter of valve stem with micrometer. G
Standard
Intake : 5.965 - 5.980 mm (0.2348 - 0.2354 in) H
Exhaust : 5.955 - 5.970 mm (0.2344 - 0.2350 in)
J
SEM938C
Valve Guide Inner Diameter

Measure the inner diameter of valve guide with inside micrometer. K
Standard
Intake and Exhaust : 6.000 - 6.018 mm (0.2362 - 0.2369 in)
L
Valve Guide Clearance
(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
Valve guide clearance: M
Standard
Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in)
Limit
Intake : 0.08 mm (0.003 in)
Exhaust : 0.09 mm (0.004 in)
● If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be
replaced, refer to EM-99, "VALVE GUIDE REPLACEMENT" .
VALVE GUIDE REPLACEMENT
When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.
EM-99
CYLINDER HEAD
[VQ]
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 lmp ton) pressure] or hammer and valve guide drift
(commercial service tool).
CAUTION:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
SEM931C
3. Using valve guide reamer (commercial service tool), ream cylin-

der head valve guide hole.
Valve guide hole diameter (for service parts):
Intake and exhaust
: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil.
SEM008A
5. Using valve guide drift (commercial service tool), press valve

guide from camshaft side to the dimensions as in the figure.
Projection “L”
Intake and exhaust
: 12.6 - 12.8 mm (0.496 - 0.504 in)
CAUTION:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
SEM950E
EM-100
CYLINDER HEAD
[VQ]
6. Using valve guide reamer (commercial service tool), apply
reamer finish to valve guide. A
Standard:
Intake and exhaust
EM
: 6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM932C
D
VALVE SEAT CONTACT
● After confirming that the dimensions of valve guides and valves
are within the specifications, perform this procedure.
E
● Apply prussian blue (or white lead) onto contacting surface of
valve seat to check the condition of the valve contact on the sur-
face.
● Check if the contact area band is continuous all around the cir- F
cumference.
● If not, grind to adjust valve fitting and check again. If the contact-
ing surface still has “NG” conditions even after the re-check, G
replace valve seat. Refer to EM-101, "VALVE SEAT REPLACE-
MENT" . SBIA0322E
VALVE SEAT REPLACEMENT H

When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-138, "Valve Seat" . I
CAUTION:
Prevent to scratch cylinder head by excessive boring.
J
2. Ream cylinder head recess diameter for service valve seat.
Oversize [0.5 mm (0.020 in)]
Intake : 38.500 - 38.516 mm (1.5157 - 1.5164 in) K
Exhaust : 32.700 - 32.716 mm (1.2874 - 1.2880 in)
● Be sure to ream in circles concentric to valve guide center.
This will enable valve to fit correctly. L
M
SEM795A
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil.
SEM008A
4. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head.
CAUTION:
● Avoid directly touching cold valve seats.
EM-101
CYLINDER HEAD
[VQ]
● Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
5. Using valve seat cutter set (commercial service tool) or valve

seat grinder, finish seat to the specified dimensions. Refer to
EM-138, "Valve Seat" .
CAUTION:
When using valve seat cutter, firmly grip cutter handle with
both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with cutter or cutting many different times may
result in stage valve seat.
SEM934C
6. Using compound, grind to adjust valve fitting.

7. Check again for normal contact. Refer to EM-101, "VALVE SEAT CONTACT" .
VALVE SPRING SQUARENESS
● Set try square along the side of valve spring and rotate spring.
Measure the maximum clearance between the top face of spring
and try square.
Limit : 2.1 mm (0.083 in)
● If it exceeds the limit, replace valve spring.
PBIC0080E
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

● Check valve spring pressure at the specified spring height.
Standard:
Intake and exhaust
Free height
: 47.07 mm (1.8531 in)
Installation height
: 37.00 mm (1.4567 in)
Installation load
SEM113
: 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)
Height during valve open
: 27.20 mm (1.0709 in)
Load with valve open
: 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb)
● If the installation load or load with valve open is out of the standard, replace valve spring.
EM-102
ENGINE ASSEMBLY
[VQ]
ENGINE ASSEMBLY PFP:10001
A
Components BBS0001E
EM
PBIC4153E
1. RH engine mounting bracket (upper) 2. RH heat shield plate 3. RH engine mounting insulator
4. RH engine mounting bracket (lower) 5. LH engine mounting bracket (lower) 6. LH engine mounting insulator
7. LH heat shield plate 8. LH engine mounting bracket (upper) 9. Rear engine mounting insulator
WARNING:
● Situate vehicle on a flat and solid surface.
● Place chocks at front and back of rear wheels.
● For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:
● Always be careful to work safely, avoid forceful or uninstructed operations.
● Do not start working until exhaust system and engine coolant are cooled sufficiently.
EM-103
ENGINE ASSEMBLY
[VQ]
● If items or work required are not covered by the engine section, refer to the applicable sections.
● Always use the support point specified for lifting.
● Use either 2-point lift type or separate type lift. If board-on type is used for unavoidable reasons,
support at the rear axle jacking point with transmission jack or similar tool before starting work, in
preparation for the backward shift of center of gravity.
● For supporting points for lifting and jacking point at rear axle, refer to GI-52, "Garage Jack and
Safety Stand" .
Removal and Installation BBS0001F
REMOVAL
Preparation
2. Disconnect both battery cables. Refer to SC-5, "BATTERY" .
3. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant" .
4. Remove the following parts.
● Engine undercover front: Refer to EI-15, "FRONT BUMPER" .
● Engine undercover middle, engine undercover rear
● Hood assembly: Refer to BL-17, "Removal and Installation of Hood Assembly" .
● Battery: Refer to SC-5, "BATTERY" .
● Engine cover: Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .
● Air duct and air cleaner case assembly: Refer to EM-17, "AIR CLEANER AND AIR DUCT" .
● Radiator, radiator shroud (upper and lower) and cooling fan assembly: Refer to CO-13, "RADIATOR"
and CO-21, "COOLING FAN" .
● Drive belt: Refer to EM-14, "DRIVE BELTS" .
5. Disconnect vacuum hose between vehicle and engine and set it aside.
6. Disconnect the engine room harness from the engine side and set it aside for easier work.
7. Disconnect the engine harness grounds.
8. Remove power steering fluid reservoir tank from engine and move it aside for easier work. Refer to PS-52,
"Components (VQ40DE RHD Models)" or PS-54, "Components (VQ40DE LHD Models)" .
9. Remove power steering oil pump from engine. Move it from its location and secure with a rope for easier
work. Refer to PS-35, "Removal and Installation" .
10. Remove the A/C compressor bolts and set aside. Refer to ATC-185, "Removal and Installation for Com-
pressor" .
11. Disconnect brake booster vacuum line.
12. Disconnect EVAP line.
13. Disconnect the fuel hose at the engine side connection. Refer to EM-36, "FUEL INJECTOR AND FUEL
TUBE" .
14. Disconnect the heater hoses at cowl, and install plugs to avoid leakage of engine coolant.
15. Remove the A/T oil level indicator and indicator tube. Refer to AT-248, "TRANSMISSION ASSEMBLY" .
16. Remove three way catalyst. Refer to EM-23, "EXHAUST MANIFOLD AND THREE WAY CATALYST" .
17. Install engine slingers into left bank and right bank.
Engine slinger bolts:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
WBIA0624E
18. Remove transmission. Refer to AT-248, "TRANSMISSION ASSEMBLY" .
EM-104
ENGINE ASSEMBLY
[VQ]
19. Lift with hoist and secure the engine in position.
20. Loosen LH and RH engine mounting insulator mounting bolts. A
21. Remove engine.
CAUTION:
● During the operation, make sure that no part interferes EM
with the body side.
● Before and during this lifting, always check if any har-
nesses are left connected. C
D
SEM896G
22. Remove alternator. Refer to SC-25, "Removal and Installation" . E

23. Remove engine mounting insulator bracket (upper).
INSTALLATION
F
● Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
● Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts. G
● Insert vacuum hose to vacuum gallery until vacuum hose comes in contact with the stopper when a stop-
per is provided at vacuum gallery.
INSPECTION AFTER INSTALLATION H
I
J
K
L
M
Engine oil Level Leakage Level (*2)
Other oils and fluid (*1) Level Leakage Level
*1: Transmission/transaxle/AT fluid, power steering fluid, brake fluid, etc.
*2: Check engine oil level 10 minutes after engine stopped.
EM-105
CYLINDER BLOCK
[VQ]
CYLINDER BLOCK PFP:11010
Components BBS0001G
PBIC4154E
EM-106
CYLINDER BLOCK
[VQ]
1. Reinforcement plate 2. Drive plate 3. Rear oil seal
4. Sub harness 5. Knock sensor 6. Water connector
A
7. Cylinder block 8. Oil jet 9. Thrust bearing
10. Pilot converter 11. Main bearing upper 12. Crankshaft
EM
13. Crankshaft key 14. Main bearing lower 15. O-ring
16. Lower cylinder block bolt 17. Lower cylinder block 18. Connecting rod bolt
19. Connecting rod bearing cap 20. Connecting rod bearing 21. Connecting rod
C
22. Snap ring 23. Piston pin 24. Piston
25. Oil ring 26. Second ring 27. Top ring
A. Refer to EM-110 B. Chamfered
D
:Crankshaft side

E
Disassembly and Assembly BBS0001H
DISASSEMBLY
1. Remove engine assembly from vehicle. Refer to EM-103, "ENGINE ASSEMBLY" .
F
2. Remove both exhaust manifolds. Refer to EM-23, "EXHAUST MANIFOLD AND THREE WAY CATALYST"
.
3. Install engine to engine stand as follows.
G
a. Remove drive plate. Fix crankshaft with ring gear stopper (SST),
and remove mounting bolts.
● Loosen mounting bolts in diagonal order.
H
J
PBIC1617E
CAUTION: K
● Do not disassemble drive plate.
● Do not place drive plate with signal plate facing down.
● When handling signal plate, take care not to damage or L

scratch it.
● Handle signal plate in a manner that prevents it from
becoming magnetized. M
PBIC2938E
b. Hoist engine and install it to the engine stand (commercial ser-

vice tool).
CAUTION:
Use engine stand that has a load capacity [approximately
220 kg (441 lb) or more] large enough for supporting the
engine weight.
NOTE:
The figure shows an example of general-purpose engine stand
that can hold mating surface of transmission with drive plate and
rear plate removed.
PBIC0085E
EM-107
CYLINDER BLOCK
[VQ]
5. Drain engine coolant by removing water drain plugs from cylin-
der block left side at “A” and cylinder block front side at “B” as
PBIC2937E
6. Remove cylinder head. Refer to EM-91, "CYLINDER HEAD" .

7. Remove sub harness, and remove knock sensors.
CAUTION:
Carefully handle sensor avoiding shocks.
8. Remove pilot converter using pilot bushing puller (A) [SST:
16610001] as necessary.
PBIC3893E
9. Remove piston and connecting rod assembly as follows:

● Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer
to EM-122, "CONNECTING ROD SIDE CLEARANCE" .
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod bearing cap.
EM-108
CYLINDER BLOCK
[VQ]
c. Using hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side. A
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big EM
end.
PBIC2940E
D
10. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
Identify installation position, and store them without mixing them up. E
11. Remove piston rings from piston.
● Before removing piston rings, check the piston ring side clearance. Refer to EM-123, "PISTON RING
SIDE CLEARANCE" . F
● Use piston ring expander (commercial service tool).
CAUTION:
● When removing piston rings, be careful not to damage G
piston.
● Be careful not to damage piston rings by expanding them
excessively. H
I
PBIC0087E
12. Remove piston from connecting rod as follows: J

a. Using snap ring pliers, remove snap rings.
M
PBIC1638E
b. Heat piston to 60 to 70°C (140 to 158°F) with industrial use drier

or equivalent.
PBIC1639E
EM-109
CYLINDER BLOCK
[VQ]
c. Push out piston pin with stick of outer diameter approximately 20
mm (0.79 in).
PBIC0262E
13. Remove lower cylinder block bolts.

● Before loosening lower cylinder block bolts, measure the crankshaft end play. Refer to EM-122,
"CRANKSHAFT END PLAY" .
● Loosen lower cylinder block bolts in reverse order as shown in
the figure in several different steps.
NOTE:
Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).
PBIC2941E
14. Remove lower cylinder block.

● Use seal cutter [SST: KV10111100] to cut liquid gasket for removal. Refer to EM-7, "REMOVAL OF LIQ-
UID GASKET SEALING" .
CAUTION:
Be careful not to damage the mounting surfaces.
15. Remove crankshaft.
16. Pull rear oil seal out from rear end of crankshaft.
NOTE:
When replacing rear oil seal without removing lower cylinder block, use a screwdriver to pull the rear oil
seal installed between crankshaft and cylinder block out.
CAUTION:
17. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
● Be careful not to drop main bearing, and to scratch the surface.
18. Remove oil jet.

ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
EM-110
CYLINDER BLOCK
[VQ]
2. Install each plug to cylinder block as shown in the figure.
● Apply sealant to the thread of water drain plugs “A” and “B”. A
● Apply sealant to the thread of plugs “C” and “E”.
Use Genuine Thread Locking Sealant or equivalent. EM
● Apply sealant to the thread of plug “D”.
Use Anaerobic Liquid Gasket or equivalent.
● Replace washers with new one. C
G
PBIC2937E
● Tighten each plug as specified below. H

Part Washer Tightening torque
A No 19.6 N·m (2.0 kg-m, 14 ft-lb)
I
Reuse: 9.8 N·m (1.0 kg-m, 87 in-lb)
B No
New: 6.0 N·m (0.61 kg-m, 53 in-lb)
C Yes 78 N·m (8.0 kg-m, 58 ft-lb) J
D Yes 62 N·m (6.3 kg-m, 46 ft-lb)
E Yes 12.3 N·m (1.3 kg-m, 9 ft-lb)
K
3. Install oil jet.
● Insert oil jet dowel pin into cylinder block dowel pin hole, and
tighten mounting bolts.
L
PBIC0898E
4. Install main bearings and thrust bearings as follows:

a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block.
EM-111
CYLINDER BLOCK
[VQ]
b. Install thrust bearings to the both sides of the No. 3 journal hous-
ing on cylinder block.
● Install thrust bearings with the oil groove facing crankshaft
arm (outside).
● Install thrust bearing with a projection on one end on cylinder
block, and thrust bearing with a projection at center on lower
cylinder block. Align each projection with mating notch.
PBIC2968E
c. Install main bearings paying attention to the direction.

● Main bearing with oil hole and groove goes on cylinder block.
The one without them goes on lower cylinder block.
● Before installing main bearings, apply engine oil to the bear-
ing surface (inside). Do not apply engine oil to the back sur-
face, but thoroughly clean it.
● When installing, align main bearing stopper protrusion to cut-
out of cylinder block and lower cylinder block.
● Ensure the oil holes on cylinder block and those on the corre-
sponding bearing are aligned. PBIC2969E
5. Install crankshaft to cylinder block.

● While turning crankshaft by hand, check that it turns smoothly.
6. Inspect the outer diameter of lower cylinder block bolt. Refer to EM-130, "LOWER CYLINDER BLOCK
BOLT OUTER DIAMETER" .
7. Install lower cylinder block as follows:
NOTE:
Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder
block.
WS39930000] to lower cylinder block as shown in the figure.
CAUTION:
After liquid gasket is applied, rear oil seal installation must
be finished within 5 minutes. Therefore, the following pro-
cedure must be performed quickly.
b. Tighten lower cylinder block mounting bolt as follows:
i. Apply new engine oil to threads and seat surfaces of the mount-
ing bolts.
PBIC2942E
ii. Tighten M8 bolts in numerical order from No. 17 to 24 in the fig-

ure.
: 22.1 N·m (2.3 kg-m, 16 ft-lb)
CAUTION:
Wipe off completely any protruding liquid gasket on rear oil
seal installation surface.
NOTE:
There are more processes to complete the tightening of mount-
ing bolts. However stop procedure here to install rear oil seal.
PBIC2941E
c. Install rear oil seal. Refer to EM-89, "Removal and Installation of Rear Oil Seal" .
d. Restart tightening of lower cylinder block bolts as follows:
EM-112
CYLINDER BLOCK
[VQ]
i. Tighten M10 bolts in numerical order from No. 1 to 16 in the fig-
ure. A
NOTE:
Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).
: 35.3 N·m (3.6 kg-m, 26 ft-lb) EM
PBIC2941E
D
ii. Turn M10 bolts 90 degrees clockwise (angle tightening) in
numerical order from No. 1 to 16 in the figure.
CAUTION:
E
Use angle wrench (A) [SST: KV10112100] to check tighten-
ing angle. Do not make judgement by visual inspection.
G
PBIC3894E
● After installing the mounting bolts, make sure that crankshaft can be rotated smoothly by hand. H
● Wipe off completely any protruding liquid gasket on front side of the engine.
● Check the crankshaft end play. Refer to EM-122, "CRANKSHAFT END PLAY" .
8. Inspect the outer diameter of connecting rod bolt. Refer to EM-131, "CONNECTING ROD BOLT OUTER I
DIAMETER" .
9. Install piston to connecting rod as follows:
a. Using snap ring pliers, install new snap ring to the groove of piston rear side. J
● Insert it fully into groove to install.
b. Install piston to connecting rod.

● Using industrial use drier or similar tool, heat piston until piston pin can be pushed in by hand without
K
excess force [approx. 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into piston
and connecting rod.
● Assemble so that the front mark on the piston head and the L
cylinder number on connecting rod are positioned as shown in
the figure.
c. Install new snap ring to the groove of the piston front side. M
● Insert it fully into groove to install.
● After installing, make sure that connecting rod moves

smoothly.
SEM838F
EM-113
CYLINDER BLOCK
[VQ]
10. Using piston ring expander (commercial service tool), install pis-
ton rings.
CAUTION:
● When installing piston rings, be careful not to damage
piston.
● Be careful not to damage piston rings by expending them
excessively.
PBIC0087E
● If there is stamped mark on ring, mount it with marked side

up.
NOTE:
If there is no stamp on ring, no specific orientation is required
for installation.
Stamped mark:
Top ring :—
Second ring : R
SEM757G
● Position each ring with the gap as shown in the figure refer-
ring to the piston front mark.
PBIC0808E
● Check the piston ring side clearance. Refer to EM-123, "PISTON RING SIDE CLEARANCE" .
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
● Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply
engine oil to the back surface, but thoroughly clean it.
● When installing, align connecting rod bearing stopper protru-
sion with cutout of connecting rods and connecting rod bear-
ing caps to install.
● Ensure the oil hole on connecting rod and that on the corre-
sponding bearing are aligned.
PBIC2067E
12. Install piston and connecting rod assembly to crankshaft.

● Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
● Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
● Match the cylinder position with the cylinder number on connecting rod to install.
● Be sure that front mark on piston head is facing front of engine.
EM-114
CYLINDER BLOCK
[VQ]
● Using piston ring compressor (A) [SST: EM03470000] or suit-
able tool, install piston with the front mark on the piston head A
facing the front of engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft EM
pin, resulting from an interference of the connecting rod big
end.
C
PBIC3895E
D
13. Install connecting rod bearing cap.
● Match the stamped cylinder number marks on connecting rod
with those on connecting rod bearing cap to install. E
● Be sure that front mark on connecting rod bearing cap is fac-
ing front of engine.
F
PBIC0809E
H
14. Tighten connecting rod bolts as follows:
a. Apply engine oil to the threads and seats of connecting rod bolts.
b. Tighten connecting rod bolts. I
: 19.6 N·m (2.0 kg-m, 14 ft-lb)
c. Then tighten all connecting rod bolts 90 degrees clockwise J
(Angle tightening).
CAUTION:
Always use angle wrench (A) [SST: KV10112100]. Avoid K
tightening based on visual check alone.
● After tightening connecting rod bolts, make sure that crank-
shaft rotates smoothly.
L
● Check the connecting rod side clearance. Refer to EM-122,
"CONNECTING ROD SIDE CLEARANCE" .
PBIC3896E M
15. Install pilot converter.

● With drift of the following outer diameter, press-fit as far as it
will go.
Pilot converter : Approx. 33 mm (1.30 in)
PBIC2947E
EM-115
CYLINDER BLOCK
[VQ]
● Press-fit pilot converter with its chamfer facing crankshaft as
SEM537E
16. Install knock sensors.

● Install knock sensor so that connector faces rear of engine.
● After installing knock sensor, connect harness connector, and

lay it out to rear of engine.
CAUTION:
● Do not tighten mounting bolts while holding connector.
● If any impact by dropping is applied to knock sensor,

replace it with new one.
NOTE:
● Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of knock sensor.
● Make sure that knock sensor does not interfere with other
parts.
PBIC2948E
17. Note the following, assemble in the reverse order of disassembly after this step.
Drive plate
● Install drive plate and reinforcement plate as shown in the fig-
ure.
● Holding ring gear with ring gear stopper [SST: KV10117700].
● Tighten mounting bolts crosswise over several times.
PBIC0910E
EM-116
CYLINDER BLOCK
[VQ]
How to Select Piston and Bearing BBS0001I
DESCRIPTION A
Selection points Selection parts Selection items Selection methods
Determined by match of cylin-
der block bearing housing
EM
Between cylinder block and Main bearing grade grade (inner diameter of hous-
Main bearing
crankshaft (bearing thickness) ing) and crankshaft journal
grade (outer diameter of jour-
C
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade D
Connecting rod bearing ter and crankshaft pin outer
necting rod (bearing thickness)
diameter determine connecting
rod bearing selection.
Piston and piston pin assembly E
Between cylinder block and pis- Piston grade Piston grade = cylinder bore
(Piston is available together
ton (piston skirt diameter) grade (inner diameter of bore)
with piston pin as assembly.)
Between piston and connecting F
— — —
rod*
*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is available.) The
information at the shipment from the plant is described as a reference.
G
● The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
● For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the H
measurement with the values of each selection table.
● For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text. I
HOW TO SELECT PISTON
When New Cylinder Block is Used
Check the cylinder bore grade (“1”, “2”, or “3”) on rear side of cylin- J
der block, and select piston of the same grade.
NOTE:
Piston is available with piston pin as a set for the service part. (Only K
“0” grade piston pin is available.)
PBIC2949E
M
When Cylinder Block is Reused

1. Measure the cylinder bore inner diameter. Refer to EM-126, "Cylinder Bore Inner Diameter" .
2. Determine the bore grade by comparing the measurement with
the values under the cylinder bore inner diameter of the “Piston
Selection Table”.
PBIC2950E
3. Select piston of the same grade.
EM-117
CYLINDER BLOCK
[VQ]
Piston Selection Table
Unit: mm (in)
Grade 1 2 (or no mark) 3
95.500 - 95.510 95.510 - 95.520 95.520 - 95.530
Cylinder bore inner diameter
(3.7598 - 3.7602) (3.7602 - 3.7606) (3.7606 - 3.7610)
95.480 - 95.490 95.490 - 95.500 95.500 - 95.510
Piston skirt diameter
(3.7590 - 3.7594) (3.7594 - 3.7598) (3.7598 - 3.7602)
NOTE:
● Piston is available together with piston pin as assembly.
● Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
piston pin grades can be selected. (Only “0” grade is available.)
● No second grade mark is available on piston.
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used
Check pin journal grade (“0”, “1”, or “2”) on front of crankshaft, and
select connecting rod bearing of the same grade.
NOTE:
There is no grading for connecting rod big end diameter.
PBIC2951E
When Crankshaft and Connecting Rod are Reused

1. Measure the connecting rod big end diameter. Refer to EM-124, "CONNECTING ROD BIG END DIAME-
TER" .
2. Make sure that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to EM-128, "CRANKSHAFT PIN JOURNAL DIAME-
TER" .
4. Determine the grade of crankshaft pin journal grade by corresponding to the measured dimension in
“Crankshaft pin journal diameter” column of “Connecting Rod Bearing Selection Table”.
5. Select connecting rod bearing of the same grade.
Connecting Rod Bearing Selection Table
Unit: mm (in)
Connecting rod big end diameter 57.000 - 57.013 (2.2441 - 2.2446)
Unit: mm (in)
Crankshaft Connecting rod bearing
Crankshaft pin journal diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
53.968 - 53.974 (2.1247 - 2.1250) 0 1.500 - 1.503 (0.0591 - 0.0592) STD 0 Black
53.962 - 53.968 (2.1245 - 2.1247) 1 1.503 - 1.506 (0.0592 - 0.0593) STD 1 Brown
53.956 - 53.962 (2.1242 - 2.1245) 2 1.506 - 1.509 (0.0593 - 0.0594) STD 2 Green
Undersize Bearings Usage Guide

● When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.
● When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
EM-118
CYLINDER BLOCK
[VQ]
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep A
the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
EM
PBIC1908E D
Bearing undersize table
Unit: mm (in)
E
Size Thickness
US 0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643)
HOW TO SELECT MAIN BEARING F

When New Cylinder Block and Crankshaft are Used
1. “Main Bearing Selection Table” rows correspond to bearing
housing grade on rear left side of cylinder block. G
PBIC2949E
J
2. “Main Bearing Selection Table” columns correspond to journal
diameter grade on front side of crankshaft.
K
M
PBIC2951E
3. Select main bearing grade at the point where selected row and column meet in “Main Bearing Selection
Table”.
When Cylinder Block and Crankshaft are Reused
1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer
to EM-126, "MAIN BEARING HOUSING INNER DIAMETER" and EM-127, "CRANKSHAFT MAIN JOUR-
NAL DIAMETER" .
2. Correspond the measured dimension in “Cylinder block main bearing housing inner diameter” row of
“Main Bearing Selection Table”.
3. Correspond the measured dimension in “Crankshaft main journal diameter” column of “Main Bearing
Selection Table”.
4. Select main bearing grade at the point where selected row and column meet in following selection table.
EM-119
CYLINDER BLOCK
[VQ]
Main Bearing Selection Table
WBIA0625E
EM-120
CYLINDER BLOCK
[VQ]
Main Bearing Grade Table (All Journals)
Thickness Width
A
Grade number Identification color Remarks
Unit: mm (in) Unit: mm (in)
0 2.500 - 2.503 (0.0984 - 0.0985) Black
EM
1 2.503 - 2.506 (0.0985 - 0.0987) Brown
2 2.506 - 2.509 (0.0987 - 0.0988) Green
3 2.509 - 2.512 (0.0988 - 0.0989) Yellow Grade is the same for
C
upper and lower bear-
4 2.512 - 2.515 (0.0989 - 0.0990) Blue ings.
5 2.515 - 2.518 (0.0990 - 0.0991) Pink
6 2.518 - 2.521 (0.0991 - 0.0993) Purple
D
7 2.521 - 2.524 (0.0993 - 0.0994) White
UPR 2.503 - 2.506 (0.0985 - 0.0987) Brown E
01
LWR 2.500 - 2.503 (0.0984 - 0.0985) Black
UPR 2.506 - 2.509 (0.0987 - 0.0988) 19.9 - 20.1 Green
12
LWR 2.503 - 2.506 (0.0985 - 0.0987) (0.783 - 0.791) Brown F
UPR 2.509 - 2.512 (0.0988 - 0.0989) Yellow
23
LWR 2.506 - 2.509 (0.0987 - 0.0988) Green
G
UPR 2.512 - 2.515 (0.0989 - 0.0990) Blue Grade is different for
34 upper and lower bear-
LWR 2.509 - 2.512 (0.0988 - 0.0989) Yellow ings.
UPR 2.515 - 2.518 (0.0990 - 0.0991) Pink H
45
LWR 2.512 - 2.515 (0.0989 - 0.0990) Blue
UPR 2.518 - 2.521 (0.0991 - 0.0993) Purple
56 I
LWR 2.515 - 2.518 (0.0990 - 0.0991) Pink
UPR 2.521 - 2.524 (0.0993 - 0.0994) White
67
LWR 2.518 - 2.521 (0.0991 - 0.0993) Purple J
Undersize Bearing Usage Guide
● When the specified main bearing oil clearance is not obtained with standard size main bearings, use
underside (US) bearing. K
● When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
L
CAUTION:
In grinding crankshaft main journal to use undersize bear-
ings, keep the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
M
PBIC1908E
Bearing undersize table

Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 2.633 - 2.641 (0.1037 - 0.1040)
EM-121
CYLINDER BLOCK
[VQ]
Inspection After Disassembly BBS0001J
CRANKSHAFT END PLAY

● Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with
dial indicator.
Standard : 0.14 - 0.22 mm (0.0055 - 0.0087 in)
Limit : 0.30 mm (0.012 in)
● If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crank-
shaft also.
PBIC2953E
CONNECTING ROD SIDE CLEARANCE

● Measure the side clearance between connecting rod and crank-
shaft arm with feeler gauge.
Standard : 0.20 - 0.35 mm (0.008 - 0.0138 in)
Limit : 0.40 mm (0.016 in)
● If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the limit, replace crank-
shaft also.
PBIC2954E
PISTON TO PISTON PIN OIL CLEARANCE

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

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

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
Standard : 0.002 - 0.006 mm (0.0001 - 0.0002 in)
● If the calculated value is out of the standard, replace piston and piston pin assembly.
EM-122
CYLINDER BLOCK
[VQ]
● When replacing piston and piston pin assembly, refer to EM-117, "HOW TO SELECT PISTON" .
NOTE: A
● Piston is available together with piston pin as assembly.
● Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts,
no piston pin grades can be selected. (Only “0” grade is available.) EM
PISTON RING SIDE CLEARANCE
● Measure side clearance of piston ring and piston ring groove
with feeler gauge. C
Standard:
Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in) D
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in)
E
Limit:
Top ring : 0.11 mm (0.0043 in)
2nd ring : 0.10 mm (0.0040 in) SEM024AA
F
● If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
replace piston also.
PISTON RING END GAP G
● Make sure that the cylinder bore inner diameter is within the
specification. Refer to EM-126, "Cylinder Bore Inner Diameter" .
H
● Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and mea-
sure the piston ring end gap with feeler gauge.
I
Standard:
Top ring : 0.23 - 0.33 mm (0.0091 - 0.0130 in)
2nd ring : 0.33 - 0.48 mm (0.0130 - 0.0189 in) J
Oil ring : 0.20 - 0.50 mm (0.0080 - 0.020 in)
PBIC0118E
Limit:
K
Top ring : 0.56 mm (0.0220 in)
2nd ring : 0.68 mm (0.0268 in)
Oil ring : 0.85 mm (0.0335 in) L
● If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
re-bore cylinder and use oversize piston and piston rings.
M
EM-123
CYLINDER BLOCK
[VQ]
CONNECTING ROD BEND AND TORSION
● Check with connecting rod aligner.
Bend:
Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion:
Limit: 0.30 mm (0.012 in) per 100 mm (3.94 in) length
● If it exceeds the limit, replace connecting rod assembly.
PBIC2077E
CONNECTING ROD BIG END DIAMETER

● Install connecting rod bearing cap without installing connecting
rod bearing, and tightening connecting rod bolts to the specified
torque. Refer to EM-110, "ASSEMBLY" for the tightening proce-
dure.
● Measure the inner diameter of connecting rod big end with
inside micrometer.
Standard : 57.000 - 57.013 mm (2.2441 - 2.2446 in)
● If out of the standard, replace connecting rod assembly.
PBIC1641E
CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with inside
micrometer.
Standard : 22.000 - 22.012 mm (0.8661 - 0.8666 in)
PBIC0120E
EM-124
CYLINDER BLOCK
[VQ]
Measure the outer diameter of piston pin with micrometer. A
Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 in)
EM
PBIC0117E
D
Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame- E
ter)
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit : 0.030 mm (0.0012 in) F
● If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin
assembly.
● If replacing piston and piston pin assembly, refer to EM-117, "HOW TO SELECT PISTON" . G
● If replacing connecting rod assembly, refer to EM-128, "CON-
NECTING ROD BEARING OIL CLEARANCE" to select the
connecting rod bearing. H
J
PBIC0809E
Factory installed parts grading: K

● Service parts apply only to grade “0”.
Unit: mm (in)
Grade 0 1 L
Connecting rod bushing 22.000 - 22.006 22.006 - 22.012
inner diameter * (0.8661 - 0.8664) (0.8664 - 0.8666)
21.993 - 21.999 21.999 - 22. 005 M
Piston pin hole diameter
(0.8659 - 0.8661) (0.8661 - 0.8663)
21.989 - 21.995 21.995 - 22.001
Piston pin outer diameter
(0.8657- 0.8659) (0.8659 - 0.8662)
*: After installing in connecting rod PBIC2950E
CYLINDER BLOCK DISTORTION

● Using scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
EM-125
CYLINDER BLOCK
[VQ]
● Measure the distortion on the cylinder block upper face at some
different points in six directions with straightedge and feeler
gauge.
Limit : 0.1 mm (0.004 in)
● If it exceeds the limit, replace cylinder block.
SEM123C
MAIN BEARING HOUSING INNER DIAMETER

● Install lower cylinder block without installing main bearings, and
tighten lower cylinder block bolts to the specified torque. Refer
to EM-110, "ASSEMBLY" for the tightening procedure.
● Measure the inner diameter of main bearing housing with bore
gauge.
Standard : 74.993 - 75.017 mm (2.9525 - 2.9534 in)
● If out of the standard, replace cylinder block and lower cylinder
block as assembly.
NOTE:
Cylinder block cannot be replaced as a single part, because it is PBIC2012E
machined together with lower cylinder block.

PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
● Using bore gauge, measure cylinder bore for wear, out-of-round
and taper at six different points on each cylinder. (“X” and “Y”
directions at “A”, “B” and “C”) (“X” is in longitudinal direction of
engine)
Standard inner diameter:
95.500 - 95.530 mm (3.7598 - 3.7610 in)
Out-of-round (Difference between “X” and “Y”):
0.015 mm (0.0006 in)
Taper limit (Difference between “A” and “C”): PBIC2955E
0.01 mm (0.0004 in)

● If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or re-bore the
inner wall.
● Oversize piston is provided. When using oversize piston, re-
bore cylinder so that the clearance of the piston-to-cylinder bore
satisfies the standard.
CAUTION:
When using oversize piston, use oversize pistons for all
cylinders with oversize piston rings.
Oversize (OS) : 0.2 mm (0.008 in) SEM843E
EM-126
CYLINDER BLOCK
[VQ]
Piston Skirt Diameter
Measure the outer diameter of piston skirt with micrometer. A
Measure point
: Distance from the top 43.03 mm (1.6941 in) EM
Standard
: 95.480 - 95.510 mm (3.7590 - 3.7602 in)
C
PBIC2956E
D
Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter (direction “Y”, position “B”). E
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter).
Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit : 0.08 mm (0.0031 in) F
● If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to EM-117, "HOW
TO SELECT PISTON" .
G
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
Re-bored size calculation: D = A + B – C H
where,
D: Bored diameter
I
A: Piston skirt diameter as measured
B: Piston to cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in) J
2. Install lower cylinder block, and tighten lower cylinder block bolts to the specified torque. Otherwise, cylin-
der bores may be distorted in final assembly.
3. Cut cylinder bores. K
NOTE:
● When any cylinder needs boring, all other cylinders must also be bored.
● Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a L
time.
4. Hone cylinders to obtain the specified piston to cylinder bore clearance.
5. Measure finished the cylinder bore for out-of-round and taper. M
NOTE:
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER
● Measure the outer diameter of crankshaft main journals with micrometer.
Standard : 69.951 - 69.975 mm (2.7540 - 2.7549 in) dia.
● If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to EM-
129, "MAIN BEARING OIL CLEARANCE" .
EM-127
CYLINDER BLOCK
[VQ]
CRANKSHAFT PIN JOURNAL DIAMETER
● Measure the outer diameter of crankshaft pin journal with
micrometer.
● If out of the standard, measure the connecting rod bearing oil
clearance. Then use undersize bearing. Refer to EM-128,
"CONNECTING ROD BEARING OIL CLEARANCE" .
PBIC0127E
CRANKSHAFT OUT-OF-ROUND AND TAPER

● Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with micrometer.
● Out-of-round is indicated by the difference in the dimensions
between “X” and “Y” at “A” and “B”.
● Taper is indicated by the difference in the dimensions between
“A” and “B” at “X” and “Y”.
Limit:
Out-of-round (Difference between “X” and “Y”)
: 0.002 mm (0.0001 in)
SBIA0535E
Taper (Difference between “A” and “B”)
: 0.002 mm (0.0001 in)
● If the measured value exceeds the limit, correct or replace crankshaft.
● If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then
select the main bearing and/or connecting rod bearing. Refer to EM-129, "MAIN BEARING OIL CLEAR-
ANCE" and/or EM-128, "CONNECTING ROD BEARING OIL CLEARANCE" .
CRANKSHAFT RUNOUT
● Place V-block on precise flat table, and support the journals on
the both end of crankshaft.
● Place dial indicator straight up on the No. 3 journal.
● While rotating crankshaft, read the movement of the pointer on
dial indicator. (Total indicator reading)
Standard : Less than 0.05 mm (0.0020 in)
Limit : 0.10 mm (0.0040 in)
● If it exceeds the limit, replace crankshaft.
SEM346D
CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation
● Install connecting rod bearings to connecting rod and cap, and
tighten connecting rod bolts to the specified torque. Refer to
EM-110, "ASSEMBLY" for the tightening procedure.
● Measure the inner diameter of connecting rod bearing with
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter) –
(Crankshaft pin journal diameter)
Standard : 0.034 - 0.059 mm (0.0013 - 0.0023 in)
(actual clearance)
Limit : 0.070 mm (0.0028 in) PBIC1642E
EM-128
CYLINDER BLOCK
[VQ]
● If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer A
to EM-118, "HOW TO SELECT CONNECTING ROD BEARING" .
Method of Using Plastigage
● Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely. EM
● Cut plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
● Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the speci- C
fied torque. Refer to EM-110, "ASSEMBLY" for the tightening procedure.
CAUTION:
Do not rotate crankshaft. D
● Remove connecting rod bearing cap and bearing, and using
scale on plastigage bag, measure the plastigage width.
NOTE: E
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
F
G
PBIC1149E
MAIN BEARING OIL CLEARANCE H

Method by Calculation
● Install main bearings to cylinder block and lower cylinder block,
and tighten lower cylinder block bolts to the specified torque. I
Refer to EM-110, "ASSEMBLY" for the tightening procedure.
● Measure the inner diameter of main bearing with bore gauge.
(Bearing clearance) = (Main bearing inner diameter) – (Crankshaft J
main journal diameter)
Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 in)
(actual clearance) K
Limit : 0.065 mm (0.0026 in)
PBIC2204E
● If the calculated value exceeds the limit, select proper main
bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain specified L
bearing oil clearance. Refer to EM-119, "HOW TO SELECT MAIN BEARING" .
M
● Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
● Cut plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
● Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block bolts to
the specified torque. Refer to EM-110, "ASSEMBLY" for the tightening procedure.
CAUTION:
Do not rotate crankshaft.
EM-129
CYLINDER BLOCK
[VQ]
● Remove lower cylinder block and main bearings, and using
scale on plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
PBIC1149E
CRUSH HEIGHT OF MAIN BEARING

● When lower cylinder block is removed after being tightened to
the specified torque with main bearings installed, the tip end of
bearing must protrude. Refer to EM-110, "ASSEMBLY" for the
tightening procedure.
Standard : There must be crush height.
● If the standard is not met, replace main bearings.
SEM502G
CRUSH HEIGHT OF CONNECTING ROD BEARING

● When connecting rod bearing cap is removed after being tight-
ened to the specified torque with connecting rod bearings
installed, the tip end of bearing must protrude. Refer to EM-110,
"ASSEMBLY" for the tightening procedure.
● If the standard is not met, replace connecting rod bearings.
PBIC1646E
LOWER CYLINDER BLOCK BOLT OUTER DIAMETER

● Measure the outer diameters (“d1 ”, “d2 ”) at two positions as
● If reduction appears in “A” range, regard it as “d2 ”.
Limit (“d1 ” – “d2 ”) : 0.11 mm (0.0051 in)
● If it exceeds the limit (large difference in dimensions), replace
lower cylinder block bolt with new one.
PBIC0911E
EM-130
CYLINDER BLOCK
[VQ]
CONNECTING ROD BOLT OUTER DIAMETER
● Measure the outer diameter “d” at position shown in the figure. A
● If the reduction appears in a position other than “d”, regard it as
“d”.
EM
Limit : 7.75 mm (0.3051 in)
● When “d” exceeds the limit (when it becomes thinner), replace
connecting rod bolt with new one. C
PBIC0912E
D
DRIVE PLATE
● Check drive plate and signal plate for deformation or cracks. E
CAUTION:
● Do not place drive plate with signal plate facing down. F

● When handling signal plate, take care not to damage or
scratch it.
● Handle signal plate in a manner that prevents it from G
becoming magnetized.
● If anything is found, replace drive plate.
PBIC2938E H
OIL JET
● Check nozzle for deformation and damage.
● Blow compressed air from nozzle, and check for clogs. I
● If it is not satisfied, clean or replace oil jet.
OIL JET RELIEF VALVE J
● Using clean plastic stick, press check valve in oil jet relief valve.
Make sure that valve moves smoothly with proper reaction
force. K
● If it is not satisfied, replace oil jet relief valve.
M
EMU0468D
EM-131
SERVICE DATA AND SPECIFICATIONS (SDS)
[VQ]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00100
Standard and Limit BBS0001K
GENERAL SPECIFICATIONS
Cylinder arrangement V-6
Displacement cm3 (cu in) 3,954 (241.27)

Bore and stroke mm (in) 95.5 × 92.0 (3.76 × 3.622)
Valve arrangement DOHC
Firing order 1-2-3-4-5-6
Compression 2
Number of piston rings
Oil 1
Number of main bearings 4
Compression ratio 9.7
Standard 1,275 (13.0, 185)
Compression pressure
Minimum 981 (10.0, 142)
kPa (kg/cm2 , psi)/300 rpm
Differential limit between cylinders 98 (1.0, 14)
Cylinder number
SEM713A
Valve timing
(Intake valve timing control - “OFF”)
PBIC0187E
Unit: degree
a b c d e f
244 240 −4 64 6 58
EM-132
[VQ]
DRIVE BELT
Tension of drive belts Auto adjustment by auto tensioner
A
INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD

Unit: mm (in)
EM
Items Limit
Intake manifold 0.1 (0.004)
Surface distortion
Exhaust manifold 0.3 (0.012) C
SPARK PLUG
Make NGK D
Standard type PLFR5A-11
Hot type PLFR4A-11
E
Cold type PLFR6A-11
Gap (Nominal) 1.1 mm (0.043 in)
F
EM-133
[VQ]
CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)
Items Standard Limit
No. 1 0.045 - 0.086 (0.0018 - 0.0034)
Camshaft journal oil clearance 0.15 (0.0059)
No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030)
No. 1 26.000 - 26.021 (1.0236 - 1.0244) —
Camshaft bracket inner diameter
No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) —
No. 1 25.935 - 25.955 (1.0211 - 1.0218) —
Camshaft journal diameter
No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) —
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)
Intake 45.465 - 45.655 (1.7900 - 1.7921) 45.265 (1.7821)
Camshaft cam height “A”
Exhaust 45.075 - 45.265 (1.7746 - 1.7821) 44.875 (1.7667)
Camshaft runout [TIR*1 ] Less than 0.02 mm (0.001) 0.05 (0.002)
Camshaft sprocket runout [TIR*2 ] — 0.15 (0.0059)
SEM671
*1 : Total indicator reading
Valve Lifter
Unit: mm (in)
Items Standard
Valve lifter outer diameter 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter hole diameter 34.000 - 34.016 (1.3386 - 1.3392)
Valve lifter clearance 0.013 - 0.039 (0.0005 - 0.0015)
Valve Clearance
Unit: mm (in)
Items Cold Hot* (reference data)
Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)
EM-134
[VQ]
Available Valve Lifter
Unit: mm (in) A
Identification (stamped) mark
Thickness
Intake Exhaust
EM
788U N788 7.88 (0.3102)
790U N790 7.90 (0.3110)
792U N792 7.92 (0.3118) C
794U N794 7.94 (0.3126)
796U N796 7.96 (0.3134)
798U N798 7.98 (0.3142) D
800U N800 8.00 (0.3150)
802U N802 8.02 (0.3157)
E
804U N804 8.04 (0.3165)
806U N806 8.06 (0.3173)
808U N808 8.08 (0.3181) F
810U N810 8.10 (0.3189)
812U N812 8.12 (0.3197)
G
814U N814 8.14 (0.3205)
816U N816 8.16 (0.3213)
818U N818 8.18 (0.3220) H
820U N820 8.20 (0.3228)
822U N822 8.22 (0.3236)
I
824U N824 8.24 (0.3244)
826U N826 8.26 (0.3252)
828U N828 8.28 (0.3260) J
830U N830 8.30 (0.3268)
832U N832 8.32 (0.3276)
834U N834 8.34 (0.3283)
K
836U N836 8.36 (0.3291)

838U — 8.38 (0.3299) L
840U — 8.40 (0.3307)
SEM758G
EM-135
[VQ]
CYLINDER HEAD
Unit: mm (in)
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Normal cylinder head height “H” 126.3 - 126.5 (4.972 - 4.980) —
PBIC0924E
Valve Dimensions
Unit: mm (in)
SEM188
Intake 37.0 - 37.3 (1.4567 - 1.4685)

Valve head diameter “D”
Exhaust 31.2 - 31.5 (1.228 - 1.240)
Intake 96.46 (3.7976)
Valve length “L”
Exhaust 93.99 (3.7004)
Intake 5.965 - 5.980 (0.2348 - 0.2354)
Valve stem diameter “d”
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Intake
Valve seat angle “α” 45°15′ - 45°45′
Exhaust
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 1.3 (0.051)
EM-136
[VQ]
Valve Guide
Unit: mm (in) A
EM
D
SEM950E
Items Standard Oversize (service) [0.2 (0.008)]

E
Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014) F
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
G
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.003)
Valve guide clearance
Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.09 (0.004)
Projection length “L” 12.6 - 12.8 (0.496 - 0.504) H
EM-137
[VQ]
Valve Seat
Unit: mm (in)
PBIC2745E
Items Standard Oversize (Service) [0.5 (0.020)]

Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164)
Cylinder head seat recess diameter “D”
Exhaust 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880)
Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202)
Valve seat outer diameter “d”
Exhaust 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2905 - 1.2912)
Intake 0.081 - 0.113 (0.0032 - 0.0044)
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038)
Intake 35 (1.38)
Diameter “d1”*1
Exhaust 28.7 (1.130)
Intake 36.3 - 36.8 (1.429 - 1.449)
Diameter “d2”*2
Exhaust 30.3 - 30.8 (1.193 - 1.213)
Intake 60°
Angle “α1”
Exhaust 60°
Intake 88°20′ - 89°50′
Angle “α2”
Exhaust 88°20′ - 89°50′
Intake 120°
Angle “α3”
Exhaust 120°
Intake 1.0 - 1.4 (0.039 - 0.055)
Contacting width “W”*3
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Intake 5.9 - 6.0 (0.232 - 0.236) 5.05 - 5.15 (0.1988 - 0.2028)
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)
Depth “H” 6.0 (0.236)
1
* : Diameter made by intersection point of conic angles “α1” and “α2”
*2 : Diameter made by intersection point of conic angles “α2” and “α3”
*3 : Machining data
Valve Spring
Free height mm (in) 47.07 (1.8531)
Installation 166 - 188 (16.9 - 19.2, 37 - 42) at 37.00 (1.4567)
Pressure N (kg, lb) at height mm (in)
Valve open 373 - 421 (38.0 - 42.9, 84 - 95) at 27.20 (1.0709)
Squareness mm (in) Limit 2.1 (0.083)
EM-138
[VQ]
CYLINDER BLOCK
Unit: mm (in) A
EM
D
PBIC2955E
Standard Less than 0.03 (0.0012)

Surface flatness E
Limit 0.1 (0.004)
Main bearing housing inner diameter Standard 74.993 - 75.017 (2.9525 - 2.9534)
Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602) F
Cylinder bore Inner diameter Standard Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606)
Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610)
G
Out-of-round (Difference between “X” and “Y”) 0.015 (0.0006)
Limit
Taper (Difference between “A” and “C”) 0.01 (0.0004)
Grade No. A 74.993 - 74.994 (2.9525 - 2.9525) H
Grade No. B 74.994 - 74.995 (2.9525 - 2.9526)
Grade No. C 74.995 - 74.996 (2.9526 - 2.9526)
Grade No. D 74.996 - 74.997 (2.9526 - 2.9526)
Grade No. E 74.997 - 74.998 (2.9526 - 2.9527) I
Grade No. F 74.998 - 74.999 (2.9527 - 2.9527)
Grade No. G 74.999 - 75.000 (2.9527 - 2.9528)
Grade No. H 75.000 - 75.001 (2.9528 - 2.9528)
Grade No. J 75.001 - 75.002 (2.9528 - 2.9528)
J
Grade No. K 75.002 - 75.003 (2.9528 - 2.9529)
Grade No. L 75.003 - 75.004 (2.9529 - 2.9529)
Grade No. M 75.004 - 75.005 (2.9529 - 2.9529) K
Main bearing housing inner diameter (Without bearing)
Grade No. N 75.005 - 75.006 (2.9529 - 2.9530)
Grade No. P 75.006 - 75.007 (2.9530 - 2.9530)
Grade No. R 75.007 - 75.008 (2.9530 - 2.9531)
Grade No. S 75.008 - 75.009 (2.9530 - 2.9531) L
Grade No. T 75.009 - 75.010 (2.9531 - 2.9531)
Grade No. U 75.010 - 75.011 (2.9531 - 2.9532)
Grade No. V 75.011 - 75.012 (2.9532 - 2.9532)
Grade No. W 75.012 - 75.013 (2.9532 - 2.9533) M
Grade No. X 75.013 - 75.014 (2.9533 - 2.9533)
Grade No. Y 75.014 - 75.015 (2.9533 - 2.9533)
Grade No. 4 75.015 - 75.016 (2.9533 - 2.9534)
Grade No. 7 75.016 - 75.017 (2.9534 - 2.9534)
Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)
EM-139
[VQ]
PISTON, PISTON RING AND PISTON PIN
Available Piston
Unit: mm (in)
SEM882E
Items Standard Oversize (service) [0.2 (0.008)]

Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) —
Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) —
Piston skirt diameter “A”
Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602) —
Service — 95.680 - 95.710 (3.7669 - 3.7681)
“a” dimension 43.03 (1.6941) —
Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) —
Piston pin hole diameter
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) —
Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)
Piston Ring
Unit: mm (in)
Top 0.045 - 0.080 (0.0018 - 0.0031) 0.11 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0040)
Oil ring 0.065 - 0.135 (0.0026 - 0.0053) —
Top 0.23 - 0.33 (0.0091 - 0.0130) 0.56 (0.0220)
End gap 2nd 0.33 - 0.48 (0.0130 - 0.0189) 0.68 (0.0268)
Oil (rail ring) 0.20 - 0.50 (0.0079 - 0.0197) 0.85 (0.0335)
Piston Pin
Unit: mm (in)
Grade No. 0 21.989 - 21.995 (0.8657 - 0.8659) —
Piston pin outer diameter
Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
Connecting rod bushing oil clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.030 (0.0012)
EM-140
[VQ]
CONNECTING ROD
Unit: mm (in) A
Center distance 165.82 - 165.92 (6.5283 - 6.5323) —
EM
Bend [per 100 (3.94)] — 0.15 (0.0059)
Torsion [per 100 (3.94)] — 0.30 (0.012)
Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664) — C
Connecting rod bushing inner diameter*
Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666) —
Connecting rod big end diameter (Without bearing) 57.000 - 57.013 (2.2441 - 2.2446) —
Side clearance 0.20 - 0.35 (0.0080 - 0.0138) 0.40 (0.016) D
*: After installing in connecting rod
EM-141
[VQ]
CRANKSHAFT
Unit: mm (in)
SEM645 SBIA0535E
Grade No. A 69.975 - 69.974 (2.7549 - 2.7549)

Grade No. B 69.974 - 69.973 (2.7549 - 2.7548)
Grade No. C 69.973 - 69.972 (2.7548 - 2.7548)
Grade No. D 69.972 - 69.971 (2.7548 - 2.7548)
Grade No. E 69.971 - 69.970 (2.7548 - 2.7547)
Grade No. F 69.970 - 69.969 (2.7547 - 2.7547)
Grade No. G 69.969 - 69.968 (2.7547 - 2.7546)
Grade No. H 69.968 - 69.967 (2.7546 - 2.7546)
Grade No. J 69.967 - 69.966 (2.7546 - 2.7546)
Grade No. K 69.966 - 69.965 (2.7546 - 2.7545)
Grade No. L 69.965 - 69.964 (2.7545 - 2.7545)
Grade No. M 69.964 - 69.963 (2.7545 - 2.7544)
Main journal diameter. “Dm” grade Standard
Grade No. N 69.963 - 69.962 (2.7544 - 2.7544)
Grade No. P 69.962 - 69.961 (2.7544 - 2.7544)
Grade No. R 69.961 - 69.960 (2.7544 - 2.7543)
Grade No. S 69.960 - 69.959 (2.7543 - 2.7543)
Grade No. T 69.959 - 69.958 (2.7543 - 2.7542)
Grade No. U 69.958 - 69.957 (2.7542 - 2.7542)
Grade No. V 69.957 - 69.956 (2.7542 - 2.7542)
Grade No. W 69.956 - 69.955 (2.7542 - 2.7541)
Grade No. X 69.955 - 69.954 (2.7541 - 2.7541)
Grade No. Y 69.954 - 69.953 (2.7541 - 2.7540)
Grade No. 4 69.953 - 69.952 (2.7540 - 2.7540)
Grade No. 7 69.952 - 69.951 (2.7540 - 2.7540)
Grade No. 0 53.968 - 53.974 (2.1247 - 2.1250)
Pin journal diameter. “Dp” Standard Grade No. 1 53.962 - 53.968 (2.1245 - 2.1247)
Grade No. 2 53.956 - 53.962 (2.1242 - 2.1245)
Center distance “r” 45.96 - 46.04 (1.8094 - 1.8126)
Taper (Difference between “A” and “B”) 0.002 (0.0001)
Limit
Out-of-round (Difference between “X” and “Y”) 0.002 (0.0001)
Crankshaft runout [TIR*]
Limit 0.10 (0.004)
Standard 0.14 - 0.22 (0.0055 - 0.0087)
Crankshaft end play
Limit 0.30 (0.012)
*: Total indicator reading
EM-142
[VQ]
MAIN BEARING
A
EM
D
PBIC2969E
Grade number UPR/LWR Thickness mm (in) Width mm (in) Identification color Remarks
0 — 2.500 - 2.503 (0.0984 - 0.0985) Black E
1 — 2.503 - 2.506 (0.0985 - 0.0987) Brown
2 — 2.506 - 2.509 (0.0987 - 0.0988) Green
Grade is the same
F
3 — 2.509 - 2.512 (0.0988 - 0.0989) Yellow
for upper and lower
4 — 2.512 - 2.515 (0.0989 - 0.0990) Blue bearings.
5 — 2.515 - 2.518 (0.0990 - 0.0991) Pink G
6 — 2.518 - 2.521 (0.0991 - 0.0993) Purple
7 — 2.521 - 2.524 (0.0993 - 0.0994) White
H
UPR 2.503 - 2.506 (0.0985 - 0.0987) Brown
01
LWR 2.500 - 2.503 (0.0984 - 0.0985) Black
UPR 2.506 - 2.509 (0.0987 - 0.0988) 19.9 - 20.1 Green I
12
LWR 2.503 - 2.506 (0.0985 - 0.0987) (0.783 - 0.791) Brown
UPR 2.509 - 2.512 (0.0988 - 0.0989) Yellow
23 J
LWR 2.506 - 2.509 (0.0987 - 0.0988) Green
UPR 2.512 - 2.515 (0.0989 - 0.0990) Blue Grade is different
34 for upper and lower
LWR 2.509 - 2.512 (0.0988 - 0.0989) Yellow bearings. K
UPR 2.515 - 2.518 (0.0990 - 0.0991) Pink
45
LWR 2.512 - 2.515 (0.0989 - 0.0990) Blue
UPR 2.518 - 2.521 (0.0991 - 0.0993) Purple L
56
LWR 2.515 - 2.518 (0.0990 - 0.0991) Pink
UPR 2.521 - 2.524 (0.0993 - 0.0994) White
67 M
LWR 2.518 - 2.521 (0.0991 - 0.0993) Purple
Undersize
Unit: mm (in)
Items Thickness Main journal diameter
0.25 (0.0098) 2.633 - 2.641 (0.1037 - 0.1040) Grind so that bearing clearance is the specified value.
Main Bearing Oil Clearance

Unit: mm (in)
Main bearing oil clearance 0.035 - 0.045 (0.0014 - 0.0018)* 0.065 (0.0026)
*: Actual clearance
EM-143
[VQ]
CONNECTING ROD BEARING
Grade number Thickness mm (in) Identification color (mark)
0 1.500 - 1.503 (0.0591 - 0.0592) Black
1 1.503 - 1.506 (0.0592 - 0.0593) Brown
2 1.506 - 1.509 (0.0593 - 0.0594) Green
Undersize
Unit: mm (in)
Items Thickness Crank pin journal diameter
0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643) Grind so that bearing clearance is the specified value.
Connecting Rod Bearing Oil Clearance

Unit: mm (in)
Connecting rod bearing oil clearance 0.034 - 0.059 (0.0013 - 0.0023)* 0.070 (0.0028)
*: Actual clearance
EM-144
APPLICATION NOTICE
[YD]
APPLICATION NOTICE
[YD] PFP:00000
A
How to Check Engine Type BBS00D21
● This model has two types of engines, EURO 3 and EURO 4. Regarding the difference, refer to the follow-
ing figures. EM
● These figure show the difference in the EGR volume control valve type.
EURO 3
C
PBIC4889E
1. EGR volume control valve (Step motor type) I

: Vehicle front
● Figure shows as an example of A/T models of EURO 3. J

EURO 4
PBIC4890E
1. EGR volume control valve (DC motor type)

: Vehicle front
EM-145
PRECAUTIONS
[YD]
PRECAUTIONS PFP:00001
Precautions for Procedures without Cowl Top Cover BBS00BI2
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
PIIB3706J
Precautions Necessary for Steering Wheel Rotation After Battery Disconnect

BBS00D1X
NOTE:
● This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT
SYSTEM).
● Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
● Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
Precautions for Draining Engine Coolant BBS00BI3
Drain engine coolant when engine is cooled.

Precautions for Disconnecting Fuel Piping BBS00BI4
● Before starting work, make sure no fire or spark producing items are in the work area.
● After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly BBS00BI5
● When instructed to use SST, use the specified tools. Always be careful to work safely, avoid forceful or
uninstructed operations.
● Exercise maximum care to avoid damage to mating or sliding surfaces.
● Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
● Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
EM-146
PRECAUTIONS
[YD]
● When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. A
Precautions for Inspection, Repair and Replacement BBS00BI6
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and EM
replace if necessary.
Precautions for Assembly and Installation BBS00BI7
● Use torque wrench to tighten bolts or nuts to specification. C

● When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified. D
● Replace with new liquid gasket, packing, oil seal or O-ring.
● Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
make sure that dowel pins are installed in the original position. E
● Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
● Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. F
Before assembly, oil sliding surfaces well.
● Release air within route when refilling after draining engine coolant.
● After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and G
exhaust systems for leakage.
Parts Requiring Angle Tightening BBS00BI8
H
● Use an angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
– Cylinder head bolts
– Main bearing cap bolts I
– Connecting rod cap nuts
– Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening) J
● Do not use a torque value for final tightening.
● The torque value for these parts are for a preliminary step.
K
● Ensure thread and seat surfaces are clean and coated with engine oil.
Precautions For Liquid Gasket BBS00BI9
REMOVAL OF LIQUID GASKET L

● After removing the mounting bolts and nuts, separate the mating
surface using the seal cutter (SST) and remove the old liquid
gasket sealing. M
CAUTION:
Be careful not to damage the mating surfaces.
● Tap seal cutter to insert it, and then slide it by tapping on the
side as shown in the figure.
● In areas where seal cutter (SST) is difficult to use, use plastic
hammer to lightly tap the parts, to remove it.
CAUTION: PBIC0275E
If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces.
EM-147
PRECAUTIONS
[YD]
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
● Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0003E
3. Attach the liquid gasket tube to the tube presser (SST).

4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
● If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.
PBIC2160E
● As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes.
Make sure to read the text of this manual.
● Within five minutes of liquid gasket application, install the mat-
ing component.
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten mounting bolts or nuts after the installation.
● After 30 minutes or more have passed from the installation, fill
the engine oil and engine coolant.
CAUTION: SEM159F
If there are instructions in this manual, observe them.
EM-148
PREPARATION
[YD]
PREPARATION PFP:00002
A
Special Service Tools BBS00D6M
Tool number
Description
Tool name EM
KV10115600 Installing valve oil seal
Valve oil seal drift Use side A.
Side A C
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia. D
e: 10.7 (0.421)
NT603 f: 5 (0.20)
Unit: mm (in)
E
KV10107902 Removing valve oil seal
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapter F
S-NT605 G
KV11103000 Removing crankshaft pulley
Pulley puller
H
I
NT676
ED19600610 Checking compression pressure

Compression gauge adapter J
ZZA1188D
KV101056S0 Preventing crankshaft from rotating L

Ring gear stopper a: 3 (0.12)
1. KV10105630 b: 6.4 (0.252)
Adapter c: 2.8 (0.110)
2. KV10105610 d: 6.6 (0.260) M
Plate e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
NT617 h: 14 (0.55) dia.
Unit: mm (in)
KV101151S0 Changing adjusting shim
Lifter stopper set
1. KV10115110
Camshaft pliers
2. KV10115120
Lifter stopper
NT041
EM-149
PREPARATION
[YD]
Tool number
Description
Tool name
KV10116200 Disassembling and assembling valve

Valve spring compressor mechanism
1. KV10115900 Part (1) is a component of KV10116200, but
Attachment Part (2) is not so.
2. KV10109220
Adapter
PBIC1650E
ST16610001 Removing crankshaft pilot bush

Pilot bushing puller
NT045
KV10111100 Removing oil pan upper, oil pan lower and

Seal cutter rear chain case, etc.
NT046
WS39930000 Pressing the tube of liquid gasket

Tube presser
NT052
KV10112100 Tightening bolts for bearing cap, cylinder

Angle wrench head, etc.
NT014
EM03470000 Installing piston assembly into cylinder bore

Piston ring compressor
NT044
KV11106010 Removing and installing chain tensioner

Hexagon wrench a: 5 mm (0.20 in) (Face to face)
b: 20 mm (0.79 in)
NT801
EM-150
PREPARATION
[YD]
Tool number
Description A
Tool name
KV11106020 Removing and installing slack guide

Hexagon wrench a: 6 mm (0.24 in) (Face to face)
b: 20 mm (0.79 in) EM
C
NT803
KV11106030 Fixing fuel pump sprocket

Positioning stopper pin a: 6 mm (0.24 in) dia. D
b: 80 mm (3.15 in)
NT804
KV11106040 Removing and installing fuel pump sprocket F

TORX wrench nut
a: T70
b: 26 mm (1.02 in)
G
NT805
H
KV11106050 Removing and installing fuel pump sprocket
Hexagonal wrench a: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)
I
SBIA0224E J
KV11106060 Holding fuel pump sprocket
Sprocket holder
K
L
SBIA0225E
Commercial Service Tools BBS00D6N

M
Valve seat cutter set Finishing valve seat dimensions
NT048
Piston ring expander Removing and installing piston ring
NT030
EM-151
PREPARATION
[YD]
Valve guide reamer Reaming valve guide with (1) or hole for
oversize valve guide with (2)
Intake and Exhaust:
d1 = 6.0 mm (0.236 in) dia.
d2 = 10.2 mm (0.402 in) dia.
NT016
Valve guide drift Removing and installing valve guide

Intake and Exhaust:
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia.
NT015
TORX socket Loosening and tightening fuel pump mounting

bolt
Size: E10
NT807
TORX socket Loosening and tightening flywheel mounting

bolt
Size: T55
PBIC1113E
TORX socket Loosening and tightening drive plate

mounting bolt
Size: E20
NT807
Cylinder head bolt wrench Loosening and tightening cylinder head bolt,
and used with angle wrench [SST:
KV10112100]
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
NT583
TORX socket Loosening and tightening main bearing cap

bolt
Size: E14
NT807
EM-152
[YD]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
A
NVH Troubleshooting — Engine Noise BBS0001U
EM
PBIC3402E
EM-153
[YD]
Use the Chart Below to Help You Find the Cause of the Symptom. BBS0001V
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 Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of Ticking or Tappet
C A — A B — Valve clearance EM-222
engine clicking noise
Rocker
cover Camshaft
Camshaft oil clearance EM-217
Cylinder Rattle C A — A B C bearing
Camshaft runout EM-217
head noise
Piston to piston pin

Slap or Piston pin clearance EM-284
— A — B B —
knock noise Connecting rod bush- EM-286
ing oil clearance
Piston to cylinder bore
clearance
Crank- EM-288
Piston ring side clear-
shaft pul- Slap or Piston EM-285
A — — B B A ance
ley rap slap noise EM-285
Piston ring end gap
Cylinder EM-286
Connecting rod bend
block and torsion
(Side of
engine) Connecting rod bush-
Connect-
Oil pan ing oil clearance
ing rod EM-286
Knock A B C B B B Connecting rod bear-
bearing EM-290
ing oil clearance (Big
noise
end)
Main Main bearing oil clear-
EM-291
Knock A B — A B C bearing ance
EM-290
noise Crankshaft runout
Front of Timing
Timing chain cracks
engine chain and
Tapping or and wear EM-243
Timing A A — B B B chain
ticking Timing chain tensioner EM-236
chain tensioner
operation
case noise
Drive belts
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belts deflection
or slip-
ing EM-155
ping)
Front of
Drive belts Idler pulley bearing
engine Creaking A B A B A B
(Slipping) operation
Water CO-51,
Squall
A B — B A B pump Water pump operation "WATER
Creak
noise PUMP"
A: Closely related B: Related C: Sometimes related —: Not related
EM-154
DRIVE BELTS
[YD]
DRIVE BELTS PFP:02117
A
Checking Drive Belts BBS00D22
EM
PBIC4038E
1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump E
A/C compressor (Models with A/C)
4. Crankshaft pulley 5. 6. Alternator
Dummy pulley (Models without A/C)
A/C compressor, alternator and F
7. Idler pulley 8. Water pump pulley 9.
water pump belt
● Before inspecting engine, make sure engine has cooled down, wait approximately 30 minutes after engine
has been stopped. G
● Visually inspect all belts for wear, damage or cracks on contacting surfaces and edge areas.
● Measure deflection at the marked point ( ).
CAUTION: H
● When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid varia-
tion in deflection between pulleys. I
● Tighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
J
Belt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
Applied belt
New Adjusted Limit for re-adjusting
A/C compressor, alternator and water 2.9 - 3.4 3.9 - 4.4 K
8.5 (0.335)
pump belt (0.114 - 0.134) (0.154 - 0.173)
4.6 - 5.4 7.1 - 7.7
Power steering oil pump belt 11.3 (0.445)
(0.181 - 0.213) (0.280 - 0.303) L
*: When engine is cold.
EM-155
DRIVE BELTS
[YD]
Deflection Adjustment BBS00D23
PBIC4039E
1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump
Dummy pulley (Models without A/C)
4. Crankshaft pulley 5. 6. Alternator
A/C compressor (Models with A/C)
A/C compressor, alternator and
7. Idler pulley 8. Water pump pulley 9.
water pump belt
A. Adjusting bolt B. Idler pulley lock nut C. Adjusting nut
D. Idler pulley lock nut
● Adjust belts with the parts shown below.

Applied belt Belt adjustment method
Power steering oil pump belt Adjusting bolt on idler pulley (A)
Alternator and water pump belt or A/C compressor, alternator and
Adjusting nut on idler pulley (C)
water pump belt
CAUTION:
● When a new belt is installed as a replacement, adjust it to the specified value under “New” value
because of insufficient adaptability with pulley grooves.
● If the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
● When checking belt deflection immediately after 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 vari-
ation in deflection between pulleys.
● Make sure the belts are fully fitted into the pulley grooves during installation.
● Handle with care to avoid smearing the belts with engine oil or engine coolant.
● Do not twist or bend the belts with strong force.
POWER STEERING OIL PUMP BELT

1. Remove engine undercover front. Refer to EI-15, "FRONT BUMPER" .
2. Loosen idler pulley lock nut (B).
3. Turn adjusting bolt (A) to adjust. Refer to EM-156, "Deflection Adjustment" .
4. Tighten idler pulley lock nut (B).
Nut B:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
EM-156
DRIVE BELTS
[YD]
A/C COMPRESSOR, ALTERNATOR AND WATER PUMP BELT
1. Loosen idler pulley lock nut (D). A
2. Turn adjusting nut (C) to adjust. Refer to EM-156, "Deflection Adjustment" .
3. Tighten lock nut (D).
EM
Nut D:
: 45.0 N·m (4.6 kg-m, 33 ft-lb)
C
Removal and Installation BBS00D24
REMOVAL
1. Loosen each belt. Refer to EM-156, "Deflection Adjustment" .
D
2. Remove power steering oil pump belt. Refer to EM-156, "POWER STEERING OIL PUMP BELT" .
3. Remove A/C compressor, alternator and water pump belt. Refer to EM-157, "A/C COMPRESSOR,
ALTERNATOR AND WATER PUMP BELT" . E
INSTALLATION
1. Install each belt on pulley in the reverse order of removal.
2. Adjust belt deflection. Refer to EM-156, "Deflection Adjustment" . F
3. Tighten nuts provided for adjustment to the specified torque.
4. Make sure again that each belt deflection is as specified.
G
EM-157
[YD]
AIR CLEANER AND AIR DUCT PFP:16500
Components (EURO 3) BBS00D1Y
PBIC4040E
1. Air duct 2. Air inlet pipe 3. Gasket

4. Bracket 5. Mass air flow sensor 6. O-ring
7. Air cleaner case (upper) 8. Air cleaner filter 9. Air cleaner case (lower)
10. Mounting rubber 11. Air duct side
A. To turbocharger
EM-158
[YD]
Components (EURO 4) BBS00D1Z
EM
J
PBIC4833E
1. Air duct 2. Ventilation hose connector 3. O-ring

4. Air inlet pipe 5. Gasket 6. Mounting rubber K
7. Mass air flow sensor 8. O-ring 9. Air cleaner case (upper)
10. Air cleaner filter 11. Air cleaner case (lower) 12. Air duct side
A. To ventilation hose B. To turbocharger L

Removal and Installation BBS00D20 M
REMOVAL
1. Remove mass air flow sensor harness clamp from air cleaner case (upper).
2. Disconnect harness connector from mass air flow sensor.
3. Remove air cleaner case (upper) and air cleaner filter.
4. Remove mass air flow sensor from air cleaner case (upper).
CAUTION:
● Do not shock it.
● Do not disassemble it.
● Do not touch its sensor.
5. Remove air duct with ventilation hose and vacuum hoses disconnected.
EM-159
[YD]
EURO 3
PBIC4043E
A. White mark B. Yellow mark

: Vehicle front
EURO 4 (Models without electronic controlled engine mount)
PBIC4867E
A. Blue mark B. Pink mark C. View A

D. Yellow mark E. White mark
: Vehicle front
EM-160
[YD]
EURO 4 (Models with electronic controlled engine mount)
A
EM
PBIC4834E
A. Blue mark B. Pink mark C. View A G

: Vehicle front
H
6. Remove air cleaner case (lower) and air duct side.
INSTALLATION
Note the following, and install in the reverse order of removal. I
● Install ventilation hose and vacuum hoses as shown in the figure.
J
EURO 3
PBIC4043E
A. White mark B. Yellow mark

: Vehicle front
EM-161
[YD]
PBIC4867E

: Vehicle front
PBIC4834E

: Vehicle front
– Install vacuum hose by referring to paint marks avoiding twisting.

– When an insert stopper is not provided with the pipe, insert the hose up to dimension A. When the pipe is
shorter than dimension A, insert hose fully until it reaches the end.
Dimension A :15 - 20 mm (0.591 - 0.787 in)
– When an insert stopper is provided on the pipe side, insert the hose until it reaches the stopper.
EM-162
[YD]
CHANGING AIR CLEANER FILTER
Removal A
1. Remove mass air flow sensor harness clamp from air cleaner case (upper).
2. Disconnect harness connector from mass air flow sensor.
EM
3. Unfasten clips and lift up air cleaner case (upper).
4. Remove air cleaner filter.
Installation C
EM-163
CHARGE AIR COOLER
[YD]
CHARGE AIR COOLER PFP:14461
Components BBS00D25
PBIC4835E
1. Turbocharger boost sensor 2. Grommet 3. Vacuum hose

4. Air inlet hose 5. Charge air cooler 6. Mounting rubber
7. Bracket 8. Bracket 9. Air inlet hose
10. Bracket 11. Air inlet tube 12. Air inlet hose
13. Bracket 14. Air inlet tube 15. Air inlet hose
Turbocharger boost control solenoid
16. AIr inlet pipe 17. Gasket 18.
valve
19. Bracket 20. Bracket
A. To throttle chamber B. To turbocharger
REMOVAL
1. Remove front grille. Refer to EI-18, "FRONT GRILLE" .
2. Disconnect harness connector from turbocharger boost sensor.
3. Remove turbocharger boost control solenoid valve.
4. Remove air inlet tube and air inlet hose.
5. Remove charge air cooler.

6. Remove turbocharger boost sensor if necessary.
CAUTION:
When removing charge air cooler, close opening on turbocharger and on intake manifold with shop
cloth or other suitable material.
EM-164
CHARGE AIR COOLER
[YD]
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace A
charge air cooler if necessary.
● Be careful not to deform core fins.
● For cleaning procedure of charge air cooler core, refer to CO-43, "Checking Radiator". EM
INSTALLATION
Note the following, and install in the reverse order of removal. C
● Pay attention to identification mark color and direction when installing air inlet hose.
D
EM-165
INTAKE MANIFOLD
[YD]
INTAKE MANIFOLD PFP:14003
Components (EURO 3) BBS00D6I
PBIC4909E
EM-166
INTAKE MANIFOLD
[YD]
1. Vacuum hose 2. Vacuum gallery 3. Vacuum hose
4. Bracket 5. Bracket 6. Gasket
A
7. Bracket 8. Intake manifold 9. Water hose
10. Heater feed pipe (M/T models) 11. O-ring 12. Vacuum hose
EM
13. Vacuum gallery 14. Vacuum hose 15. Gasket
16. Throttle chamber 17. Gasket 18. Gasket
19. EGR passage 20. Gasket 21. Bracket
C
22. EGR volume control valve 23. Vacuum gallery 24. Bracket
25. Washer 26. Gasket 27. EGR tube (M/T models)
28. Water hose 29. Water hose 30. Clip (A/T models)
D
31. Water hose (A/T models) 32. Heater feed pipe (A/T models) 33. Water hose (A/T models)
34. EGR cooler (A/T models) 35. Gasket (A/T models) 36. EGR tube (A/T models)
37. Bracket (A/T models)
E
C. To heater return pipe E. To cylinder head F. To water outlet
G. To exhaust manifold H. To air inlet hose
: Vehicle front
F
EM-167
INTAKE MANIFOLD
[YD]
Components (EURO 4) BBS00D6J
PBIC4836E
EM-168
INTAKE MANIFOLD
[YD]
4. Bracket 5. Bracket 6. Gasket
A
7. Bracket 8. Bracket 9. Intake manifold
10. Water hose 11. Heater feed pipe 12. O-ring
EM
13. Throttle chamber 14. Gasket 15. Gasket
16. EGR passage 17. Gasket 18. EGR volume control valve
19. Washer 20. Vacuum gallery 21. Bracket
C
22. Bracket 23. Washer 24. Power steering pipe bracket
25. Water hose 26. Water hose 27. Water hose
28. Clip 29. Water hose 30. Water hose
D
31. Bracket (2WD models) 32. Gasket 33. EGR cooler
34. Bracket
A. To heater return pipe B. To cylinder head C. To air inlet hose
E
D. To water outlet E. To exhaust manifold
: Vehicle front
● Refer to GI-11, "Components" for symbol marks in the figure. F
Removal and Installation BBS00D6K
REMOVAL G
WARNING:
To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
1. Drain engine coolant. Refer to CO-37, "Changing Engine Coolant" . H
2. Remove engine cover (1).
CAUTION:
Be careful not to damage engine cover surface. I
K
PBIC3409E
3. Disconnect air inlet hose from throttle chamber. Refer to EM-164, "CHARGE AIR COOLER" . L
4. Remove fuel filter. Refer to FL-15, "FUEL FILTER" .
5. Remove oil level gauge guide. Refer to EM-190, "OIL PAN AND OIL STRAINER" .
6. Remove fuel hoses and fuel gallery. Refer to EM-198, "INJECTION TUBE AND FUEL INJECTOR" . M
● To prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
7. Remove vacuum galleries and vacuum hoses.

8. Disconnect EGR volume control valve water hoses and wiring harness.
9. Disconnect heater feed hose, water hoses, and remove heater feed pipe.
10. Remove EGR cooler (EURO 4 and A/T models of EURO 3) or EGR tube (M/T models of EURO 3).
11. Remove injection tube center. Refer to EM-198, "Removal and Installation" .
CAUTION:
12. Remove water pipe.
13. Loosen bolts and nuts in the reverse order of that shown in the figure, and remove intake manifold.
EM-169
INTAKE MANIFOLD
[YD]
CAUTION:
● EURO 3
PBIC3410E
● EURO 4
PBIC4837E
14. Remove EGR volume control valve and throttle chamber from intake manifold.
Surface Distortion
● Check distortion on the mounting surface with a straightedge
and feeler gauge.
Limit : 0.1 mm (0.004 in)
● If it exceeds the limit, replace intake manifold.
PBIC3411E
INSTALLATION
1. Install intake manifold.
● Tighten fixing bolts and nuts in numerical order as shown in the figure.
● If stud bolts were removed, tighten them to the specified torque.
: 10.8 N·m (1.1 kg-m, 8 ft-lb)
EM-170
INTAKE MANIFOLD
[YD]
– EURO 3
A
EM
PBIC3410E
D
– EURO 4
G
PBIC4837E
H
2. Install EGR cooler or EGR tube. Tighten fixing bolts and nuts in numerical order as shown in the figure.
● M/T models of EURO 3
I
PBIC4105E
1. EGR volume control valve 2. EGR tube
● A/T models of EURO 3
EM-171
INTAKE MANIFOLD
[YD]
PBIC4912E
1. EGR volume control valve 2. EGR cooler 3. Bracket

4. EGR tube
● EURO 4
PBIC4838E
1. EGR volume control valve 2. Bracket (2WD models) 3. EGR cooler

4. Bracket
3. Install EGR volume control valve. (EURO 4)
EM-172
INTAKE MANIFOLD
[YD]
● Tighten fixing bolts in numerical order as shown in the figure.
A
1 : EGR volume control valve
2 : Bracket
3 : Bracket
EM
4 : Power steering pipe bracket
G
PBIC4839E
4. Install water hoses and heater feed hose.

H
EURO 3
PBIC3412E
1. Heater return pipe 2. Heater feed pipe 3. EGR volume control valve
EGR cooler (A/T models)
4. 5. Water outlet
EGR tube (M/T models)
A. Paint mark B. A/T models
: Vehicle front
EM-173
INTAKE MANIFOLD
[YD]
EURO 4
PBIC4871E
1. Heater return pipe 2. Heater feed pipe 3. EGR volume control valve
4. EGR cooler 5. Water outlet
A. Paint mark B. View B C. View C
: Vehicle front
● Install water hose by referring to paint marks avoiding twisting.

● When an insert stopper is not provided with the pipe, insert the hose up to dimension A. When the pipe
is shorter than dimension A, insert hose fully until it reaches the end.
Dimension A : 27 - 32 mm (1.063 - 1.260 in)
● When an insert stopper is provided on the pipe side, insert the hose until it reaches the stopper.
5. Install vacuum hoses.
EM-174
INTAKE MANIFOLD
[YD]
EURO 3
A
EM
PBIC3899E
1. EGR volume control valve 2. Throttle chamber 3. Intake shutter control solenoid valve G
A. Yellow mark B. White mark C. To brake booster
D. To vacuum pump
: Vehicle front H
I
PBIC4868E
A. White mark
: Vehicle front
EM-175
INTAKE MANIFOLD
[YD]
PBIC4840E
1. Engine mount control solenoid valve

A. Yellow mark
: Engine front
● Install vacuum hose by referring to paint marks avoiding twisting.

● When an insert stopper is not provided with the pipe, insert the hose up to dimension A. When the pipe
is shorter than dimension A, insert hose fully until it reaches the end.
Dimension A : 15 – 20 mm (0.591 – 0.787 in)
● When an insert stopper is provided on the pipe side, insert the hose until it reaches the stopper.
6. Before starting engine, bleed air from fuel piping. Refer to FL-16, "Air Bleeding" .
Start engine and increase engine speed to check for fuel leak.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:
EM-176
CATALYST
[YD]
CATALYST PFP:20905
A
Components (EURO 3) BBS00D27
EM
PBIC3414E
K
1. Gasket 2. Exhaust outlet 3. Exhaust outlet cover
4. Gasket 5. Gasket cap 6. Catalyst
7. Catalyst cover 8. Bracket L
A. To exhaust front tube

M
EM-177
CATALYST
[YD]
PBIC4841E
1. Exhaust outlet 2. Gasket 3. Exhaust outlet support

4. Catalyst cover 5. Catalyst 6. Catalyst cover (lower)
7. Catalyst cover 8. Bracket 9. Bracket
10. Bracket
A. Front mark

REMOVAL
1. Remove engine undercover.
2. Remove catalyst cover, turbocharger insulator (EURO 4) and exhaust outlet cover (EURO 3).
3. Remove exhaust front tube. Refer to EX-3, "EXHAUST SYSTEM" .
4. Remove air inlet hose and air inlet tube. Refer to EM-164, "CHARGE AIR COOLER" .
5. Remove exhaust manifold cover. Refer to EM-187, "EXHAUST MANIFOLD" .
6. Remove catalyst and exhaust outlet.
7. Remove catalyst from exhaust outlet, as necessary.
EM-178
CATALYST
[YD]
INSTALLATION
Note the following, and install in the reverse order of removal. A
● If stud bolts of turbocharger were removed, tighten them to the specified torque.
: 25.5 N·m (2.6 kg-m, 19 ft-lb) EM
● If stud bolts of catalyst were removed, tighten them to the specified torque.
: 45.0 N·m (4.6 kg-m, 33 ft-lb) C
● Pushing bracket against the cylinder block and the catalyst, temporarily tighten the mounting bolt. And
then tighten it to the specified torque.
D
Exhaust outlet support
Tighten fixing bolts in numerical order as shown in the figure.
E
PBIC4908E
EM-179
TURBO CHARGER
[YD]
TURBO CHARGER PFP:14411
Components (EURO 3) BBS00D2A
PBIC4045E
1. Exhaust manifold 2. Water hose 3. Water tube

4. Copper washer 5. Eye-bolt 6. Gasket
7. Gasket 8. Gasket 9. Exhaust outlet
10. Exhaust outlet cover 11. Air inlet pipe 12. Gasket
13. Turbocharger 14. Gasket 15. Copper washer
16. Oil feed and return tube 17. Washer 18. Connector
19. Oil return hose 20. Eye-bolt
A. To heater return pipe B. To cylinder block
EM-180
TURBO CHARGER
[YD]
Components (EURO 4) BBS00D2B
EM
PBIC4842E
1. Air inlet tube 2. Water tube 3. Clamp

4. Water hose 5. Copper washer 6. Eye-bolt
7. Water hose 8. Gasket 9. Gasket
10. Turbocharger insulator 11. Exhaust outlet 12. Gasket
13. Turbocharger 14. Gasket 15. Bracket
16. Oil feed tube and oil return tube 17. Clamp 18. Oil return hose
19. Connector 20. Washer 21. Copper washer
22. Eye-bolt 23. Gasket 24. Air inlet pipe
25. Exhaust manifold 26. Gasket
A. To air inlet hose B. To water outlet C. To cylinder block
D. To heater return pipe
EM-181
TURBO CHARGER
[YD]
Removal and Installation BBS00D2C
REMOVAL
● After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
1. Drain engine coolant. Refer to CO-37, "Changing Engine Coolant"
2. Remove air inlet hose and air inlet pipe. Refer to EM-164, "CHARGE AIR COOLER" .
3. Remove air duct and air inlet pipes. Refer to EM-158, "AIR CLEANER AND AIR DUCT" .
4. Remove exhaust manifold cover. Refer to EM-187, "EXHAUST MANIFOLD" .
5. Remove exhaust outlet and catalyst. Refer to EM-177, "CATALYST" .
6. Remove eye bolts and water hose from water tube and oil-feed-and-return tube.
7. Remove turbocharger with water tube and oil-feed-and-return tube.
CAUTION:
Be careful not to deform water tube and oil-feed-and-return tube.
8. Remove water tube and oil-feed-and-return tube from turbocharger.
9. Remove turbocharger.
CAUTION:
● Do not disassemble or adjust the turbocharger.
● Be careful not to contact with the vehicle.
● Do not hold turbocharger boost control actuator and actuator rod.
Oil Tube and Water Tube

● Clean inside of oil-feed-and-return tube and water tube, and check tubes for clogging.
● Replace oil-feed-and-return tube and/or water tube if clogging still exists after cleaning.
INSPECTION AFTER REMOVAL (EURO 3)
EURO 3
PBIC3416E
1. Compressor housing 2. Turbocharger boost control actuator 3. Turbine housing

Check for negative air pressure
A. Check for charge air pressure leaks B. Check for exhaust gas leaks C.
leaks
D. Check for engine coolant leaks E. Check for engine oil leaks
CAUTION:
When the compressor wheel turbine, wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:
Suction side : Between turbocharger and charge air cooler
Exhaust side : Between turbocharger and catalyst
EM-182
TURBO CHARGER
[YD]
Rotor Shaft Clearance
● Make sure that the rotor shaft (1) rotates smoothly without any A
resistance when it is rotated by your fingertips.
● Make sure that the rotor shaft (1) is not loose when it is moved
vertically or horizontally. EM
● Measure looseness with a dial gauge inserting its measuring rod
through oil drain hole of turbocharger.
C
Standard : 0.086 - 0.117 mm (0.0034 - 0.0046 in)
● Replace turbocharger if out of standard.
PBIC3417E
D
Rotor Shaft End Play

● Place a dial gauge (A) at the rotor shaft (1) end in the axial direc- E
tion to measure the end play.
Standard : 0.036 - 0.090 mm (0.0014 - 0.0035 in)
● Replace turbocharger if out of standard. F
PBIC3418E H
Turbine Wheel
● Make sure that there is no engine oil adhesion.
● Make sure that there is no carbon accumulation. I
● Make sure that blades of turbine wheel (1) are not bent or bro-
ken.
J
● Make sure that turbine wheel (1) does not interfere with turbine
housing (2).
PBIC3419E
L
Compressor Wheel
● Make sure that there is no engine oil adhesion inside the air
inlet. M
● Make sure that compressor wheel (1) does not interfere with
compressor housing (2).
● Make sure that compressor wheel (1) is not bent or broken.
PBIC3420E
EM-183
TURBO CHARGER
[YD]
Turbocharger Boost Control Actuator
● Connect the handy vacuum pump (B) to the turbocharger boost
control actuator (1), and make sure that the rod (2) strokes
smoothly in compliance with the following pressure.
A : Dial gauge
● Pressure to be applied at the turbocharger boost control actua-
tor (1) part to move rod (2) end as follows:
Standard (Pressure/rod stroke amount):
:–52.0 to –54.6 kPa (–520 to –546 mbar, –390 to –410
mmHg, –15.4 to –16.1 inHg)/0.2 mm (0.0080 in) PBIC3421E
: –32.0 to –40.0 kPa (–320 to –400 mbar, –240 to –300

mmHg, –9.45 to –11.8 inHg)/5.0 mm (0.197 in)
INSPECTION AFTER REMOVAL (EURO 4)
EURO 4
PBIC4843E
1. Turbocharger boost control actuator 2. Turbine housing 3. Compressor housing

Check for negative air pressure
A. B. Check for exhaust gas leaks C. Check for charge air pressure leaks
leaks
D. Check for engine coolant leaks E. Check for engine oil leaks
CAUTION:
When the compressor wheel turbine, wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:
Suction side : Between turbocharger and charge air cooler
Exhaust side : Between turbocharger and catalyst
EM-184
TURBO CHARGER
[YD]
Rotor Shaft Clearance
● Make sure that the rotor shaft (1) rotates smoothly without any A
resistance when it is rotated by your fingertips.
● Make sure that the rotor shaft (1) is not loose when it is moved
vertically or horizontally. EM
● Measure looseness with a dial gauge inserting its measuring rod
through oil drain hole of turbocharger.
C
Standard : 0.086 - 0.111 mm (0.0034 - 0.0043 in)
● Replace turbocharger if out of standard.
PBIC4844E
D
Rotor Shaft End Play

● Place a dial gauge (A) at the rotor shaft (1) end in the axial direc- E
tion to measure the end play.
Standard : 0.030 - 0.111 mm (0.0011 - 0.0043 in)
● Replace turbocharger if out of standard. F
PBIC4845E H
Turbine Wheel
● Make sure that there is no engine oil adhesion.
● Make sure that there is no carbon accumulation. I
● Make sure that blades of turbine wheel (1) are not bent or bro-
ken.
J
● Make sure that turbine wheel (1) does not interfere with turbine
housing (2).
PBIC4846E
L
Compressor Wheel
● Make sure that there is no engine oil adhesion inside the air
inlet. M
● Make sure that compressor wheel (1) does not interfere with
compressor housing (2).
● Make sure that compressor wheel (1) is not bent or broken.
PBIC4847E
EM-185
TURBO CHARGER
[YD]
Turbocharger Boost Control Actuator
● Connect the handy vacuum pump (B) to the turbocharger boost
control actuator (1), and make sure that the rod (2) strokes
smoothly in compliance with the following pressure.
A : Dial gauge
● Pressure to be applied at the turbocharger boost control actua-
tor (1) part to move rod (2) end as follows:
Standard (Pressure/rod stroke amount):
:–51.3 to –55.3 kPa (–513 to –553 mbar, –385 to –415
mmHg, –15.16 to –16.34 inHg)/0.2 mm (0.0080 in) PBIC3421E
:–28.0 to –36.0 kPa (–280 to –360 mbar, –210 to –270

mmHg, –8.27 to –10.63 inHg)/5.0 mm (0.197 in)
TROUBLE DIAGNOSIS OF TURBOCHARGER
Preliminary check:
● Make sure that the engine oil level is between MIN and MAX of the oil level gauge. (When engine oil
amount is more than MAX, engine oil flows into the inlet duct through blow-by gas passage, and turbo-
charger is misjudged malfunction.)
● Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.
● Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.
● If no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunction.
Check the other parts again.
Symptom
Inspection item Inspection result
(when each inspection item meets each inspection result)
Engine oil Insufficient power/accel-
Smoke Noise
leakage eration malfunction
Engine oil leaks C A C C
Carbon is accumulated C A B B
Turbine wheel
Friction with housing C B A B
Blades are bent or broken — — A A
Inside the air inlet is seriously con-
B B — —
taminated by engine oil.
Compressor wheel
Friction with housing C B A B
Blades are bent or broken — — A A
There is resistance when the rotor
— C C B
shaft is rotated by your fingertips.
After checking both turbine and
The rotor shaft sometimes does not
compressor, inspect rotor shaft — — — A
rotate by your fingertips.
end play.
There is too much play in the bear-
C C B C
ing.
Carbon or sludge is accumulated in
Oil return port C A C C
the waste oil hole.
A: Large possibility
B: Medium possibility
C: Small possibility
INSTALLATION
● When a stud bolt is pulled out, replace it with a new one and tighten it to the following torque.
: 25.5 N·m (2.6 kg-m, 19 ft-lb)
EM-186
EXHAUST MANIFOLD
[YD]
EXHAUST MANIFOLD PFP:14004
A
Components (EURO 3) BBS00D2D
EM
PBIC4047E
K
1. Cylinder head 2. Exhaust manifold cover 3. Exhaust manifold
4. Gasket 5. Turbocharger 6. Gasket
7. EGR tube (cooler) 8. Gasket L
A. No.1 port B. No.2 port C. No.3 port
D. No.4 port E. Alignment protrusion
: Vehicle front M
EM-187
EXHAUST MANIFOLD
[YD]
Components (EURO 4) BBS00D2E
PBIC4848E
1. Turbocharger 2. Exhaust manifold cover 3. Exhaust manifold cover

4. Cylinder head 5. Gasket 6. EGR cooler
7. Gasket 8. Exhaust manifold 9. Gasket
A. No.1 port B. No.2 port C. No.3 port
D. No.4 port E. Alignment protrusion
: Vehicle front

Removal and Installation BBS00D2F
NOTE:
Unless otherwise specified in the text, EURO 4 shown as an example of the figure.
REMOVAL
2. Remove exhaust manifold cover.
3. Remove turbocharger. Refer to EM-180, "TURBO CHARGER" .
4. Remove EGR tube or EGR cooler. Refer to EM-166, "INTAKE MANIFOLD" .
EM-188
EXHAUST MANIFOLD
[YD]
5. Loosen exhaust manifold mounting nuts in the reverse order in
the figure. A
: Vehicle front
EM
PBIC4849E
D
6. Rotate exhaust manifold.
E
Surface Distortion
● Use a reliable straight edge and feeler gauge to check the flat-
ness of exhaust manifold fitting surface.
F
Limit : 0.3 mm (0.012 in)
G
PBIC2210E
INSTALLATION I
● If stud bolts were removed, replace them with new ones, and tighten them to the specified torque:
: 14.7 N·m (1.5 kg-m, 11 ft-lb) J
● Tighten the exhaust manifold mounting nuts in the following procedure:
1. Install gasket so that the alignment protrusion faces the No. 4 port. Refer to EM-188, "Removal and Instal-
lation" . K
2. Tighten the nuts in order specified in the figure.
: Vehicle front
L
3. Re-tighten the nuts 1 to 8.
4. Install in the reverse order of removal.
M
PBIC4849E

Start engine and raise engine speed to check no exhaust gas and engine oil leaks.
EM-189
[YD]
OIL PAN AND OIL STRAINER PFP:11110
Components BBS00D2G
PBIC3424E
1. Oil level gauge 2. Oil level gauge guide 3. Oil level sensor
4. O-ring 5. O-ring 6. O-ring
7. Oil pan upper 8. Crankshaft position sensor 9. O-ring
10. Rear plate 11. Rear plate cover 12. Oil strainer
13. Oil pan drain plug 14. Drain plug washer 15. Oil pan lower

Removal and Installation BBS00D2H
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
1. Remove engine undercover.
EM-190
[YD]
3. Remove oil pan lower bolts. Loosen bolts in the reverse order of
that shown in the figure. A
: Vehicle front
EM
PBIC3425E
D
4. Remove oil pan lower.
a. Insert the seal cutter (special service tool) between oil pan upper
and oil pan lower. E
CAUTION:
● Be careful not to damage aluminum mating surface.
● Do not insert screwdriver, or oil pan flange will be F

deformed.
b. Slide the seal cutter by tapping on the side of the seal cutter with
a hammer. G
c. Remove oil pan lower.
SEM365EA
H
5. Remove oil strainer.
6. Remove power steering oil pump belt. Refer to EM-155, "DRIVE BELTS" .
7. Remove power steering oil pump bracket and move power steering oil pump aside with its piping con- I
nected. Temporarily secure it on the vehicle side with a rope to avoid putting load on it. Refer to PS-35,
"POWER STEERING OIL PUMP" .
8. Disconnect oil return hose (vacuum pump) from oil pan upper. Refer to EM-196, "VACUUM PUMP" . J
9. Remove A/C compressor bracket mounting bolts (A).

1 : Oil pan upper K
2 : A/C compressor bracket
: Vehicle front
L
PBIC3426E
10. Remove crankshaft position sensor and oil level sensor.

CAUTION:
● Avoid impacts such as a dropping.
● Do not disassemble.
● Keep it away from metal particles.
● Do not place sensor close to magnetic materials.
11. Remove front propeller shaft. Refer to PR-3, "FRONT PROPELLER SHAFT" .
12. Remove RH and LH front drive shaft. Refer to FAX-7, "DRIVE SHAFT" .
13. Remove front final drive assembly. Refer to FFD-15, "FRONT FINAL DRIVE ASSEMBLY" .
14. Remove rear plate cover and transmission joint bolts.
EM-191
[YD]
15. Loosen bolts in the reverse order of illustration to remove oil pan
upper.
: Vehicle front
PBIC3431E
16. Remove oil pan upper.

● Insert the seal cutter (special service tool) between oil pan
upper and cylinder block. Slide the seal cutter by tapping on
the side of the seal cutter with a hammer. Remove oil pan
upper.
● Be careful not to damage aluminum mating surface.
● Do not insert screwdriver, or oil pan flange will be

deformed.
SEM365EA

Clean oil strainer if any object attached.
INSTALLATION
● Install oil pan upper with the following procedure.
– Use the scraper (A) to remove old liquid gasket from mating sur-
face of oil pan upper (1).
• Also remove old liquid gasket from mating surface of cylin-
der block and rear chain case.
• Remove old liquid gasket from the bolt hole and thread.
PBIC3432E
– Apply a continuous bead of liquid gasket with the tube presser

[special service tool: WS39930000] to areas shown in the figure.
: Vehicle front

CAUTION:
● At the 2 bolt holes marked , liquid gasket should be
applied outside holes.
● 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
PBIC3433E
the diameter of the liquid gasket bead is different around
the front.)
● Attaching should be done within 5 minutes after coating.
– Install oil pan upper.
EM-192
[YD]
CAUTION:
Install avoiding misalignment of O-ring. A
• Tighten bolts in numerical order to the specified torque.
: Vehicle front
EM
• Bolt dimensions vary depending on the installation location.
Refer to the following and use appropriate bolts.
M6 x 30 mm (1.18 in) : Bolt No. 15, 16 C
M8 x 25 mm (0.98 in) : Bolt No. 2, 4, 5, 8, 9, 10, 14
M8 x 60 mm (2.36 in) : Bolt No. 1, 3, 6, 7, 11, 12, 13, 17
D
• The shank length under the bolt neck above is the length of the PBIC3431E
threaded part (pilot portion not included).
● Install oil pan lower with the following procedure. E
– Use a scraper (A) to remove old liquid gasket from mating sur-
face of oil pan lower (1).
CAUTION: F
● Also remove old liquid gasket from mating surface of oil
pan upper.
G
H
PBIC3430E
– Apply a continuous bead of liquid gasket with the tube presser I

[special service tool: WS39930000] as shown in the figure.
: Vehicle front
J
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
K
• Attaching should be done within 5 minutes after coating.
PBIC3434E L
SEM159F
– Install oil pan lower.
EM-193
[YD]
• Tighten bolts in numerical order to the specified torque.
: Vehicle front
NOTE:
Pour engine oil or start engine at least 30 minutes after oil pan is
installed.
PBIC3425E

1. Check engine oil level and add engine oil. Refer to LU-20, "ENGINE OIL" .
2. Check for leakage of engine oil when engine is warmed.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-20, "ENGINE OIL" .
EM-194
GLOW PLUG
[YD]
GLOW PLUG PFP:22401
A
Components BBS00D2I
EM
PBIC4851E
1. Glow plate 2. Glow harness 3. Glow nut J

4. Cap 5. Glow plug
Removal and Installation BBS00D2J

K
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
L
1. Disconnect glow harness from glow plate.
2. Remove glow nut to remove glow plate.
3. Remove glow plug. M
CAUTION:
● When removing or installing, do not use such tools as an air impact wrench.
● Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a reamer.
2. Install glow plug.
3. Install remaining parts in the reverse order of removal.
EM-195
VACUUM PUMP
[YD]
VACUUM PUMP PFP:41920
Components BBS00D2K
PBIC3435E
1. O-ring 2. Vacuum pump 3. Bracket

4. Oil feed tube 5. Cooper washer 6. Eye-bolt
7. Oil return hose
: Vehicle front

Removal and Installation BBS00D2L
INSPECTION BEFORE REMOVAL

1. Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
● Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way con-
nector.
2. Start engine and measure generated vacuum at idle speed.
Standard:
–94.0 to –96.1 kPa (–940 to –961 mbar, –705 to –721 mmHg, –27.76 to –28.38 inHg)
● If out of standard, check for air suction in vacuum route, and measure again.
● If still outside of standard, replace vacuum pump.
REMOVAL
2. Remove primary timing chain. Refer to EM-236, "PRIMARY TIMING CHAIN" .
3. Disconnect vacuum hose from vacuum pump side.
4. Remove oil feed tube and oil return hose.
5. Remove bracket.
6. Remove vacuum pump and O-ring.
EM-196
VACUUM PUMP
[YD]
INSTALLATION
Note the following, and install in the reverse order of removal. A
Bracket
Tighten fixing bolts in numerical order as shown in the figure. EM
: Cylinder block side
PBIC4907E
E
EM-197
INJECTION TUBE AND FUEL INJECTOR
[YD]
INJECTION TUBE AND FUEL INJECTOR PFP:00018
Components BBS00D2M
PBIC4046E
1. Eye-bolt 2. Cooper washer 3. Spill tube

4. Nozzle support 5. Pin 6. Fuel injector
7. O-ring 8. Nozzle gasket 9. Rocker cover
10. Nozzle oil seal 11. Washer 12. Injection tube No. 4
13. Injection tube No. 3 14. Injection tube No. 2 15. Injection tube No. 1
16. Insert rubber 17. Clip 18. Injection tube center
19. Spill hose 20. Fuel gallery 21. Spill hose
22. Fuel hose 23. Fuel pump 24. Cylinder head
25. Cooper washer 26. Fuel hose 27. Fuel rail
A. To fuel filter B. To fuel cooler (under floor)
: Vehicle front
● Refer to GI-11, "Components"

Removal and Installation BBS00D2N
NOTE:
Unless otherwise specified in the text, EURO 4 shown as an example of the figure.
REMOVAL
1. Remove engine cover. Refer to EM-166, "INTAKE MANIFOLD" .
EM-198
[YD]
CAUTION:
Be careful not to allow leaked fuel to contaminate engine room. Especially, ensure to keep engine A
mounting insulator clear of fuel.
3. Disconnect harness connector from fuel injector.
4. Remove spill hose. EM
5. Following steps below, remove injection tubes.
a. Put a paint mark or tag on injection tubes to identify each cylinder.
● Use a fuel-resistant method. C
b. Remove injection tubes in order of 2-1-4-3 individually.
CAUTION:
Be careful not to allow leaked fuel to contaminate engine D
room. Especially, ensure to keep engine mounting insulator
clear of fuel.
E
F
SBIA0203E
G
6. Remove nozzle oil seal.
● Using the flat-bladed screwdriver, pry flange to remove oil
seal.
H
NOTE:
Nozzle oil seal seals between fuel injector and rocker cover. If
only injection tube shall be removed and installed, nozzle oil
seal replacement is not required. I
J
PBIC0944E
7. Remove rocker cover. Refer to EM-211, "ROCKER COVER" .

K
8. Remove spill tube mounting bolts and nut.
● Loosen bolts and nut to the reverse order in the figure and
remove them. L
CAUTION:
When loosening nut, fix spill tube retaining bolt with span-
ner. M
B : Spill tube retaining bolt
C : SECT A – A
D : OK
: Engine front
PBIC4898E
EM-199
[YD]
9. Following steps below, remove fuel injector.
1 : Fuel injector
2 : O-ring
3 : Nozzle gasket
4 : Nozzle support
a. Remove nozzle support.

b. Remove fuel injector. While rotating it to left and right, raise it to
remove.
CAUTION:
PBIC4852E
● Handle fuel injector carefully without giving any impact.
● Do not disassemble fuel injector.
c. If nozzle gasket remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out.
d. Remove O-ring from fuel injector.
INSTALLATION
1. Record “INJECTOR ADJUSTMENT VALUE” on the top surface when replacing fuel injector.
● Refer to EC-994, "Injector Adjustment Value Registration" (TYPE 1) or EC-1377, "Injector Adjustment
Value Registration" (TYPE 2) for use of “INJECTOR ADJUSTMENT VALUE”.
MBIB1251E
Example: Injector Adjustment value = D021ABCD1A061234000000000000E6

2. Following steps below, install fuel injector.
a. Install O-ring and nozzle gasket to fuel injector, and insert them into cylinder head.
b. Tighten injection tubes temporarily in the order of 3-4-1-2.
c. Be sure to fit nozzle support and pin without looseness.
d. Tighten nozzle support bolts.
e. Loosen injection tubes in the order of 2-1-4-3.
EM-200
[YD]
3. Connect spill tube.
● Tighten fixing bolts and nut in numerical order shown in the A
figure.
CAUTION:
When tightening nut, fix spill tube retaining bolt with EM
spanner.
NOTE:
Connection of spill tube gasket may be broken, even if it is C
tighten to the specified torque. It does not affect performance.
B : Spill tube retaining bolt
C : SECT A – A D
D : OK
: Engine front
E
G
PBIC4898E
4. Perform air tightness test for spill tube.

● Connect a handy vacuum pump to spill connector. Make sure H
that vacuum is retained while applying following vacuum.
Standard:
I
–53.3 to –66.7 kPa (–533 to –667 mbar, –400 to –
500 mmHg, –15.75 to –19.69 inHg)
● If outside of standard, reconnect spill tube. (Replace gasket in J
this case.)
5. Install rocker cover. Refer to EM-212, "Removal and Installation" JEF250Z
. K
6. Install nozzle oil seal.
● Insert it straight until its flange fully contacts rocker cover.
CAUTION: L
● Check gutter spring in nozzle oil seal on fuel injector for missing.
7. Connect injection tubes individually to each cylinder in order of

3-4-1-2. M
SBIA0203E
8. Install fuel hoses, spill hose and fuel gallery as shown in the figure.
EM-201
[YD]
PBIC4858E
1. Rocker cover 2. Fuel filter 3. Fuel hose

4. Fuel hose 5. Fuel hose 6. Fuel hose
7. Fuel hose 8. Fuel hose 9. Clamp
10. Fuel pump 11. Fuel rail 12. Priming pump
13. Fuel hose
A. Align paint mark B. Insert the hose up to 28 mm (1.10 in) C. Insert the hose up to 26 mm (1.02 in)
D. To fuel centralized under-floor piping E. Insert the hose up to 30 mm (1.18 in) F. Insert the hose up to the wall face
: Vehicle front
NOTE:
Intake manifold and other related parts are omitted for explanation.

● Input “INJECTOR ADJUSTMENT VALUE” to ECM after installing to the vehicle when replacing fuel injec-
tor. Refer to EC-994, "Injector Adjustment Value Registration" (TYPE 1) or EC-1377, "Injector Adjustment
Value Registration" (TYPE 2) for use of “INJECTOR ADJUSTMENT VALUE”.
MBIB1251E
Example: Injector Adjustment value = D021ABCD1A061234000000000000E6
EM-202
[YD]
● Start engine and increase engine speed to check for fuel leak.
CAUTION: A
Do not touch engine immediately after stopped as engine becomes extremely hot.
EM
EM-203
FUEL PUMP
[YD]
FUEL PUMP PFP:17042
Components BBS00D2Q
PBIC3438E
1. Washer 2. Fuel pump sprocket 3. Seal washer

4. O-ring 5. Adjusting shim 6. Sprocket nut
7. Coupling 8. Oil seal 9. Spacer
10. Key 11. Fuel pump 12. Fuel hose
13. Spill hose
: Engine front

Removal and Installation BBS00D2R
CAUTION:
● Before removing and installing fuel pump, be sure to remove sprocket. Do not loosen or remove
installation nut in the center of fuel pump. If loosened or removed, replace fuel pump.
● After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
● When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
● When fuel pump is replaced with new one or another one, perform fuel pump leaning value clean-
ing before starting engine. Refer to EC-996, "Fuel Pump Learning Value Clearing" (TYPE 1) or EC-
1378, "Fuel Pump Learning Value Clearing" (TYPE 2).
REMOVAL
1. Remove engine cover, vacuum gallery and heater feed pipe. Refer to EM-166, "INTAKE MANIFOLD" .
EM-204
FUEL PUMP
[YD]
2. Remove fuel hose and spill hose from fuel pump. Refer to EM-198, "INJECTION TUBE AND FUEL
INJECTOR" . A
CAUTION:
3. Disconnect harness connectors from fuel pump. EM
4. Remove injection tube center, clip and insert rubber. Refer to EM-198, "INJECTION TUBE AND FUEL
INJECTOR" .
CAUTION: C
5. Remove secondary timing chain. Refer to EM-229, "SECONDARY TIMING CHAIN" . D

6. Hold fuel pump sprocket and remove bolt.
a. Insert the positioning stopper pin (special service tool) into the
hole 6 mm (0.24 in) in the diameter on the fuel pump sprocket. E
b. Using the TORX wrench (special service tool), turn pump shaft
little by little to adjust the position of fuel pump sprocket so that
the holes align.
F
c. Push the positioning stopper pin (special service tool) through
fuel pump sprocket to fuel pump body to hold fuel pump
sprocket.
G
MBIA0049E
● Insert the positioning stopper pin until its flange contacts the fuel
pump sprocket. H
PBIC2535E
K
7. Using the hexagon wrench (special service tool) remove tighten-
ing bolts of fuel pump sprocket.
L
PBIC2404E
MBIA0074E
EM-205
FUEL PUMP
[YD]
8. Using the sprocket holder (special service tool), hold fuel pump
sprocket to prevent falling.
● For sprocket holder, use [special service tool: KV11106060]
machined as shown in the figure, because the previous bore
is not fitting.
SBIA0217E
● When the sprocket holder is installed, if the positioning stop-

per pin (special service tool) interferes, pull out the positioning
stopper pin approximately 10 mm (0.39 in), then install it.
● After the sprocket holder is installed temporarily, tighten the
sprocket holder after making extension bar and TORX socket
(size: E10) (commercial service tool) insert into the machined
bore.
● The length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).
● Make sure that the a- and b-faces of the sprocket holder con-
tact the bottom side of the sprocket (small diameter side). PBIC2534E
CAUTION:
Do not remove the sprocket holder (special service tool) until fuel pump is installed.
● After the sprocket holder is installed, pull out the positioning
stopper pin from fuel pump sprocket.
MBIA0075E
9. Using the extension bar and the TORX socket (size: E10) (com-
mercial service tool), remove the tightening bolts.
CAUTION:
Do not disassemble or adjust fuel pump.
PBIC2405E
10. Remove the fuel pump toward the rear of engine.

CAUTION:
For removal, be careful not to drop the seal washer into the engine.
NOTE:
The seal washer of the tightening bolts cannot be reused.
11. Remove adjusting shim.
12. Attach a suitable tool in the M8 bolt hole on coupling.
EM-206
FUEL PUMP
[YD]
13. Loosen sprocket nut with the TORX wrench (special service
tool). A
EM
MBIA0013E
D
14. Remove coupling with a suitable puller.
G
MBIA0014E
15. Remove spacer from fuel pump. H

16. Remove oil seal from spacer.
Timing Chain I
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.
J
L
SEM984C
INSTALLATION M
1. Install new oil seal to spacer.
MBIA0045E
2. Install spacer to fuel pump.
EM-207
FUEL PUMP
[YD]
3. Install coupling to fuel pump of spacer.
● Using the TORX wrench (special service tool), tighten the
sprocket nut to fix the coupling.
MBIA0013E
4. Install adjusting shim.

● For shim adjustment, measure dimension L [Distance
between front surface of coupling and the fuel pump flange
(spacer)] at two opposing points near the coupling bolt center.
Use the average of these two measurements to select the
shim grade that marked on adjusting shim.
MBIA0077E
● The shim adjustment is required only when the fuel pump is

replaced.
PBIC3439E
Part No. of adjusting shim Grade number Measuring dimension L mm (in) Type
16614 8H800 0.5 t 39.23 - 39.77 (1.5445 - 1.5657) A
16614 8H810 1.0 t 38.76 - 39.23 (1.5260 - 1.5445) B
16614 8H860 1.2 t 38.57 - 38.76 (1.5185 - 1.5260) C
16614 8H820 1.6 t 38.18 - 38.57 (1.5031 - 1.5185) D
16614 8H800 + 16614 8H860 0.5 t + 1.2 t 38.09 - 38.18 (1.4996 - 1.5031) A+C
16614 8H810 + 16614 8H810 1.0 t + 1.0 t 37.80 - 38.09 (1.4882 - 1.4996) B+B
16614 8H860 + 16614 8H810 1.2 t + 1.0 t 37.60 - 37.80 (1.4803 - 1.4882) C+B
16614 8H820 + 16614 8H810 1.6 t + 1.0 t 37.21 - 37.60 (1.4650 - 1.4803) D+B
EM-208
FUEL PUMP
[YD]
5. Before fuel pump is installed, make sure that spacer and the 6
mm (0.24 in) dia. hole on coupling are aligned. A
EM
MBIA0016E
D
6. Insert fuel pump to the mounting position from the rear side of
the engine, and install the tightening bolts with seal washer.
CAUTION: E
Be careful not to drop the seal washer into engine.
G
PBIC2438E
7. Using the extension bar and the TORX socket (size: E10) (com- H
mercial service tool), tighten the tightening bolts of fuel pump.
8. Remove the sprocket holder (special service tool).
I
PBIC2405E
K
9. Using the TORX wrench (special service tool), turn the pump
shaft gradually to adjust the position of fuel pump sprocket.
Then, insert the positioning stopper pin (special service tool) to L
the 6 mm (0.24 in) dia. hole of the fuel pump sprocket through
the pump body.
10. Remove the TORX wrench (special service tool). M
MBIA0049E
11. Using the hexagon wrench (special service tool), tighten the
sprocket tightening bolt.
● When the washer of the fuel pump sprocket is removed,
install it with the marking “F” (front) facing the front of the
engine.
12. Pull out the positioning stopper pin (special service tool).
PBIC2404E
EM-209
FUEL PUMP
[YD]
13. Install secondary timing chain. Refer to EM-229, "SECONDARY TIMING CHAIN" .
14. Following steps below, install injection tube center. Refer to EM-198, "INJECTION TUBE AND FUEL
INJECTOR" .
a. Pre-set clip and insert rubber to injection tube center.
b. Pre-tight nut of injection tube center to fuel pump and fuel rail by hand. (until seal surface touched)
c. Adjust clip dimension and tight bolt for clip to intake manifold by tool.
d. Tight nut of injection tube center to fuel pump by tool.
e. Tight nut of injection tube center to fuel rail by tool.
15. Connect the harness connector to fuel pump.
16. Install fuel hoses. Refer to EM-198, "INJECTION TUBE AND FUEL INJECTOR" .
17. Hereafter, install in the reverse order of removal.
CAUTION:
When fuel pump is replaced with new one or another one, perform fuel pump leaning value clean-
ing before starting engine. Refer to EC-996, "Fuel Pump Learning Value Clearing" (TYPE 1) or EC-
1378, "Fuel Pump Learning Value Clearing" (TYPE 2).
EM-210
ROCKER COVER
[YD]
ROCKER COVER PFP:13264
A
Components (EURO 3) BBS00D2S
EM
PBIC3440E
1. Nozzle oil seal 2. Rocker cover 3. Ventilation hose J

4. Washer 5. Oil filler cap 6. Gasket
A. Refer to EM-213 B. To ventilation hose
K
EM-211
ROCKER COVER
[YD]
Components (EURO 4) BBS00D2T
PBIC4854E
1. Nozzle oil seal 2. Oil filler cap 3. Rocker cover

4. Gasket 5. Ventilation hose
A. Refer to EM-213 B. To ventilation hose connector

Removal and Installation BBS00D2U
REMOVAL
1. Remove engine cover. Refer to EM-166, "INTAKE MANIFOLD" .
2. Remove vacuum gallery and engine cover bracket on rocker cover and ventilation hose. Refer to EM-166,
"INTAKE MANIFOLD" and EM-158, "AIR CLEANER AND AIR DUCT" .
3. Disconnect harness connector from fuel injector. Refer to EM-198, "INJECTION TUBE AND FUEL INJEC-
TOR" .
4. Following steps below, remove injection tube. Refer to EM-198, "INJECTION TUBE AND FUEL INJEC-
TOR" .
a. Put a paint mark or tag on injection tubes to identify each cylinder.
● Use a fuel-resistant method.
b. Remove injection tubes in order of 2-1-4-3 individually.

CAUTION:
Be careful not to allow leaked fuel to contaminate engine room. Especially, ensure to keep engine
mounting insulator clear of fuel.
5. Remove injection nozzle oil seal.
EM-212
ROCKER COVER
[YD]
● Using the flat-bladed screwdriver, pry flange to remove nozzle
oil seal. A
EM
PBIC0944E
D
6. Remove rocker cover.
● Loosen holding bolts in the reverse order of that shown in the figure and remove.
– EURO 4 E
: Engine front
PBIC4853E H
– EURO 3
I
: Engine front
PBIC3441E
L
7. Remove gasket from rocker cover.
INSTALLATION
1. Install new gasket to rocker cover. M
2. Apply liquid gasket with tube presser [SST: WS39930000] on
locations shown in the figure.
● Use Genuine Liquid Gasket or equivalent.
1 : Cylinder head
2 : Cylinder head rear cover
A : Liquid gasket application area
: Engine front
PBIC3442E
3. Tighten holding bolts.

● Tighten all bolts in numerical order as shown in the figure.
: 7.8 N·m (0.8 kg-m, 69 in-lb)
EM-213
ROCKER COVER
[YD]
● Re-tighten to the same torque in the same order as above.
– EURO 3
: Engine front
PBIC3441E
– EURO 4
: Engine front
PBIC4853E
4. Install nozzle oil seal.

● Insert it straight until flange fully contacts rocker cover.

6. Before starting engine, bleed air from fuel piping. Refer to FL-16, "Air Bleeding" .
Start engine and increase engine speed to check for fuel leak and engine oil leak.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
EM-214
CAMSHAFT
[YD]
CAMSHAFT PFP:13001
A
Components BBS00D2V
EM
PBIC4906E
K
1. Camshaft bracket 2. Camshaft (right side) 3. Camshaft (left side)
4. Signal plate 5. Rubber washer 6. Adjusting shim
7. Valve lifter 8. Camshaft sprocket 9. Cylinder head L
10. Cylinder head rear cover 11. O-ring 12. Camshaft position sensor

CAUTION: M
● This engine will have a different valve arrangement from
normal DOHC 4-valve type engines. As both camshafts on
this engine have intake and exhaust camshafts, in this
chapter they are named as follows:
Camshaft (right side) : Intake manifold side
Camshaft (left side) : Exhaust manifold side
● Refer to the figure for intake and exhaust valve arrange-
ment.
(The camshafts have, alternately, either intake valve or an
exhaust valve.) SBIA0178E
Removal and Installation BBS00D2W
REMOVAL
EM-215
CAMSHAFT
[YD]
3. Remove cylinder head rear cover, camshaft position sensor and rubber washer.
Loosen cylinder head rear cover mounting bolts in the reverse
order shown in the figure.
PBIC3445E
4. Remove fuel injector. Refer to EM-198, "INJECTION TUBE AND FUEL INJECTOR" .
5. Remove secondary timing chain. Refer to EM-229, "SECONDARY TIMING CHAIN" .
6. Remove camshaft sprockets and signal plate.
● Loosen the camshaft sprocket mounting bolts and signal plate
mounting bolt by fixing the hexagonal portion of camshaft.
JEM159G
7. Remove camshaft.
● Place distinguishing marks on the right and left sides with paint.
● Loosen and remove the camshaft sprocket bolts in the

reverse order shown in the figure.
JEM160G
8. Remove adjusting shim and valve lifter.

● Remove by taking notice of the installation position, and place outside engine in order to prevent confu-
sion.
Visual Check of Camshaft
● Check the camshaft for one sided wear or scratches.
● Replace the camshaft if there are abnormalities.
EM-216
CAMSHAFT
[YD]
Camshaft Runout
● Prepare V-block on a flat surface and secure camshaft journals A
No. 2 and No. 5.
● Set the dial gauge vertically on journal No. 3.
● Rotate camshaft in one direction by hand, then read needle EM
movement on dial gauge. (Total indicator reading)
Limit : 0.02 mm (0.0008 in)
C
● If it exceeds the limit, replace camshaft.
JEM161G
D
Height of Cam Nose

● Measure the height of cam nose using the micrometer. E
Standard:
Intake : 39.505 - 39.695 mm (1.5553 - 1.5628 in)
F
Exhaust : 39.905 - 40.095 mm (1.5711 - 1.5785 in)
● If out of the standard, replace camshaft.
G
SEM549A H
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER
● Measure outer diameter of camshaft journal with micrometer. I
Standard:
No. 1 : 30.435 - 30.455 mm J
(1.1982 - 1.1990 in)
No. 2, 3, 4, 5 : 23.935 - 23.955 mm
(0.9423 - 0.9431 in) K
L
SEM012A
CAMSHAFT BRACKET INNER DIAMETER

● Install camshaft bracket and tighten bolts to the specified torque. Refer to EM-219, "INSTALLATION" for M
the tightening procedure.
● Measure inner diameter of camshaft bracket using the inside
micrometer.
Standard:
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
CAMSHAFT OIL CLEARANCE CALCULATIONS

● (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal outer diameter)
EM-217
CAMSHAFT
[YD]
Standard : 0.045 - 0.086 mm (0.0018 - 0.0034 in)

● If out of standard, refer to the standard value of each unit, then replace the camshaft and/or cylinder head.
NOTE:
As the camshaft bracket is manufactured with the cylinder head, it is impossible to replace only the cam-
shaft bracket.
Camshaft End Play
● Install dial gauge in thrust direction on front end of camshaft.
Measure end play of dial gauge when camshaft is moved for-
ward/backward (in direction to axis).
Standard : 0.070 - 0.148 mm (0.0028 - 0.0058 in)
Limit : 0.24 mm (0.0094 in)
PBIC0366E
● Measure the following parts if out of the standard.

– Dimension “A” for camshaft
Standard : 6.882 - 6.930 mm (0.2709 - 0.2728 in)
– Dimension “B” for cylinder head
Standard : 7.000 - 7.030 mm (0.2755 - 0.2767 in)
● Refer to the standards above, and then replace camshaft and/or
cylinder head.
PBIC2320E
Camshaft Sprocket Runout

1. Install camshaft in cylinder head. Refer to EM-219, "INSTALLATION" for the tightening procedure.
2. Install sprocket on camshaft. Refer to EM-219, "INSTALLA-
TION" .
3. Measure camshaft sprocket runout. (Total indicator reading)
Limit : 0.15 mm (0.0059 in)
● If it exceeds the limit, replace camshaft sprocket.
JEM164G
Visual Inspection of Valve Lifter and Adjusting Shim

Check if surface of valve lifter and adjusting shim has any wear or
cracks.
● If anything above is found, replace valve lifter or adjusting shim.
SEM160D
EM-218
CAMSHAFT
[YD]
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER A
● Measure the outer diameter of the valve lifter with the microme-
ter.
EM
Standard : 29.960 - 29.975 mm (1.1795 - 1.1801 in)
D
SEM961E
VALVE LIFTER BORE DIAMETER E

● Measure the bore diameter of the cylinder head valve lifter with
the inside micrometer.
F
Standard : 30.000 - 30.021 mm (1.1811 - 1.1819 in)
H
PBIC0367E
VALVE LIFTER CLEARANCE CALCULATIONS I

● (Clearance) = (Valve lifter bore diameter) – (Valve lifter outer diameter)
Standard : 0.025 - 0.061 mm (0.0010 - 0.0024 in) J
● If out of standard, refer to the outer diameter and bore diameter standard values and replace valve lifter
and/or cylinder head.
INSTALLATION K
1. Install valve lifter and adjusting shim.
● Make sure that these are installed in the same position as before the removal process.
L
2. Install camshaft.
: Engine front
● Identify camshafts by the paint position and screw hole at the M

rear end.
Camshaft (right side) Intake manifold side (1):
Paint is at position (C) (Blue) without screw hole (A).
Camshaft (left side) Exhaust manifold side (2):
No paint with screw hole (B).
PBIC3444E
EM-219
CAMSHAFT
[YD]
● Install so that knock pins are positioned in the directions
PBIC2026E
3. Install camshaft brackets.

● Completely remove any foreign material on back surfaces of camshaft brackets and top surface of cyl-
inder head.
● Install correctly, identifying brackets by the journal No. and
front mark on top surface.
JEM175G
4. Tighten camshaft bolts in numerical order as shown in the figure

according to the following procedure:
a. Tighten No.13 to 15.
: 1.96 N·m (0.20 kg-m, 1 ft-lb)
● Make sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten No.1 to 12.
: 5.88 N·m (0.60 kg-m, 4 ft-lb)

JEM160G
c. Tighten all bolts.
: 5.88 N·m (0.60 kg-m, 4 ft-lb)

d. Tighten all bolts.
: 12.8 N·m (1.3 kg-m, 9 ft-lb)

5. Install camshaft sprockets and signal plate.
● Camshaft sprockets are commonly used for right side and left side.
● Align camshaft sprocket and knock pin on camshaft, and install.
● Holding the hexagonal part of camshaft with a wrench, tighten bolt securing camshaft sprockets and
signal plate.
6. Install rubber washer to cylinder head rear side.
EM-220
CAMSHAFT
[YD]
7. Apply liquid gasket to cylinder head rear cover as shown in the
figure. A
Use Genuine Liquid Gasket or Equivalent.
EM
PBIC3446E
D
8. Install cylinder head rear cover and tighten mounting bolts in
numerical order shown in the figure.
M6 × 50 mm : Bolt No.1, 2 E
M6 × 20 mm : Bolt No.3, 4
M8 × 20 mm : Bolt No.5, 6
F
G
PBIC3445E
9. Before installing spill tube after installing secondary timing chain, check and adjust valve clearance. Refer
to EM-222, "Valve Clearance" . H
INSPECTION AFTER INSTALLATION I
● Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required J
– Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel K
● Run engine to check for unusual noise and vibration. L
● Bleed air from lines and hoses of applicable lines, such as in cooling system. M
Item Before starting engine Engine running After engine stopped
*1: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
EM-221
CAMSHAFT
[YD]
Valve Clearance BBS00D2X
INSPECTION
● When the camshaft or parts in connection with valves are removed or replaced, and a malfunction has
occurred (poor starting, idling, or other malfunction) due to the misadjustment of the valve clearance,
inspect as follows.
● Inspect and adjust when the engine is cool (at normal temperature).
● 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 intake valve or exhaust
valve. (Refer to figure.)
SBIA0178E

3. Set the No. 1 piston to TDC on its compression stroke.
● Turn crankshaft pulley clockwise so that the knock pin on
camshaft left side faces straight above. (No position indicator,
etc. is provided on the crankshaft pulley.)
PBIC2533E
4. Remove undercover, put an alignment mark with paint, etc. on

crankshaft pulley and on oil pump housing as an angle indicator.
1 : Crankshaft pulley
A : Alignment mark
: Vehicle front
PBIC3447E
5. While referring to the figure, measure the valve clearance

marked in the table below.
No. 1 No. 2 No. 3 No. 4
Measuring point
INT EXH INT EXH INT EXH INT EXH
When the No. 1
cylinder is in the X X X X
TDC
NOTE:
●The injection order is 1-3-4-2.
SBIA0180E
EM-222
CAMSHAFT
[YD]
● Measure the valve clearance using the feeler gauge when
engine is cool (at normal temperature). A
EM
SBIA0181E
D
Valve clearance:
Unit: mm (in)
Items Cold Hot* (Reference data)
E
Intake 0.24 - 0.32 (0.0094 - 0.0126) 0.274 - 0.386 (0.0108 - 0.0152)
Exhaust 0.26 - 0.34 (0.0102 - 0.0134) 0.308 - 0.432 (0.0121 - 0.0170)
*: Reference data approximately 80°C (176°F) F
6. Set the No. 4 cylinder at TDC by rotating the crankshaft clockwise once. (360 degrees)
7. While referring to the figure, measure the valve clearance G
marked in the table below.
No. 1 No. 2 No. 3 No. 4
Measuring point H
INT EXH INT EXH INT EXH INT EXH
When the No. 4
cylinder is in the X X X X
TDC
I
8. If the valve clearance is outside the specification, adjust as fol-

lows.
SBIA0182E J
ADJUSTMENTS
● Remove adjusting shim for parts which are outside the specified valve clearance.
K
1. Extract engine oil on the upper side of the cylinder head (for the air blowing in step 6).
2. Rotate crankshaft to face the camshaft for adjusting shims that
are to be removed upward. L
SBIA0183E
3. Grip camshaft with the camshaft pliers (special service tool),

then using camshaft as a support point, push adjusting shim
downward to compress valve spring.
CAUTION:
Do not damage camshaft, cylinder head and the outer cir-
cumference of valve lifter.
PBIC2321E
EM-223
CAMSHAFT
[YD]
4. With valve spring in a compressed state, remove the camshaft
pliers (special service tool) by securely setting the outer circum-
ference of the valve lifter with the end of the lifter stopper (spe-
cial service tool).
● Hold the lifter stopper by hand until the shim is removed.
CAUTION:
Do not retrieve the camshaft pliers forcefully, as cam-
shaft will be damaged.
PBIC2322E
5. Move the round hole of adjusting shim to the front with the very
thin screwdriver or like that.
● When adjusting shim on valve lifter will not rotate smoothly,
restart from step 3 to release the end of the lifter stopper (spe-
cial service tool) from touching adjusting shim.
6. Remove adjusting shim from valve lifter by blowing air through
the round hole of the adjusting shim with the air gun.
CAUTION:
To prevent any remaining engine oil from being blown
around, thoroughly wipe the area clean and wear protective
goggles. PBIC2323E
7. Remove adjusting shim by using the magnet hand.
PBIC2324E
8. Measure the thickness of adjusting shim using the micrometer.

● Measure near the center of the shim (the part that touches
camshaft).
FEM032
9. Select the new adjusting shim from the following methods.

Calculation method of the adjusting shim thickness:
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake
N = R + [M - 0.28 mm (0.0010 in)]
Exhaust
N = R + [M - 0.30 mm (0.0118 in)]
EM-224
CAMSHAFT
[YD]
● New adjusting shims have the thickness stamped on the rear
side. A
● Shims are available in 33 size from 2.10 mm (0.0827 in) to
2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in). Refer to
EM-295, "Available Shims" . EM
JEM184G
D
10. Fit the selected adjusting shim to valve lifter.
CAUTION:
Place the stamped side of adjusting shim to valve lifter. E
G
PBIC2325E
11. Compress valve spring using the camshaft pliers [special service tool: KV10115110] and remove the lifter H
stopper (special service tool).
12. Rotate crankshaft 2 to 3 turns by hand.
I
13. Confirm that the valve clearance is within the specification. Refer to EM-222, "INSPECTION" .
15. Warm up engine, and check for unusual noise and vibration. J
EM-225
OIL SEAL
[YD]
OIL SEAL PFP:12279
Removal and Installation of Valve Oil Seal BBS00D2Y
REMOVAL
1. Turn crankshaft until the cylinder requiring new valve oil seals is at TDC. This will prevent valve from drop-
ping into cylinder.
2. Remove camshafts. Refer to EM-215, "CAMSHAFT" .
3. Remove adjusting shims and valve lifters. Refer to EM-215, "CAMSHAFT" .
● Check the installation positions, and keep them to avoid being confused.
4. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
● Compress the valve spring with valve spring compressor,
attachment and adapter (special service tool). Remove valve
collet with a magnet hand.
CAUTION:
When working, be careful not to damage valve lifter holes.
PBIC2388E
6. Remove valve spring retainer and valve spring.

7. Remove valve oil seal with the valve oil seal puller (special ser-
vice tool).
JEM153G
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Using the valve oil seal drift (special service tool), install valve oil
seals referring to the dimension shown in the figure.
JEM165G
EM-226
OIL SEAL
[YD]
Removal and Installation of Front Oil Seal BBS00D2Z
REMOVAL A
● Undercover
● Drive belt: Refer to EM-155, "DRIVE BELTS" .

EM
● Crankshaft pulley: Refer to EM-236, "PRIMARY TIMING CHAIN" .
2. Remove front oil seal with a suitable tool.

C
CAUTION:
Be careful not to damage oil pump housing and crankshaft.
D
PBIC4050E
F
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
G
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
H
J
SEM715A
● Using the suitable drift [60 mm (2.36 in) dia.] (A), press fit the K
oil seal (2) so that the dimension is as specified in the figure.
1 : Oil pump
CAUTION: L
Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
M
PBIC4051E
EM-227
OIL SEAL
[YD]
Removal and Installation of Rear Oil Seal BBS00D30
REMOVAL
1. Remove transmission and transfer assembly. Refer to MT-16, "TRANSMISSION ASSEMBLY" (M/T mod-
els) and AT-248, "TRANSMISSION ASSEMBLY" (A/T models).
2. Remove flywheel (M/T models) or drive plate (A/T models). Refer to EM-269, "CYLINDER BLOCK" .
3. Remove rear oil seal with a suitable tool.
CAUTION:
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.
SEM715A
● Press in rear oil seal (2) to rear oil seal retainer (1) as shown
in the figure.
● Using the drift [100 mm (3.94 in) dia.] (A), press fit so that the
dimension is as specified in the figure.
● Avoid inclined fitting. Force fit perpendicularly.
PBIC4052E
EM-228
SECONDARY TIMING CHAIN
[YD]
SECONDARY TIMING CHAIN PFP:13028
A
EM
PBIC2326E
K
1. Chain tensioner 2. Spring 3. Plunger
4. Slack guide 5. Front chain case 6. Rubber washer
7. Tension guide 8. Gasket 9. Secondary timing chain L
EM-229
[YD]
PBIC4855E
1. Gasket 2. Chain tensioner 3. Spring

4. Plunger 5. Slack guide 6. Front chain case
7. Tension guide 8. Gasket 9. Secondary timing chain
10. Tension guide
A. Oil pump side B. Tighten twice

CAUTION:
piston heads.
● When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
REMOVAL
● For preparative work for removing/installing secondary timing chain to remove/install fuel pump, refer to
EM-204, "FUEL PUMP" .
● To prepare for removing/installing secondary timing chain to remove/install camshaft, refer to EM-215,
"Removal and Installation" .
1. Remove radiator shroud (upper and lower) and cooling fan (crankshaft driven type). Refer to CO-41,
"RADIATOR" and CO-49, "COOLING FAN" .
2. Remove EGR cooler (A/T models of EURO 3 and EURO 4) and related water hoses, or EGR tube (M/T
models of EURO 3).
EM-230
[YD]
CAUTION:
● Perform this step when engine is cold. A
3. Remove front chain case.

● Loosen fixing bolts in reverse order of that shown in the figure EM
and remove them.
CAUTION:
● While front chain case is removed, cover openings to C
prevent entry of foreign material into engine.
JEM121G
E
● Do not remove two mass dampers on the back of

cover. F
SBIA0189E
I
4. Set the No. 1 piston to TDC on its compression stroke.
● Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as J
● No position indicator is provided on crankshaft pulley.
● When installing, color coded links on secondary timing K

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
pump sprocket may not be easy to see. L
SEM515G
M
5. Remove chain tensioner.
a. Push the plunger of chain tensioner and keep it pressed with a
push pin.
JEM124G
EM-231
[YD]
b. Using the hexagon wrench (special service tool), remove bolts
to remove chain tensioner.
SBIA0227E
6. Remove slack guide.

● Using the hexagon wrench (special service tool), remove bolt
to remove slack guide.
SBIA0228E
7. Remove tension guide.

8. Remove secondary timing chain.
● Timing chain alone can be removed without removing sprock-
ets.
JEM127G

Timing Chain
SEM984C
INSTALLATION
1. Install secondary timing chain.
EM-232
[YD]
● When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the timing A
chain.
1 : Secondary timing chain
2 : Chain tensioner EM
3 : Slack guide
4 : Fuel pump sprocket
5 : Tension guide C
6 : Camshaft sprocket
A : Alignment mark (silver link)
B : Alignment mark (punched mark) D
C : Alignment mark (yellow link)
2. Install tension guide. E
● The upper bolt has a longer shank than the lower bolt.
G
PBIC4048E
3. Using the hexagon wrench (special service tool), install slack

guide. H
SBIA0228E
K
4. Install chain tensioner.
a. Push the plunger of chain tensioner. While holding it with a push
pin, install chain tensioner. L
b. Using the hexagon wrench (special service tool), tighten bolts.
c. Pull out the push pin, etc. holding the plunger.
● Make sure again that the alignment marks on the sprock-
M
ets and the colored alignment marks on the timing chain
are aligned.
SBIA0227E
5. Install front chain case.
EM-233
[YD]
a. Install tension guide on the back surface of front chain case.
● Hold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.
SBIA0189E
b. Apply a continuous bead of liquid gasket on both ends of arched

area (locations where rear chain case is adjoined) as shown in
the figure.
● Use Genuine Liquid Gasket or equivalent.
JEF370Y
c. Install front chain case.

● When installing, align dowel pin on oil pump housing with the pin hole.
● Install No. 6, 10 and 11 bolts with the rubber washer to front chain case.
d. Tighten fixing bolts in numerical order shown in the figure.

e. After tightening all the bolts, re-tighten in the same order.
JEM121G

EM-234
[YD]
A
EM
Exhaust gases — Leakage — C
D
EM-235
PRIMARY TIMING CHAIN
[YD]
PRIMARY TIMING CHAIN PFP:13028
PBIC3468E
EM-236
[YD]
1. Chain tensioner 2. Spring 3. Slack guide
4. Plunger 5. Camshaft sprocket 6. Washer
A
7. Fuel pump sprocket 8. O-ring 9. Tension guide
10. Tension guide 11. Chain guide 12. Slack guide
EM
13. Spacer 14. Front chain case 15. Rubber washer
16. Gasket 17. Secondary timing chain 18. Chain guide
19. Idler pulley 20. Vacuum pump cover 21. Crankshaft pulley
C
22. Front oil seal 23. Oil pump housing 24. Crankshaft gear
25. Primary timing chain 26. Crankshaft sprocket 27. Key
28. Fuel pump 29. Vacuum pump 30. Seal washer
D
34. Rear chain case 35. Balancer unit 36. Tension guide
37. A/C compressor bracket 38. Idler pulley 39. Plunger
E
40. Plug 41. Spring 42. Chain tensioner
A. Oil pump side B. Tighten twice C. Refer to EM-244
EM-237
[YD]
PBIC4856E
EM-238
[YD]
1. Gasket 2. Chain tensioner 3. Spring
4. Slack guide 5. Plunger 6. Camshaft sprocket
A
7. Washer 8. Fuel pump sprocket 9. O-ring
10. Tension guide 11. Tension guide 12. Chain guide
EM
13. Slack guide 14. Spacer 15. Front chain case
16. Gasket 17. Secondary timing chain 18. Chain guide
19. Idler pulley 20. Vacuum pump cover 21. Crankshaft pulley
C
22. Front oil seal 23. Oil pump housing 24. Crankshaft gear
25. Primary timing chain 26. Crankshaft sprocket 27. Key
28. Fuel pump 29. Vacuum pump 30. Seal washer
D
34. Rear chain case 35. Balancer unit 36. Tension guide
37. A/C compressor bracket 38. Idler pulley 39. Plunger
E
40. Plug 41. Spring 42. Chain tensioner
A. Oil pump side B. Tighten twice C. Refer to EM-244

CAUTION: G
piston heads.
● When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting H
REMOVAL
1. Remove power steering oil pump and power steering oil pump bracket. Refer to PS-35, "POWER STEER- I
ING OIL PUMP" .
2. Remove idler pulleys.
3. Remove rocker cover. Refer to EM-211, "ROCKER COVER" . J
4. Remove oil pan (upper and lower). Refer to EM-190, "OIL PAN AND OIL STRAINER" .
6. Remove secondary timing chain and associated parts. Refer to EM-229, "SECONDARY TIMING CHAIN" K
.
7. When removing rear chain case, remove camshaft sprockets. Refer to EM-215, "CAMSHAFT" .
8. Remove crankshaft pulley. L
a. Hold crankshaft pulley with the pulley holder (commercial ser-
vice tool).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt approx- M
imately 10 mm (0.39 in).
PBIC3469E
EM-239
[YD]
c. Using the pulley puller (special service tool), remove crankshaft
pulley.
● Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
JEM132G
9. Remove oil pump housing.

● Loosen bolts in reverse order of that shown in the figure and
remove them.
● Use the seal cutter [special service tool: KV10111100] etc. for
removal.
PBIC3470E
10. Remove crankshaft gear (1) with the following procedure.

a. Make sure that No.1 piston is TDC on its compression stroke.
b. Turn the idler sub gear (3) counterclockwise with snap ring plier
(B) or suitable tool for aligning idler sub gear (3) and idler main
gear (2).
● If idler gear rotates, hold the flat faces on balancer drive shaft
front end (4).
c. Install internal mechanism securing bolt and plate (Service part:
13012 EB30A and 13013 EB30A) (A) and tighten to the speci-
fied torque.
: 4.0 N·m (0.41 kg-m, 35 in-lb)
CAUTION:
●Do not loosen idler gear mounting bolt (5).
● Only use the genuine internal mechanism securing bolt
and plate (A), or the idler gear (2) and (3) will be damaged.
● Do not remove internal mechanism securing bolt and
plate (A) from idler gear (2) and (3) until crankshaft gear
(1) and all of the parts in connection have been installed.
● If internal mechanism securing bolt and plate (A) is not
installed, internal mechanism of idler gear (2) and (3) will PBIC3471E
disengage after crankshaft gear (1) is removed. This will
prohibit the balancer unit from being reusable.
d. Apply mating marks (C) to crankshaft gear (1) and idler sub gear (3).
e. Remove crankshaft gear (1).
11. Remove front oil seal from oil pump housing.
● Punch out the seal off from the back surface of the oil pump housing using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage oil pump housing.
EM-240
[YD]
12. Remove chain tensioner.
● When removing chain tensioner, push the plunger of chain A
tensioner and keep it pressed with a push pin, etc.
13. Remove slack guide.
EM
JEM134G
D
14. Hold fuel pump sprocket and remove bolt.
a. Insert positioning stopper pin (special service tool) into the hole
6 mm (0.24 in) in the diameter on fuel pump sprocket. E
b. Using the TORX wrench, turn pump shaft little by little to adjust
the position of fuel pump sprocket so that the holes align.
c. Push positioning stopper pin through fuel pump sprocket to fuel F
pump body to hold fuel pump sprocket.
G
MBIA0049E
● Insert the positioning stopper pin until its flange contacts fuel H
pump sprocket.
PBIC2535E
K
15. Using the hexagon wrench (special service tool) remove tighten-
ing bolts to fuel pump sprocket. L
PBIC2404E
EM-241
[YD]
MBIA0074E
16. Remove primary timing chain with fuel pump sprocket and
crankshaft sprocket.
MBIA0079E
17. Remove chain guide and tension guides.
JEM885G
18. Remove fuel pump. Refer to EM-204, "FUEL PUMP" .

19. Remove vacuum pump. Refer to EM-196, "VACUUM PUMP" .
EM-242
[YD]
20. Remove rear chain case.
● Loosen fixing bolts in the reverse order of that shown in the A
figure and remove them.
● Use the seal cutter [special service tool: KV10111100] for
removal. EM
G
SBIA0211E
21. Remove balancer unit. H

● Loosen mounting bolts in the reverse order as shown in the
figure.
: Engine front I
K
PBIC4049E

Timing Chain L
M
SEM984C
EM-243
[YD]
Balancer Unit Mounting Bolt Outer Diameter
● Measure the outer diameters (“d1” , “d2” ) at two positions as
● If reduction appears in “A” range, regard it as “d2 ”.
Limit (“d1 ” - “d2 : 0.15 mm (0.0059 in)
”)
● If it exceeds the limit (large difference in dimensions), replace it
with a new one.
PBIC1137E
INSTALLATION
NOTE:
The figure shows the relationship between the mating mark on each timing chain and that on the correspond-
ing sprocket, with the components installed.
PBIC3473E
1. Chain tensioner 2. Slack guide 3. Fuel pump sprocket

4. Chain guide 5. Primary timing chain 6. Vacuum pump sprocket
7. Slack guide 8. Chain tensioner 9. Crankshaft sprocket
10. Key 11. Tension guide 12. Tension guide
13. Tension guide 14. Camshaft sprocket 15. Secondary timing chain
A. Alignment mark (silver link) B. Alignment mark (punched mark) C. Alignment mark (cut-out area)
D. Alignment mark (yellow link)
CAUTION:
Before starting work, make sure that No. 1 piston is on its compression stroke.
1. Install balancer unit, and tighten mounting bolts in numerical
: Engine front
CAUTION:
If mounting bolts are re-used, check their outer diameter
before installation. Refer to EM-244, "Balancer Unit Mount-
ing Bolt Outer Diameter" .
a. Apply new engine oil to threads and seat surfaces of mounting
bolts.
b. Tighten all bolts. PBIC4049E
EM-244
[YD]
: 29.4 N·m (3.0 kg-m, 22 ft-lb)

A
c. Turn all bolts 65 degrees clockwise (angle tightening).
1 : Balancer unit
EM
A : KV10112100
d. Completely loosen.
: 0 N·m (0 kg-m, 0 ft-lb) C
CAUTION:
In this step, loosen bolts in the reverse order as shown in
the figure. D
e. Tighten all bolts. PBIC3474E
: 29.4 N·m (3.0 kg-m, 22 ft-lb) E

f. Turn them another 65 degrees clockwise (angle tightening).
CAUTION:
F
Check tightening angle with an angle wrench (special service tool) (A) or a protractor. Do not make
judgment by visual check alone.
2. Install rear chain case.
G
a. Apply a continuous bead of liquid gasket with the tube presser
[special service tool: WS39930000] on locations shown in the
figure.
Use Genuine Liquid Gasket or equivalent. H
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by starting and ending
at areas of bead as shown in the figure. Apply so that the portion I
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 protruding
from the case surface. J
PBIC1255E
b. Install four O-rings to the grooves of the cylinder block and fuel
pump bracket.
JEM141G
c. Install rear chain case.

● When installing, align the dowel pin with the pin hole.
EM-245
[YD]
d. Tighten bolts in numerical order shown in the figure.
● 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
● The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
SBIA0211E
3. Install vacuum pump. Refer to EM-196, "VACUUM PUMP" .

4. Install fuel pump. Refer to EM-204, "FUEL PUMP" .
● Before installing, make sure that spacer and the hole 6 mm
(0.24 in) in diameter on coupling are aligned.
5. Install chain guide and tension guides.
6. Install crankshaft sprocket, aligning it with crankshaft key on the
far side.
JEM885G
7. Install primary timing chain with fuel pump sprocket.

● When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on primary timing
chain.
● Install fuel pump sprocket washer with the surface marked “F”
(front mark) facing the front of the engine.
8. Install timing chain onto power steering oil pump sprocket and
through chain guide.
MBIA0079E
9. Use the positioning stopper pin (special service tool) to hold the
fuel pump sprocket and install the bolt.
● Using the TORX wrench (special service tool), turn the fuel
pump shaft little by little to adjust the position of the fuel pump
sprocket. Insert positioning stopper pin into the hole 6 mm
(0.24 in) in diameter on fuel pump sprocket so that the stop-
per pin goes through the fuel pump body. While the stopper
pin is in place, install the bolt.
MBIA0049E
EM-246
[YD]
EM
PBIC2404E
D
10. Install timing chain slack guide.
11. Install chain tensioner.
E
● Push the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin, etc., install chain
tensioner.
● After installation, pull out the push pin holding the plunger. F
CAUTION:
Make sure again that the alignment marks on sprockets and
the colored alignment marks on timing chain are aligned. G
JEM134G
12. Install front oil seal (1) to oil pump housing (2). H
● Using the suitable drift (A) [62 mm (2.44 in) dia.], force fit the
seal until it hits the bottom.
CAUTION: I
Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
J
PBIC3448E K
13. Install vacuum pump cover to oil pump housing.

● Apply a continuous bead of liquid gasket with the tube presser L
● Apply liquid gasket on oil pump-side surface.
M
JEM143G
14. Install crankshaft gear.
EM-247
[YD]
● Align crankshaft gear (1) mating mark and idler sub gear (3)
mating mark (C).
2 : Idler main gear
4 : Balancer drive shaft front end
5 : Idler gear mounting bolt (do not loosen)
B : Snap ring plier
● Remove internal mechanism securing bolt and plate (Service
part: 13012 EB30A and 13013 EB30A) (A).
PBIC3471E
– If new balancer unit (2) is used, align matching marks (B) of

each gear as shown in the figure.
– Remove securing-bolt-and-plate (A) and securing pin (C) after
installing crankshaft gear (1).
PBIC3475E
15. Install oil pump housing.

a. Apply a continuous bead of liquid gasket with the tube presser
A: Leave the start and end areas of the bead slightly protruding
from the surface.
B: Apply liquid gasket along upper end surface of oil pump hous-
ing.
JEM144G
EM-248
[YD]
b. Install O-ring into the groove of rear chain case.
A
c. Install oil pump housing.
● When installing, align the inner rotor in the direction of the two facing flats of oil pump drive spacer.
● When installing, align the dowel pin with the pin hole. EM
d. Tighten fixing bolts in numerical order shown in the figure.
C
E
PBIC3470E
16. Check gaps on upper oil pan mounting surface. F

● Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
G
Oil pump housing and rear chain case:
Rear chain case and cylinder block: H
● If the measured value is out of the standard, install again.
JEM146G I
17. Install crankshaft pulley.

CAUTION: J
Be careful not to damage front oil seal.
a. Install crankshaft pulley to crankshaft.
b. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. K
c. Hold crankshaft pulley with the pulley holder (special service
tool).
d. Tighten crankshaft pulley fixing bolt. L
: 75.0 N·m (7.7 kg-m, 55 ft-lb)

e. Completely loosen. M
: 0 N·m (0 kg-m, 0 ft-lb)
f. Tighten crankshaft pulley bolt.

PBIC3469E
: 75.0 N·m (7.7 kg-m, 55 ft-lb)

g. Put an alignment mark on crankshaft pulley that aligns with one of the punched marks on the bolt.
EM-249
[YD]
h. Tighten fixing bolt another 120 degrees (angle tightening) (turn
by 2 notch).
A : Indicate embossments
B : Alignment mark
PBIC3476E
18. Install secondary timing chain and the associated parts.

Refer to EM-232, "INSTALLATION" .
EM-250
CYLINDER HEAD
[YD]
CYLINDER HEAD PFP:11041
A
On-Vehicle Service BBS00D37
CHECKING COMPRESSION PRESSURE

1. Warm up engine thoroughly. Then, stop it.
EM
2. Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer to EC-1008,
"Basic Inspection" (TYPE 1) or EC-1402, "Basic Inspection" (TYPE 2).
● Do not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and
C
for error detection at the end of this operation.
3. Disconnect the battery cable from the negative terminal.
4. Remove the engine cover and bracket. Refer to EM-166, "INTAKE MANIFOLD" D
5. To prevent fuel from being injected during inspection, disconnect
all the connectors of the fuel injector.
A : Injector E
B : Connector
● Figure shows as an example of EURO 4.

F
G
PBIC4872E
6. Wind the insulating tape around the electrode of the discon- H

nected connectors. Tie them together and fix them on the har-
ness side.
A : Connector I
PBIC4772E K
7. Remove glow plugs from all the cylinders. Refer to EM-195, "GLOW PLUG" .
CAUTION: L
● Before removal, clean the surrounding area to prevent entry of any foreign materials into
engine.
● Carefully remove glow plugs to prevent any damage or breakage. M
● Handle with care to avoid applying any shock to glow plugs.
8. Install compression gauge adapter (special service tool) to

installation holes of glow plugs and connect compression gauge
for diesel engine.
: 20.0 N·m (2.0 kg-m, 15 ft-lb)
9. Connect the battery cable to the negative terminal.
10. Turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and engine
rpm. Perform these steps to check each cylinder.
● Always use a fully-charged battery to obtain specified engine
SEM112G
speed.
EM-251
CYLINDER HEAD
[YD]
Unit: kPa (bar, kg/cm2 , psi)/rpm
Standard Minimum Difference limit between cylinders
3,100 (31, 31.6, 450)/200 2,500 (25, 25.5, 363)/200 490 (4.9, 5.0, 71)/200
● When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
● If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
● If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
– If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring.
– If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.
● If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be
leaking from gasket. In this case, replace cylinder head gasket.
11. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect the battery cable from the negative terminal.
c. Install glow plug and install all the parts removed in step 4.
d. Connect all the connectors of the fuel injector.
e. Connect the battery cable to the negative terminal.
f. Check DTC. If DTC is displayed, erase it. Refer to EC-997, "ON BOARD DIAGNOSTIC (OBD) SYSTEM"
(TYPE 1) or EC-1384, "ON BOARD DIAGNOSTIC (OBD) SYSTEM" (TYPE 2).
Components BBS00D38
PBIC3477E
EM-252
CYLINDER HEAD
[YD]
1. Cylinder head bolt 2. Cylinder head assembly 3. Gasket
4. Dowel pin 5. Cylinder block
A
A. Refer to EM-255
● Refer to GI-11, "Components" for symbol marks in the figure. EM

REMOVAL
1. Drain engine coolant. Refer to CO-37, "Changing Engine Coolant" . C
2. Remove the following:
● Rocker cover: Refer to EM-211, "ROCKER COVER" .
D
● Spill tube and fuel injector: Refer to EM-198, "INJECTION TUBE AND FUEL INJECTOR" .
● Intake manifold and vacuum gallery: Refer to EM-166, "INTAKE MANIFOLD" .
● Turbocharger: Refer to EM-180, "TURBO CHARGER" .

E
● Exhaust manifold: Refer to EM-187, "EXHAUST MANIFOLD" .
● Secondary timing chain: Refer to EM-229, "SECONDARY TIMING CHAIN" .
● Camshaft: Refer to EM-215, "CAMSHAFT" . F

3. Remove cylinder head assembly.
● Remove bolts between rear chain case and cylinder head. Refer to EM-236, "PRIMARY TIMING
CHAIN" . G
● Remove cylinder head bolts in the reverse order as shown in
the figure with the cylinder head bolt wrench (commercial ser-
vice tool). H
● Lift up cylinder head assembly to avoid interference with
dowel pins located between the cylinder block and cylinder
head, and remove cylinder head assembly. I
CAUTION:
Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of cylinder
J
head, or, place wood blocks beneath both ends of cylin-
der head to keep the cylinder bottom from any contact. JEM149G
● For glow plug removal, the following shall be noted.

K
CAUTION:
● To avoid breakage, do not remove glow plug unless necessary.
● Perform continuity test with glow plug installed.

L
● Keep glow plug from any impact. [Replace if dropped from a height 10 cm (3.94 in) or higher.]
● Do not use air impact wrench.
INSPECTION AFTER REMOVAL M

Cylinder Head Bolt Deformation
● Using micrometer, measure the outer diameters “d1” and “d2” of
bolt thread as shown in the figure.
● If the necking point can be identified, set it as measuring point
d1.
● Calculate the difference between “d1” and “d2”.
Limit : 0.15 mm (0.0059 in)
● If it exceeds the limit, replace cylinder head bolt.
JEM171G
Cylinder Head Distortion

1. Wipe off oil and remove water scale (like deposit), gasket, sealer, carbon, etc. with scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for oil or water.
EM-253
CYLINDER HEAD
[YD]
2. At each of several locations on bottom surface of cylinder head,
measure distortion in six directions.
Limit : 0.1mm (0.004 in)
● If it exceeds the limit, replace cylinder head.
SEM496G
EM-254
CYLINDER HEAD
[YD]
INSTALLATION
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts. A
1. Install cylinder head gasket.
● Cylinder head gasket to be installed is selected by its thickness through the following procedure.
EM
– When replacing gasket alone:
• Install a gasket with same thickness as that of the one removed.

• Identify the thickness of gasket by the number of cut-outs on C
the rear RH side.
Gasket thickness* mm (in) Number of grade Number of cut-outs
0.900 (0.0354) 1 0 D
0.925 (0.0364) 2 1
0.950 (0.0374) 3 2
E
0.975 (0.0384) 4 3
1.000 (0.0394) 5 4
1.025 (0.0404) 6 5 MBIA0020E
F
*: Measured with head bolts tightened
• Gasket (3) thickness can be identified at the location (A)
shown in the figure by the numbers of cut-outs before G
removal.
1 : Cylinder head rear cover
2 : Oil filter
H
: Vehicle front
• Heater return tube is omitted for explanation. I

NOTE:
PBIC3478E
– When the following parts have been repaired/replaced: J
● With cylinder block upper surface and/or crankshaft pin journal ground.
● With cylinder block, pistons, connecting rods, and/or crankshaft replaced.

K
a. Set piston at a point close to TDC.
b. Set the dial gauge at the location as shown in the figure. Turning
crankshaft gradually, set the gauge scale to “0” where the piston
protrusion is maximized. L
c. Move the dial gauge stand so that the tip of dial gauge can con-
tact cylinder block. Read the difference.
d. Measure two points from each cylinder in order to obtain each M
mean value of them. Choose a properly thick gasket corre-
sponding the highest number of the four values.
SEM507G
Identification
Piston protrusion mm (in) Gasket thickness* mm (in)
Number of cut-outs
0.230 - 0.255 (0.0091 - 0.0100) 0.900 (0.0354) 0
0.255 - 0.280 (0.0100 - 0.0110) 0.925 (0.0364) 1
0.280 - 0.305 (0.0110 - 0.0120) 0.950 (0.0374) 2
0.305 - 0.330 (0.0120 - 0.0130) 0.975 (0.0384) 3
0.330 - 0.355 (0.0130 - 0.0140) 1.000 (0.0394) 4
0.355 - 0.400 (0.0140 - 0.0157) 1.025 (0.0404) 5
EM-255
CYLINDER HEAD
[YD]
*: Measured with head bolts tightened
e. If out of above protrusion, check replaced parts.
2. Apply a continuous bead of liquid gasket with the tube presser
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external loca-
tion but cannot be viewed externally after engine is assembled.
PBIC1256E
3. Install cylinder head assembly.

● Tighten bolts in numerical order as shown in the figure
according to the following procedure:
a. Apply engine oil to bolt threads and seat surfaces.
b. Tighten all bolts.
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
JEM149G
c. Tighten 180 degrees (angle tightening).

d. Loosen completely in the reverse order of that shown in the fig-
ure.
: 0 N·m (0 kg-m, 0 ft-lb)

e. Tighten all bolts.
: 39.2 N·m (4.0 kg-m, 29 ft-lb)

f. Tighten 90 degrees (angle tightening).
g. Tighten another 90 degrees (angular tightening). JEM166G
CAUTION:
● When the angle wrench (special service tool) is not used, paint an alignment mark on the head
of cylinder head bolt and cylinder head surface before tightening. Check the angle with a pro-
tractor.
4. Tighten bolts between rear chain case and cylinder head. Refer to EM-236, "PRIMARY TIMING CHAIN" .
5. After installing cylinder head, measure dimension from the front
end surface of cylinder block to that of cylinder head (If rear
chain case is removed).
Standard : 23.53 - 24.07 mm (0.9264 - 0.9476 in)
● If out of the standard, check fitting of dowel pins and cylinder
head.
JEM172G
6. Install glow plug.

CAUTION:
● To avoid damage, glow plugs should be removed only when required.
EM-256
CYLINDER HEAD
[YD]
● Handle with care to avoid applying shock. When dropped from approx. 10 cm (3.94 in) or higher,
always replace with a new one. A
● Before installing, remove carbon depositing on mounting hole of glow plug with a reamer.
7. Install engine coolant temperature sensor.

8. Install vacuum gallery. EM
INSPECTION AFTER INSTALLATION C
● Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required D
– Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel E
● Run engine to check for unusual noise and vibration. F
● Bleed air from lines and hoses of applicable lines, such as in cooling system. G
H
Engine coolant Level Leakage Level I
J
*1: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc. K
EM-257
CYLINDER HEAD
[YD]
Components BBS00D3A
PBIC2328E
1. Adjusting shim 2. Valve lifter 3. Valve collet

4. Valve spring retainer 5. Valve spring 6. Valve oil seal
7. Valve spring seat 8. Valve guide 9. Cylinder head
10. Valve seat 11. Valve (Exhaust) 12. Valve (Intake)
Disassembly and Assembly BBS00D3B
DISASSEMBLY
1. Remove adjusting shims and valve lifters.
● Check the installation positions, and keep them to avoid being confused.

● Using the valve spring compressor (special service tool),
compress valve spring. Using magnet hand, remove valve
collets.
PBIC2388E
3. Remove valve spring retainers and valve springs.

4. Remove valves as pressing valve stems toward combustion chamber.
● Before removing valve, check the valve guide clearance. Refer to EM-260, "Valve Guide Clearance" .
EM-258
CYLINDER HEAD
[YD]
NOTE:
Refer to the figure for intake and exhaust valve positions. A
Intake and exhaust valve driving cams are provided alter-
nately for each camshaft.
EM
SBIA0196E D
5. Remove valve oil seals using the valve oil seal puller (special
service tool).
E
6. Remove valve spring seats.
7. Before removing valve seats, perform valve seat contact check.
Refer to EM-262, "Valve Seat Contact" .
F
8. Before removing valve guides, perform valve guide clearance
check. Refer to EM-260, "Valve Guide Clearance" .
G
JEM153G
ASSEMBLY H
1. Install valve guides. Refer to EM-261, "Valve Guide Replacement" .
2. Install valve seats. Refer to EM-262, "Valve Seat Replacement" .
3. Using the valve oil seal drift (special service tool), install valve oil I
seals referring to the dimension shown in the figure.
4. Install valve spring seats.
J
L
JEM165G
5. Install valves.
● Install the valves with bigger outer diameter to intake valve M
side.
● Note that valve layout here is different from that of conven-
tional engine.
SBIA0196E
6. Install valve spring.

7. Install valve spring retainers.
EM-259
CYLINDER HEAD
[YD]
8. Using the valve spring compressor (special service tool), com-
press valve springs.
Then install valve collets using magnet hand.
● After installing valve collets, tap the stem end using the plastic
hammer, and check the installation status.
PBIC2388E
9. Install valve lifters and adjusting shims to the same positions as before.
INSPECTION AFTER DISASSEMBLY
Valve Dimension
● Check dimensions of each valve. For dimensions, refer to EM-
295, "Valve Dimensions" .
● If dimensions are out of the standard, replace valve.
SEM188A

Valve Stem Diameter
● Measure diameter of valve stem with micrometer.
Standard
Intake : 5.965 - 5.980 mm (0.2348 - 0.2354 in)
Exhaust : 5.945 - 5.960 mm (0.2341 - 0.2346 in)
SEM938C
Valve Guide Inner Diameter

● Measure inner diameter of valve guide with inside micrometer.
Standard
Intake and Exhaust : 6.000 - 6.018 mm (0.2362 - 0.2369 in)
● (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
Valve guide clearance:
Standard
Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.040 - 0.073 mm (0.0016 - 0.0029 in)
Limit
Intake : 0.08 mm (0.0031 in)
Exhaust : 0.10 mm (0.0039 in)
EM-260
CYLINDER HEAD
[YD]
● If it exceeds the limit, replace valve and/or valve guide.
A
Valve Guide Replacement
When removing valve guide, replace it with oversized [0.2 mm (0.0008 in)] valve guide.
1. Heat cylinder head to 110 to 130°C (230 to 266°F) in oil bath. EM
SEM008A
E
2. Using the valve guide drift (commercial service tool), tap valve
guides out from the combustion chamber side.
WARNING: F
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
G
SEM931C
3. Ream cylinder head valve guide hole with the valve guide I
reamer (commercial service tool).
Valve guide hole diameter (for service parts):
J
10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
L
4. Heat cylinder head to 110 to 130°C (230 to 266°F) in oil bath.

M
SEM008A
EM-261
CYLINDER HEAD
[YD]
5. Using the valve guide drift (commercial service tool), press fit
valve guides from camshaft side, referring to the dimension
Projection “L” : 10.4 - 10.6 mm (0.409 - 0.417 in)
WARNING:
PBIC2497E
6. Using the valve guide reamer (commercial service tool), perform

reaming to the press-fitted valve guides.
Reaming specifications:
Intake and Exhaust
6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM932C
Valve Seat Contact

● Before starting this check, confirm that the dimension of valve
guide and valves are as specified.
● Apply red lead primer on contacting surfaces of valves seat and
of valve face to examine the conditions of contacting surfaces.
● Make sure that the paint on contacting surfaces is continuous
along the entire circumference.
● If there are abnormal indications, grind the valve and check the
contact again. If malfunction indications still persist, replace
valve seat.
SBIA0322E
Valve Seat Replacement

When removing valve seat, replace it with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-298, "Valve Seat" .
2. Ream cylinder head recess diameter for service valve seat.
Oversize [0.5 mm (0.020 in)]:
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.
● This will enable valve seat to fit correctly.
SEM795A
EM-262
CYLINDER HEAD
[YD]
3. Heat cylinder head to approximately 110 to 130°C (230 to
266°F) in oil bath. A
4. After cooling valve seats sufficiently with dry ice, press fit it to
cylinder head.
WARNING: EM
CAUTION: C
Do not touch the cooled valve seats directly by hand.
SEM008A
D
5. Using the valve seat cutter set (commercial service tool), finish
processing referring to the dimensions shown in the figure.
Refer to EM-298, "Valve Seat" .
E
CAUTION:
When using the valve seat cutter set, grasp cutter handle
with both hands, press cutter onto contacting face all
around, and cut thoroughly. If cutter is pressed unevenly or F
repeatedly, the valve seat surface may be damaged.
G
SEM934C
6. Using compound, perform valve fitting. H

7. Check again to make sure that contacting status is satisfactory.
For details, Refer to EM-262, "Valve Seat Contact" .
8. Use the depth gauge to measure the distance between the I

mounting surface of 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 valve seat with a new J
one.
Valve seat resurface limit “L”:
Intake : 36.53 - 36.98 mm (1.4382 - 1.4559 in) K
Exhaust : 36.53 - 37.01 mm (1.4382 - 1.4571 in)

L
JEM253G
Valve Spring Square

● Position the try square to valve spring, turn the spring, and mea- M
sure the maximum clearance value between top surface of
spring and the try square.
Limit : 1.9 mm (0.075 in)
● If it exceeds the limit, replace valve spring.
PBIC0080E
EM-263
CYLINDER HEAD
[YD]
Valve Spring Dimensions and Valve Spring Pressure Load
● Using valve spring tester, check the following.
Standard:
Free height : 43.7 mm (1.72 in)
Installation height : 32.82 mm (1.2921 in)
Installation load : 184 - 208 N
(18.77 - 21.22 kg, 41.4 - 46.8 lb)
Height during : 24.82 mm (0.9772 in)
valve open
Load with valve : 320 - 360 N SEM113
open (32.65 - 36.73 kg, 71.9 - 80.9 lb)

● If out of the standard, replace the valve spring.
EM-264
ENGINE ASSEMBLY
[YD]
ENGINE ASSEMBLY PFP:10001
A
Components BBS00D3E
EM
PBIC4053E

4. Vacuum hose 5. RH engine mounting insulator 6. RH engine mounting bracket
7. Engine mount control solenoid valve 8. Vacuum gallery 9. LH engine mounting bracket
10. Heat insulator 11. Vacuum hose 12. LH engine mounting insulator
13. Transmission cross member 14. Engine mounting insulator (rear) 15. RH engine mounting insulator
16. RH engine mounting bracket 17. LH engine mounting bracket 18. Heat insulator
19. LH engine mounting insulator
Models with electronic controlled Models without electronic controlled
A. B.
engine mount engine mount
EM-265
ENGINE ASSEMBLY
[YD]
Removal and Installation BBS00D3F
WARNING:
● Situate vehicle on a flat and solid surface.
● Place chocks at front and back of rear wheels.
● For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:
● Always be careful to work safely, avoid forceful or uninstructed operations.
● Do not start working until exhaust system and engine coolant are cool enough.
● If items or work required are not covered by the engine main body section, refer to the applicable
sections.
● Always use the support point specified for lifting.
● Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.
● For supporting points for lifting and jacking point at rear axle, refer to GI-52, "Garage Jack and
Safety Stand" .
REMOVAL
Description of work
Remove transmission assembly from vehicle downward. Then hoist the engine from vehicle upward.
Preparation
1. Disconnect battery cable from negative terminal. Refer to SC-5, "BATTERY" .
● Engine undercover front, engine undercover middle, engine undercover rear; Refer to EI-15, "FRONT
BUMPER" .
● Hood assembly: Refer to BL-15, "HOOD" .
● Engine cover: Refer to EM-166, "INTAKE MANIFOLD" .
● Drive belts: Refer to EM-155, "DRIVE BELTS" .
● Cooling fan, fan coupling and water pump pulley: Refer to CO-49, "COOLING FAN" .
● Air duct and air cleaner case: Refer to EM-158, "AIR CLEANER AND AIR DUCT" .
● Air inlet tube and air inlet hose: Refer to EM-164, "CHARGE AIR COOLER" .
● Alternator: Refer to SC-25, "Removal and Installation" .
● Radiator, radiator shroud (upper and lower) and cooling fan assembly: Refer to CO-41, "RADIATOR"
and CO-49, "COOLING FAN" .
4. Disconnect engine room harness from the engine side and set it aside for easier work.
5. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Engine room RH
1. Disconnect fuel feed hose and return hose, and plug it to prevent fuel from draining. Refer to EM-198,
"INJECTION TUBE AND FUEL INJECTOR" .
3. Disconnect heater hose, and install plug it to prevent engine coolant from draining. Refer to CO-53,
"THERMOSTAT AND WATER PIPING" .
Engine room LH
1. Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to
avoid putting load on it. Refer to ATC-185, "Removal and Installation for Compressor" .
Vehicle underbody
1. Remove exhaust front tube. Refer to EX-3, "EXHAUST SYSTEM" .
2. Remove front and rear propeller shaft. Refer to PR-3, "FRONT PROPELLER SHAFT" and PR-7, "REAR
PROPELLER SHAFT" .
EM-266
ENGINE ASSEMBLY
[YD]
3. Remove clutch operating cylinder from transmission, and move it aside (M/T models). Refer to MT-16,
"TRANSMISSION ASSEMBLY" and CL-13, "OPERATING CYLINDER" . A
4. Disconnect power steering fluid piping at a point between body and engine. Refer to PS-44, "HYDRAULIC
LINE" .
5. Remove starter motor. Refer to SC-35, "Removal and Installation" . EM
6. Remove transmission assembly. Refer to MT-16, "TRANSMISSION ASSEMBLY" (M/T models) or AT-
248, "TRANSMISSION ASSEMBLY" (A/T models).
Removal C
1. Install engine slingers into front right of cylinder head (A) and
rear left of cylinder head (B).
1 : Engine slinger (front)
D
2 : Engine slinger (rear)
: Engine front
E
Engine slinger bolts:
: 28.0 N·m (2.9 kg-m, 21 ft-lb) F
PBIC3480E
2. Lift with hoist and secure engine in position. G

3. Loosen LH and RH engine mounting insulator mounting nuts.
4. Remove engine.
H
CAUTION:
● During the operation, make sure that no part interferes
with body side.
● Before and during this lifting, always check if any har-
I
nesses are left connected.
SEM896G
K
INSTALLATION
Install in the reverse order of removal.
● Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator. L
● When installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer to EM-265, "ENGINE ASSEMBLY" .
● Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts. M
● Insert vacuum hose to vacuum gallery until vacuum hose comes in contact with the stopper when a stop-
per is provided at vacuum gallery.
● Insert vacuum hose up to 15 mm (0. 59 in) when a stopper is not provided at vacuum gallery.
– Before starting engine, check for fuel leakage at connection points.
EM-267
ENGINE ASSEMBLY
[YD]
Item Before starting engine Engine running After engine stopped
*1: Transmission/transaxle/AT fluid, power steering fluid, brake fluid, etc.
EM-268
CYLINDER BLOCK
[YD]
CYLINDER BLOCK PFP:11010
A
Components BBS00D3G
EM
PBIC3481E
EM-269
CYLINDER BLOCK
[YD]
1. Fuel pump bracket 2. Oil pressure switch 3. Cylinder block
4. Rear oil seal retainer 5. Rear oil seal 6. Top ring
7. Second ring 8. Oil ring 9. Piston pin
10. Snap ring 11. Piston 12. Connecting rod
13. Connecting rod bearing 14. Connecting rod cap 15. Connecting rod nut
16. A/C compressor bracket 17. Oil jet 18. Copper washer
19. Oil jet relief valve 20. Drain plug 21. Thrust bearing
22. Main bearing upper 23. Key 24. Crankshaft
25. Main bearing lower 26. Main bearing cap bolt 27. Main bearing cap
28. Flywheel (M/T models) 29. Pilot bushing (M/T models) 30. Rear plate
31. Pilot converter (A/T models) 32. Drive plate (A/T models) 33. Reinforcement plate (A/T models)
A. Refer to EM-273

Disassembly and Assembly BBS00D3H
DISASSEMBLY
1. Remove engine from the vehicle. Refer to EM-265, "ENGINE ASSEMBLY" .
2. Remove clutch cover and disk. (M/T models) Refer to CL-19,
"CLUTCH DISC, CLUTCH COVER AND FLYWHEEL" .
3. If they need to be replaced, replace pilot bush (M/T models) or
pilot converter (A/T models).
● Using the pilot bushing puller (special service tool), remove
the pilot bush (M/T models) or pilot converter (A/T models)
from rear end of crankshaft.
SEM500G
4. Install engine to engine stand as follows.

a. Remove flywheel (M/T models) or drive plate (A/T models).
● Secure ring gear with the ring gear stopper (A) (special ser-
vice tool), then loosen mounting bolts with TORX socket (B)
(commercial service tool) and remove them. As an alternative
method hold crankshaft pulley with the pulley holder (com-
mercial service tool) to remove flywheel (M/T models) or drive
plate (A/T models).
1 : Flywheel (M/T models) or drive plate (A/T models)
A : KV10105630
: TORX bit (size: T55)(M/T models) or TORX socket (size: E20)(A/T
B
models)
PBIC3482E
CAUTION:
● Do not disassemble flywheel (M/T models) or drive plate (A/T models).
● Do not place flywheel (M/T models) or drive plate (A/T models) with signal plate facing down.
● When handling signal plate, take care not to damage or scratch it.
● Handle signal plate in a manner that prevents it from becoming magnetized.
EM-270
CYLINDER BLOCK
[YD]
b. Hoist engine and install it to the engine stand (commercial ser-
vice tool). A
NOTE:
The figure shows an example of general-purpose engine stand
that can hold mating surface of transmission with drive plate and EM
rear plate removed.
PBIC0085E
D
5. Drain engine oil and engine coolant from inside engine. Refer to LU-21, "Changing Engine Oil" .
6. Drain engine coolant by removing drain plug from inside of
engine. E
1 : Cylinder block
2 : Drain plug
F
PBIC3483E
H
7. Remove the following parts and related parts. (Only major parts are listed.)
● Intake manifold: Refer to EM-166, "INTAKE MANIFOLD" .
● Turbocharger: Refer to EM-180, "TURBO CHARGER" . I

● Exhaust manifold: Refer to EM-187, "EXHAUST MANIFOLD" .
● Rocker cover: Refer to EM-211, "ROCKER COVER" .
● Fuel injector: Refer toEM-198, "INJECTION TUBE AND FUEL INJECTOR" .

J
● Oil pan and oil strainer: Refer to EM-190, "OIL PAN AND OIL STRAINER" .
● Water pump: Refer to CO-51, "WATER PUMP" .

K
● Thermostat and water piping: Refer to CO-53, "THERMOSTAT AND WATER PIPING" .
● Secondary timing chain: Refer to EM-229, "SECONDARY TIMING CHAIN" .
● Primary timing chain: Refer to EM-236, "PRIMARY TIMING CHAIN" . L

● Fuel pump: Refer to EM-204, "FUEL PUMP" .
● Vacuum pump: Refer to EM-196, "VACUUM PUMP" .
● Camshaft: Refer to EM-215, "CAMSHAFT" . M

● Cylinder head: Refer to EM-251, "CYLINDER HEAD" .
● Oil cooler: Refer to LU-26, "OIL COOLER" .
● Accessory, accessory bracket and mount brackets
8. Remove fuel pump bracket.

9. Remove rear oil seal retainer.
● Insert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer.
10. Remove rear oil seal from rear oil seal retainer. Refer to EM-226, "OIL SEAL" .
● Punch out with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage rear oil seal retainer.
EM-271
CYLINDER BLOCK
[YD]
11. Remove piston and connecting rod assembly.
● Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-284, "CONNECT-
ING ROD SIDE CLEARANCE" .
a. Move crankshaft pin to be removed to approximately BDC.
b. Remove connecting rod caps.
c. Using the grip of a hammer, press the piston and connecting rod
assembly out to cylinder head side.
CAUTION:
● Be careful not to damage the cylinder wall and crankshaft JEM195G
pin, resulting from an interference of the connecting rod
big end.
● When removing piston and connecting rod assembly,

prevent the big end of connecting rod from interfering
with oil jet.
12. Remove connecting rod bearings from connecting rods and
caps.
● Keep them by cylinder to avoid confusion.
FEM086
13. Remove piston rings from pistons using the piston ring expander
(commercial service tool).
CAUTION:
● When removing, prevent pistons from being damaged.
● Do not expand piston rings excessively. This may dam-

age piston rings.
JEM196G
14. Remove pistons from connecting rods.

a. Using the snap ring pliers, remove snap rings.
JEM197G
EM-272
CYLINDER BLOCK
[YD]
b. Using the industrial use dryer, heat pistons up to 60 to 70°C (140
to 158°F). A
EM
PBIC0089E
D
c. Using rod with outer diameter of 26 mm (1.02 in), press piston
pins out.
E
G
EMM0072D
15. Remove main bearing cap bolts. H

● With a TORX socket (size: E14, 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-283, "CRANKSHAFT END PLAY" .
JEM200G
K
16. Remove main bearing caps.
● Using main bearing cap bolts, remove by rocking bearing cap
back and forth. L
17. Remove crankshaft.
18. Remove main bearings and thrust bearings from cylinder block
and main bearing caps. M
CAUTION:
Check the correct installation locations of removed parts.
Store them so they do not get mixed up.
19. Remove oil jet. JEM201G
20. Remove oil jet relief valve.

ASSEMBLY
1. Blow air sufficiently to inside engine coolant passage, engine oil passage, crankcase and cylinder bore to
remove foreign matter.
CAUTION:
Use a goggles to protect your eye.
EM-273
CYLINDER BLOCK
[YD]
2. Install drain plug to cylinder block.
1 : Cylinder block
2 : Drain plug
● Apply liquid gasket to drain plug.

Use Genuine Liquid Gasket or equivalent
PBIC3483E
3. Install oil jet relief valve.

4. Install oil jet.
● Align knock pin on back of oil jet with hole on block when
installing oil jet.
PBIC0389E
5. Install main bearings and thrust bearings.

a. Remove contamination, dust and engine oil from bearing mount-
ing positions on cylinder block and main bearing caps.
b. Install thrust bearings on both sides of No. 3 housing on cylinder
block.
● Install thrust bearings with oil groove facing to crankshaft arm
(outside).
JEM224G
c. Being careful with the direction, install main bearings.

● Install main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the main cap side.
● While installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply engine oil to rear surfaces, but clean
them completely.
● Align stopper notches on bearings to install them.
● Make sure that the oil holes on the cylinder block body are
mated with the oil hole positions on the bearings. JEM213G
6. Install crankshaft to cylinder block.
● Make sure crankshaft rotates smoothly by hand.
EM-274
CYLINDER BLOCK
[YD]
7. Install main bearing caps.
● Identify main bearing caps by the punched mark. Install cor- A
rectly matching the journal No. on the bearing cap and the
journal with the front mark facing forward.
● Main bearing caps are commonly processed with the cylinder EM
block. Therefore, caps and cylinder block should be replaced
as a set.
8. Check the main bearing cap bolts for deformation. Refer to EM- C
292, "MAIN BEARING CAP BOLT DEFORMATION" .
JEM225G
D
9. With the TORX socket (size: E14, commercial service tool),
tighten the main bearing cap bolts according to the following
procedure:
E
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten all bolts in numerical order shown in the figure.
F
: 27.0 N·m (2.8 kg-m, 20 ft-lb)
c. Put alignment marks (with paint) on each bolt and the main G
bearing cap, all in the same direction. (When using a protractor) JEM200G
d. Then, tighten 90 degrees. (angle tightening) H

CAUTION:
Always use either the angle wrench (special service tool) or
protractor during angular tightening. Avoid tightening
based on visual checks alone. I
● After tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.
● Check crankshaft end play. Refer to EM-283, "CRANKSHAFT
J
END PLAY" .
10. Check the outer diameter of connecting rod bolts. Refer to EM- JEM226G
292, "CONNECTING ROD BOLT DEFORMATION" . K
11. Install piston to connecting rod.
a. Using the snap ring pliers, install snap rings to groove on piston rear side.
L
● Fit snap ring correctly into grooves.
b. Install pistons to connecting rods.

● Using the industrial use dryer, heat pistons up to approx. 60 to
M
70°C (140 to 158°F) until piston pin can be pressed down by
finger touch. Then insert piston pin into piston and connecting
rod from front side of piston toward rear.
PBIC0089E
EM-275
CYLINDER BLOCK
[YD]
● Assemble piston and connecting rod with front mark of piston
head and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
c. Install snap ring to front side of piston.
● Refer to above step a for precaution on snap ring installation.
● After installation, check connecting rods for smooth move-

ment.
MBIA0024E
12. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.
● Install top ring and second ring with punched mark surfaces
facing upward.
Punched mark:
Top ring : RTOP
Second ring : R2ND
● Install rings so that three closed gap position 120 degrees
apart one another.
● Closed gaps do not need to face in a specific directions, as
long as each are positioned 120 degrees apart. JEM228G
13. Install connecting rod bearing to connecting rod and cap.

● While installing connecting rod bearing, apply engine oil to
bearing surfaces (inside). Do not apply engine oil to rear sur-
faces, but clean them completely.
● Align protrusions on connecting rod bearings with connecting
rod cut-outs to install connecting rod bearings.
JEM229G
14. Install piston and connecting rod assembly to crankshaft.

● Move crankshaft pin to be assembled to BDC.
● Align cylinder position with cylinder No. on connecting rod to

install piston and connecting rod assembly.
● Using the piston ring compressor (special service tool) or suit-
able tool, install piston and connecting rod assembly with front
mark on piston head facing toward the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with PBIC1619E
oil jet.
EM-276
CYLINDER BLOCK
[YD]
15. Install connecting rod caps and mounting nuts.
● Align cylinder No. stamped on connecting rod with that on cap A
to install connecting rod cap.
● Make sure that the front mark on connecting rod cap faces
towards the front of the engine. EM
MBIA0024E
D
16. Tighten connecting rod nuts according to the following procedure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten bolts. E
: 29.4 N·m (3.0 kg-m, 22 ft-lb)

c. Loosen completely. F
: 0 N·m (0 kg-m, 0 in-lb)

d. Tighten bolts. G
: 19.6 N·m (2.0 kg-m, 14 ft-lb)

H
e. Tighten 120 degrees. (angle tightening)
● Always use either the angle wrench (special service tool)
or protractor during angular tightening. Avoid tightening
based on visual checks alone. I
● After tightening nuts, make sure that crankshaft rotates
smoothly.
J
● Check connecting rod side clearance. Refer to EM-284,
"CONNECTING ROD SIDE CLEARANCE" .
K
JEM231G
17. Press fit rear oil seal into rear oil seal retainer.
L
● Using the drift [105 mm (4.13 in) dia.], press fit so that the
dimension is as specified in the figure.
● Avoid inclined fitting. Force fit perpendicularly.
M
JEM232G
EM-277
CYLINDER BLOCK
[YD]
18. Install rear oil seal retainer to cylinder block.
● Apply new engine oil to the oil and dust seal lips.
● Apply liquid gasket to rear oil seal retainer using the tube
presser [special service tool: WS39930000] as shown in the
figure.
JEM233G
19. Press fit pilot bushing into crankshaft (M/T models).

● Using the drift with outer diameter of 19 mm (0.75 in), press fit
pilot bushing until it stops.
JEM234G
20. Press fit pilot converter into crankshaft (A/T models).

● Using the drift with outer diameter of 33 mm (1.30 in), press fit pilot converter until it stops.
● Press fit pilot converter with its chamfer facing crankshaft as

SEM537E
21. Install fuel pump bracket.

● Align the bracket with the dowel pins on cylinder block to
install.
● The two bolts used for dowel pins have a longer shanks than
the other two.
PBIC2329E
22. Install parts to engine in the reverse order of disassembly.

23. Remove engine from engine stand in the reverse order of assembly.
24. Install flywheel (M/T models).
● Ensure the dowel pins install in the crankshaft.
EM-278
CYLINDER BLOCK
[YD]
● When installing flywheel to crankshaft, be sure to correctly
align crankshaft side dowel pin and flywheel side dowel pin A
hole.
CAUTION:
If these are not aligned correctly, engine runs roughly EM
and “MI” turns on.
PBIC2538E
D
● There is a mating mark on the clutch cover side of flywheel.
Refer it during installation.
E
G
PBIC1112E
● Holding ring gear with ring gear stopper (SST), tighten secur- H
ing bolts with TORX socket (size: T55, commercial service
tool).
● Tighten bolts uniformly in a crisscross manner. I
PBIC2406E K
– If these are not aligned correctly, engine runs roughly and “MI” turns on.
25. Install drive plate (A/T models). L
● When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive
plate side dowel pin hole.
CAUTION: M
If these are not aligned correctly, engine runs roughly and “MI” turns on.
● Install drive plate and reinforcement plate as shown in the fig-
ure.
● Holding ring gear with ring gear stopper [SST: KV10105630],
tighten securing bolts with TORX socket (size: E20) (commer-
cial service tool).
● Tighten bolts uniformly in a crisscross manner.
PBIC0910E
EM-279
CYLINDER BLOCK
[YD]
How to Select Piston and Bearing BBS00D3I
DESCRIPTION
Selection points Selection parts Selection items Selection methods
Determined by match of cylin-
der block bearing housing
Between cylinder block to Main bearing grade (bearing grade (inner diameter of hous-
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft to connect- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer
ing rod (bearing thickness)
diameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block to pis- Piston grade (piston outer Piston grade = cylinder bore
The piston is available together
ton diameter) grade (inner diameter of bore)
with piston pin as an assembly.
● The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
● For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
● For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON
When Using New Cylinder Block
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
● The part No. of piston is specified together with piston pin as
an assembly.
JEM208G
When Re-using an Old Cylinder Block
MBIA0025E
1. Measure cylinder bore inner diameter. Refer to EM-288, "Cylinder Bore Inner Diameter" .
2. Referring to “Cylinder bore inner diameter” in “Piston Selection Table”, determine the bore grade.
Piston Selection Table
Unit: mm (in)
Grade (punched) 1 2 3
EM-280
CYLINDER BLOCK
[YD]
Cylinder bore
89.000 - 89.010 (3.5039 - 3.5043) 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
inner diameter A
Piston outer
88.928 - 88.942 (3.5011 - 3.5016) 88.938 - 88.952 (3.5015 - 3.5020) 88.948 - 88.962 (3.5019 - 3.5024)
diameter
EM
NOTE:
Piston is available together with piston pin as an assembly.
HOW TO SELECT CONNECTING ROD BEARING C
When Using New Crankshaft and Connecting Rod
1. Identify the pin diameter grade (No. 0, 1, or 2) on front surface of
crankshaft. D
2. Select connecting rod bearings of the same grade.
NOTE:
There is no grading for the inner diameter of the big end of the E
connecting rod.
JEM215G
When Re-using the Removed Crankshaft and Connecting Rod G

1. Measure the inner diameter of the big end of connecting rod and make sure it is within the specified
range. Refer to EM-286, "CONNECTING ROD BIG END INNER DIAMETER" .
2. Measure the outer diameter of the crankshaft pin. Refer to EM-289, "CRANKSHAFT PIN JOURNAL H
DIAMETER" .
3. Determine the crankshaft pin grade by comparing the measurement with the values under the column
“Crankshaft pin outer diameter” in “Selection Table of connecting Rod Bearing”. I
4. Choose bearings of the same grade.
Selection Table of connecting Rod Bearing
J
Unit: mm (in)
Connecting rod big end inner diameter 55.000 - 55.013 (2.1654 - 2.1659)
Unit: mm (in) K
Crankshaft pin outer diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
51.968 - 51.974 (2.0460 - 2.0462) 0 1.492 - 1.496 (0.0587 - 0.0589) STD 0 Black
L
51.961 - 51.968 (2.0457 - 2.0460) 1 1.496 - 1.500 (0.0589 - 0.0591) STD 1 Brown
51.954 - 51.961 (2.0454 - 2.0457) 2 1.500 - 1.504 (0.0591 - 0.0592) STD 2 Green
M
Under Size Bearing Usage

● If bearing clearance is out of the specifications for connecting rod bearings in standard size, use under
size bearings.
● When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft pins to adjust clearance to specification.
Connecting Rod Bearing Under Size List

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)
EM-281
CYLINDER BLOCK
[YD]
CAUTION:
When grinding the crankshaft pin to use an under size bearing,
avoid damaging the fillet R.
Standard dimension R : 1.5 - 1.7 mm (0.0591 - 0.0669 in)
JEM216G
HOW TO SELECT MAIN BEARING

When Using New Cylinder Block and Crankshaft
1. Identify the crank journal grade (No. 0, 1, or 2) on LH surface at
the rear of the cylinder block, and locate the applicable grade on
the “Grade” row in the “Main Bearing Grade Table”.
JEM208G
2. Identify the journal grade (No. 0, 1, or 2) on the front surface of

crankshaft, and locate the applicable grade under the “Grade”
column in the “Main Bearing Grade Table”.
JEM215G
3. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
When Re-using Removed Cylinder Block and Crankshaft
1. Measure the inner diameter of cylinder block main bearing housing. Refer to EM-287, "MAIN BEARING
HOUSING INNER DIAMETER" .
2. Locate the applicable cell where the measurement falls, on “Inner diameter of Cylinder block main bearing
housing” row in the “Main Bearing Grade Table”.
3. Measure the outer diameter of crankshaft journal. Refer to EM-289, "CRANKSHAFT MAIN JOURNAL
DIAMETER" .
4. Locate the applicable cell where the measurement falls, under “Crankshaft journal outer diameter” column
in the “Main Bearing Grade Table”.
5. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
Main Bearing Grade Table
Unit: mm (in)
66.654 - 66.663 66.663 - 66.672 66.672 - 66.681
Inner diameter of Cylinder block main bearing housing
(2.6242 - 2.6245) (2.6245 - 2.6249) (2.6249 - 2.6252)
Crankshaft journal Grade
0 1 2
outer diameter (punched)
EM-282
CYLINDER BLOCK
[YD]
STD 0 STD 1 STD 2
● Bearing grade No.
1.816 - 1.820 1.820 - 1.824 1.824 - 1.828 A
62.967 - 62.975 ● Bearing thickness (0.0715 - 0.0717) (0.0717 - 0.0718) (0.0718 - 0.0720)
0
(2.4790 - 2.4793) ● Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
(0.0015 - 0.0026) (0.0015 - 0.0026) (0.0015 - 0.0026)
● Identification color EM
Black Brown Green
STD 1 STD 2 STD 3
1.820 - 1.824 1.824 - 1.828 1.828 - 1.832
62.959 - 62.967 ● Bearing thickness (0.0717 - 0.0718) (0.0718 - 0.0720) (0.0720 - 0.0721) C
1
(2.4787 - 2.6790) ● Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
(0.0015 - 0.0026) (0.0015 - 0.0026) (0.0015 - 0.0026)
● Identification color
Brown Green Yellow
D
STD 2 STD 3 STD 4
1.824 - 1.828 1.828 - 1.832 1.832 - 1.836
62.951 - 62.959 ● Bearing thickness (0.0718 - 0.0720) (0.0720 - 0.0721) (0.0721 - 0.0723)
2
(2.4784 - 2.4787) ● Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066 E
(0.0015 - 0.0026) (0.0015 - 0.0026) (0.0015 - 0.0026)
● Identification color
Green Yellow Blue
Under Size Bearing Usage F

● If bearing clearance is out of the specifications for main bearings in standard size, use under size bear-
ings.
● When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank- G
shaft journals to adjust clearance to the specification.
Main Bearing Under Size List
Unit: mm (in) H
Size Thickness
US 0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
I
CAUTION:
When grinding crank journals to use under size bearings, keep
corners radius of fillet R. (All journals) J
Standard dimension R : 1.5 - 1.7 mm (0.0591 - 0.0669 in)
JEM216G
M
Inspection After Disassembly BBS00D3J
CRANKSHAFT END PLAY

● Using dial gauge, measure crankshaft travel amount by moving
the crankshaft forward or backward.
Standard : 0.10 - 0.25 mm (0.0040 - 0.0098 in)
Limit : 0.30 mm (0.012 in)
● 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-283
CYLINDER BLOCK
[YD]
CONNECTING ROD SIDE CLEARANCE
● Using feeler gauge, measure side clearance between connect-
ing rod and crankshaft arm.
Standard : 0.20 - 0.35 (0.0080 - 0.0138 in)
Limit : 0.40 mm (0.016 in)
● If measured value exceeds the limit, replace connecting rod and
repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
JEM203G
PISTON TO PISTON PIN CLEARANCE

Piston Pin Bore Diameter
Using inside micrometer, measure piston pin bore diameter.
Standard : 28.003 - 28.009 mm (1.1025 - 1.1027 in)
PBIC0116E

Using micrometer, measure piston pin outer diameter.
Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
Calculation of Piston to Piston Pin Clearance

(Piston pin clearance) = (Piston pin bore diameter) − (Piston pin outer diameter)
Standard : 0.003 - 0.014 mm (0.0001 - 0.0006 in)
● If out of the standard, replace piston/piston pin assembly.
NOTE:
Piston is available together with piston pin as assembly.
EM-284
CYLINDER BLOCK
[YD]
PISTON RING SIDE CLEARANCE
● Using feeler gauge, measure the side clearance between piston A
ring and piston ring groove.
Unit: mm (in)
Items Standard Limit EM
Top ring 0.050 - 0.090 (0.0020 - 0.0035) 0.2 (0.008)
2nd ring 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004)
C
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
SEM024AA
D
● Align top ring and external surface of piston. Measure lower side
clearance of top ring with top ring pressed onto upper side of E
ring groove.
● If side clearance exceeds the limit, replace piston ring.
● Check clearance again. If side clearance still exceeds the limit, F
replace piston.
FEM100
H
PISTON RING END GAP
● Make sure that cylinder bore diameter is within the specifica-
tions. Refer to EM-288, "PISTON TO CYLINDER BORE
CLEARANCE" . I
● Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and mea-
sure piston ring end gap with feeler gauge. J
Unit: mm (in)
K
Top ring 0.21 - 0.28 (0.0083 - 0.0110)
2nd ring 0.32 - 0.47 (0.0126 - 0.0185) 1.0 (0.039) FEM101
Oil ring 0.30 - 0.55 (0.0118 - 0.0217) L

● If out of the limit, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder
and use oversized piston and piston ring. Refer to EM-288, "PISTON TO CYLINDER BORE CLEAR-
ANCE" . M
EM-285
CYLINDER BLOCK
[YD]
CONNECTING ROD BEND AND TORSION
● Use connecting rod aligner to check bend and torsion.
Bend limit : 0.12 mm (0.0047 in)/100 mm (3.94 in)
Torsion limit : 0.12 mm (0.0047 in)/100 mm (3.94 in)
● If it exceeds the limit, replace connecting rod assembly.
PBIC2077E
CONNECTING ROD BIG END INNER DIAMETER

● Install connecting rod caps without connecting rod bearings and
tighten connecting rod nuts to the specified torque. Refer to EM-
273, "ASSEMBLY" .
● Using inside micrometer, measure connecting rod big end inner
diameter.
Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in)
● If out of the standard, replace connecting rod.
PBIC1641E
CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner Diameter
Use inside micrometer to measure bushing inner diameter.
Standard : 28.026 - 28.038 mm (1.1034 - 1.1039 in)
PBIC0120E
EM-286
CYLINDER BLOCK
[YD]
Use micrometer to measure piston pin outer diameter. A
Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
EM
PBIC0117E
D
Calculation of Connecting Rod Bushing Clearance

(Connecting rod bushing clearance) = (Connecting rod bushing inner diameter) − (Piston pin outer diameter) E
Standard : 0.026 - 0.043 mm (0.0010 - 0.0017 in)
Limit : 0.057 mm (0.0022 in)
● If it exceeds the limit, replace connecting rod and/or piston and piston pin assembly. Refer to EM-281, F
"HOW TO SELECT CONNECTING ROD BEARING" and/or EM-280, "HOW TO SELECT PISTON" .
CYLINDER BLOCK TOP SURFACE DISTORTION G
● Using scraper, remove gasket installed onto cylinder block sur-
face. Remove contamination such as engine oil, scale, and car-
bon.
H
CAUTION:
Keep broken pieces of gasket clear of engine oil and engine
coolant passages.
I
● Use straightedge and feeler gauge to check block upper surface
for six distortion.
Limit : 0.1 mm (0.004 in) J
● If it exceeds the limit, replace cylinder block. SEM501G
MAIN BEARING HOUSING INNER DIAMETER

K
● Without installing main bearings, install main bearing caps, and
tighten bolts to the specified torque. Refer to EM-273, "ASSEM-
BLY"EM-273, "ASSEMBLY" .
L
● Measure the inner diameter of main bearing housing with a bore
gauge.
Standard : 66.654 - 66.681 mm (2.6242 - 2.6252 in) M
● If the measurement is out of the standard, replace cylinder block
and main bearing caps.
NOTE:
These components cannot be replaced as a single unit, because PBIC1643E
they were processed together.
EM-287
CYLINDER BLOCK
[YD]
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
● Using bore gauge, measure cylinder inner diameters at six posi-
tions; top, middle, and bottom (A, B, C) in 2 directions (X, Y).
Cylinder bore inner diameter
: 89.000 – 89.030 mm (3.5039 – 3.5051 in)
Wear limit
: 0.07 mm (0.028 in)
Out-of-round limit (Difference between X and Y)
: 0.015 mm (0.0006 in)
Taper limit (Difference between A and C) SEM899G
: 0.010 mm (0.0004 in)
● If the measured value exceeds the limit, or if there are scratches

and/or seizure on the cylinder inner wall, hone or bore the inner
wall.
● Oversize piston is provided. When using oversize piston, hone
the cylinder so that the clearance between piston and cylinder
satisfies the standard.
CAUTION:
If oversize piston is used, use it for all cylinders with over-
size piston rings.
Oversize (OS) : 0.25 mm (0.0098 in) FEM110
: 0.50 mm (0.0197 in)

Piston Outer Diameter
Use micrometer to measure piston outer diameter.
Piston outer diameter
Measurement position : 11.0 mm (0.43 in)
Distance from the bottom
Standard : 88.928 – 88.962 mm
(3.5011 – 3.5024 in)
0.25 (0.0098) O/S : 89.188 – 89.202
(3.5113 – 3.5119 in)
0.50 (0.0197) O/S : 89.438 – 89.452 PBIC0125E
(3.5212 – 3.5217 in)
Calculation of Piston to Cylinder Bore Clearance
● Calculate using piston outer diameter and cylinder bore inner diameter (direction X, position B).
(Clearance) = (Cylinder bore inner diameter) − (Piston outer diameter)
Specifications at room temperature [20°C (68°F)]:
Standard : 0.058 - 0.082 mm (0.0023 - 0.0032 in)
● If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-280, "HOW TO SELECT PIS-
TON" .
Reboring Cylinder Bore
1. Determine the cylinder bore size by adding piston-to-cylinder bore clearance to piston diameter.
Rebore size calculation:
D=A+B–C
Where,
D: Bored diameter
EM-288
CYLINDER BLOCK
[YD]
A: Piston outer diameter as measured
A
B: Piston-to-cylinder bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
2. Install main bearing caps and tighten bolts to the specified torque. Refer to EM-273, "ASSEMBLY" . This EM
will prevent distortion of cylinder bores.
3. Cut cylinder bore.
NOTE: C
● When any cylinder needs boring, all other cylinders must also be bored.
● Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so at a time.
4. Hone cylinders to obtain the specified piston-to-cylinder bore clearance. D

5. Measure finished cylinder bore for the out-of-round and taper.
NOTE:
● Measurement should be done after cylinder bore cools down. E
CRANKSHAFT MAIN JOURNAL DIAMETER

● Use micrometer to measure crankshaft main journal diameter.
F
Standard : 62.951 - 62.975 mm (2.4784 - 2.4793 in)
● If out of the standard, measure the main bearing oil clearance.
then use the undersize bearing. Refer to EM-291, "MAIN BEAR- G
ING OIL CLEARANCE" .
FEM114
I
CRANKSHAFT PIN JOURNAL DIAMETER
● Use micrometer to measure crankshaft pin journal diameter.
J
Standard : 51.954 - 51.974 mm (2.0454 - 2.0462 in)
● If out of the standard, measure the connecting rod bearing oil
clearance. then use the undersize bearing. Refer to EM-290, K
"CONNECTING ROD BEARING OIL CLEARANCE" .
PBIC0127E
M
CRANKSHAFT OUT-OF-ROUND AND TAPER
● Using micrometer, measure each journal and pin at four points
● Out-of-round value is indicated by difference in dimensions
between directions X and Y at points A and B.
● Taper value is indicated by difference in dimensions between
points A and B in directions X and Y.
Out-of-round: (Difference between X and Y)
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
PBIC2203E
Taper: (Difference between A and B)
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
● If the measured value exceeds the limit, correct or replace crankshaft.
EM-289
CYLINDER BLOCK
[YD]
● If corrected, measure the bearing oil clearance of the corrected journal and/or pin. Then select the main
bearing or connecting rod bearing. Refer to EM-291, "MAIN BEARING OIL CLEARANCE" and/or EM-
290, "CONNECTING ROD BEARING OIL CLEARANCE" .
CRANKSHAFT RUNOUT
● Place V-block onto surface plate to support journals at both ends
of crankshaft.
● Position dial gauge vertically onto No. 3 journal.
● Rotate crankshaft to read needle movement on dial gauge.
(Total indicator reading)
Standard : 0.05 mm (0.0020 in)
Limit : 0.10 mm (0.0039 in)
● If it exceeds the limit, replace crankshaft.
FEM116
CONNECTING ROD BEARING OIL CLEARANCE

Method by Measurement
● Install connecting rod bearings to connecting rod and cap, and
tighten connecting nuts to the specified torque. Refer to EM-273,
"ASSEMBLY" . Use inside micrometer to measure connecting
rod bearing inner diameter.
(Bearing clearance) = (Connecting rod bearing inner diameter) −
(Crankshaft pin outer diameter)
Standard : 0.039 - 0.070 mm (0.0015 - 0.0028 in)
● If clearance exceeds the standard, select proper connecting rod
bearing according to connecting rod big end diameter and
crankshaft pin outer diameter to obtain specified bearing oil PBIC1642E
clearance. Refer to EM-281, "HOW TO SELECT CONNECTING
ROD BEARING" .
● Remove contamination such as engine oil, dust completely from
crankshaft pins and each bearing surface.
● Cut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
● Install connecting rod bearings to caps, and tighten connecting
rod nuts to the specified torque.
CAUTION:
Do not rotate crankshaft.
● Remove connecting rod caps and bearings, and measure
plastigage width using scale on plastigage bag. EM142
NOTE:
If out of specification, take same action mentioned in “Method by Measurement”.
EM-290
CYLINDER BLOCK
[YD]
MAIN BEARING OIL CLEARANCE
Method by Measurement A
● Install main bearings to cylinder block and bearing cap, and
tighten the bolts to the specified torque. Refer to EM-273,
"ASSEMBLY" . Then, measure the inner diameter of main bear- EM
ings.
(Bearing clearance) = (Bearing inner diameter) − (Crankshaft
journal outer diameter) C
Standard : 0.047 - 0.077 mm (0.0019 - 0.0030 in)
● If out of the standard, check main bearing housing inner diame-
ter and crankshaft journal outer diameter, and select appropriate D
main bearing to adjust clearance to specifications. Refer to EM- PBIC1644E
282, "HOW TO SELECT MAIN BEARING" .
E
● Remove contamination such as engine oil and dust completely
from crankshaft journals and each bearing surface.
F
● Cut plastigage slightly shorter than bearing width. Place it in
crankshaft turning direction, avoiding oil holes.
● Install main bearings and bearing cap and tighten to the speci-
fied torque. Refer to EM-273, "ASSEMBLY" for the tightening G
procedure.
CAUTION:
Do not rotate crankshaft. H
● Remove main bearings and bearing caps, and measure EM142
plastigage width using scale on plastigage bag.
NOTE: I
If out of specification, take same action mentioned in “Method by Measurement”.
CRUSH HEIGHT OF MAIN BEARING
J
● When bearing cap is removed after being tightened to the speci-
fied torque with main bearings installed, the tip end of bearing
must protrude. Refer to EM-273, "ASSEMBLY" .
K
● If out of the standard, replace main bearings.
L
M
SEM502G
CRUSH HEIGHT OF CONNECTING ROD BEARING

● When connecting rod bearing cap is removed after being tight-
ened to the specified torque with connecting rod bearings
installed, the tip end of bearing must protrude. Refer to EM-273,
"ASSEMBLY" .
● If out of the standard, replace connecting rod bearings.
PBIC1646E
EM-291
CYLINDER BLOCK
[YD]
MAIN BEARING CAP BOLT DEFORMATION
● Measure the outer diameter of threaded area, “d1” and “d2”, at
the points specified in the figure.
● When the necked point is identified at a point other than where
specified, measure at the point as “d2”.
● Calculate the difference between “d1” and “d2”.
Limit : 0.13 mm (0.0051 in)
● If it exceeds the limit, replace main bearing cap bolt.
JEM219G
CONNECTING ROD BOLT DEFORMATION

● Install nuts to connecting rod bolts. Make sure that the nut can
be screwed smoothly on bolt threads by hand to the last thread
on the bolt.
● If the nut does not screw in smoothly, measure the outer diame-
ter of the bolt thread at the point specified in the figure.
● If a necked point is identified, measure at that point.
Limit : 8.75 mm (0. 3445 in) dia.
● If it exceeds the limit, replace connecting rod bolts and nuts. JEM220G
OIL JET
● Check nozzle for deformation and damage.
● Blow compressed air from nozzle, and check for clogs.
Standard : No deformation and no damage.
● If out of the standard, replace oil jet.
JEM221G
OIL JET RELIEF VALVE

● Using clean plastic stick, press check valve in oil jet relief valve.
Make sure that valve moves smoothly with proper reaction
force.
Standard:
Valve moves smoothly with proper reaction force.
● If out of the standard, replace oil jet relief valve.
JEM222G
EM-292
CYLINDER BLOCK
[YD]
FLYWHEEL DEFLECTION
● Measure the deflection of flywheel contact surface to clutch with A
a dial indicator.
● Measure the deflection at 210 mm (8.27 in) dia.
EM
Standard : 0.45 mm (0.0177 in) or less.
● If measured value is out of the standard, replace flywheel.
CAUTION: C
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft.
PBIC2646E
D
MOVEMENT AMOUNT OF FLYWHEEL

CAUTION: E
Do not disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
● Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is F
added at the portion of 125 mm (4.92 in) radius from the center of flywheel.
Standard : 1.3 mm (0.051 in) or less
G
● If measured value is out of the standard, replace flywheel.
Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure: H
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.
● Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening. I
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points). J
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transmis-
sion side. K
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of the flywheel on the transmission side.
L
Standard: 32.0 mm (1.620 in) or less.
● If measured value is out of the standard, replace flywheel. PBIC1263E
DRIVE PLATE M
● Check drive plate and signal plate for deformation or cracks.
CAUTION:
● Do not place drive plate with signal plate facing down.
● When handling signal plate, take care not to damage or

scratch it.
● Handle signal plate in a manner that prevents it from
becoming magnetized.
● If anything is found, replace drive plate.
SEM760G
EM-293
[YD]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
Standard and Limit BBS00D3K
GENERAL SPECIFICATIONS
Cylinder arrangement In-line 4
Displacement Unit: cm3 (cu in) 2,488 (151.82)
Bore and stroke Unit: mm (in) 89.0 x 100 (3.504 x 3.937)
Valve arrangement DOHC
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1
Number of main bearings 5
Compression ratio 16.5
Standard 3,100 (31, 31.6, 450)
Minimum 2,500 (25, 25.5, 363)
Unit: kPa (bar, kg/cm2 , psi)/200 rpm
Differential limit between cylinders 490 (4.9, 5.0, 71)
Valve timing
EM120
Unit: degree
a b c d e f
226 210 2 28 −2 48
INTAKE MANIFOLD AND EXHAUST MANIFOLD

Unit: mm (in)
Items Limit
Intake manifold 0.1 (0.004)
Surface distortion
Exhaust manifold 0.3 (0.012)
DRIVE BELTS
Belt Deflection:
Belt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
Applied belt
New Adjusted Limit for re-adjusting
A/C compressor, alternator and water 2.9 - 3.4 3.9 - 4.4
8.5 (0.335)
pump belt (0.114 - 0.134) (0.154 - 0.173)
4.6 - 5.4 7.1 - 7.7
Power steering oil pump belt 11.3 (0.445)
(0.181 - 0.213) (0.280 - 0.303)
*: When engine is cold.
EM-294
[YD]
CYLINDER HEAD
Unit: mm (in) A
Cylinder head distortion Less than 0.04 (0.0016) 0.1 (0.004)
EM
E
JEM204G
VALVE
Valve Dimensions F
Unit: mm (in)
SEM188
J
Intake 28.0 - 28.3 (1.102 - 1.114)
Valve head diameter “D”
Exhaust 26.0 - 26.3 (1.024 - 1.035)
Intake 106.72 (4.2016) K
Valve length “L”
Exhaust 106.36 (4.1874)
Intake 5.965 - 5.980 (0.2348 - 0.2354)
Valve stem diameter “d” L
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
Valve seat angle “α” Intake and exhaust 45 degrees 15′ - 45 degrees 45′
Intake 1.60 (0.0630) M
Valve margin “T”
Exhaust 1.48 (0.0583)
Valve margin “T” limit More than 1.0 (0.039)
Valve stem end surface grinding limit Less than 0.2 (0.008)
Valve Clearance
Unit: mm (in)
Items Cold Hot* (Reference data)
Intake 0.24 - 0.32 (0.0094 - 0.0126) 0.274 - 0.386 (0.0108 - 0.0152)
Exhaust 0.26 - 0.34 (0.0102 - 0.0134) 0.308 - 0.432 (0.0121 - 0.0170)
Available Shims
Stamped mark Thickness mm (in)
2.10 2.10 (0.0827)
2.12 2.12 (0.0835)
EM-295
[YD]
Stamped mark Thickness mm (in)
2.14 2.14 (0.0843)
2.16 2.16 (0.0850)
2.18 2.18 (0.0858)
2.20 2.20 (0.0866)
2.22 2.22 (0.0874)
2.24 2.24 (0.0882)
2.26 2.26 (0.0890)
2.28 2.28 (0.0898)
2.30 2.30 (0.0906)
2.32 2.32 (0.0913)
2.34 2.34 (0.0921)
2.36 2.36 (0.0929)
2.38 2.38 (0.0937)
2.40 2.40 (0.0954)
2.42 2.42 (0.0953)
2.44 2.44 (0.0961)
2.46 2.46 (0.0969)
2.48 2.48 (0.0976)
2.50 2.50 (0.0984)
2.52 2.52 (0.0992)
2.54 2.54 (0.1000)
2.56 2.56 (0.1008)
2.58 2.58 (0.1016)
2.60 2.60 (0.1024)
2.62 2.62 (0.1031)
2.64 2.64 (0.1039)
2.66 2.66 (0.1047)
2.68 2.68 (0.1055)
2.70 2.70 (0.1063)
2.72 2.72 (0.1071)
2.74 2.74 (0.1079)
SEM512G
Valve Spring
Valve spring square mm (in) 1.9 (0.075)
Free height mm (in) 43.7 (1.72)
Pressure N (kg, lb) at height mm (in) 184 - 208 (18.77 - 21.22, 41.4 - 46.8) at 32.82 (1.2921)
EM-296
[YD]
Height during valve open mm (in) 24.82 (0.9772)
A
Load with valve open N (kg, lb) 320 - 360 (32.65 - 36.73, 71.9 - 80.9)
Valve Lifter
Unit: mm (in) EM
Items Standard
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801)
Valve lifter bore diameter 30.000 - 30.021 (1.1811 - 1.1819) C
Valve lifter clearance 0.025 - 0.061 (0.0010 - 0.0024)
Valve Guide D
Unit: mm (in)
JEM156G
H
Items Standard Service
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) I
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Items Standard Limit J
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Valve guide clearance
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.10 (0.0040)
K
Projection length 10.4 - 10.6 (0.409 - 0.417)
EM-297
[YD]
Valve Seat
Unit: mm (in)
PBIC4054E
JEM253G
Items Standard Oversize (Service) [0.5 (0.020)]
Cylinder head seat (1) recess diam- Intake 30.000 - 30.016 (1.1811 - 1.1817) 30.500 - 30.516 (1.2008 - 1.2014)
eter “D” Exhaust 29.000 - 29.016 (1.1417 - 1.1424) 29.500 - 29.516 (1.1614 - 1.1620)
Intake (A) 30.080 - 30.100 (1.1842 - 1.1850) 30.580 - 30.600 (1.2039 - 1.2047)
Valve seat outer diameter “d”
Exhaust (B) 29.080 - 29.096 (1.1449 - 1.1455) 29.580 - 29.596 (1.1646 - 1.1652)
Intake (A) 0.064 - 0.100 (0.0025 - 0.0039)
Valve seat interference fit
Exhaust (B) 0.064 - 0.096 (0.0025 - 0.0038)
Intake (A) 27.15 - 27.65 (1.0689 - 1.0886) 26.05 - 26.55 (1.0256 - 1.0453)
Diameter “d1”
Exhaust (B) 24.95 - 25.45 (0.982 - 1.0020) 24.15 - 24.65 (0.9508 - 0.9705)
EM-298
[YD]
Intake (A) 26.00 - 26.50 (1.0236 - 1.0433) —
Diameter “d2” A
Exhaust (B) —
Intake (A) 25.3 - 25.7 (0.996 - 1.012)
Diameter “d3”
Exhaust (B) 23.3 - 23.7 (0.917 - 0.933) EM
Angle “α” 43°30′ - 46°30′
Intake (A) 7.0 - 7.1 (0.276 - 0.280) 6.6 - 6.7 (0.260 - 0.264)
Height “h1”
Exhaust (B) 6.7 - 6.8 (0.264 - 0.268) 6.3 - 6.4 (0.248 - 0.252) C
Intake (A) 2.23 - 2.43 (0.0878 - 0.0957) 2.13 - 2.53 (0.0839 - 0.0996)
Height “h2”
Exhaust (B) 2.76 - 2.96 (0.1087 - 0.1165) 2.66 - 3.06 (0.1047 - 0.1205)
D
Intake 8.83 - 9.13 (0.3476 - 0.3594)
Depth “H”
Exhaust 9.06 - 9.36 (0.3567 - 0.3685)
Intake 36.53 - 36.98 (1.4382 - 1.4559) E
Projection (L)
Exhaust 36.53 - 37.01 (1.4382 - 1.4571)
CAMSHAFT F
Unit: mm (in)
Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034) G
No.1 30.500 - 30.521 (1.2008 - 1.2016)
Camshaft bracket inner diameter
No. 2, 3, 4, 5 24.000 - 24.021 (0.9449 - 0.9457) —
H
No. 1 30.435 - 30.455 (1.1982 - 1.1990)
Camshaft journal outer diameter
No. 2, 3, 4, 5 23.935 - 23.955 (0.9423 - 0.9431)
Camshaft runout [TIR*] — 0.02 (0.0008) I
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.24 (0.0094)
J
M
SEM671
Intake 39.505 - 39.695 (1.5553 - 1.5628)

Cam height “A”
Exhaust 39.905 - 40.095 (1.5711 - 1.5785)
EM-299
[YD]
CYLINDER BLOCK
Unit: mm (in)
SEM899G

Top surface distortion
Limit 0.1 (0.004)
Grade No. 1 89.000 - 89.010 (3.5039 - 3.5043)
Standard Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047)
Cylinder bore Inner diameter
Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.07 (0.0028)
Out-of-round (Difference between X and Y) 0.015 (0.0006)
Limit
Taper (Difference between A and C) 0.010 (0.0004)
Main bearing housing inner diameter (Without bearing) 66.654 - 66.681 (2.6242 - 2.6252)
Difference in inner diameter
Limit Less than 0.05 (0.0020)
between cylinders
PISTON, PISTON RING AND PISTON PIN

Available Piston
Unit: mm (in)
MBIA0026E
Grade No. 1 88.928 - 88.942 (3.5011 - 3.5016)

Grade No. 2 88.938 - 88.952 (3.5015 - 3.5020)
Piston outer diameter “A” Standard Grade No. 3 88.948 - 88.962 (3.5019 - 3.5024)
Oversize (Service) [0.25 (0.0098)] 89.188 - 89.202 (3.5113 - 3.5119)
Oversize (Service) [0.5 (0.020)] 89.438 - 89.452 (3.5212 - 3.5217)
“a” dimension 11.0 (0.43)
Piston pin bore diameter 28.003 - 28.009 (1.1025 - 1.1027)
Piston to cylinder bore clearance 0.058 - 0.082 (0.0023 - 0.0032)
EM-300
[YD]
Piston Ring
Unit: mm (in) A
Top 0.050 - 0.090 (0.0020 - 0.0035) 0.2 (0.008)
EM
Side clearance 2nd 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004)
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
Top 0.21 - 0.28 (0.0083 - 0.0110) C
End gap 2nd 0.32 - 0.47 (0.0126 - 0.0185) 1.0 (0.039)
Oil ring 0.30 - 0.55 (0.0118 - 0.0217)
D
Piston Pin
Unit: mm (in)
Piston pin outer diameter 27.995 - 28.000 (1.1022 - 1.1024)
E
Piston to piston pin clearance 0.003 - 0.014 (0.0001 - 0.0006)
Standard 0.026 - 0.043 (0.0010 - 0.0017)
Connecting rod bushing clearance
Limit 0.057 (0.0022) F
EM-301
[YD]
CONNECTING ROD
Unit: mm (in)
Center distance 154.5 (6.083)
Bend [per 100 (3.94)] Limit 0.12 (0.0047)
Torsion [per 100 (3.94)] Limit 0.12 (0.0047)
Connecting rod bushing inner diameter* 28.026 - 28.038 (1.1034 - 1.1039)
Connecting rod big end inner diameter* 55.000 - 55.013 (2.1654 - 2.1659)
Standard 0.20 - 0.35 (0.0080 - 0.0138)
Side clearance
Limit 0.40 (0.016)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
Main journal dia. “Dm” 62.951 - 62.975 (2.4784 - 2.4793)
Pin journal dia. “Dp” 51.954 - 51.974 (2.0454 - 2.0462)
Center distance “r” 49.97 - 50.03 (1.9673 - 1.9697)
Out-of-round (Difference between X Standard 0.003 (0.0001)

and Y) Limit 0.005 (0.0002)
Standard 0.003 (0.0001)
Taper (Difference between A and B)
Limit 0.005 (0.0002)
Standard 0.05 (0.0020)
Runout [TIR*]
Limit 0.10 (0.0040)
Standard 0.10 - 0.25 (0.0040 - 0.0098)
End play
Limit 0.30 (0.012)
SEM645 SBIA0535E
EM-302
[YD]
AVAILABLE MAIN BEARING
Main bearing A
Unit: mm (in)
EM
SEM255G
E
Grade number Thickness Width Identification color
STD 0 1.816 - 1.820 (0.0715 - 0.0717) Black
STD 1 1.820 - 1.824 (0.0717 - 0.0718) Brown F
STD 2 1.824 - 1.828 (0.0718 - 0.0720) 19.9 - 20.1 (0.783 - 0.791) Green
STD 3 1.828 - 1.832 (0.0720 - 0.0721) Yellow
G
STD 4 1.832 - 1.836 (0.0721 - 0.0723) Blue
Undersize
Unit: mm (in) H
Size Thickness Main journal diameter “Dm”
Grind so that bearing clearance is the
0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
specified value. I
AVAILABLE CONNECTING ROD BEARING
Connecting Rod Bearing J
Unit: mm (in)
Grade number Thickness Width Identification color (mark)
STD 0 1.492 - 1.496 (0.0587 - 0.0589) Black K
22.9 - 23.1
STD 1 1.496 - 1.500 (0.0589 - 0.0591) Brown
(0.902 - 0.909)
STD 2 1.500 - 1.504 (0.0591 - 0.0592) Green
L
Undersize
Unit: mm (in)
Size Thickness Crank pin journal diameter “Dp”
M
0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
Grind so that bearing clearance is the
0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
specified value.
0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
MISCELLANEOUS COMPONENTS
Flywheel
Unit: mm (in)
Flywheel deflection [TIR]* Standard 0.45 (0.0177) or less
EM-303
[YD]
Bearing Clearance
Unit: mm (in)
Main bearing oil clearance Standard 0.047 - 0.077 (0.0019 - 0.0030)
Connecting rod bearing oil
Standard 0.039 - 0.070 (0.0015 - 0.0028)
clearance
EM-304

NISSAN Pathfinder R51 EM (ENGINE MECHANICAL)

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NISSAN Pathfinder R51 EM (ENGINE MECHANICAL)

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ENGINE MECHANICAL

Precautions for Procedures without Cowl Top Cover BBS00BG2

Precautions Necessary for Steering Wheel Rotation After Battery Disconnect

Drain engine coolant when engine is cooled.

REMOVAL OF LIQUID GASKET SEALING

3. Attach liquid gasket tube to tube presser (SST).

● Do not retighten mounting bolts or nuts after the installation.

● After 30 minutes or more have passed from the installation, fill

KV10107902 Replacing valve oil seal

KV10115600 Installing valve oil seal G

KV10111100 Removing oil pan (lower and upper), front

WS39930000 Pressing the tube of liquid gasket

KV10112100 Tightening bolts for bearing cap, cylinder

KV991- J0050 Loosening or tightening air fuel ratio sensor 1

KV10114400 Loosening or tightening heated oxygen

KV10117700 Removing and installing crankshaft pulley

— Removing fuel tube quick connectors in

Commercial Service Tools BBS00009

Tool name Description

TORX socket Removing and installing flywheel

Piston ring expander Removing and installing piston ring

Valve guide drift Removing and installing valve guide H

Anti-seize lubricant (Permatex 133AR Lubricating oxygen sensor thread cleaning

NVH Troubleshooting —Engine Noise BBS0000A

Piston to piston pin oil F

Checking Drive Belts BBS0000C

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

● When new drive belt is installed, the range should be (C).

● The indicator notch is located on the moving side of auto

● Visually check drive belt for wear, damage or cracks.

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

1. Idler pulley 2. Drive belt auto tensioner

3. Remove auto tensioner and idler pulley.

● Do not disassemble it.

● Do not touch its sensor. L

1. Vacuum tank 2. VIAS control solenoid valve 3. Vacuum hose

Removal and Installation BBS0000K

● Do not spill engine coolant on drive belt. EM

: 6.9 N·m (0.70 kg-m, 61 in-lb)

Electric Throttle Control Actuator

1. Intake manifold 2. Gasket

Removal and Installation BBS0000M

: 10.8 N·m (1.1 kg-m, 8 ft-lb)

REMOVAL (LEFT BANK)

replace with a new sensor.

7. Remove three way catalyst (manifold) (left bank).

INSTALLATION (LEFT BANK) E

: 14.7 N·m (1.5 kg-m, 11 ft-lb)

: 25.4 N·m (2.6 kg-m, 19 ft-lb)

INSTALLATION (RIGHT BANK)

Three Way Catalyst M

: 25.4 N·m (2.6 kg-m, 19 ft-lb)

1. Oil pan (upper) 2. Oil pressure switch 3. O-ring

● Refer to GI-11, "Components" for symbol marks in the figure.

5. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant" . A

● Do not spill engine coolant on drive belts. EM

INSPECTION AFTER REMOVAL

e. Tighten transmission joint bolts. Refer to AT-248, "TRANSMISSION ASSEMBLY" .

c. Install oil pan (lower).