Em Yd1

ENGINE MECHANICAL GI
SECTION EM MA
LC
EC
CONTENTS FE
APPLICATION NOTICE ..................................................3 PREPARATIVE WORK .............................................34

CL
How to Check Vehicle Type ........................................3 FUEL PIPING ..........................................................35
INTAKE MANIFOLD .................................................35
MT
EGR VOLUME CONTROL VALVE .............................35
YD TYPE 1
WATER HOSE .........................................................35
PRECAUTIONS ...............................................................4 Inspection...................................................................36 AT
Parts Requiring Angular Tightening.............................4 INTAKE MANIFOLD .................................................36
Liquid Gasket Application Procedure ..........................4 CATALYST ....................................................................37
PREPARATION ...............................................................5 Removal and Installation ...........................................37 AX
Special Service Tools ..................................................5 PREPARATIVE WORK .............................................37
Commercial Service Tools ...........................................7 CATALYST ..............................................................37
NOISE, VIBRATION AND HARSHNESS (NVH) GUSSET .................................................................38 SU
TROUBLESHOOTING .....................................................9 EXHAUST MANIFOLD, TURBOCHARGER .................39
NVH Troubleshooting - Engine Noise .........................9 Removal and Installation ...........................................39
PREPARATIVE WORK .............................................39 BR
MEASUREMENT OF COMPRESSION PRESSURE ....10
EXHAUST MANIFOLD AND TURBOCHARGER .........39
DRIVE BELTS................................................................12
EXHAUST MANIFOLD GASKET ...............................40
Inspection...................................................................12
Disassembly and Assembly.......................................40 ST
Adjustment .................................................................12 TURBOCHARGER ...................................................40
AIR CONDITIONER COMPRESSOR BELT ................13
Inspection...................................................................41
ALTERNATOR & WATER PUMP BELT .....................13
EXHAUST MANIFOLD .............................................41
RS
Removal.....................................................................13 TURBOCHARGER ...................................................41
Installation..................................................................14 ROCKER COVER ..........................................................44
AIR CLEANER...............................................................15 BT
Removal and Installation ...........................................44
Changing Air Cleaner Filter .......................................15 PREPARATIVE WORK .............................................44
VISCOUS PAPER TYPE ...........................................15 ROCKER COVER ....................................................44 HA
OIL PAN.........................................................................16 CYLINDER HEAD..........................................................46
Components...............................................................16 Components...............................................................46
Removal.....................................................................16 Removal.....................................................................47 SC
Installation..................................................................18 PREPARATIVE WORK .............................................47
TIMING CHAIN ..............................................................21 CAMSHAFT .............................................................47
Secondary Timing Chain ...........................................21 CYLINDER HEAD ....................................................48 EL
REMOVAL ...............................................................21 Disassembly...............................................................48
INSPECTION ...........................................................23 Inspection...................................................................49
INSTALLATION........................................................23 CYLINDER HEAD DISTORTION ...............................49
IDX
Primary Timing Chain ................................................26 CAMSHAFT VISUAL CHECK ....................................50
REMOVAL ...............................................................27 CAMSHAFT RUNOUT ..............................................50
INSPECTION ...........................................................29 CAMSHAFT CAM HEIGHT .......................................50
INSTALLATION........................................................29 CAMSHAFT JOURNAL CLEARANCE ........................50
INTAKE MANIFOLD ......................................................34 CAMSHAFT END PLAY............................................51
Removal and Installation ...........................................34 CAMSHAFT SPROCKET RUNOUT ...........................51
CONTENTS (Cont’d)
VALVE GUIDE CLEARANCE ....................................51 MAIN BEARING CRUSH HEIGHT .............................80
VALVE GUIDE REPLACEMENT ................................52 MAIN BEARING CAP BOLT DEFORMATION .............80
VALVE SEATS .........................................................53 CONNECTING ROD BUSHING CLEARANCE
REPLACING VALVE SEAT FOR SERVICE PARTS ....53 (SMALL END) ..........................................................80
VALVE DIMENSIONS ...............................................55 CONNECTING ROD BOLT DEFORMATION ..............81
VALVE SPRING .......................................................55 FLYWHEEL RUNOUT ..............................................81
VALVE LIFTER ........................................................55 OIL JET ..................................................................81
Assembly ...................................................................56 OIL JET RELIEF VALVE ...........................................81
Installation..................................................................57 Assembly ...................................................................82
CYLINDER HEAD GASKET SELECTION ...................57 PISTON ..................................................................82
CYLINDER HEAD BOLT DEFORMATION CHECK .....58 CRANKSHAFT.........................................................82
CYLINDER HEAD-TO-BLOCK DIFFERENCE REPLACEMENT OF PILOT BUSHING.......................85
CHECK ...................................................................58 SERVICE DATA AND SPECIFICATIONS (SDS) .........87
LIQUID GASKET APPLICATION ON REAR CHAIN General Specifications...............................................87
CASE ......................................................................58 Compression Pressure ..............................................87
CYLINDER HEAD INSTALLATION ............................59 Belt Deflection............................................................87
GLOW PLUG INSTALLATION ...................................59 Cylinder Head ............................................................87
CAMSHAFT INSTALLATION .....................................59
Valve ..........................................................................88
Valve Clearance.........................................................60 VALVE ....................................................................88
CHECKING .............................................................60 VALVE CLEARANCE................................................88
ADJUSTING ............................................................61 AVAILABLE SHIMS ..................................................88
ENGINE ASSEMBLY.....................................................64 VALVE SPRING .......................................................89
Removal and Installation ...........................................64 VALVE LIFTER ........................................................90
REMOVAL ...............................................................65 VALVE GUIDE .........................................................90
INSTALLATION........................................................66 Valve Seat..................................................................91
CYLINDER BLOCK .......................................................67 Camshaft and Camshaft Bearing ..............................93
Components...............................................................67 Cylinder Block............................................................94
Removal and Installation ...........................................68 Piston, Piston Ring and Piston Pin ...........................95
Disassembly...............................................................68 AVAILABLE PISTON ................................................95
PISTON AND CRANKSHAFT ....................................68 PISTON RING .........................................................95
Inspection...................................................................71 PISTON PIN ............................................................95
CRANKSHAFT END PLAY .......................................71 Connecting Rod .........................................................96
CONNECTING ROD SIDE CLEARANCE ...................71 Crankshaft..................................................................96
PISTON AND PISTON PIN CLEARANCE ..................72 Available Main Bearing..............................................97
PISTON RING SIDE CLEARANCE ............................72 UNDERSIZE ............................................................97
PISTON RING END GAP..........................................73
Available Connecting Rod Bearing............................97
CONNECTING ROD BEND AND TORSION ...............73
CONNECTING ROD BEARING .................................97
CYLINDER BLOCK DISTORTION AND WEAR ...........73
UNDERSIZE ............................................................97
PISTON-TO-BORE CLEARANCE ..............................74
Miscellaneous Components.......................................97
CRANKSHAFT.........................................................76
BEARING CLEARANCE ...........................................98
MAIN BEARING HOUSING INNER DIAMETER ..........76
BEARING CLEARANCE ...........................................76
EM-2
APPLICATION NOTICE
How to Check Vehicle Type
How to Check Vehicle Type NJEM0112

Check the vehicle specification to confirm the service information for YD engine in EM section. For further
information, refer to GI-38. GI
Service information Specification
YD type 1 Without common rail

MA
YD type 2 With common rail
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-3
PRECAUTIONS YD TYPE 1
Parts Requiring Angular Tightening
Parts Requiring Angular Tightening NJEM0047

I Use an angle wrench for the final tightening of the following
engine parts:
a) Cylinder head bolts
b) Main bearing cap bolts
c) Connecting rod cap nuts
d) Crankshaft pulley bolt
I Do not use a torque value for final tightening.
I The torque value for these parts are for a preliminary step.
I Ensure thread and seat surfaces are clean and coated with
engine oil.
Liquid Gasket Application Procedure NJEM0048

1. Use a scraper to remove all traces of old liquid gasket
from mating surfaces and grooves. Also, completely clean
any oil from these areas.
2. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
I Be sure liquid gasket diameter is as specified.
SEM164F
3. Apply liquid gasket around the inner side of bolt holes

(unless otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and
engine coolant.
AEM080
EM-4
PREPARATION YD TYPE 1
Special Service Tools
Special Service Tools NJEM0049
Tool number
Description GI
Tool name
ST0501S000 Disassembling and assembling

Engine stand assembly MA
1 ST05011000
Engine stand
2 ST05012000
Base
LC
NT042
EC
KV10106500
Engine stand shaft
FE
NT028
CL
KV11105900 KV10115900 has been replaced with
Engine sub-attachment KV10106500. MT
AT
NT799 AX
KV10115600 Installing valve oil seal
Valve oil seal drift Use side A.
Side A SU
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia. BR
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
NT603
Unit: mm (in)
ST
KV10107902 Removing valve oil seal
Valve oil seal puller RS
1 KV10116100
Valve oil seal puller
adapter BT
NT605
HA
KV11103000
Injection pump drive gear
puller
SC
EL
NT676
IDX
EM-5
Special Service Tools (Cont’d)
Tool number
Description
Tool name
KV101056S0 Preventing crankshaft from rotating

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)
Plate e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)
NT617
KV101151S0 Changing shims

Lifter stopper set
1 KV10115110
Camshaft pliers
2 KV10115120
Lifter stopper
NT041
ST16610001 Removing crankshaft pilot bushing

Pilot bushing puller
NT045
KV10111100 Removing steel oil pan and rear timing chain

Seal cutter case
NT046
WS39930000 Pressing the tube of liquid gasket

Tube presser
NT052
KV10112100 Tightening bolts for bearing cap, cylinder

Angle wrench head, etc.
NT014
KV10109300 a: 68 mm (2.68 in)

Pulley holder b: 8 mm (0.31 in) dia.
NT628
EM-6
Special Service Tools (Cont’d)
Tool number
Description
Tool name
GI
KV11106010 a: 5 mm (Face to face)
Hexagon wrench b: 20 mm
MA
NT801
KV11106020 a: 6 mm (Face to face)

LC
Hexagon wrench b: 20 mm
EC
FE
NT803
KV11106030 a: 6 mm dia. CL
Positioning stopper pin b: 80 mm
MT
AT
NT804
KV11106040 a: T70
TORX wrench b: 26 mm
AX
SU
BR
NT805
Commercial Service Tools NJEM0050

ST
Tool name Description
Valve seat cutter set Finishing valve seat dimensions RS
BT
NT048
HA
Piston ring compressor Installing piston assembly into cylinder bore
SC
NT044 EL
Piston ring expander Removing and installing piston ring
IDX
NT030
EM-7
Commercial Service Tools (Cont’d)
Tool name Description
TORX socket
NT807
Standard Universal
NT808
EM-8
NOISE, VIBRATION AND HARSHNESS (NVH) NJEM0051
TROUBLESHOOTING YD TYPE 1
NVH Troubleshooting — Engine Noise
NVH Troubleshooting — Engine Noise NJEM0051S01

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

C A — A B — I Valve clearance EM-61
engine clicking noise EC
Rocker
cover Camshaft I Camshaft journal
Cylinder Rattle C A — A B C bearing clearance EM-50, 50 FE
head noise I Camshaft runout
I Piston and piston

Slap or Piston pin pin clearance CL
— A — B B — EM-72, 80
knock noise I Connecting rod
bushing clearance
MT
I Piston-to-bore
clearance
I Piston ring side
Crankshaft Slap or A — — B B A
Piston slap
clearance
EM-72, 73, AT
rap noise 73, 74
pulley I Piston ring end gap
Cylinder I Connecting rod
block bend and torsion AX
(Side of
engine) I Connecting rod
Oil pan Connect- bushing clearance SU
ing rod (Small end)
Knock A B C B B B EM-80, 78
bearing I Connecting rod
noise bearing clearance
(Big end)
BR
I Main bearing oil
Main bear-
Knock A B — A B C
ing noise
clearance EM-76, 76 ST
I Crankshaft runout
Front of Timing
engine chain and
I Timing chain RS
Tapping or cracks and wear
Timing A A — B B B chain ten- EM-23, 21
ticking I Timing chain ten-
chain sioner
sioner operation BT
cover noise
Other
Squeaking drive belts I Drive belts deflec- HA
A B — B — C
or fizzing (Sticking tion
or slipping) EM-12
Front of Other SC
I Idler pulley bearing
engine Creaking A B A B A B drive belts
operation
(Slipping)
Water
EL
Squall I Water pump opera-
A B — B A B pump LC-40
Creak tion
noise
IDX
A: Closely related B: Related C: Sometimes related —: Not related
EM-9
MEASUREMENT OF COMPRESSION NJEM0053
PRESSURE YD TYPE 1
1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated for
self-diagnosis items. Refer to EC-40, “CONSULT-II Inspection
Procedure”.
I Do not disconnect CONSULT-II until the end of this operation;
it will be used to check engine rpm and for error detection at
the end of this operation.
4. Disconnect the negative battery terminal.
5. To prevent fuel from being injected during inspection, remove
JEM111G fuel injection pump fuse [ENG CONT2 (20A)] from fuse box on
the left side of engine compartment.
6. Remove glow plugs from all the cylinders.
I Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
I Carefully remove glow plugs to prevent any damage or
breakage.
I Handle with care to avoid applying any shock to glow
plugs.
7. Install adapter (SST) to installation holes of glow plugs and

connect compression gauge for diesel engine.
: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
8. Connect battery negative terminal.
9. Set the ignition switch to “START” and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
I Always use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (bar, kg/cm2, psi)/rpm
SEM112G Difference limit between
Standard Minimum
cylinders
3,138 (31.38, 32.0, 455)/ 2,452 (24.52, 25.0, 356)/

490 (4.90, 5.0, 71)/200
200 200
I When engine rpm is out of the specified range, check the spe-
cific gravity of battery liquid. Measure again under corrected
conditions.
I If engine rpm exceeds the limit, check valve clearance and
combustion chamber components (valves, valve seats, cylin-
der head gaskets, piston rings, pistons, cylinder bores, cylin-
der block upper and lower surfaces) and measure again.
10. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect battery negative terminal.
c. Install glow plugs.
EM-10
MEASUREMENT OF COMPRESSION
PRESSURE YD TYPE 1
d. Install fuel injection pump fuse [ENG CONT2 (20A)].

e. Connect battery negative terminal.
f. Using CONSULT-II make sure no error code is indicated for GI
items of self-diagnosis. Refer to EC-40, “CONSULT-II Inspection
Procedure”.
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-11
DRIVE BELTS YD TYPE 1
Inspection
Inspection NJEM0088
I Before inspecting the engine, make sure the engine has
cooled down; wait approximately 30 minutes after the engine
has been stopped.
I Visually inspect all belts for wear, damage, or cracks on con-
tacting surfaces and edge areas.
I When measuring deflection, apply 98 N (10 kg, 22 lb) at the H
marked point.
I When checking belt deflection immediately after
installation, first adjust it to the specified value. Then,
JEM249G after turning the crankshaft two turns or more, re-adjust to
the specified value to avoid variation in deflection
between pulleys.
I Tighten idler pulley lock nut by hand and measure deflec-
tion without looseness.
Belt Deflection:
Belt deflection with 98 N (10 kg, 22 lb) force
Belt specifica- applied* mm (in)
Applied belt
tion Limit for re-
New Adjusted
tightening
Air conditioner
HA type low 4-5 6-7
compressor 8.5 (0.335)
edge belt (0.16 - 0.20) (0.24 - 0.28)
belt
Alternator & HA type low- 9.0 - 10.5 11.0 - 12.5

water pump edge wide (0.354 - (0.433 - 16.5 (0.650)
belt angle belt 0.413) 0.492)
*: When engine is cold.
Adjustment NJEM0089
I Adjust belts with the parts shown below.
Applied belt Belt tightening method for adjustment
Air conditioner compressor belt Adjusting bolt on idler pulley
Alternator water pump belt Adjusting bolt on alternator
CAUTION:
I When a new belt is installed as a replacement, adjust it to
the value specified under “New” accommodations
because of insufficient adaptability with pulley grooves.
EM-12
Adjustment (Cont’d)
I If the belt deflection of the current belt is out of the “Limit
for re-tightening”, adjust to the “Adjusted value”.
I When checking belt deflection immediately after GI
installation, first adjust it to the specified value. Then,
after turning crankshaft two turns or more, re-adjust it to
the specified value to avoid variation in deflection MA
between pulleys.
I Make sure the belts are fully fitted into the pulley grooves
during installation.
I Handle with care to avoid smearing the belts with oil or
cooling water etc.
LC
I Do not twist or bend the belts with strong force.
EC
FE
CL
MT
AIR CONDITIONER COMPRESSOR BELT NJEM0089S01
1. Remove RH splash cover (with undercover attached). AT
2. Loosen idler pulley lock nut (A).
3. Turn adjusting bolt (B) to adjust.
AX
I Refer to EM-12, “Inspection” for adjustment values.
4. Tighten lock nut (A).
Nut A: SU
: 31 - 39 N·m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
ALTERNATOR & WATER PUMP BELT NJEM0089S02
BR
1. Loosen adjuster lock nut (C).
2. Loosen alternator fixing bolts (D) (each on front and rear).
3. Turn adjusting bolt (E) to adjust.
ST
I Refer to EM-12, “Inspection” for adjustment values.
4. Tighten nut (C) and bolt (D) in this order. RS
Nut C:
: 19 - 24 N·m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
Bolt D:
BT
: 44 - 57 N·m (4.4 - 5.9 kg-m, 32 - 42 ft-lb)
HA
JEM251G
Removal NJEM0090
SC
1. Loosen each belt. Refer to EM-12, “Adjustment”.
2. Remove air conditioner compressor belt.
EL
3. Remove alternator & water pump belt.
IDX
EM-13
Installation
Installation NJEM0091
1. Install each belt on pulley in reverse order of removal.
2. Adjust belt tension. Refer to EM-12, “Adjustment”.
3. Tighten nuts and bolts provided for adjustment to the specified
torque.
4. Check again that each belt tension is as specified.
EM-14
AIR CLEANER YD TYPE 1
Changing Air Cleaner Filter
Changing Air Cleaner Filter NJEM0092

VISCOUS PAPER TYPE
The viscous paper type filter does not need cleaning.
NJEM0092S01
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-15
OIL PAN YD TYPE 1
Components
Components NJEM0054
YEM052-A
Removal NJEM0055
CAUTION:
When removing the upper oil pan from engine, first remove
the crankshaft position sensor (TDC sensor) from the assem-
bly.
Be careful not to damage sensor edges and signal plate teeth.
1. Remove right engine undercover.
2. Drain engine oil.
EM-16
OIL PAN YD TYPE 1
Removal (Cont’d)
3. Remove air compressor bracket.
4. Remove lower oil pan bolts.
I Loosen bolts in the reverse order of that shown in the figure. GI
MA
JEM114G LC
5. Remove lower oil pan.
a. Insert Tool between upper oil pan and lower oil pan.
EC
I Be careful not to damage aluminum mating surface.
I Do not insert screwdriver, or oil pan flange will be
deformed. FE
CL
SEM544G
MT
b. Slide Tool by tapping on the side of the Tool with a hammer.
c. Remove lower oil pan. AT
AX
SU
BR
SEM545G
6. Remove oil strainer.

7. Remove front exhaust tube and its support.
ST
Refer to FE-24, “Removal and Installation”.
RS
BT
HA
8. Set a suitable transmission jack under transaxle and hoist SC

engine with engine slinger.
I Place the jack as close to the center as possible for support.
9. Remove front and rear engine mounting nuts and bolts. EL
10. Remove center member.
11. Remove crankshaft position sensor (TDC sensor) from oil pan. IDX
12. Remove oil pan cover.
JEM553G
EM-17
OIL PAN YD TYPE 1
Removal (Cont’d)
13. For Europe only, remove catalyst rear diffuser, EM-37, “Cata-
lyst (For Europe)”.
14. Remove upper oil pan bolts in reverse order.
JEM116G
15. Remove four engine-to-transaxle bolts using a universal

socket. (Commercial Service Tool).
16. Remove upper oil pan.
a. Insert an appropriate size tool into the notch of upper oil pan.
I Be careful not to damage aluminum mating surface.
I Do not insert screwdriver, or oil pan flange will be
deformed.
b. Pry off upper oil pan by moving the tool up and down.
c. Remove upper oil pan.
I Be careful to prevent No. 15 and 16 blots from falling into
transaxle case.
Installation NJEM0056
1. Install upper oil pan.
a. Use a scraper to remove old liquid gasket from mating sur-
faces.
I Also remove old liquid gasket from mating surface of cyl-
inder block, front cover and lower oil pan.
I Remove old liquid gasket from the bolt hole and thread.
JEM117G
b. Apply a continuous bead of liquid gasket to mating surface of

aluminum oil pan.
I Use Genuine Liquid Gasket or equivalent.
SEM159F
c. Apply Genuine Liquid Gasket or equivalent, to areas shown in

the figure.
I At the 8 bolt holes marked ★, liquid gasket should be
applied on the rims of the holes.
I Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
or 4.5 to 5.5 mm (0.177 to 0.217 in) wide. (Be careful that
the diameter of the silicon bead is different around the
front.)
I Attaching should be done within 5 minutes after coating.
JEM118G
EM-18
OIL PAN YD TYPE 1
Installation (Cont’d)
d. Install upper oil pan.
I Tighten bolts in numerical order.
I Bolt dimensions vary depending on the installation location. GI
Refer to the following and use appropriate bolts.
M6 x 30 mm: Bolt No. 15, 16
M8 x 25 mm: Bolt No. 3, 4, 9, 10
MA
M8 x 60 mm: Bolt No. 1, 2, 5, 6, 7, 8, 11, 12, 13, 14
I The shank length under the bolt neck above is the length of the
threaded part (pilot portion not included).
I Wait at least 30 minutes before refilling engine oil.
JEM116G LC
2. Install the four engine-to-transaxle bolts. For tightening torque,
refer to MT-25, “Installation”.
3. Install oil pan cover.
EC
4. Install air compressor bracket.
: 57 - 65 N·m (5.8 - 6.7 kg-m, 42 - 48 ft-lb) FE
5. Install drive belts.
6. Install center member.
7. Install front and rear engine mounting insulator nuts and bolts.
CL
MT
8. Install crankshaft position sensor (TDC sensor).
I Tighten bolt while positioning and setting the side surface of AT
the crankshaft position sensor (TDC sensor) sleeve against
the arc of the upper oil pan.
9. Install front exhaust tube and its support. AX
10. Install oil strainer.
SU
BR
JEM119G
11. Install lower oil pan.

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

lower oil pan.
I Use Genuine Liquid Gasket or equivalent.
EL
IDX
SEM159F
EM-19
OIL PAN YD TYPE 1
I Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
I Attaching should be done within 5 minutes after coating.
SEM494G
c. Install lower oil pan.

I Tighten in numerical order shown in the figure.
I Wait at least 30 minutes before refilling engine oil.
JEM114G
EM-20
TIMING CHAIN YD TYPE 1
Secondary Timing Chain
Secondary Timing Chain NJEM0093

CAUTION:
I After removing timing chain, do not turn crankshaft and GI
camshaft separately, or valves will strike piston heads.
I When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
MA
engine oil.
I Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprockets, crankshaft pulley,
and camshaft brackets.
I When removing the oil pans, oil pump assembly and tim- LC
ing chain from engine, first remove the crankshaft posi-
tion sensor (TDC sensor).
Be careful not to damage sensor edges. EC
I Do not spill engine coolant on drive belts.
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
YEM069
SC
REMOVAL NJEM0093S01
I For preparative work for removing/installing secondary timing
chain to remove/install fuel injection pump, refer to EC-26,
EL
“Electronic control fuel injection pump”.
I To prepare for removing/installing secondary timing chain to IDX
remove/install camshaft, refer to EM-47, “CAMSHAFT”.
1. Drain engine oil.
2. Drain coolant by removing cylinder block drain plugs. Refer to
LC-44, “Changing Engine Coolant”.
EM-21
Secondary Timing Chain (Cont’d)
3. Remove front chain case.
I Move power steering fluid reservoir tank from the bracket.
I Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
I Remove No. 6, 10, and 11 bolts with the rubber washer as
space is limited for pulling them out.
JEM121G
CAUTION:
I While front chain case is removed, cover openings to pre-
vent entry of foreign material into engine.
I Do not remove two mass dampers on the back of cover.
SEM514G
4. Set the No. 1 piston to TDC on its compression stroke.

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

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

remove bolts to remove chain tensioner.
JEM125G
EM-22
6. Remove timing chain slack guide.
I Using a hexagon-head wrench (face to face: 6 mm, SST),
remove bolt to remove timing chain slack guide. GI
MA
JEM126G LC
7. Remove timing chain tension guide.
8. Remove secondary timing chain.
EC
I Timing chain alone can be removed without removing sprock-
ets.
FE
CL
JEM127G
MT
INSPECTION NJEM0093S02
Check for cracks and excessive wear at roller links. Replace AT
chain if necessary.
AX
SU
BR
SEM885F
INSTALLATION
1. Install secondary timing chain.
NJEM0093S03 ST
I When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the chain. RS
2. Install timing chain tension guide.
I The upper bolt has a longer shank than the lower bolt.
BT
HA
SC
EL
IDX
JEM128G
EM-23
3. Using a hexagon-head wrench (face to face: 6 mm, SST),
install timing chain slack guide.
JEM126G
4. Install chain tensioner.

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

a. Install tension guide on the back surface of front chain case.
I Hold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.
SEM514G
b. Apply specified liquid gasket (Refer to EM-4, “Liquid Gasket

Application Procedure”.) on both ends of arched area (loca-
tions where rear chain case is adjoined) as shown in the fig-
ure.
c. Install front chain case.
I When installing, align dowel pin on oil pump case with the pin
hole.
JEM129G
I Install No. 6, 10, and 11 bolts with the rubber washer to the
front chain case.
d. Tighten fixing bolts in the numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order.
JEM121G
EM-24
6. Hereafter, install in the reverse order of removal.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-25
Primary Timing Chain
Primary Timing Chain NJEM0094
YEM070
EM-26
Primary Timing Chain (Cont’d)
REMOVAL NJEM0094S01
1. Remove engine and transaxle assembly. Refer to EM-64,
“ENGINE ASSEMBLY”. GI
2. Remove transaxle from engine. Place engine onto engine
stand (SST). Refer to EM-68, “CYLINDER BLOCK”, “Disas-
sembly”. MA
3. Remove the following parts:
I Oil pan (upper and lower)
Refer to EM-16, “OIL PAN”.
I Oil filter bracket
Refer to LC-31, “Oil Filter Bracket”. LC
I Injection tube
Refer to EC-22, “Injection Tube and Injection Nozzle”.
4. Remove secondary timing chain and associated parts. EC
Refer to EM-21, “Secondary Timing Chain”.
5. When removing rear chain case, remove camshaft sprockets. FE
Refer to EM-47, “CAMSHAFT”.
CL
MT
6. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (SST). AT
b. Loosen crankshaft pulley fixing bolt and pull out the bolt
approximately 10 mm (0.39 in).
AX
SU
BR
JEM131G
c. Using pulley puller (SST), remove crankshaft pulley.

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

I Loosen bolts in the reverse order of that shown in the figure
and remove them.
I Use seal cutter (SST) etc. for removal. EL
8. Remove front oil seal from oil pump.
I Punch out the seal off from the back surface of the oil pump IDX
using a flat-bladed screwdriver.
I Be careful not to damage the oil pump.
JEM133G
EM-27
9. Remove chain tensioner.
I When removing chain tensioner, push the sleeve of chain ten-
sioner and keep it pressed with a push pin, etc.
10. Remove timing chain slack guide.
JEM134G
11. Hold fuel injection pump sprocket and remove bolt.

a. Insert positioning stopper pin (SST) into the hole 6 mm (0.24
in) in the diameter on the fuel injection pump sprocket.
b. Using a TORX wrench (SST), turn pump shaft little by little to
adjust the position of fuel injection pump sprocket so that the
holes align.
c. Push positioning stopper pin (SST) through pump sprocket to
fuel injection pump body to hold pump sprocket, and remove
bolt.
JEM135G
12. Remove primary timing chain with fuel injection pump sprocket
and crankshaft sprocket.
JEM136G
13. Remove chain guide and tension guides.

14. Remove fuel injection pump.
15. Remove power steering pump.
JEM137G
EM-28
16. Remove rear chain case.
I Loosen fixing bolts in the reverse order of that shown in the
figure and remove them. GI
I Use seal cutter (SST) for removal.
MA
LC
EC
FE
CL
JEM138G
MT
INSPECTION NJEM0094S02
Check for cracks and excessive wear at roller links. Replace AT
chain if necessary.
INSTALLATION NJEM0094S03 AX
SU
BR
ST
RS
BT
HA
JEM139G SC
EL
IDX
EM-29
1. Install rear chain case.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-4, “Liquid Gasket Application Procedure”.) on locations
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by start and end
areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protrud-
ing from the case surface.
JEM140G
b. Install four O-rings to the grooves of the cylinder block, fuel

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

I When installing, align the dowel pin with the pin hole.
d. Tighten bolts in the numerical order shown in the figure.
I Install the following four types of bolts, referring to the figure.
16 mm (0.63 in): Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22
20 mm (0.79 in): Bolt No. 3, 4, 6, 9, 10, 11, 13, 14
25 mm (0.98 in): Bolt No. 12, 15
35 mm (1.38 in): Bolt No. 5, 7, 8
I The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.
JEM138G
EM-30
2. Install power steering pump.
3. Install fuel injection pump.
I Before installing, make sure the notch on the fuel injection GI
pump flange and the hole 6 mm (0.24 in) in diameter on the
pump body are aligned.
4. Install chain guide and tension guides. MA
5. Install crankshaft sprocket, aligning it with the crankshaft key
on the far side.
JEM137G LC
6. Install primary timing chain with fuel injection pump sprocket.
I When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the chain.
EC
I Install fuel injection pump sprocket washer with the surface
marked “F” (front mark) facing the front of the engine. FE
7. Install timing chain onto power steering pump sprocket and
through chain guide.
CL
JEM136G
MT
8. Use the positioning stopper pin (SST) to hold the fuel injection
pump sprocket and install the bolt. AT
I Using a TORX wrench (SST), turn the pump shaft little by little
to adjust the position of the pump flange. Insert positioning
stopper pin (SST) into the hole 6 mm (0.24 in) in diameter on AX
the fuel injection pump sprocket so that the stopper pin goes
through the pump flange to the pump body. While the stopper
pin is in place, install the bolt. SU
BR
JEM135G
9. Install timing chain slack guide.

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

I Using a suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
I Do not touch lips of oil seal. Make sure seal surfaces are EL
free of foreign materials.
IDX
JEM142G
EM-31
12. Install chain case cover (for opening for power steering pump
removal/installation) to oil pump.
I Apply a continuous bead of specified liquid gasket (Refer to
EM-4, “Liquid Gasket Application Procedure”.) as shown in the
figure.
I Apply liquid gasket on oil pump-side surface.
JEM143G
13. Install oil pump.

a. Apply a continuous bead of specified liquid gasket (Refer to
EM-4, “Liquid Gasket Application Procedure”.) on locations
A: Leave the start and end areas of the bead slightly protrud-
ing from the surface.
B: Apply liquid gasket along upper end surface of oil pump.
JEM144G
b. Install oil pump drive spacer to crankshaft.

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

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

I Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
Standard:
Oil pump and rear chain case
–0.14 to 0.14 mm (–0.0055 to 0.0055 in)
Rear chain case and cylinder block
–0.25 to 0.13 mm (–0.0098 to 0.0051 in)
I If the measured value is out of the above range, install again.
JEM146G
EM-32
15. Install crankshaft pulley.
a. Install crankshaft pulley to crankshaft.
b. Hold crankshaft pulley with the pulley holder (SST). GI
c. Tighten bolt to 20 to 29 N·m (2.0 to 3.0 kg-m, 15 to 21 ft-lb).
d. Put an alignment mark on crankshaft pulley that aligns with MA
one of the punched marks on the bolt.
e. Tighten fixing bolt another 60° - 66° [target: 60° (turn by one
notch)].
16. Install secondary timing chain and the associated parts.
Refer to EM-23, “Secondary Timing Chain”, “INSTALLATION”.
JEM147G
17. Install in the reverse order of removal hereafter. LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-33
INTAKE MANIFOLD YD TYPE 1
Removal and Installation
Removal and Installation NJEM0109
YEM053-A
PREPARATIVE WORK NJEM0109S01

1. Drain engine coolant. Refer to LC-44, “Changing engine cool-
ant”.
2. Remove engine cover. Refer to the figure at left.
3. Remove injection tube.
4. Remove blow-by hose (on rocker cover side).
5. Remove or relocate fuel pipes.
6. Remove or relocate wires/harnesses and tubes/pipes.
SEM565G
EM-34
Removal and Installation (Cont’d)
FUEL PIPING NJEM0109S02
Removal
I
NJEM0109S0201
To prevent fuel from flowing out, plug the opening of the hose GI
with a blind plug after disconnection.
I Be careful not to spill fuel in the engine compartment. MA
Installation NJEM0109S0202
I After repairing, bleed air in pipes by shifting priming pump up
and down until the touch is heavy.
I For further air bleeding, idle at least 1 minute or more.
JEM238G LC
INTAKE MANIFOLD NJEM0109S03
Removal NJEM0109S0301 EC
I Loosen bolts and nuts in the reverse order of that shown in the
figure.
Installation FE
NJEM0109S0302
I When stud bolts come off, install with the following torque:
: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb) CL
I Tighten fixing bolts in the numerical order shown in the figure.
EGR VOLUME CONTROL VALVE NJEM0109S04 MT
SEM489G
I Handle with care avoiding any shocks.
I Do not disassemble or adjust.
AT
AX
SU
BR
WATER HOSE NJEM0109S05 ST

I Install water hose by referring to identification marks; avoiding
twisting. RS
I When an insert stopper is not provided with the pipe, insert the
hose up to dimension A. When the pipe is shorter than dimen-
sion A, insert hose fully until it reaches the end. BT
Dimension A: 25 - 30 mm (0.984 - 1.181 in)
I When an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
HA
I When marking is provided on the pipe, insert hose until it cov-
ers half of the marking. SC
EL
IDX
YEM054
EM-35
Inspection
Inspection NJEM0110
INTAKE MANIFOLD NJEM0110S01
Check distortion on the mounting surface with a straightedge and
feeler gauge.
Limit: 0.1 mm (0.004 in)
SEM491G
EM-36
CATALYST YD TYPE 1
GI
MA
LC
EC
FE
CL
MT
AT
YEM071
AX
PREPARATIVE WORK NJEM0101S01 SU

Remove the following parts.
I Under cover
I Engine coolant (drain) BR
Refer to LC-44, “Changing Engine Coolant”.
I Radiator upper hose ST
I Cooling fan
Refer to LC-43, “Radiator”.
I Radiator mount bracket RS
I Water inlet pipe
I Exhaust front tube (disconnect)
Refer to FE-24, “Removal and Installation”, “EXHAUST SYS- BT
TEM”.
CATALYST NJEM0101S02
HA
Removal NJEM0101S0201
I Remove the catalyst, refer to above illustration. SC
CAUTION:
Do not disassemble.
Installation
EL
NJEM0101S0202
Install two locking pins into both sides of the catalytic converter. Be
careful not to confuse locking pins with insulator mounting bolts. IDX
Catalytic converter locking pin:
Flange bolt (black)
Insulator mounting bolt:
Washer bolt (silver or yellow)
EM-37
CATALYST YD TYPE 1
GUSSET NJEM0101S03
Pushing gussets against the oil pan and the catalytic converter,
temporarily tighten the mounting bolt. And then tighten it to the
specified torque.
EM-38
EXHAUST MANIFOLD,
TURBOCHARGER YD TYPE 1
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
YEM072
BR
Remove the following parts.
I Engine coolant (drain)
ST
Refer to LC-44, “Changing Engine Coolant”.
I Air duct, air inlet pipe RS
I Water inlet pipe
I Catalytic converter
I Exhaust manifold cover BT
I Insulator
I Each wiring and piping (disconnect/move) HA
EXHAUST MANIFOLD AND TURBOCHARGER NJEM0102S02

SC
I Loosen exhaust manifold mounting nuts in the reverse order
specified in the figure. EL
I Rotate the exhaust manifold and turbocharger assembly so
that the rear side (EGR tube mounting side) faces upward. And IDX
then pull out the assembly from between the engine and the
air conditioning piping.
CAUTION:
Be careful not to deform each turbocharger piping when pull-
JEM266G ing out the assembly.
EM-39
EXHAUST MANIFOLD,
I When a stud bolt is pulled out, tighten it to the following torque:
: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
I Tighten the exhaust manifold mounting nuts in the following
procedure:
a) Tighten the nuts in the order specified in the figure.
b) Re-tighten the nuts 1 to 4.
EXHAUST MANIFOLD GASKET NJEM0102S03
Install the gasket so that the alignment protrusion faces the No. 4
port.
Disassembly and Assembly NJEM0103
YEM073
TURBOCHARGER NJEM0103S01
Disassembly NJEM0103S0101
After applying penetration lubricant (Lucen, etc.) to the mounting
nuts, check for the penetration of the lubricant, and then loosen the
nuts to remove.
EM-40
EXHAUST MANIFOLD,
Disassembly and Assembly (Cont’d)
CAUTION:
Do not disassemble or adjust the turbocharger body.
Assembly GI
NJEM0103S0102
When a stud bolt is pulled out, tighten it to the following torque:
: 24 - 27 N·m (2.4 - 2.8 kg-m, 18 - 20 ft-lb) MA
LC
Inspection NJEM0104
EXHAUST MANIFOLD NJEM0104S01
EC
Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.
Limit: 0.3 mm (0.012 in) FE
CL
JEM267G
MT
TURBOCHARGER NJEM0104S02
AT
AX
SU
BR
ST
RS
BT
SEM269G
HA
CAUTION:
When the compressor wheel, turbine wheel, or rotor shaft is
damaged, remove all the fragments and foreign matter left in SC
the following passages in order to prevent a secondary failure:
Suction side: Between turbocharger and air cleaner
EL
Exhaust side: Between turbocharger and catalytic con-
verter
IDX
EM-41
EXHAUST MANIFOLD,
Inspection (Cont’d)
Rotor Shaft NJEM0104S0201
I Check that the rotor shaft rotates smoothly without any resis-
tance when it is rotated by your fingertips.
I Check that the rotor shaft is not loose when it is moved verti-
cally or horizontally.
Standard value for rotor shaft oil clearance:
0.086 - 0.117 mm (0.0034 - 0.0046 in)
SEM270G
Rotor Shaft End Play NJEM0104S0202

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

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

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

I Connect the handy pump to the actuator, and check that the
rod strokes smoothly in compliance with the following pres-
sure.
I Pressure to be applied at actuator part to move rod end as
follows:
Standard (Pressure/rod stroke amount):
115.44 - 120.76 kPa (1,154 - 1,208 mbar, 866.0 - 906.0
mmHg, 34.1 - 35.7 inHg)/0.38 mm (0.0150 in)
140.54 - 149.86 kPa (1,405 - 1,498 mbar, 1,054.3 -
SEM274G 1,124.2 mmHg, 41.5 - 44.3 inHg)/4.0 mm (0.157 in)
EM-42
EXHAUST MANIFOLD,
Trouble Diagnosis of Turbocharger =NJEM0104S0206
Preliminary check:
I Check that the engine oil level is between MIN and MAX of the GI
dipstick. (When the engine oil amount is more than MAX, the
oil flows into the inlet duct through the blow-by gas passage,
and the turbocharger is misjudged failure.) MA
I Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
I Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
I If no malfunction is found after the unit inspections, judge that LC
the turbocharger body has no failure. Check the other parts
again.
EC
Symptom (when each inspection
item meets each inspection result)
Insuffi- FE
Inspection item Inspection result cient
Oil power/
Smoke Noise
leakage accel- CL
eration
failure
Oil leaks. g g g
MT
Carbon is accumulated. g q q
Turbine wheel
Friction with housing. g q q
AT
Blades are bent or broken.
AX
Inside the air inlet is seriously contami-
q q
nated by oil.
Compressor wheel
Friction with housing. g q q SU
Blades are bent or broken.
There is resistance when the rotor shaft BR

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

RS
Carbon or sludge is accumulated in the
Oil return port g g g
waste oil hole.
: Large possibility
BT
q: Medium possibility
g: Small possibility
HA
SC
EL
IDX
EM-43
ROCKER COVER YD TYPE 1
YEM014-A

Remove engine cover.
ROCKER COVER NJEM0099S02

Loosen holding bolts in the reverse order of that shown in the fig-
ure and remove.
CAUTION:
Do not remove mass damper on top. If damper must be
removed, remove all traces of old locking sealant from threads
of bolts and holes, and apply new locking sealant on the bolts
before tightening.
YEM015
I Tighten holding bolts in the numerical order shown in the fig-
ure.
I Re-tighten to the same torque in the same order as above.
EM-44
ROCKER COVER YD TYPE 1
I Apply 3.0 mm (0.118 in) dia. of specified liquid gasket (Refer
to EM-4, “Liquid Gasket Application Procedure”.) on locactions
shown in the figure. GI
MA
JEM248G LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-45
CYLINDER HEAD YD TYPE 1
Components
Components NJEM0062
YEM016-A
EM-46
Components (Cont’d)
CAUTION:
I When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new GI
engine oil.
I Apply new engine oil to threads and seat surfaces when
installing cylinder head, camshaft sprocket, crankshaft MA
pulley, and camshaft bracket.
I Attach tags to valve lifters so as not to mix them up.
LC
Removal NJEM0063
EC
1. Drain engine coolant. Refer to LC-44, “Changing Engine Cool-
ant”.
2. Remove exhaust manifold. Refer to EM-39, “Removal”. FE
3. Remove intake manifold. Refer to EM-35, “Removal”.
I Apply paint to camshaft sprockets for alignment during CL
installation.
MT
CAMSHAFT NJEM0063S02
1. Remove the following parts: AT
I Rocker cover
I Vacuum pump and cylinder head rear cover assembly
AX
I Spill tube
I High pressure injection nozzle assembly
I Secondary timing chain and associated parts SU
BR
JEM152G
2. Remove camshaft sprockets.

I Holding the hexagonal part of the camshaft with a wrench
ST
having 21 mm (0.83 in) width between facing flats, loosen the
bolt holding the camshaft sprocket.
RS
BT
HA
JEM159G
3. Remove camshafts. SC
I Loosen bolts holding the camshaft bracket in several stages in
the reverse order of that shown in the figure, and remove them.
4. Remove adjusting shims and valve lifters. EL
I Confirm the correct location of each part removed. Store them
so they do not get mixed up.
IDX
I For re-installation, be sure to put mark on camshaft
bracket before removal.
JEM160G
EM-47
Removal (Cont’d)
CYLINDER HEAD NJEM0063S03
I Loosen bolts in the reverse order of that shown in the figure
and remove them.
I Be careful not to damage the tips of glow plugs project-
ing out of the bottom surface of the cylinder head. To
avoid damage to glow plugs, either remove them
beforehand, or support cylinder head with wooden blocks
to create a space below the bottom surface.
JEM149G
Disassembly NJEM0100
YEM074
1. Remove adjusting shims and valve lifters. Confirm the correct

location of each part removed. Store them in order to avoid
mixing them up.
2. Remove valve collets.

I Compress valve spring with a valve spring compressor, and
remove valve collet with a magnet hand.
3. Remove valve spring retainers, and valve springs.
4. Push valve stem toward combustion chamber and remove
valve.
I Before removing valves, check valve guide clearance. Refer to
EM-51, “VALVE GUIDE CLEARANCE”.
I Confirm the correct location of each valve. Store them so they
do not get mixed up.
JEM151G
EM-48
Disassembly (Cont’d)
I For the locations and arrangement of intake and exhaust
valves, refer to the figure.
GI
MA
JEM152G LC
5. Remove valve oil seals.
I Use a valve oil seal puller (SST) for removal.
EC
6. Remove valve spring seats.
7. When removing valve seats, check valve seat contact. Refer
to EM-53. FE
8. Before removing valve guides, check valve guide clearance.
Refer to EM-51, “VALVE GUIDE CLEARANCE”.
9. Remove glow plugs. CL
I To avoid damage, glow plugs should be removed only
when required.
MT
JEM153G
I Handle with care to avoid applying shock. (When dropped
from approx. 100 mm (3.94 in) or higher, always replace
with a new one.) AT
AX
SU
BR
Inspection NJEM0065 ST
CYLINDER HEAD DISTORTION NJEM0065S01
Clean surface of cylinder head.
Use a reliable straightedge and feeler gauge to check the flatness RS
of cylinder head surface.
Check along six positions shown in the figure.
Head surface flatness: Limit 0.04 mm (0.0016 in) BT
If beyond the specified limit, resurface or replace it.
The limit for cylinder head resurfacing is determined by the HA
cylinder block resurfacing.
SEM496G
Resurfacing limit:
Amount of cylinder head resurfacing is “A”. SC
Amount of cylinder block resurfacing is “B”.
The maximum limit: A + B = 0.07 mm (0.0028 in)
EL
After resurfacing cylinder head, check that camshaft rotates freely
by hand. If resistance is felt, cylinder head must be replaced.
Nominal cylinder head height: IDX
153.9 - 154.1 mm (6.059 - 6.067 in)
EM-49
CAMSHAFT VISUAL CHECK NJEM0065S02
Check camshaft for scratches, seizure and wear.
CAMSHAFT RUNOUT NJEM0065S03

1. Place V-blocks on a work bench and support camshaft at No.
1 and No. 5 journal.
2. Set dial gauge perpendicularly at camshaft No. 3 journal.
3. Turn camshaft by hand in one direction and read runout on dial
gauge.
Runout (Total indicator reading):
Limit 0.02 mm (0.0008 in)
4. If it exceeds the limit, replace camshaft.
JEM161G
CAMSHAFT CAM HEIGHT NJEM0065S04

1. Measure camshaft cam height.
Standard cam height:
Intake
39.505 - 39.695 mm (1.5553 - 1.5628 in)
Exhaust
39.905 - 40.095 mm (1.5711 - 1.5785 in)
Cam wear limit:
0.2 mm (0.008 in)
SEM549A 2. If wear is beyond the limit, replace camshaft.
CAMSHAFT JOURNAL CLEARANCE NJEM0065S05
1. Install camshaft bracket and tighten bolts to the specified
torque.
2. Measure inner diameter of camshaft bearing.
Standard inner diameter:
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
3. Measure outer diameter of camshaft journal.

Standard outer diameter:
No. 1: 30.435 - 30.455 mm (1.1982 - 1.1990 in)
No. 2, 3, 4, 5: 23.935 - 23.955 mm (0.9423 - 0.9431 in)
4. If clearance exceeds the limit, replace camshaft and/or cylin-
der head.
Camshaft journal clearance:
Standard No. 1 - 5: 0.045 - 0.086 mm (0.0018 - 0.0034
in)
Limit 0.045 - 0.086 mm (0.0018 - 0.0034 in)
SEM012A
EM-50
CAMSHAFT END PLAY NJEM0065S06
1. Install camshaft in cylinder head.
2. Measure camshaft end play. GI
Camshaft end play:
Standard MA
0.070 - 0.148 mm (0.0028 - 0.0058 in)
Limit
0.24 mm (0.0094 in)
I If the value exceeds the limit, replace camshaft and measure
again.
JEM163G LC
I If the measurement exceeds the limit again, replace cylinder
head.
EC
FE
CL
MT
CAMSHAFT SPROCKET RUNOUT NJEM0065S07
1. Install sprocket on camshaft. AT
2. Measure camshaft sprocket runout.
AX
Less than 0.15 mm (0.0059 in)
3. If it exceeds the limit, replace camshaft sprocket.
SU
BR
JEM164G
VALVE GUIDE CLEARANCE

1.
NJEM0065S08
Check that valve stem diameter is within the specified range.
ST
2. Push out valve approx. 25 mm (0.98 in) toward combustion
chamber. Swing valve in the direction of the dial gauge to RS
measure the runout.
I This inspection should be performed before removing valve
guides. BT
I Half of the runout reading on the dial gauge is the valve guide
clearance.
Standard: HA
JEM155G Intake 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust 0.040 - 0.073 mm (0.0016 - 0.0029 in) SC
3. If it exceeds the limit, check valve to valve guide clearance.
a. Measure valve stem diameter and valve guide inner diameter.
b. Check that clearance is within specification. EL
Valve to valve guide clearance limit:
Intake 0.08 mm (0.0031 in) IDX
Exhaust 0.1 mm (0.004 in)
c. If it exceeds the limit, replace valve or valve guide.
EM-51
VALVE GUIDE REPLACEMENT NJEM0065S09
I When a valve guide is removed, replace with an oversized [0.2
mm (0.008 in)] valve guide.
1. To remove valve guide, heat cylinder head to 110 to 130°C
(230 to 266°F) by soaking in heated oil.
SEM008A
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2

US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.
SEM931C
3. Ream cylinder head valve guide hole.

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

service valve guide onto cylinder head.
Projection “L”:
10.4 - 10.6 mm (0.409 - 0.417 in)
5. Ream valve guide.
Finished size:
6.000 - 6.018 mm (0.2362 - 0.2369 in)
JEM156G
EM-52
VALVE SEATS NJEM0065S10
I Before starting this check, confirm that the dimensions of valve
guides and valves are as specified. GI
I Apply red lead primer on contacting surfaces of valve seat and
of valve face to examine the conditions of contacting surfaces.
I Check that the paint on contacting surfaces is continuous
MA
along the entire circumference.
I If there are abnormal indications, grind the valve and check the
contact again. If abnormal indications still persist, replace
valve seat.
SEM934C LC
EC
FE
CL
JEM157G
MT
REPLACING VALVE SEAT FOR SERVICE PARTS NJEM0065S11
1. Bore out old seat until it collapses. Boring should not continue AT
beyond the bottom face of the seat recess in cylinder head. Set
the machine depth stop to ensure this.
2. Ream cylinder head recess for service valve seat. AX
Oversize [0.5 mm (0.020 in)]:
Intake 30.500 - 30.516 mm (1.2008 - 1.2014 in) SU
Exhaust 29.500 - 29.516 mm (1.1614 - 1.1620 in)
Be sure to ream in circles concentric to the valve guide
center. BR
SEM795A
This will enable valve seat to fit correctly.
ST
RS
BT
HA
SC
EL
IDX
EM-53
3. Heat cylinder head to 110 to 120°C (230 to 248°F) by soaking
in heated oil.
4. Sufficiently cool valve seat with dry ice. Force fit valve seat into
cylinder head.
WARNING:
Do not touch cold valve seat with your bare hands.
5. Cut or grind valve seat using suitable tool to the specified
dimensions as shown in SDS (EM-91).
CAUTION:
Use the valve seat cutter properly. Securely gripping the cut-
ter handle with both hands, press the cutter down onto the
entire circumference of the contacting surface and finish cut-
ting at one time. Improper pressing of the cutter or cutting in
several steps may result in staged surface on the valve seat.
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. Refer to EM-53, “Valve Seats”.
JEM158G
SEM301G
8. Use a depth gauge to measure the distance between the

mounting surface of the cylinder head spring seat and the
valve stem end. If the distance is shorter than specified, repeat
step 5 above to adjust it. If it is longer, replace the valve seat
with a new one.
Valve seat resurface limit “L”:
Intake 36.53 - 36.98 mm (1.4382 - 1.4559 in)
Exhaust 36.53 - 37.01 mm (1.4382 - 1.4571 in)
JEM253G
EM-54
VALVE DIMENSIONS NJEM0065S12
Check dimensions of each valve. For dimensions, refer to SDS
(EM-88). GI
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or MA
less.
SEM188A LC
VALVE SPRING NJEM0065S13
Squareness NJEM0065S1301 EC
1. Measure dimension “S”.
Out-of-square “S”:
Limit 1.5 mm (0.059 in) FE
2. If it exceeds the limit, replace spring.
CL
SEM288A
MT
Pressure NJEM0065S1302
Check valve spring pressure at specified spring height. AT
Standard:
Installation height 32.82 mm (1.2921 in)
AX
Installation load 168 - 186 N (17.13 - 18.97 kg, 37.8 -
41.8 lb)
Height during valve open 24.82 mm (0.9772 in) SU
Load with valve open 350 - 382 N (35.7 - 37.9 kg, 78.7
- 83.6 lb)
If it exceeds the standard, replace spring. BR
EM113
VALVE LIFTER
1. Check contact and sliding surfaces for wear or scratches.
NJEM0065S14 ST
RS
BT
HA
SEM960E
2. Check diameter of valve lifter and valve lifter guide bore. SC

Valve lifter outer diameter:
29.960 - 29.975 mm (1.1795 - 1.1801 in)
EL
IDX
SEM961E
EM-55
Lifter guide bore diameter:
30.000 - 30.021 mm (1.1811 - 1.1819 in)
Clearance between lifter and lifter guide:
Standard 0.025 - 0.061 mm (0.0010 - 0.0024 in)
I If the value is out of the range, replace valve lifter and/or cyl-
inder head, referring to the specified values for the outer diam-
eter and bore diameter.
SEM867E
Assembly NJEM0066
1. Install valve oil seal.
I Using valve oil seal drift (SST), install so that the dimension
shown in the figure is obtained. The dimension in the figure
shows the dimension before the valve spring seat is installed.
I Different parts should be used depending on the valve oil seal
location. Identify by the rubber color.
For intake: Black
For exhaust: Brown
I Always use new valve oil seal.
JEM165G
I Before installing valve oil seal, install valve spring seat.
2. Install other valve component parts. Refer to “Disassembly”,
EM-48.
I After installing valve collets, tap valve stem tip with plastic
hammer to assure a proper fit.
EM-56
Installation
Installation =NJEM0067
I Before installation, remove old liquid gasket from mating
surface of all liquid gasket applied parts. GI
MA
LC
CYLINDER HEAD GASKET SELECTION NJEM0067S01
I Select and install cylinder head gasket with appropriate thick- EC
ness according to the following procedure:
When replacing gasket alone:
I Install a gasket with the same thickness as that of the one FE
removed.
I Identify the thickness of gasket by the number of holes on the
RH side. CL
Gasket thickness*
Number of holes
SEM505G
mm (in) MT
0.900 (0.0354) 1
0.925 (0.0364) 2 AT
0.950 (0.0374) 3
0.975 (0.0384) 4 AX
1.000 (0.0394) 5
1.025 (0.0404) 6 SU
*: Measured with head bolts tightened
BR
When the following parts have been repaired/replaced:
I With cylinder block upper surface and/or crankshaft pin journal
ST
ground
I With cylinder block, pistons, connecting rods, and/or crank- RS
shaft replaced
1. Set piston at a point close to TDC.
2. Set a dial gauge at the location as shown in the figure. Turn- BT
ing crankshaft gradually, set the gauge scale to “0” where the
piston protrusion is maximized.
3. Move the dial gauge stand so that the tip of dial gauge can HA
SEM507G contact the cylinder block. Read the difference.
4. Measure at two locations per cylinder, that is eight locations for SC
four cylinders. Select gasket based on the maximum protru-
sion of eight measurements.
5. Measure front and rear at two locations for each cylinder and EL
calculate the mean value.
Among the four measured points for each cylinder, determine
the maximum protrusion value as the engine’s piston protru- IDX
sion value, and select and install a head gasket according to
the value.
I This SELECTION has been discontinued since June, 2000.
EM-57
Gasket thickness* Identification

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

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

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

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

1.000 (0.0394) 5
(0.0130 - 0.0140)
More than 0.355 (0.0140) 1.025 (0.0404) 6
*: Measured with head bolts tightened
CYLINDER HEAD BOLT DEFORMATION CHECK NJEM0067S02

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

NJEM0067S03
I After installing cylinder head, measure dimension from the
front end surface of cylinder block to that of cylinder head.
Standard: 23.53 - 24.07 mm (0.9264 - 0.9476 in)
I If the difference is out of the range, check fitting of dowel pins
and cylinder head.
JEM172G
LIQUID GASKET APPLICATION ON REAR CHAIN CASE

NJEM0067S04
Apply a continuous bead of specified liquid gasket (Refer to EM-4,
“Liquid Gasket Application Procedure”.) on the surface shown in
the figure.
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external location
but cannot be viewed externally after engine is assembled.
JEM167G
EM-58
CYLINDER HEAD INSTALLATION NJEM0067S05
I Tighten bolts in numerical order as shown in the figure accord-
ing to the following procedure: GI
1. Apply engine oil to bolt threads and seat surfaces.
2. Tighten bolts to 29 to 38 N·m (2.9 to 3.9 kg-m, 21 to 28 ft-lb).
MA
3. Tighten 180° to 185° [target: 180°] (angular tightening).
4. Loosen completely to 0 N·m (0 kg-m, 0 in-lb) in the reverse
order of that shown in the figure.
5. Tighten bolts to 35 to 44 N·m (3.5 to 4.5 kg-m, 26 to 32 ft-lb).
6. Tighten 90° to 95° [target: 90°] (angular tightening).
JEM149G
7. Tighten another 90° to 95° [target: 90°] (angular tightening). LC
I When an angle wrench is not used, paint an alignment
mark on the head of cylinder head bolt and cylinder head EC
surface before tightening. Check the angle with a protrac-
tor.
FE
CL
JEM166G
MT
GLOW PLUG INSTALLATION NJEM0067S06
I To avoid damage, glow plugs should be removed only AT
when required.
I Handle with care to avoid applying shock. (When dropped
from approx. 100 mm (3.94 in) or higher, always replace AX
with a new one.)
I Before installing, remove carbon depositing on mounting hole
of glow plug with a reamer.
SU
BR
CAMSHAFT INSTALLATION
1. Install valve lifters and adjusting shims.
NJEM0067S07 ST
I Install in the correct locations (the same places as before
removal). RS
2. Install camshafts.
I Identify camshafts by the paint position and screw hole at the
rear end. BT
Camshaft RH: Paint is at position A without screw hole.
Camshaft LH: Paint is at position B with screw hole. HA
JEM173G
I Install so that knock pins are positioned in the directions shown SC

in the figure.
EL
IDX
SEM516G
EM-59
3. Install camshaft brackets.
I Install correctly, identifying brackets by the journal No. and
front mark on top surface.
JEM175G
4. Tighten bolts in the order shown in the figure according to the

following procedure:
a. Tighten to 2.0 N·m (0.2 kg-m, 17 in-lb).
I Make sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten to 6 N·m (0.6 kg-m, 52 in-lb).
c. Tighten to 12 to 13 N·m (1.2 to 1.4 kg-m, 9 to 10 ft-lb).
5. Install camshaft sprockets.
I Camshaft sprockets are commonly used for RH and LH.
I Align camshaft sprocket and dowel pin on camshaft, and
JEM160G
install.
I Holding the hexagonal part of camshaft with a wrench, tighten
bolt securing camshaft sprocket.
6. Before installing spill tube after installing secondary timing
chain, check and adjust valve clearance. Refer to EM-60,
“Valve Clearance”.
7. Hereafter, install in the reverse order of removal.
Valve Clearance NJEM0068

CHECKING NJEM0068S01
Check valve clearance while engine is cold and not running.
1. Set the No. 1 piston to TDC on its compression stroke.
I Turn crankshaft pulley clockwise so that the knock pin on cam-
shaft LH faces straight above. (No position indicator, etc. is
provided on the crankshaft pulley.)
JEM176G
2. Put an alignment mark with paint, etc. on the crankshaft pul-

ley and on the oil pump as an angle indicator.
JEM177G
EM-60
Valve Clearance (Cont’d)
3. Check only those valves shown in the figure.
Valve
GI
No. 1 No. 2 No. 3 No. 4
Crank position INT EXH INT EXH INT EXH INT EXH
MA
No. 1 TDC
(Compression q q q q
stroke)
JEM178G LC
I Using a feeler gauge, measure clearance between valve lifter
and camshaft.
I Record any valve clearance measurements which are out of
EC
specification. They will be used later to determine the required
replacement adjusting shim.
FE
Valve clearance for checking (Cold):
Intake
0.24 - 0.32 mm (0.0094 - 0.0126 in) CL
Exhaust
0.26 - 0.34 mm (0.0102 - 0.0134 in)
JEM179G
MT
4. Rotate crankshaft clockwise by one turn to set the No. 4 pis-
ton to TDC on the compression stroke. AT
5. Check only those valves shown in the figure.
Valve AX
No. 1 No. 2 No. 3 No. 4
Crank position INT EXH INT EXH INT EXH INT EXH SU
No. 4 TDC
(Compression q q q q
stroke) BR
JEM180G
ADJUSTING
Adjust valve clearance while engine is cold.
NJEM0068S02 ST
1. Turn crankshaft, to position cam lobe on camshaft of valve that
must be adjusted upward. RS
2. Place Tool (A) around camshaft as shown in figure.
Before placing Tool (A) (SST), rotate notch toward center
of cylinder head (See figure.), to simplify shim removal BT
later.
CAUTION:
Be careful not to damage cam surface with Tool (A). HA
JEM181G
3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down. SC
EL
IDX
SEM497G
EM-61
4. Place Tool (B) (SST) between camshaft and the edge of the
valve lifter to retain valve lifter.
CAUTION:
I Tool (B) must be placed as close to camshaft bracket as
possible.
I Be careful not to damage cam surface with Tool (B).
5. Remove Tool (A).
SEM498G
6. Blow air into the hole to separate adjusting shim from valve
lifter.
I To avoid engine oil spills, wipe off oil fully beforehand.
Wear safety goggles, etc. during work if necessary.
JEM555G
7. Remove adjusting shim using a small screwdriver and a mag-

netic finger.
8. Determine replacement adjusting shim size following formula.
I Using a micrometer determine thickness of removed shim.
I Calculate thickness of new adjusting shim so valve clearance
comes within specified values.
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake:
JEM556G N = R + [M − 0.28 mm (0.0110 in)]
Exhaust:
N = R + [M − 0.30 mm (0.0118 in)]
Shims are available in 33 sizes from 2.10 mm (0.0827 in)
to 2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in).
I Select new shim with thickness as close as possible to calcu-
lated value.
SEM145D
JEM184G
EM-62
9. Install new shim using a suitable tool.
I Install with the surface on which the thickness is stamped
facing down. GI
MA
SEM552G LC
10. Place Tool (A) as mentioned in steps 2 and 3.
11. Remove Tool (B).
EC
12. Remove Tool (A).
13. Recheck valve clearance.
Valve clearance: FE
Unit: mm (in)
Cold Hot* (reference data) CL

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

*: Approximately 80°C (176°F)
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-63
ENGINE ASSEMBLY YD TYPE 1
SEM554G
WARNING:
I Situate vehicle on a flat and solid surface.
I Place chocks at front and back of rear wheels.
I Do not remove engine until exhaust system has com-
pletely cooled off. Otherwise, you may burn yourself
and/or fire may break out in fuel line.
I For safety during subsequent steps, the tension of wires
should be slackened against the engine.
I Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI-45, “Garage Jack and Safety Stand”.
I Be sure to hoist engine and transaxle in a safe manner.
I For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
I When lifting engine, be careful not to strike adjacent parts,
especially the following: Accelerator wire casing, brake
lines, and brake master cylinder.
I In hoisting the engine, always use engine slingers in a
safe manner.
I In removing drive shaft, be careful not to damage grease
seal of transaxle.
I Before separating engine and transaxle, remove the
EM-64
crankshaft position sensor (TDC sensor) from the assem-
bly.
I Always pay extra attention not to damage edge of crank- GI
shaft position sensor (TDC sensor) or ring gear teeth.
REMOVAL NJEM0069S01 MA
1. Remove engine undercover, and hood for hoisting.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-44, “Changing Engine Coolant”.
3. Remove the following parts:
I Battery
LC
I RH and LH front wheels
I RH and LH splash covers (combined with undercover)
I Auxiliary belts EC
I Alternator
I Alternator brackets
FE
I Radiator and cooling fan
I Engine cover
I Air ducts and air cleaner case CL
LH side of engine room:
4. Disconnect all harnesses and grounds that are connected to MT
components on vehicle.
5. Disconnect vacuum hose on vacuum pump side.
6. Disconnect fuel feed and fuel return hoses on engine side. AT
I Immediately put blind plugs into the openings to prevent
fuel from flowing out.
7. Disconnect heater hose. Plug opening of hose to prevent cool- AX
ant from flowing out.
RH side of engine room: SU
8. Remove air conditioner compressor from brackets and move
it toward vehicle side. Secure compressor on vehicle side with
rope. BR
Vehicle underside:
9. Remove exhaust front tube.
ST
10. Disconnect two hoses from power steering pump and plug to
stop fluid.
11. Remove M/T control rod and support rod. RS
12. Remove ABS wheel sensor, and temporarily hang brake cali-
per with rope on vehicle side.
13. Remove RH and LH drive shafts. BT
HA
14. Install engine slingers to cylinder head. SC

: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
I Use engine slingers and securing bolts of the specified
service parts. EL
15. Lift up vehicle to appropriate level where work can be per-
formed efficiently. Using two transmission jacks, securely sup-
port engine oil pan and bottom surface of transaxle. IDX
YEM024
EM-65
I Make sure that support is stable with the use of safety
blocks.
16. Install hooks of lifting chain into engine slingers and tighten
chain so that engine still remains on transmission jacks with-
out being lifted up.
17. Remove engine mount insulator RH.
18. Remove through-bolt of engine mount insulator LH.
19. Remove bolts securing center member at front and rear.
SEM189G
20. Carefully lower transmission jacks in accordance with the low-

ering pace of the hoist, and remove engine and transaxle
assembly from vehicle.
I While working, check that no parts of engine assembly
interfere with adjacent parts on the vehicle.
I While working, make sure that parts requiring disconnec-
tion are not left connected, and that no parts interfere with
vehicle.
I To prevent vehicle from falling down, perform operation
carefully so that the center of gravity of the vehicle will not
JEM190G
shift.
21. Remove center member.
I Before starting removal operation, first place the assem-
bly on a level surface and securely support the bottom
surface with wood blocks. Using a hoist, lift engine
slingers, and make sure the assembly is stable.
22. Separate engine and transaxle.
INSTALLATION NJEM0069S02
Install in the reverse order of removal, observing the following:
I While installing, be careful to keep mount insulators free of oil
smear and damage.
I When parts require specified installation directions/positions,
install by using the identifying marks indicating up or front.
I While keeping the mount insulators free of twists or distortions,
start tightening from the through-bolt on the engine mount
insulator LH. This mount is used as the reference position.
EM-66
CYLINDER BLOCK YD TYPE 1
Components
Components NJEM0070
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
SEM510GC
EM-67

CAUTION:
I When installing bearings, pistons, or other sliding parts,
lubricate contacting surfaces with new engine oil.
I Place removed parts such as bearings and bearing caps
in their proper order and direction.
I When installing connecting rod nuts, and main bearing
cap bolts, apply new engine oil to threads and seating
surfaces.
I Do not allow any magnetic materials to contact the signal
plate of flywheel.
I Do not remove the signal plate at back.
I Do not place the signal plate side facing under.
I Handle with care so as not to damage the signal plate
[especially four places on protrusions for signal of crank
position sensor (TDC sensor)].
Disassembly NJEM0072
PISTON AND CRANKSHAFT NJEM0072S01
1. Remove engine. Refer to “ENGINE ASSEMBLY”, “Removal
and Installation”, EM-64.
2. Place engine on a work stand.
a. Remove flywheel.
I Hold ring gear with ring gear stopper (KV10105630,
KV10105610). Then, loosen securing bolts with TORX socket
(size: Q8 E20, Commercial Service Tool) and remove them.
As an alternative method, hold the crankshaft pulley with a
pulley holder (SST) to remove the flywheel.
b. Install engine sub-attachment (SST) to rear surface of cylinder
block.
I To install, align the hole on the sub-attachment with the knock
pin on the cylinder block.
I The engine sub-attachment has five bolts.
c. Install engine attachment (SST).
I The four sets of bolts and nuts are multi-purpose products.
JEM192G
EM-68
d. Hoist up engine and install it on the engine stand (SST).
I Another method is to set engine sub-attachment and engine
attachment on engine stand beforehand, and then, install GI
engine.
3. Drain engine oil and coolant from engine.
4. Remove the following and the associated parts: MA
I Exhaust manifold
I Turbocharger assembly (For Europe)
I Injection tube
I Intake manifold
I Oil pan (upper and lower) LC
I Secondary timing chain
I Fuel injection pump EC
I Primary timing chain
I Rocker cover
I High pressure injection nozzle assembly FE
I Camshaft
I Cylinder head CL
I Thermostat, water pipes
I Oil cooler
JEM193G I Auxiliary component brackets MT
5. Remove fuel injection pump bracket.
AT
AX
SU
BR
6. If the replacement of pilot bushing is necessary, remove it with
pilot bushing puller (SST). ST
7. Remove rear oil seal retainer.
I Insert a flat-bladed screwdriver between main bearing cap and RS
rear oil seal retainer to remove retainer.
8. Remove rear oil seal from rear oil seal retainer.
I Punch out with a flat-bladed screwdriver. BT
I Be careful not to damage rear oil seal retainer.
HA
SEM500G
9. Remove piston and connecting rod assembly. SC

a. Set crankshaft pin of the removal location at a position close
to BDC.
b. Remove connecting rod cap. EL
c. Push piston and connecting rod assembly toward cylinder
head using a hammer handle.
IDX
I Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-71, “CONNECT-
ING ROD SIDE CLEARANCE”.
10. Remove connecting rod bearings from connecting rod and
JEM195G connecting rod cap.
EM-69
I Store the removed parts in sets by the cylinder No. to avoid
mixing them up.
11.Remove piston rings from pistons.

I Use piston ring expander (Commercial Service Tool).
I Avoid scratching pistons during removal.
I Be careful not to damage piston rings by expanding
excessively.
CAUTION:
I When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
JEM196G
12. Remove piston from connecting rod.

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

158°F).
JEM198G
c. Push out piston pin with a rod approx. 26 mm (1.02 in) in

diameter.
JEM199G
EM-70
13. Remove main bearing cap bolts.
I With a TORX socket (size: E-14, Commercial Service Tool),
loosen main bearing cap bolts in several stages in the reverse GI
order of that shown in the figure and remove them.
I Before loosening main bearing cap bolts, measure crankshaft
end play. Refer to EM-71, “CRANKSHAFT END PLAY”. MA
JEM200G LC
14. Remove main bearing caps.
I Using main bearing cap bolts, remove by rocking bearing cap
back and forth.
EC
FE
CL
JEM201G
MT
15. Remove crankshaft.
16. Remove main bearings and thrust bearings from cylinder block AT
and main bearing caps.
I Check the correct installation locations of removed parts.
Store them so they do not get mixed up. AX
17. Remove oil jet.
18. Remove oil jet check valve. SU
BR
Inspection NJEM0073 ST
CRANKSHAFT END PLAY NJEM0073S13
I Measure the moving distance of the crankshaft with the dial
gauge when the crankshaft is moved fully forward or back- RS
ward.
Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit: 0.30 mm (0.0118 in)
BT
I If the value exceeds the limit, replace thrust bearings with new
ones and measure again. If the measurement exceeds the limit HA
again, replace crankshaft with a new one.
JEM202G
CONNECTING ROD SIDE CLEARANCE NJEM0073S14

SC
I Measure the side clearance between connecting rod and crank
arm with feeler gauge.
Standard: 0.200 - 0.350 mm (0.0079 - 0.0138 in) EL
Limit: 0.4 mm (0.0157 in)
I If the value exceeds the limit, replace connecting rod and mea- IDX
sure again. If the measurement exceeds the limit again,
replace the crankshaft.
JEM203G
EM-71
PISTON AND PISTON PIN CLEARANCE NJEM0073S01
1. Measure inner diameter of piston pin hole “dp”.
Standard diameter “dp”:
27.997 - 28.005 mm (1.1022 - 1.1026 in)
AEM023
2. Measure outer diameter of piston pin “Dp”.

Standard diameter “Dp”:
27.994 - 28.000 mm (1.1021 - 1.1024 in)
3. Calculate interference fit of piston pin to piston.
Dp − dp = 0.002 - 0.006 mm (0.0001 - 0.0002 in)
If it exceeds the above value, replace piston assembly with pin.
AEM024
PISTON RING SIDE CLEARANCE NJEM0073S02

Side clearance:
Top ring
0.120 - 0.180 mm (0.0047 - 0.0071 in)
2nd ring
0.050 - 0.090 mm (0.0020 - 0.0035 in)
Oil ring
0.030 - 0.070 mm (0.0012 - 0.0028 in)
Max. limit of side clearance:
SEM024AA Top ring 0.2 mm (0.008 in)
2nd ring 0.1 mm (0.004 in)
I To measure top ring side clearance, align the outer circumfer-

ences of the ring and piston while pressing ring upward against
the upper surface of the ring groove. Under this condition,
measure the clearance between ring and bottom surface of the
ring groove.
I If out of specification, replace piston ring. If clearance exceeds
maximum limit with new ring, replace piston.
JEM205G
EM-72
PISTON RING END GAP NJEM0073S03
End gap:
Top ring 0.20 - 0.35 mm (0.0079 - 0.0138 in) GI
2nd ring 0.39 - 0.54 mm (0.0154 - 0.0213 in)
Oil ring 0.25 - 0.37 mm (0.0098 - 0.0146 in) MA
Max. limit of ring gap:
Top ring 1.0 mm (0.039 in)
2nd ring 1.0 mm (0.039 in)
Oil ring 0.87 mm (0.0343 in)
SEM599A If out of specification, replace piston ring. If gap still exceeds the LC
limit even with a new ring, do the following. Rebore cylinder and
use oversized piston and piston rings.
Refer to SDS (EM-95). EC
I When replacing the piston, check the cylinder block surface for
scratches or seizure. If scratches or seizure is found, hone or
replace the cylinder block. FE
CL
MT
CONNECTING ROD BEND AND TORSION NJEM0073S04
Bend: AT
Limit 0.12 mm (0.0047 in)
per 100 mm (3.94 in) length
AX
Torsion:
Limit 0.12 mm (0.0047 in)
per 100 mm (3.94 in) length SU
If it exceeds the limit, replace connecting rod assembly.
BR
SEM038F
ST
RS
BT
HA
SEM003F
CYLINDER BLOCK DISTORTION AND WEAR NJEM0073S05

SC
I Clean upper surface of cylinder block.
Use a reliable straightedge and feeler gauge to check the flat-
ness of cylinder block surface. EL
Check along six positions shown in the figure.
Distortion limit: 0.04 mm (0.0016 in)
I If out of specification, resurface it. The limit for cylinder block
IDX
resurfacing is determined by cylinder head resurfacing in
engine.
Resurfacing limit:
SEM501G Amount of cylinder head resurfacing is “A”.
EM-73
Amount of cylinder block resurfacing is “B”.
The maximum limit is as follows:
A + B = 0.07mm (0.0028 in)
Nominal cylinder block height from crankshaft center:
252.95 - 253.05 mm (9.9586 - 9.9626 in)
I If necessary, replace cylinder block.
PISTON-TO-BORE CLEARANCE NJEM0073S06

1. Using a bore gauge, measure cylinder bore in X and Y direc-
tions at A, B and C for wear, out-of-round and taper.
Cylinder bore inner diameter:
Standard
86.000 - 86.030 mm (3.3858 - 3.3870 in)
Wear limit
0.20 mm (0.0079 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
JEM206G
block if necessary.
Out-of-round (X − Y):
Limit 0.015 mm (0.0006 in)
Taper (A − B − C):
Limit 0.010 mm (0.0004 in)
2. Check for scratches and seizure. If seizure is found, hone it.
JEM207G
3. Measure piston skirt diameter.

Piston diameter “A”:
85.920 - 85.950 mm (3.3827 - 3.3839 in)
Measuring point “a” (Distance from the top):
58.0 mm (2.28 in)
4. Check that piston-to-bore clearance is within specification.
I Calculate the clearance by using outer diameter at piston skirt
and inner diameter of cylinder (direction of X, point B):
Piston-to-bore clearance = Cylinder bore – Piston
diameter “A”
SEM258C
Standard [at room temperature 20°C (68°F)]:
0.070 - 0.090 mm (0.0028 - 0.0035 in)
I If the value is out of the specified range, replace piston and
piston pin assembly.
EM-74
I If cylinder block or pistons are replaced with new ones, select
piston as follows:
When using a new cylinder block: GI
I Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface
at the rear of cylinder block and select a piston of the same
grade. MA
I The part No. of piston is specified together with the piston pin
as an assembly.
JEM208G LC
When re-using a removed cylinder block:
I Measure the inner diameter of the cylinder block bore.
EC
I Determine the bore grade by comparing the measurement with
the values under “Cylinder bore ID” of the table below. Choose
a piston of the same grade. FE
Selective fitting for piston:
Unit: mm (in)
Grade (punched) 1 2 3
CL
86.000 - 86.010 86.010 - 86.020 86.020 - 86.030
Cylinder bore ID
YEM025
(3.3858 - 3.3862) (3.3862 - 3.3866) (3.3866 - 3.3870) MT
85.920 - 85.930 85.930 - 85.940 85.940 - 85.950
Piston OD
(3.3827 - 3.3831) (3.3831 - 3.3835) (3.3835 - 3.3839)
AT
5. Determine piston oversize according to amount of cylinder
wear.
AX
I For oversize pistons, 0.25 and 0.5OS [0.25 mm (0.0098 in),
0.5 mm (0.0197 in) oversize] are available as service parts.
Refer to SDS, EM-95. When using an oversize piston, hone SU
cylinder so that the clearance between piston and cylinder
becomes the specified value. Be sure to use appropriate
oversize piston ring for the oversize piston. BR
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter “A”.
Rebored size calculation: D = A + B − C ST
where,
D: Bored diameter RS
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in) BT
7. Cut cylinder bores.
I When any cylinder needs boring, all other cylinders must HA
also be bored.
I Do not cut too much out of cylinder bore at a time. Cut
only 0.05 mm (0.0020 in) or so in diameter at a time. SC
8. Hone cylinders to obtain specified piston-to-bore clearance.
9. Measure finished cylinder bore for out-of-round and taper.
I Measurement should be done after cylinder bore cools EL
down.
IDX
EM-75
CRANKSHAFT NJEM0073S07
1. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-of-
round.
Out-of-round (X − Y):
Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
SEM316A
Taper (A − B):
Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
3. Measure crankshaft runout at No. 3 (center) journal.

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

I Without installing main bearings, install main bearing caps,
and tighten bolts to the specified torque.
I Measure the inner diameter of main bearing housing with a
bore gauge.
Standard:
66.654 - 66.681 mm (2.6242 - 2.6252 in) dia.
I If the measurement is out of the specified range, replace cyl-
inder block and main bearing caps.
JEM214G
BEARING CLEARANCE NJEM0073S08

I Use either of the following two methods, however, method “A”
gives more reliable results and is preferable.
Method A (Using bore gauge & micrometer)
Main bearing NJEM0073S0801
1. Install main bearings to the cylinder block and bearing cap, and
tighten the bolts to the specified torque. Then, measure the
inner diameter of the main bearings.
Oil clearance = Bearing ID – Crankshaft journal OD
JEM213G Standard: 0.039 - 0.066 mm (0.0015 - 0.0026 in)
EM-76
2. If the value is out of the specified range, select main bearings
to obtain the specified oil clearance, based on the measure-
ments of the main bearing housing inner diameter and crank- GI
shaft journal outer diameter.
MA
LC
When using a new cylinder block and crankshaft:
1) Identify the bearing housing grade (No. 0, 1, or 2) on LH sur-
face at the rear of the cylinder block, and locate the applicable
EC
grade on the “Grade” row in the table below.
2) Identify the journal grade (No. 0, 1, or 2) on the front surface FE
of the crankshaft, and locate the applicable grade under the
“Grade” column on the table.
3) The main bearing to be used (STD 0 to STD 4) can be located CL
in the cell where the row and column cross.
JEM208G
MT
When re-using removed cylinder block and crankshaft:
1) Measure the inner diameter of cylinder block main bearing AT
housing.
2) Locate the applicable cell where the measurement falls, on
“Cylinder block main bearing housing ID” row on the table. AX
3) Measure the outer diameter of the crankshaft journal.
4) Locate the applicable cell where the measurement falls, under SU
“Crankshaft journal OD” column on the 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. BR
JEM215G
Selective fitting for main bearing ST

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

Cylinder block main bearing housing ID
(2.6242 - 2.6245) (2.6245 - 2.6249) (2.6249 - 2.6252) RS
Crankshaft journal Grade
0 1 2
OD (punched)
BT
STD 0 STD 1 STD 2
I Bearing grade No. 1.816 - 1.820 1.820 - 1.824 1.824 - 1.828
62.967 - 62.975
0
I Bearing thickness (0.0715 - 0.0717) (0.0717 - 0.0718) (0.0718 - 0.0720) HA
(2.4790 - 2.4793) I Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
I Identification color (0.0015 - 0.0026) (0.0015 - 0.0026) (0.0015 - 0.0026)
Black Red or Brown Green SC
STD 1 STD 2 STD 3
62.959 - 62.967 I Bearing thickness (0.0717 - 0.0718) (0.0718 - 0.0720) (0.0720 - 0.0721) EL
1
(2.4787 - 2.6790) I Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
Red or Brown Green Yellow IDX
EM-77
STD 2 STD 3 STD 4

62.951 - 62.959 I Bearing thickness (0.0718 - 0.0720) (0.0720 - 0.0721) (0.0721 - 0.0723)
2
(2.4784 - 2.4787) I Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
Green Yellow Blue
3. When the specified oil clearance is not obtained with standard

size main bearings, use undersized bearings.
I When an undersized bearing is used, measure the inner diam-
eter of the bearing while the bearing is installed. Grind crank-
shaft journal so that the specified oil clearance is obtained.
Undersize bearing
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
CAUTION:
When grinding the crankshaft journal to use an undersize
bearing, avoid damaging the fillet R.
JEM216G
Connecting Rod Bearing (Big end) NJEM0073S0802

1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter “C” of connecting rod.
Inner diameter:
Standard 55.000 - 55.013 mm (2.1654 - 2.1659 in)
AEM027
4. Measure outer diameter “Dp” of each crankshaft pin journal.

5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C − Dp
Standard: 0.031 - 0.061 mm (0.0012 - 0.0024 in)
6. If it exceeds the standard, replace bearing.
AEM034
When using a new crankshaft and connecting rods:

I Identify the pin diameter grade (No. 0, 1, or 2) on front surface
of crankshaft and select the connecting rod bearings of the
same grade.
I There is no grading for the inner diameter of the big end of the
connecting rod.
When re-using the removed crankshaft and connecting rods:
I Measure the inner diameter of the big end of the connecting
rod and make sure it is within the specified range.
I Measure the outer diameter of the crankshaft pin.
JEM215G
EM-78
I Determine the crankshaft pin grade by comparing the mea-
surement with the values under the column “Crankshaft pin
OD” of the table below. Choose the bearings of the same GI
grade.
Selective fitting for connecting rod bearing
Unit: mm (in) MA
Connecting rod big end ID 55.000 - 55.013 (2.1654 - 2.1659)
Crankshaft pin OD Grade (punched) 0 (no punching)
STD 0
I Bearing grade No. 1.492 - 1.496 LC
51.968 - 51.974 I Bearing thickness (0.0587 - 0.0589)
0
(2.0460 - 2.0462) I Oil clearance 0.031 - 0.061
I Identification color (0.0012 - 0.0024)
Black
EC
STD 1
I Bearing grade No. 1.496 - 1.500 FE
1
(2.0457 - 2.0460) I Oil clearance 0.031 - 0.061
I Identification color (0.0012 - 0.0024) CL
Brown
STD 2
I Bearing grade No. 1.500 - 1.504 MT
2
(2.0454 - 2.0457) I Oil clearance 0.031 - 0.061
I Identification color (0.0012 - 0.0024) AT
Green
7. If clearance cannot be adjusted within the standard of any AX

bearing, grind crankshaft journal and use undersized bearing.
I When an undersized bearing is used, measure the inner diam-
eter of the bearing while the bearing is installed. Grind the pins SU
so that the specified oil clearance is obtained.
BR
Undersize bearing
Unit: mm (in) ST
Size Thickness
US 0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606) RS

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)

BT
CAUTION:
When grinding the crankshaft journal to use an undersize
HA
JEM216G bearing, avoid damaging the fillet R.
Standard dimension R: SC
1.5 - 1.7 mm (0.0591 - 0.0669 in)
EL
IDX
EM-79
Method B (Using plastigage)
CAUTION:
I Do not turn crankshaft or connecting rod while plastigage
is being inserted.
I When bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. If incor-
rect bearing clearance exists, use a thicker or undersized
main bearing to ensure specified clearance.
EM142
MAIN BEARING CRUSH HEIGHT NJEM0073S16

I When the bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of
bearing must protrude.
Standard: There must be crush height.
I If the standard is not met, replace main bearings.
SEM502G
MAIN BEARING CAP BOLT DEFORMATION NJEM0073S17

I Measure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.
I When the necked point is identified at a point other than where
specified, measure at the point as d2.
I Calculate the difference between d1 and d2.
Limit: 0.13 mm (0.0051 in)
JEM219G
CONNECTING ROD BUSHING CLEARANCE (SMALL

END) NJEM0073S09
1. Measure inner diameter “C” of bushing.
Inner diameter “C”:
Standard 28.026 - 28.038 mm (1.1034 - 1.1039 in)
2. Measure outer diameter “Dp” of piston pin.
Outer diameter “Dp”:
Standard 27.994 - 28.000 mm (1.1021 - 1.1024 in)
3. Calculate connecting rod bushing clearance.
SEM673E
Connecting rod bushing clearance = C − Dp
Standard: 0.026 - 0.044 mm (0.0010 - 0.0017 in)
Limit: 0.057 mm (0.0022 in)
If it exceeds the limit, replace connecting rod assembly and/or
piston set with pin.
EM-80
CONNECTING ROD BOLT DEFORMATION NJEM0073S18
I Install nuts to connecting rod bolts. Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread GI
on the bolt.
I If the nut does not screw in smoothly, measure the outer diam-
eter of the bolt thread at the point specified in the figure. MA
I If a necked point is identified, measure at that point.
Standard: 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.
Limit: 8.75 mm (0. 3445 in) dia.
I If the measurement exceeds the limit, replace connecting rod
JEM220G bolts and nuts. LC
FLYWHEEL RUNOUT NJEM0073S11
Runout (Total indicator reading): EC
Flywheel★
Less than 0.15 mm (0.0059 in)
CAUTION: FE
I The signal plate is built into the flywheel assembly. Be
careful not to damage the signal plate, especially the
teeth. CL
I Check the signal plate for deformation or cracks.
I Never place the flywheel assembly with the signal plate MT
AEM100
facing down.
I Keep any magnetized objects away from the signal plate.
I Do not allow any magnetic materials to contact the signal AT
plate teeth.
AX
SU
BR
OIL JET
I Check nozzle for deformation or damage.
NJEM0073S19 ST
I Check oil passage for obstruction by blowing in air on nozzle
side. RS
I If abnormality is found, clean or replace.
BT
HA
JEM221G
OIL JET RELIEF VALVE NJEM0073S20

SC
Using a clean resin rod, press down on the check valve inside relief
valve. Check for appropriate bounce/repulsion and smooth
operation. EL
IDX
JEM222G
EM-81
Assembly
Assembly NJEM0074
PISTON NJEM0074S01
1. With using snap ring pliers, install snap rings to grooves at the
rear side of the piston.
I Install securely to fully fit into the groove.
2. Install piston to the connecting rod.
I Heat the piston with an industrial drier to 60 to 70°C (140 to
158°F) so that the piston pin can be easily inserted by finger.
Then, insert the piston pin from the front of the piston into the
piston and into the connecting rod.
I Assemble so that the front mark on the piston top surface and
cylinder No. stamped on connecting rod are positioned as
3. Install snap ring on piston front.
I Refer to step 1. above for notes for installation.
I After installing, check that the connecting rod moves smoothly.
4. Install piston rings using piston ring expander (Commercial
Service Tool).
I Be extremely careful to avoid any damage to the piston.
JEM227G
I Install top ring and second ring with the punched surface fac-
ing upward.
Identification mark:
Top ring AE
Second ring AE2
I Install rings so that three closed gap position 120° apart one
another.
I Closed gaps do not need to face in a specific directions, as
long as each are positioned 120° apart.
JEM228G
CRANKSHAFT NJEM0074S02
1. Blow air sufficiently into the coolant passage, oil passage in the
cylinder block, inside of crankshaft case, and inside of cylinder
bores to remove any foreign materials.
2. Install oil jet relief valves.
3. Install oil jets.
JEM223G
4. Install main bearings and thrust bearings.

a. Remove debris, dust, and oil from the locations on the cylin-
der block and main bearing caps where bearings are installed.
b. Install thrust bearing on each side of cylinder block No. 3
housing.
I Install thrust bearings with oil groove facing in the direction of
the crankshaft arm (outside).
JEM224G
EM-82
Assembly (Cont’d)
c. Be sure to install main bearings in the correct direction.
I Make sure those with oil holes or oil grooves are mounted on
the cylinder block side, and those without oil holes or oil GI
grooves are on the main cap side.
I Before installing, apply engine oil on the front (inner) surfaces
of bearings. Do not apply oil to the back surfaces, but thor- MA
oughly clean them.
I Align stopper notches on bearings and install.
I Check the oil holes on cylinder block and those on bearings
are aligned.
JEM213G LC
5. Install crankshaft to cylinder block.
I Make sure crankshaft rotates smoothly by hand.
EC
6. Install main bearing caps.
I Identify main bearing caps by the punched mark. Install
correctly, matching the journal No. on the bearing cap and the FE
journal, with the front mark facing forward.
I Main bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced CL
as a set.
JEM225G
MT
7. Check the main bearing cap bolts for deformation.
Refer to EM-80, “MAIN BEARING CAP BOLT DEFORMA- AT
TION”.
8. Tighten the main bearing cap bolts according to the following
procedure: AX
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten to 25 to 30 N·m (2.5 to 3.1 kg-m, 18 to 22 ft-lb) in the SU
numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main BR
JEM200G bearing cap, all in the same direction. (when using a protrac-
tor)
d. Then, tighten 90° to 95° [target: 90°]. ST
I Always use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone. RS
I After tightening bolts to specified torque, make sure that crank-
shaft rotates smoothly.
I Check crankshaft end play. Refer to EM-71, “CRANKSHAFT
BT
END PLAY”.
9. Check the outer diameter of connecting rod bolts. Refer to HA
EM-81, “CONNECTING ROD BOLT DEFORMATION”.
JEM226G
10. Install piston to connecting rod.
SC
EL
IDX
EM-83
Assembly (Cont’d)
11. Install connecting rod bearing to connecting rod and connect-
ing rod cap.
I Before installing, apply engine oil on the front (inner) surface
of bearing. Do not apply oil to the back surface, but thoroughly
clean it.
I Align stopper notches on connecting rod and protrusions on
bearing and install.
JEM229G
12. Install piston and connecting rod assembly to crankshaft.

I Set crankshaft pin of the installation location at BDC.
I Match the cylinder No. of connecting rod to the location of cyl-
inder.
I Using piston ring compressor (Commercial Service Tool),
install so that the front mark on the piston top surface faces in
the direction of engine front.
JEM230G
13. Install connecting rod caps.

I Match the cylinder No. punched on connecting rod and that on
cap.
I Make sure that the front mark on connecting rod cap faces
towards the front of the engine.
JEM227G
14. Tighten connecting rod nuts according to the following proce-

dure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten to 29 to 30 N·m (2.9 to 3.1 kg-m, 21 to 22 ft-lb).
c. Loosen completely to 0 N·m (0 kg-m, 0 in-lb).
d. Tighten to 19 to 20 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).
e. Tighten 120° to 125° [target: 120°]. (angular tightening)
I Always use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
JEM231G
I After tightening nuts, check that crankshaft rotates smoothly.
I Check connecting rod side clearance. Refer to EM-71, “CON-
NECTING ROD SIDE CLEARANCE”.
15. Force fit rear oil seal into rear oil seal retainer.
I Using a drift [105 mm (4.13 in) dia.], force fit so that the dimen-
sion is as specified in the figure.
I Avoid inclined fitting. Force fit perpendicularly.
JEM232G
EM-84
Assembly (Cont’d)
16. Install rear oil seal retainer.
I Apply a continuous bead of specified liquid gasket (Refer to
EM-4, “Liquid Gasket Application Procedure”.) on locations GI
MA
JEM233G LC
17. Install pilot bushing.
I Force fit with the drift [approx. 19 mm (0.75 in) dia.].
EC
FE
CL
JEM234G
MT
18. Install fuel injection pump bracket.
I Install insulator according to the shape of the block, and secure AT
by placing the bracket against the insulator. (Not installed on
some models)
I Align the bracket with the dowel pins on the block to install. AX
I The two bolts used for dowel pins have a longer shanks than
the other two.
SU
I Check the protruding distance of the dowel pin for fuel injec-
tion pump.
Standard: 13.0 - 15.0 mm (0.512 - 0.591 in) BR
SEM513G
19. Install parts to the engine in the reverse order of disassembly.

I Tighten bolts securing brackets of auxiliary components (A/C
ST
compressor, alternator) to the specified torque.
: 57 - 65 N·m (5.8 - 6.7 kg-m, 42 - 48 ft-lb) RS
20. Remove engine from engine stand in the reverse order of
assembly.
21. Install flywheel. BT
I Holding ring gear with ring stopper (SST), tighten securing
bolts with TORX-socket (size: Q8 E20, Commercial Service
Tool). HA
I Tighten bolts uniformly in a crisscross manner.
REPLACEMENT OF PILOT BUSHING NJEM0074S03
SC
1. Remove pilot bushing using tool or suitable tool.
EL
IDX
SEM500GA
EM-85
Assembly (Cont’d)
2. Install pilot bushing as shown.
SEM275GA
EM-86
SERVICE DATA AND SPECIFICATIONS
(SDS) YD TYPE 1
General Specifications
General Specifications NJEM0075
Cylinder arrangement In-line 4 GI

3
Displacement cm (cu in) 2,184 (133.27)
Bore and stroke mm (in) 86 x 94 (3.39 x 3.70) MA

Valve arrangement DOHC
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1 LC
Number of main bearings 5
Compression ratio 18.0 EC

Compression Pressure
Unit: kPa (bar, kg/cm2, psi)/200 rpm
NJEM0076
FE
Standard 3,138 (31.4, 32.0, 455)
Compression pressure Minimum 2,452 (24.5, 25.0, 356) CL

Differential limit between cylinders 490 (4.9, 5.0, 71)
MT
Belt Deflection NJEM0111
Belt deflection with 98 N (10 kg, 22 lb) force applied* AT

mm (in)
Applied belt Belt specification
Limit for re-tighten-
New Adjusted
ing AX
4-5 6-7
Air conditioner compressor belt HA type low edge belt 8.5 (0.335)
(0.16 - 0.20) (0.24 - 0.28) SU
HA type low-edge wide angle 9.0 - 10.5 11.0 - 12.5
Alternator & water pump belt 16.5 (0.650)
belt (0.354 - 0.413) (0.433 - 0.492)
BR
*: When engine is cold.
Cylinder Head NJEM0077 ST

Unit: mm (in)
Standard Limit
RS
Head surface distortion Less than 0.03 (0.0012) 0.04 (0.0016)
BT
HA
SC
EL
JEM204G
IDX
EM-87
(SDS) YD TYPE 1
Valve
Valve NJEM0078
VALVE NJEM0078S01
Unit: mm (in)
SEM188
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)

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

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

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 NJEM0078S02

Unit: mm (in)
Cold Hot* (reference data)
Intake 0.24 - 0.32 (0.009 - 0.013) 0.274 - 0.386 (0.011 - 0.015)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)
AVAILABLE SHIMS NJEM0078S03
Thickness mm (in) Identification mark
2.10 (0.0827) 2.10
2.12 (0.0835) 2.12
2.14 (0.0843) 2.14
2.16 (0.0850) 2.16
2.18 (0.0858) 2.18
2.20 (0.0866) 2.20
2.22 (0.0874) 2.22
2.24 (0.0882) 2.24
2.26 (0.0890) 2.26
2.28 (0.0898) 2.28
EM-88
(SDS) YD TYPE 1
Valve (Cont’d)
Thickness mm (in) Identification mark
2.30 (0.0906) 2.30 GI

2.32 (0.0913) 2.32
2.34 (0.0921) 2.34 MA

2.36 (0.0929) 2.36
2.38 (0.0937) 2.38
2.40 (0.0945) 2.40
2.42 (0.0953) 2.42 LC

2.44 (0.0961) 2.44
2.46 (0.0969) 2.46 EC

2.48 (0.0976) 2.48
2.50 (0.0984) 2.50 FE

2.52 (0.0992) 2.52
2.54 (0.1000) 2.54 CL

2.56 (0.1008) 2.56
2.58 (0.1016) 2.58 MT

2.60 (0.1024) 2.60
2.62 (0.1031) 2.62 AT

2.64 (0.1039) 2.64
2.66 (0.1047) 2.66 AX

2.68 (0.1055) 2.68
2.70 (0.1063) 2.70 SU

2.72 (0.1071) 2.72
2.74 (0.1079) 2.74 BR
ST
RS
BT
SEM512G
HA
VALVE SPRING SC
NJEM0078S04
Free height mm (in) Outer 42.3 (1.6654)

EL
Pressure N (kg, lb) at height mm (in) 350 - 382 (35.7 - 37.9, 78.7 - 83.6) at 24.82
Outer
(0.9772)
Out-of-square mm (in) Outer Limit 2.1 (0.083) IDX
EM-89
(SDS) YD TYPE 1
Valve (Cont’d)
VALVE LIFTER NJEM0078S05
Unit: mm (in)
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801)
Lifter guide inner diameter 30.000 - 30.021 (1.1181 - 1.1819)
Clearance between lifter and lifter guide 0.025 - 0.061 (0.0010 - 0.0024)
VALVE GUIDE NJEM0078S06

Unit: mm (in)
JEM156G
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)
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)
Standard Limit
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)

Stem to guide clearance
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.1 (0.004)
Valve deflection limit 0.15 (0.0059)
Projection length 10.4 - 10.6 (0.4094 - 0.4173)
EM-90
(SDS) YD TYPE 1
Valve Seat
Valve Seat NJEM0079

Unit: mm (in)
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
SEM546G
ST
RS
BT
HA
JEM253G
Standard Service SC
Intake 30.000 - 30.016 (1.1181 - 1.1817) 30.500 - 30.516 (1.2008 - 1.2014)
Cylinder head seat recess diameter (D)
Exhaust 29.000 - 29.016 (1.1417 - 1.1424) 29.500 - 29.516 (1.1614 - 1.1620) EL
Intake 0.064 - 0.100 (0.0025 - 0.0039)
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038) IDX
Intake 30.080 - 30.100 (1.1842 - 1.1850) 30.580 - 30.600 (1.2039 - 1.2047)
Valve seat outer diameter (d)
Exhaust 29.080 - 29.096 (1.1449 - 1.1455) 29.580 - 29.596 (1.1646 - 1.1652)
EM-91
(SDS) YD TYPE 1
Valve Seat (Cont’d)
Intake 7.0 - 7.1 (0.276 - 0.280) 6.60 - 6.70 (0.2598 - 0.2638)

Height (h)
Exhaust 6.7 - 6.8 (0.264 - 0.268) 6.3 - 6.4 (0.248 - 0.252)
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)

Depth (L)
Exhaust 36.53 - 37.01 (1.4382 - 1.4571)
EM-92
(SDS) YD TYPE 1
Camshaft and Camshaft Bearing
Camshaft and Camshaft Bearing =NJEM0080

Unit: mm (in)
GI
Standard Limit
Camshaft journal to bearing clearance 0.045 - 0.086 (0.0018 - 0.0034) 0.045 - 0.086 (0.0018 - 0.0034)
MA
No. 1
30.500 - 30.521 (1.2008 - 1.2016)
Inner diameter of camshaft bearing —
No. 2, 3, 4, 5
24.000 - 24.021 (0.9449 - 0.9457)
No. 1
30.435 - 30.455 (1.1982 - 1.1990)
Outer diameter of camshaft journal
No. 2, 3, 4, 5
— LC
23.935 - 23.955 (0.9423 - 0.9431)
Camshaft runout [TIR*] — 0.02 (0.0008) EC

Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059) —
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.24 (0.0094) FE

*: Total indicator reading
CL
MT
AT
EM671
AX
Intake 39.505 - 39.695 (1.5553 - 1.5628)
Cam height “A”
Exhaust 39.905 - 40.095 (1.5711 - 1.5785) SU
Wear limit of cam height 0.15 (0.0059)
BR
ST
Valve timing
RS
BT
EM120
HA
Unit: degree
a b c d e f
SC
Valve timing 224 212 2 30 –2 46
EL
IDX
EM-93
(SDS) YD TYPE 1
Cylinder Block
Cylinder Block NJEM0081

Unit: mm (in)
JEM207G
Standard Less than 0.03 (0.0012)

Surface flatness
Limit 0.04 (0.0016)
Grade No. 1 86.000 - 86.010 (3.3858 - 3.3862)
Standard Grade No. 2 86.010 - 86.020 (3.3862 - 3.3866)

Cylinder bore Inner diameter
Grade No. 3 86.020 - 86.030 (3.3866 - 3.3870)
Wear limit 0.07 (0.0028)
Out-of-round (X − Y) Less than 0.015 (0.0006)
Taper (A − B − C) Less than 0.010 (0.0004)
Main journal inner Grade No. 0 66.654 - 66.663 (2.6242 - 2.6245)

diameter grade Grade No. 1 66.663 - 66.672 (2.6245 - 2.6249)
(Without bearing) Grade No. 2 66.672 - 66.681 (2.6249 - 2.6252)
Difference in inner
diameter between Limit Less than 0.05 (0.0020)
cylinders
EM-94
(SDS) YD TYPE 1
Piston, Piston Ring and Piston Pin
Piston, Piston Ring and Piston Pin =NJEM0082

AVAILABLE PISTON NJEM0082S01
Unit: mm (in)
GI
MA
LC
EC
SEM882E
Grade No. 1 85.920 - 85.930 (3.3827 - 3.3831) FE

Grade No. 2 85.930 - 85.940 (3.3831 - 3.3835)
Piston skirt diameter “A” Standard Grade No. 3 85.940 - 85.950 (3.3835 - 3.3839) CL
0.25 (0.0098) oversize (Service) 86.170 - 86.200 (3.3925 - 3.3937)
0.50 (0.0197) oversize (Service) 86.420 - 86.450 (3.4024 - 3.4035) MT

“a” dimension 58.0 (2.28)
Piston pin hole diameter 27.997 - 28.005 (1.1022 - 1.1026) AT

Piston clearance to cylinder block 0.070 -0.090 (0.0028 - 0.0035)
PISTON RING AX
NJEM0082S02
Unit: mm (in)
Standard Limit SU
Top 0.120 - 0.180 (0.0047 - 0.0071) 0.2 (0.008)
Side clearance 2nd 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004) BR

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

End gap 2nd 0.39 - 0.54 (0.0154 - 0.0213) 1.0 (0.039)
Oil 0.25 - 0.37 (0.0098 - 0.0146) 0.87 (0.0343) RS

PISTON PIN NJEM0082S03
Unit: mm (in) BT
Piston pin outer diameter 27.994 - 28.000 (1.1021 - 1.1024)
Interference fit of piston pin to piston 0.002 - 0.006 (0.0001 - 0.0002)

HA
Standard 0.026 - 0.044 (0.0010 - 0.0017)
Piston pin to connecting rod bushing clearance
Limit 0.057 (0.0022)
SC
*: Values measured at ambient temperature of 20°C (68°F)
EL
IDX
EM-95
(SDS) YD TYPE 1
Connecting Rod
Connecting Rod NJEM0083

Unit: mm (in)
Center distance 157.5 (6.201)
Bend [per 100 (3.94)] Limit 0.12 (0.0047)
Torsion [per 100 (3.94)] Limit 0.12 (0.0047)
Connecting rod small end inner diameter 30.080 - 31.000 (1.1842 - 1.2205)
Piston pin 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 0.200 - 0.350 (0.0079 - 0.0138)

Side clearance
Limit 0.4 (0.016)
*: After installing in connecting rod
Crankshaft NJEM0084
Unit: mm (in)
Grade No. 0 62.967 - 62.975 (2.4790 - 2.4793)

Main journal dia. “Dm” grade Grade No. 1 62.959 - 62.967 (2.4787 - 2.4790)
Grade No. 2 62.951 - 62.959 (2.4784 - 2.4787)
Grade No. 0 51.968 - 51.974 (2.0460 - 2.0462)
Pin journal dia. “Dp” Grade No. 1 51.961 - 51.968 (2.0457 - 2.0460)
Grade No. 2 51.954 - 51.961 (2.0454 - 2.0457)
Center distance “r” 46.97 - 47.03 (1.8492 - 1.8516)
Out-of-round (X − Y) Standard/Limit Less than 0.003 (0.0001)/Less than 0.005 (0.0002)
Taper (A − B) Standard/Limit Less than 0.003 (0.0001)/Less than 0.005 (0.0002)
Standard Less than 0.05 (0.0020)

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

Free end play
Limit 0.30 (0.0118)
SEM645 EM715
EM-96
(SDS) YD TYPE 1
Available Main Bearing
Available Main Bearing NJEM0085
GI
MA
LC
SEM255G
Grade number Thickness “T” mm (in) Width “W” mm (in) Identification color
EC
0 1.816 - 1.820 (0.0715 - 0.0717) Black
1 1.820 - 1.824 (0.0717 - 0.0718) Red or Brown

FE
2 1.824 - 1.828 (0.0718 - 0.0720) 19.9 - 20.1 (0.783 - 0.791) Green
3 1.828 - 1.832 (0.0720 - 0.0721) Yellow

CL
4 1.832 - 1.836 (0.0721 - 0.0723) Blue
MT
UNDERSIZE NJEM0085S01
Unit: mm (in)
AT
Thickness Main journal diameter “Dm”
Grind so that bearing clearance is the specified

0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
value. AX
Available Connecting Rod Bearing NJEM0086
SU
CONNECTING ROD BEARING NJEM0086S01
Grade number Thickness “T” mm (in) Width “W” mm (in) Identification color (mark)
BR
0 1.492 - 1.496 (0.0587 - 0.0589) Black
22.9 - 23.1
1 1.496 - 1.500 (0.0589 - 0.0591) Brown
(0.902 - 0.909) ST
2 1.500 - 1.504 (0.0591 - 0.0592) Green
UNDERSIZE NJEM0086S02
RS
Unit: mm (in)
Thickness Crank pin journal diameter “Dp”

BT
0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
Grind so that bearing clearance is the specified
0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
value. HA
0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
Miscellaneous Components SC
NJEM0087
Unit: mm (in)
Flywheel runout [TIR]* Less than 0.15 (0.0059) EL

IDX
EM-97
(SDS) YD TYPE 1
Miscellaneous Components (Cont’d)
BEARING CLEARANCE NJEM0087S01
Unit: mm (in)
Standard 0.039 - 0.066 (0.0015 - 0.0026)

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

Connecting rod bearing clearance
Limit 0.09 (0.0035)
EM-98

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ENGINE MECHANICAL GI

APPLICATION NOTICE ..................................................3 PREPARATIVE WORK .............................................34

How to Check Vehicle Type NJEM0112

YD type 1 Without common rail

Parts Requiring Angular Tightening NJEM0047

Liquid Gasket Application Procedure NJEM0048

3. Apply liquid gasket around the inner side of bolt holes

Special Service Tools NJEM0049

ST0501S000 Disassembling and assembling

KV101056S0 Preventing crankshaft from rotating

KV101151S0 Changing shims

ST16610001 Removing crankshaft pilot bushing

KV10111100 Removing steel oil pan and rear timing chain

WS39930000 Pressing the tube of liquid gasket

KV10112100 Tightening bolts for bearing cap, cylinder

KV10109300 a: 68 mm (2.68 in)

KV11106020 a: 6 mm (Face to face)

Commercial Service Tools NJEM0050

Valve seat cutter set Finishing valve seat dimensions RS

Tool name Description

NVH Troubleshooting — Engine Noise NJEM0051S01

Top of Ticking or Tappet

I Piston and piston

7. Install adapter (SST) to installation holes of glow plugs and

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

d. Install fuel injection pump fuse [ENG CONT2 (20A)].

Alternator & HA type low- 9.0 - 10.5 11.0 - 12.5

*: When engine is cold.

Air conditioner compressor belt Adjusting bolt on idler pulley

Alternator water pump belt Adjusting bolt on alternator

Changing Air Cleaner Filter NJEM0092

6. Remove oil strainer.

8. Set a suitable transmission jack under transaxle and hoist SC

15. Remove four engine-to-transaxle bolts using a universal

b. Apply a continuous bead of liquid gasket to mating surface of

c. Apply Genuine Liquid Gasket or equivalent, to areas shown in

11. Install lower oil pan.

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

c. Install lower oil pan.

Secondary Timing Chain NJEM0093

4. Set the No. 1 piston to TDC on its compression stroke.

5. Remove chain tensioner.

b. Using a hexagon-head wrench (face to face: 5 mm, SST),

4. Install chain tensioner.

5. Install front chain case.

b. Apply specified liquid gasket (Refer to EM-4, “Liquid Gasket

Primary Timing Chain NJEM0094

c. Using pulley puller (SST), remove crankshaft pulley.

7. Remove oil pump. SC

11. Hold fuel injection pump sprocket and remove bolt.

13. Remove chain guide and tension guides.

b. Install four O-rings to the grooves of the cylinder block, fuel

c. Install rear chain case.

9. Install timing chain slack guide.

11. Install front oil seal to oil pump. SC

13. Install oil pump.

b. Install oil pump drive spacer to crankshaft.

d. Install oil pump.

14. Check gaps on upper oil pan mounting surface.