Manual Motor Máxima Taller

EXIT
ENGINE MECHANICAL GI
SECTION EM MA
LC
EC
CONTENTS FE
PRECAUTIONS ...............................................................3 CAMSHAFT SPROCKET RUNOUT ...........................43

CL
Parts Requiring Angular Tightening.............................3 VALVE GUIDE CLEARANCE ....................................44
Liquid Gasket Application Procedure ..........................3 VALVE GUIDE REPLACEMENT ................................44
MT
PREPARATION ...............................................................4 VALVE SEATS .........................................................45
REPLACING VALVE SEAT FOR SERVICE PARTS ....45
Special Service Tools ..................................................4
VALVE DIMENSIONS ...............................................46
Commercial Service Tools ...........................................6 AT
VALVE SPRING .......................................................46
NOISE, VIBRATION AND HARSHNESS (NVH)
VALVE LIFTER ........................................................46
TROUBLESHOOTING .....................................................7 Assembly ...................................................................47
NVH Troubleshooting - Engine Noise .........................8
AX
Installation..................................................................47
OUTER COMPONENT PARTS .......................................9 Valve Clearance.........................................................52
Removal and Installation .............................................9 CHECKING .............................................................52 SU
TIGHTENING PROCEDURES ...................................11 ADJUSTING ............................................................54
MEASUREMENT OF COMPRESSION PRESSURE ....12 ENGINE ASSEMBLY.....................................................57
OIL PAN.........................................................................13 Removal and Installation ...........................................57 BR
Components...............................................................13 REMOVAL ...............................................................58
Removal.....................................................................13 INSTALLATION........................................................59
Installation..................................................................16 CYLINDER BLOCK .......................................................60 ST
TIMING CHAIN ..............................................................20 Components...............................................................60
Components...............................................................20 Removal and Installation ...........................................61
POSITION FOR APPLYING LIQUID GASKET ............21
RS
Disassembly...............................................................61
Removal.....................................................................23 PISTON AND CRANKSHAFT ....................................61
Inspection...................................................................31 Inspection...................................................................61 BT
Installation..................................................................31 PISTON AND PISTON PIN CLEARANCE ..................61
OIL SEAL.......................................................................36 PISTON RING SIDE CLEARANCE ............................62
Replacement..............................................................36 PISTON RING END GAP..........................................62 HA
VALVE OIL SEAL .....................................................36 CONNECTING ROD BEND AND TORSION ...............63
OIL SEAL INSTALLATION DIRECTION .....................37 CYLINDER BLOCK DISTORTION AND WEAR ...........63
FRONT OIL SEAL ....................................................37 PISTON-TO-BORE CLEARANCE ..............................64 SC
REAR OIL SEAL ......................................................38 CRANKSHAFT.........................................................65
CYLINDER HEAD..........................................................39 BEARING CLEARANCE ...........................................65
Components...............................................................39 CONNECTING ROD BUSHING CLEARANCE EL
Removal.....................................................................40 (SMALL END) ..........................................................68
REPLACEMENT OF CONNECTING ROD
Disassembly...............................................................40
BUSHING (SMALL END) ..........................................68 IDX
Inspection...................................................................42
FLYWHEEL/DRIVE PLATE RUNOUT ........................68
CYLINDER HEAD DISTORTION ...............................42
Assembly ...................................................................69
CAMSHAFT VISUAL CHECK ....................................42
PISTON ..................................................................69
CAMSHAFT RUNOUT ..............................................42
CRANKSHAFT.........................................................69
CAMSHAFT CAM HEIGHT .......................................42
REPLACEMENT OF PILOT BUSHING (M/T) OR
CAMSHAFT JOURNAL CLEARANCE ........................43
PILOT CONVERTER (A/T)........................................71
CAMSHAFT END PLAY............................................43
EXIT
CONTENTS (Cont’d)
SERVICE DATA AND SPECIFICATIONS (SDS) .........72 Piston, Piston Ring and Piston Pin ...........................79
General Specifications...............................................72 AVAILABLE PISTON ................................................79
Compression Pressure ..............................................72 PISTON RING .........................................................80
Cylinder Head ............................................................72 PISTON PIN ............................................................80
Valve ..........................................................................73 Connecting Rod .........................................................80
VALVE ....................................................................73 Crankshaft..................................................................81
VALVE CLEARANCE................................................73 Available Main Bearing..............................................82
AVAILABLE SHIMS ..................................................73 UNDERSIZE ............................................................82
VALVE SPRING .......................................................75 Available Connecting Rod Bearing............................83
VALVE LIFTER ........................................................75 CONNECTING ROD BEARING .................................83
VALVE GUIDE .........................................................76 UNDERSIZE ............................................................83
Valve Seat..................................................................76 Miscellaneous Components.......................................83
Camshaft and Camshaft Bearing ..............................77 BEARING CLEARANCE ...........................................83
Cylinder Block............................................................78
EM-2
EXIT
PRECAUTIONS
Parts Requiring Angular Tightening
Parts Requiring Angular Tightening NFEM0001

I Use an angle wrench for the final tightening of the following
engine parts: GI
a) Cylinder head bolts
b) Main bearing cap bolts MA
c) Connecting rod cap nuts
d) Crankshaft pulley bolt
I Do not use a torque value for final tightening.
I The torque value for these parts are for a preliminary step.
I Ensure thread and seat surfaces are clean and coated with LC
engine oil.
EC
FE
CL
MT
Liquid Gasket Application Procedure NFEM0002
1. Use a scraper to remove all traces of old liquid gasket AT
from mating surfaces and grooves. Also, completely clean
any oil from these areas.
2. Apply a continuous bead of liquid gasket to mating sur-
AX
faces. (Use Genuine RTV silicone sealant Part No. 999MP-
A7007 or equivalent.)
SU
I Be sure liquid gasket diameter is as specified.
BR
SEM164F
3. Apply liquid gasket around the inner side of bolt holes

(unless otherwise specified). ST
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and RS
engine coolant.
BT
HA
AEM080
SC
EL
IDX
EM-3
EXIT
PREPARATION
Special Service Tools
Special Service Tools NFEM0003

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name
ST0501S000 Disassembling and assembling

( — )
Engine stand assembly
1 ST05011000
( — )
Engine stand
2 ST05012000
( — )
Base
NT042
KV10106500
( — )
Engine stand shaft
NT028
KV10117000 KV10117000 has been replaced with KV10117001

(J41262) (KV10117000 is no longer in production, but it is
Engine sub-attachment usable).
NT373
KV10117001 Installing on the cylinder block

( — )
Engine sub-attachment
NT372
ST10120000 Loosening and tightening cylinder head bolt

(J24239-01) a: 13 (0.51) dia.
Cylinder head bolt b: 12 (0.47)
wrench c: 10 (0.39)
Unit: mm (in)
NT583
KV10116200 Disassembling valve mechanism

(J26336-A)
Valve spring compres-
sor
1 KV10115900
(J26336-20)
Attachment
NT022
EM-4
EXIT
PREPARATION
Special Service Tools (Cont’d)
Tool number
Tool name GI
(J39386) Installing valve oil seal
Valve oil seal drift MA
NT024
KV101151S0 Changing shims

(J38972) LC
Lifter stopper set
1 KV10115110
(J38972-1) EC
Camshaft pliers
2 KV10115120
(J38972-2)
Lifter stopper
NT041 FE
EM03470000 Installing piston assembly into cylinder bore
(J8037) CL
Piston ring compressor
MT
NT044
ST16610001 Removing crankshaft pilot bushing AT

(J23907)
Pilot bushing puller
AX
NT045
SU
KV10111100 Removing steel oil pan and rear timing chain case
(J37228)
Seal cutter
BR
NT046 ST
WS39930000 Pressing the tube of liquid gasket
( — )
Tube presser RS
NT052
BT
KV10112100 Tightening bolts for bearing cap, cylinder head, etc.
(BT8653-A) HA
Angle wrench
SC
NT014 EL
IDX
EM-5
EXIT
PREPARATION
Commercial Service Tools
Commercial Service Tools NFEM0004
Tool number
Tool name
Spark plug wrench Removing and installing spark plug
NT047
Valve seat cutter set Finishing valve seat dimensions
NT048
Piston ring expander Removing and installing piston ring
NT030
Valve guide drift Removing and installing valve guide

Intake & Exhaust:
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia.
NT015
Valve guide reamer Reaming valve guide 1 or hole for oversize valve
guide 2
Intake & Exhaust:
d1 = 6.0 mm (0.236 in) dia.
d2 = 10.2 mm (0.402 in) dia.
NT016
(J-43897-18) Reconditioning the exhaust system threads before

(J-43897-12) installing a new oxygen sensor (Use with anti-seize
Oxygen sensor thread lubricant shown below.)
cleaner a = J-43897-18 (18 mm dia.) for zirconia oxygen
sensor
b = J-43897-12 (12 mm dia.) for titania oxygen
sensor
AEM488
Anti-seize lubricant Lubricating oxygen sensor thread cleaning tool

(Permatex 133AR or when reconditioning exhaust system threads
equivalent meeting MIL
specification MIL-A-
907)
AEM489
EM-6
NFEM0005 EXIT
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
SEM646F
EM-7
EXIT
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting — Engine Noise
NVH Troubleshooting — Engine Noise NFEM0005S01

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

C A — A B — Valve clearance EM-54
engine clicking noise
Rocker
cover Camshaft Camshaft journal clear-
Cylinder Rattle C A — A B C bearing ance EM-42, 43
head noise Camshaft runout
Piston and piston pin

Slap or Piston pin clearance
— A — B B — EM-61, 68
knock noise Connecting rod bush-
ing clearance
Piston-to-bore clear-
ance
Crankshaft Slap or Piston ring side clear-
Piston slap EM-62, 62,
pulley A — — B B A ance
rap noise 63, 64
Cylinder Piston ring end gap
block Connecting rod bend
(Side of and torsion
engine) Connecting rod bush-
Oil pan Connect-
ing clearance (Small
ing rod
Knock A B C B B B end) EM-68, 67
bearing
Connecting rod bearing
noise
clearance (Big end)
Main bearing oil clear-

Main bear-
Knock A B — A B C ance EM-65, 65
ing noise
Crankshaft runout
Front of Timing
Timing chain cracks
engine chain and
Tapping or and wear
Timing A A — B B B chain ten- EM-31, 20
ticking Timing chain tensioner
chain sioner
operation
cover noise
Other MA section
Squeaking drive belts (“Checking
A B — B — C Drive belts deflection
or fizzing (Sticking Drive
or slipping) Belts”,
Other “ENGINE
Idler pulley bearing MAINTE-
Creaking A B A B A B drive belts
operation NANCE”)
Front of (Slipping)
engine
LC section
(“Water
Water Pump
Squall
A B — B A B pump Water pump operation Inspection”,
Creak
noise “ENGINE
COOLING
SYSTEM”)
A: Closely related B: Related C: Sometimes related —: Not related
EM-8
EXIT
OUTER COMPONENT PARTS
Removal and Installation
Removal and Installation NFEM0006
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
SEM305G
HA
1. Intake manifold collector support 5. Fuel tube assembly 9. Intake manifold
2. Intake manifold collector 6. Fuel pressure regulator 10. Throttle body SC
3. Fuel damper and fuel feed hose 7. Ignition coil with power transistor 11. IACV-AAC valve
assembly 8. Ornament cover 12. EVAP canister purge volume con-
4. Injector trol solenoid valve
EL
IDX
EM-9
EXIT
Removal and Installation (Cont’d)
SEM276G
1. EGR valve 4. Thermostat with water inlet 8. Water control valve

2. EGR temperature sensor 5. Exhaust manifold 9. Water connector
3. Camshaft position sensor 6. Water outlet 10. Cylinder block water outlet
(PHASE) 7. EGR guide tube
EM-10
EXIT
TIGHTENING PROCEDURES NFEM0006S01
Intake Manifold
I Tighten in numerical order shown in the figure.
NFEM0006S0101
GI
1. Tighten all bolts and nuts to 5 to 10 N·m (0.5 to 1.0 kg-m, 44
to 86 in-lb). MA
2. Finally tighten all bolts and nuts to 26 to 31 N·m (2.7 to 3.2
kg-m, 20 to 23 ft-lb).
I Tighten all bolts and nuts to the final torque, evenly dividing the
tightening into at least five steps.
SEM950F LC
Fuel Tube NFEM0006S0102
I Tighten in numerical order shown in the figure. EC
1. Tighten all bolts to 9.3 to 10.8 N·m (0.95 to 1.1 kg-m, 83 to 95
in-lb).
2. Then tighten all bolts to 21 to 26 N·m (2.1 to 2.7 kg-m, 15 to FE
20 ft-lb).
CL
SEM951F
MT
Fuel Pressure Regulator NFEM0006S0103
Tighten fuel pressure regulator to 2.9 to 3.8 N·m (0.3 to 0.39 kg-m, AT
26.0 to 33.9 in-lb).
I Tighten screws evenly several times to have the fuel pres-
sure regulator tightened at the specified torque. AX
I Always replace O-ring with new ones.
I Lubricate O-ring with new engine oil. SU
BR
SEM952F
Throttle Body
NFEM0006S0105 ST
1. Tighten all bolts to 8.8 to 10.8 N·m (0.9 to 1.1 kg-m, 79 to 95
in-lb). RS
2. Then tighten all bolts to 17.7 to 21.6 N·m (1.8 to 2.2 kg-m, 13
to 16 ft-lb).
BT
HA
SEM953F
Intake Manifold Collector NFEM0006S0107

SC
Tighten bolts and nuts to 11 to 15 N·m (1.1 to 1.6 kg-m, 8 to 11 ft-lb)
in numerical order shown in the figure.
EL
IDX
SEM954F
EM-11
NFEM0007 EXIT
MEASUREMENT OF COMPRESSION PRESSURE
1. Warm up engine.
2. Turn ignition switch OFF.
3. Release fuel pressure.
Refer to EC-54, “Fuel Pressure Release”.
4. Disconnect ignition coil with power transistor harness
connectors, then remove ignition coils.
5. Remove all spark plugs.
6. Remove fuse for fuel injector.
SEM087G
7. Attach a compression tester to No. 1 cylinder.

8. Depress accelerator pedal fully to keep throttle valve wide
open.
9. Crank engine and record highest gauge indication.
10. Repeat the measurement on each cylinder as shown above.
I Always use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (kg/cm2, psi)/rpm
Difference limit between

Standard Minimum
cylinders
SEM909E
1,275 (13.0, 185)/300 981 (10.0, 142)/300 98 (1.0, 14)/300
11. If compression in one or more cylinders is low:

a. Pour a small amount of engine oil into cylinders through spark
plug holes.
b. Retest compression.
I If adding oil helps compression, piston rings may be worn
or damaged. If so, replace piston rings after checking pis-
ton.
I If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. (Refer
SEM387C to SDS, EM-73 and EM-76.) If valve or valve seat is dam-
aged excessively, replace them.
I If compression stays low in two cylinders that are next to
each other:
a) The cylinder head gasket may be leaking, or
b) Both cylinders may have valve component damage. Inspect
and repair as necessary.
EM-12
EXIT
OIL PAN
Components
Components NFEM0008
GI
MA
LC
EC
FE
CL
SEM006G
MT
Removal NFEM0009
CAUTION: AT
When removing the aluminum oil pan from engine, first
remove the crankshaft position sensors (POS and REF) from
the assembly. AX
Be careful not to damage sensor edges and signal plate teeth.
1. Remove engine undercover.
SU
2. Drain engine oil.
BR
3. Remove steel oil pan bolts.
ST
RS
BT
HA
SEM956F
4. Remove steel oil pan. SC

a. Insert Tool between aluminum oil pan and steel oil pan.
I Be careful not to damage aluminum mating surface.
I Do not insert screwdriver, or oil pan flange will be EL
deformed.
IDX
SEM957F
EM-13
EXIT
OIL PAN
Removal (Cont’d)
b. Slide Tool by tapping on the side of the Tool with a hammer.
c. Remove steel oil pan.
SEM960F
5. Remove oil strainer.
SEM809E
6. Remove front exhaust tube and its support.

Refer to FE-11, “Removal and Installation”.
SEM810E
SEM834F
EM-14
EXIT
OIL PAN
Removal (Cont’d)
7. Set a suitable transmission jack under transaxle and hoist
engine with engine slinger.
8. Remove crankshaft position sensors (POS and REF) from oil GI
pan.
9. Remove front and rear engine mounting nuts and bolts.
10. Remove center member. MA
LC
EC
FE
CL
SEM811E
MT
11. Remove drive belts.
12. Remove air compressor and bracket. AT
AX
SU
BR
SEM812E
13. Remove rear cover plate.

ST
RS
BT
HA
SEM813E
14. Remove aluminum oil pan bolts in numerical order. SC
EL
IDX
SEM184F
EM-15
EXIT
OIL PAN
Removal (Cont’d)
15. Remove four engine-to-transaxle bolts.
SEM815E
16. Remove aluminum oil pan.

a. Insert an appropriate size tool into the notch of aluminum oil
pan as shown in the figure.
I Be careful not to damage aluminum mating surface.
I Do not insert screwdriver, or oil pan flange will be
deformed.
b. Pry off aluminum oil pan by moving the tool up and down.
c. Remove aluminum oil pan.
SEM155F
17. Remove O-rings from cylinder block and oil pump body.
SEM819E
Installation NFEM0010
1. Install aluminum 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 steel oil pan.
I Remove old liquid gasket from the bolt hole and thread.
MEM108A
b. Apply sealant to front cover gasket and rear oil seal retainer
gasket.
SEM964E
EM-16
EXIT
OIL PAN
Installation (Cont’d)
c. Apply a continuous bead of liquid gasket to mating surface of
aluminum oil pan.
I Use Genuine RTV silicone sealant Part No. 999MP-A7007 GI
or equivalent.
MA
SEM159F LC
d. Apply liquid gasket to inner sealing surface as shown in figure.
I Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in)
or 4.5 to 5.5 mm (0.177 to 0.217 in) wide.
EC
I Attaching should be done within 5 minutes after coating.
FE
CL
SEM185FA
MT
e. Install O-rings, cylinder block and oil pump body.
AT
AX
SU
BR
SEM819E
f. Install aluminum oil pan.

I Tighten bolts in numerical order.
ST
I Wait at least 30 minutes before refilling engine oil.
RS
BT
HA
SEM186F
2. Install the four engine-to-transaxle bolts. For tightening torque, SC

refer to MT-10 or AT-284, “Installation”.
3. Install rear cover plate.
EL
IDX
SEM822E
EM-17
EXIT
OIL PAN
4. Install air compressor and bracket.
Refer to HA-113, “Removal and Installation”.
5. Install drive belts.
6. Install center member.
7. Install front and rear engine mounting insulator nuts and bolts.
SEM812E
8. Install crankshaft position sensors (POS and REF) and front

heated oxygen sensor (left bank) harness clamp.
I Make sure that crankshaft position sensor (POS) and front
heated oxygen sensor (left bank) harness clamp are
installed correctly as shown in figure.
9. Install front exhaust tube and its support.
10. Install oil strainer.
SEM222F
11. Install steel 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 alu-
minum oil pan.
SEM958F
b. Apply a continuous bead of liquid gasket to mating surface of

steel oil pan.
I Use Genuine RTV silicone sealant Part No. 999MP-A7007
or equivalent.
SEM159F
I Be sure liquid gasket is 4.5 to 5.5 mm (0.177 to 0.217 in)

wide.
I Attaching should be done within 5 minutes after coating.
SEM959F
EM-18
EXIT
OIL PAN
c. Install steel oil pan.
I Wait at least 30 minutes before refilling engine oil. GI
MA
SEM956F LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-19
EXIT
TIMING CHAIN
Components
Components NFEM0011
SEM277G
1. Rear timing chain case 8. Timing chain 14. Water pump cover
2. Left camshaft chain tensioner 9. Crankshaft sprocket 15. Chain tensioner cover
3. Internal chain guide 10. Lower chain guide 16. Exhaust camshaft sprocket 2ND
4. Camshaft chain 11. Upper chain guide 17. Intake camshaft sprocket 2ND
5. Right camshaft chain tensioner 12. Front timing chain case 18. Camshaft sprocket 1ST
6. Timing chain tensioner 13. Crankshaft pulley 19. Water pump
7. Slack side chain guide
EM-20
EXIT
TIMING CHAIN
Components (Cont’d)
POSITION FOR APPLYING LIQUID GASKET =NFEM0011S01
Refer to “Installation” in “OIL PAN”, EM-16.
I Before installation, wipe off the protruding sealant. GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-21
EXIT
TIMING CHAIN
SEM443FA
EM-22
EXIT
TIMING CHAIN
CAUTION:
I After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads. GI
I When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
engine oil. MA
I Apply new engine oil to bolt threads and seat surfaces
when installing cylinder head, camshaft sprockets, crank-
shaft pulley, and camshaft brackets.
I Before disconnecting fuel hose, release fuel pressure.
LC
I When removing the oil pans, oil pump assembly and tim-
ing chain from engine, first remove the camshaft position
sensor (PHASE) and the crankshaft position sensors EC
(REF)/(POS) from the assembly.
Be careful not to damage sensor edges.
I Do not spill engine coolant on drive belts. FE
CL
MT
Removal NFEM0012
1. Drain engine oil. AT
2. Release fuel pressure.
AX
3. Drain coolant by removing cylinder block drain plugs. Refer to
MA-14, “Changing Engine Coolant”.
4. Remove left side ornament cover. SU
5. Remove air duct to intake manifold, collector, blow-by hose,
vacuum hoses, fuel hoses, wires, harness, connectors and so
on. BR
6. Remove the following.
I Vacuum hoses
ST
I Water hoses
I EVAP canister purge hose
I Blow-by hose RS
BT
HA
7. Remove RH and LH ignition coils. SC
EL
IDX
SMA040D
EM-23
EXIT
TIMING CHAIN
Removal (Cont’d)
8. Remove EGR guide tube.
SEM961F
9. Remove intake manifold collector supports and intake manifold

collector (RH cylinder head only).
SEM962F
10. Remove fuel tube assembly. Refer to EC-56, “Injector Removal

and Installation”.
SEM963F
EM-24
EXIT
TIMING CHAIN
Removal (Cont’d)
11. Remove intake manifold in reverse order of installation. Refer
to “TIGHTENING PROCEDURES”, EM-11.
GI
MA
SEM964F LC
12. Remove RH and LH rocker covers from cylinder head.
EC
FE
CL
SEM910E
MT
13. Remove engine undercover.
14. Remove front RH wheel and engine side cover. AT
15. Remove drive belts and idler pulley bracket.
AX
SU
BR
16. Remove power steering oil pump belt and power steering oil
pump assembly. ST
RS
BT
HA
SEM911E
SC
EL
IDX
EM-25
EXIT
TIMING CHAIN
Removal (Cont’d)
17. Remove camshaft position sensor (PHASE) and crankshaft
position sensors (REF)/(POS).
SEM912E
18. Set No. 1 piston at TDC on the compression stroke by rotat-

ing crankshaft.
SEM913E
19. Loosen crankshaft pulley bolt. (At this time remove oil pan rear
cover plate and set a suitable tool to ring gear so that crank-
shaft cannot rotate.)
I Be careful not to damage the signal plate teeth.
SEM965F
EM-26
EXIT
TIMING CHAIN
Removal (Cont’d)
20. Remove crankshaft pulley with a suitable puller.
GI
MA
SEM915E LC
21. Remove air compressor and bracket.
22. Remove front exhaust tube and its support.
EC
23. Hang engine at right and left side engine slingers with a suit-
able hoist.
24. Remove right side engine mounting, mounting bracket and FE
nuts.
25. Remove center member assembly.
26. Remove upper and lower oil pans. CL
I For procedures described in steps 21 through 26, refer to
“Removal”, EM-13.
SEM812E
MT
27. Remove water pump cover.
AT
AX
SU
BR
SEM916E
28. Remove front timing chain case bolts.

I Loosen bolts in numerical order as shown in the figure.
ST
RS
BT
HA
SC
EL
IDX
SEM917EA
EM-27
EXIT
TIMING CHAIN
Removal (Cont’d)
29. Remove front timing chain case.
I Do not scratch sealing surfaces.
SEM156F
30. Remove internal chain guide.

31. Remove upper chain guide.
32. Remove timing chain tensioner and slack side chain guide.
SEM919E
I Remove timing chain tensioner. (Push piston and insert a suit-

able pin into pinhole.)
SEM966F
EM-28
EXIT
TIMING CHAIN
Removal (Cont’d)
33. Remove RH & LH camshaft sprocket 1ST bolts.
34. Remove camshaft sprockets 1ST on both sides, crankshaft
sprocket and timing chain. GI
I Apply paint to timing chain and camshaft sprockets 1ST
for alignment during installation.
MA
LC
EC
FE
CL
SEM004G
MT
35. Attach a suitable stopper pin to RH and LH camshaft chain
tensioners. AT
AX
SU
BR
SEM927EA
36. Remove exhaust camshaft sprocket 2ND bolts on both sides.

I Apply paint to timing chain and camshaft sprockets 2ND
ST
for alignment during installation.
RS
BT
HA
SC
EL
IDX
SEM922E
EM-29
EXIT
TIMING CHAIN
Removal (Cont’d)
37. Remove exhaust camshaft sprockets 2ND, intake camshaft
sprockets 2ND and camshaft chains on both sides.
SEM160F
38. Remove lower chain guide.
SEM924E
39. Use a scraper to remove all traces of liquid gasket from front
timing chain case.
SEM925E
SEM161F
40. Use a scraper to remove all traces of liquid gasket from water
pump cover.
SEM926E
EM-30
EXIT
TIMING CHAIN
Inspection
Inspection NFEM0013
Check for cracks and excessive wear at roller links. Replace
chain if necessary. GI
MA
SEM928E LC
Installation NFEM0014
1. Install crankshaft sprocket on crankshaft. EC
I Make sure that mating marks on crankshaft sprocket face
front of engine.
FE
CL
SEM929E
MT
2. Position crankshaft so that No. 1 piston is set at TDC on com-
pression stroke. AT
AX
SU
BR
SEM930E
3. Install lower chain guide on dowel pin, with front mark on the
guide facing upside. ST
RS
BT
HA
SEM931E
SC
EL
IDX
EM-31
EXIT
TIMING CHAIN
4. Align the marks on RH and LH intake camshaft sprockets 2ND,
exhaust camshaft sprockets 2ND and camshaft chain, as
shown.
5. Put LH camshaft dowel pin into camshaft sprocket dowel
groove and install these on camshaft. Tighten LH exhaust
camshaft sprocket 2ND bolt.
6. Put RH camshaft dowel pin in camshaft sprocket dowel groove
and install sprocket on camshaft.
7. Tighten RH exhaust camshaft sprocket 2ND bolt.
I Make sure that the timing marks on RH and LH intake
camshaft sprockets 2ND are aligned with the camshaft
chain mark.
I Lubricate threads and seat surfaces of camshaft sprocket
bolts with new engine oil.
SEM162F
I Be careful not to confuse intake and exhaust camshaft

sprockets 2ND (their thicknesses are different).
SEM932E
8. Remove RH and LH camshaft chain tensioner stopper pins.
SEM934E
EM-32
EXIT
TIMING CHAIN
9. Align mating mark on crankshaft sprocket with matchmark on
chain as shown.
10. Attach lower timing chain on the water pump sprocket. GI
11. Install RH and LH camshaft sprockets 1ST onto camshafts by
matching sprocket dowel grooves with camshaft.
12. Tighten RH and LH camshaft sprocket 1ST bolts. MA
I Lubricate threads and seat surfaces of the bolts with new
engine oil.
13. Install timing chain. Make sure that mating marks on crank-
shaft sprocket and RH and LH camshaft sprockets are aligned
with matchmarks on timing chain. LC
EC
FE
CL
SEM163F
MT
14. Install internal chain guide.
15. Install upper chain guide and slack side chain guide. AT
AX
SU
BR
ST
RS
BT
HA
SEM919E
16. Install timing chain tensioner, then remove the stopper pin. SC
I When installing the timing chain tensioner, engine oil
should be applied to the oil hole and tensioner.
17. Apply liquid gasket to front timing chain case. EL
I Refer to “POSITION FOR APPLYING LIQUID GASKET”,
EM-21.
IDX
I Before installation, wipe off the protruding sealant.
SEM967F
EM-33
EXIT
TIMING CHAIN
18. Install rear case pin into dowel pin hole on front timing chain
case.
19. Tighten bolts to the specified torque in order shown in the fig-
ure.
I Leave the bolts unattended for 30 minutes or more after
tightening.
SEM938E
20. Apply liquid gasket to water pump cover.

I Apply a continuous bead of liquid gasket to mating surface of
water pump cover. Refer to LC-12, “Water Pump Installation”.
21. Install water pump cover.
22. Apply liquid gasket to RH and LH rocker covers.
I Use genuine liquid gasket or equivalent.
EM-21.
23. Install RH and LH rocker covers.

Rocker cover tightening procedure:
I Tighten in numerical order as shown in the figure.
a. Tighten bolts 1 to 10 in that order to 6.9 to 8.8 N·m (0.7 to 0.9
kg-m, 61 to 78 in-lb).
b. Then tighten bolts 1 to 10 as indicated in figure to 6.9 to 8.8
N·m (0.7 to 0.9 kg-m, 61 to 78 in-lb).
SEM941EA
SEM942EB
EM-34
EXIT
TIMING CHAIN
24. Install intake manifold. Tighten intake manifold nuts and bolts.
Refer to “TIGHTENING PROCEDURES”, EM-11.
25. Install fuel tube assembly. GI
26. Install intake manifold collector gasket.
27. Install intake manifold collector supports and intake manifold
collector bolt. MA
28. Install EGR guide tube.
29. Install RH and LH ignition coils.
30. Install rocker cover ornament on left side.
SEM944E LC
31. Install crankshaft pulley to crankshaft.
I Lubricate thread and seat surface of the bolt with new
engine oil.
EC
a. Tighten to 39 to 49 N·m (4.0 to 5.0 kg-m, 29 to 36 ft-lb).
b. Put a paint mark on the crankshaft pulley. FE
c. Again tighten by turning 60° to 66°, about the angle from one
hexagon bolt head corner to another.
CL
SEM968F
MT
32. Install camshaft position sensor (PHASE), crankshaft position
sensors (REF)/(POS) and front heated oxygen sensor (left AT
bank) harness clamp.
I Make sure that crankshaft position sensor (POS) and front
heated oxygen sensor (left bank) harness clamp are AX
installed correctly as shown in figure.
33. Reinstall removed parts in reverse order of removal.
I When installing fuel tube assembly. Refer to EC-56, “Injector SU
Removal and Installation”.
I After starting engine, keep idling for three minutes. Then BR
SEM963E rev engine up to 3,000 rpm under no load to purge air from
the high-pressure chamber of the chain tensioners. The
engine may produce a rattling noise. This indicates that ST
air still remains in the chamber and is not a matter of
concern.
RS
BT
HA
SEM222F
SC
EL
IDX
EM-35
EXIT
OIL SEAL
Replacement
Replacement NFEM0015
CAUTION:
When removing the oil pans, oil pump assembly and timing
chain from engine, first remove the camshaft position sensor
(PHASE) and the crankshaft position sensors (REF)/(POS)
from the assembly.
Be careful not to damage sensor edges.
VALVE OIL SEAL NFEM0015S01
1. Remove LH ornament cover.
2. Remove RH and LH ignition coils.
SEM948E
3. Remove EGR guide tube.
4. Remove intake manifold collector supports and intake manifold
collector (RH cylinder head only).
5. Remove RH and LH rocker covers from cylinder head.
6. Remove camshaft position sensor (PHASE) and crankshaft
position sensors (REF)/(POS).
7. Remove oil pan. Refer to “Removal”, EM-13.
8. Remove timing chain. Refer to “Removal, EM-23.
9. Remove camshaft brackets and camshaft. Refer to
“Disassembly”, EM-40.
10. Remove valve lifters and shims.
11. Remove valve spring with Tool.
12. Reinstall any parts removed in reverse order of removal.
Before removing valve spring, fix valve as follows.
Method A:
Piston concerned should be set at TDC to prevent valve
from falling.
Method B:
Remove spark plug, then install air hose adapter into
spark plug hole and apply air pressure to hold valves in
place. Apply a pressure of 490 kPa (5 kg/cm2, 71 psi).
SEM826E
Method C:
Install spark plug with suitable washer into spark plug
hole from combustion chamber side.
SEM983D
EM-36
EXIT
OIL SEAL
Replacement (Cont’d)
13. Remove valve oil seal.
GI
MA
SEM827E LC
14. Apply engine oil to new valve oil seal and install it with Tool.
EC
FE
CL
SEM828E
MT
OIL SEAL INSTALLATION DIRECTION NFEM0015S02
I Install new oil seal in the direction shown in the figure. AT
AX
SU
BR
SEM715A
FRONT OIL SEAL

1. Remove the following parts:
NFEM0015S03 ST
I Engine undercover
I Front RH wheel and engine side cover RS
I Drive belts
I Crankshaft position sensor (REF)
I Crankshaft pulley
BT
Be careful not to damage sensor edge.
HA
2. Remove front oil seal using a suitable tool. SC

Be careful not to scratch front cover.
3. Apply engine oil to new oil seal and install it using a suitable
tool. EL
IDX
SEM829E
EM-37
EXIT
OIL SEAL
Replacement (Cont’d)
REAR OIL SEAL NFEM0015S04
1. Remove transaxle. Refer to MT-10 or AT-284.
2. Remove flywheel or drive plate.
3. Remove oil pan. Refer to EM-13.
4. Remove rear oil seal retainer.
SEM830E
5. Remove old liquid gasket using scraper.

SEM831E
6. Apply liquid gasket to rear oil seal retainer.
SEM832EA
EM-38
EXIT
CYLINDER HEAD
Components
Components NFEM0016
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
SEM278G
HA
1. Oil filler cap 6. Cylinder head 11. Valve spring
2. Rocker cover 7. Blow-by hose 12. Valve spring retainer SC
3. Camshaft bracket 8. Spark plug 13. Valve collet
4. Camshaft 9. Valve 14. Valve lifter
5. PCV valve 10. Valve spring seat 15. Shim EL
IDX
EM-39
EXIT
CYLINDER HEAD
CAUTION:
I When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
engine oil.
I Apply new engine oil to threads and seat surfaces when
installing cylinder head, camshaft sprocket, crankshaft
pulley, and camshaft bracket.
I Attach tags to valve lifters so as not to mix them up.
Removal NFEM0017
I This removal is the same procedure as that for timing
chain. Refer to “Removal”, EM-23.
I Apply paint to camshaft sprockets for alignment during
installation.
Disassembly NFEM0018
1. Remove rear timing chain case bolts.
SEM167F
2. Remove rear timing chain case.
SEM279G
3. Remove intake and exhaust camshafts and camshaft brackets.

I Equally loosen camshaft bracket bolts in several steps in the
numerical order shown in the figure.
For reinstallation, be sure to put marks on camshaft
bracket before removal.
4. Remove valve component parts.
Refer to “VALVE OIL SEAL”, EM-36.
SEM856E
EM-40
EXIT
CYLINDER HEAD
Disassembly (Cont’d)
GI
MA
SEM857E LC
5. Remove RH and LH camshaft chain tensioners from cylinder
head.
EC
FE
CL
MT
AT
AX
SU
BR
SEM489F
6. Remove cylinder head bolts.

I Cylinder head bolts should be loosened in two or three
ST
steps.
I A warped or cracked cylinder head could result from RS
removing in incorrect order.
BT
HA
SEM859E
SC
EL
IDX
SEM860E
EM-41
EXIT
CYLINDER HEAD
Disassembly (Cont’d)
7. Remove cylinder head.
SEM863E
Inspection NFEM0019
CYLINDER HEAD DISTORTION NFEM0019S01
Clean surface of cylinder head.
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder head surface.
Check along six positions shown in the figure.
Head surface flatness: Limit 0.1 mm (0.004 in)
If beyond the specified limit, resurface or replace it.
The limit for cylinder head resurfacing is determined by the
cylinder block resurfacing.
SEM861E
Resurfacing limit:
Amount of cylinder head resurfacing is “A”.
Amount of cylinder block resurfacing is “B”.
The maximum limit: A + B = 0.2 mm (0.008 in)
After resurfacing cylinder head, check that camshaft rotates freely
by hand. If resistance is felt, cylinder head must be replaced.
Nominal cylinder head height:
126.3 - 126.5 mm (4.972 - 4.980 in)
CAMSHAFT VISUAL CHECK NFEM0019S02

Check camshaft for scratches, seizure and wear.
CAMSHAFT RUNOUT NFEM0019S03
1. Measure camshaft runout at A and B as shown in the figure.
Runout (Total indicator reading):
Limit 0.05 mm (0.0020 in)
2. If it exceeds the limit, replace camshaft.
SEM191F
CAMSHAFT CAM HEIGHT NFEM0019S04

1. Measure camshaft cam height.
Standard cam height:
Intake 43.940 - 44.130 mm (1.7299 - 1.7374 in)
Exhaust 44.465 - 44.655 mm (1.7506 - 1.7581 in)
Cam wear limit:
0.2 mm (0.008 in)
2. If wear is beyond the limit, replace camshaft.
SEM549A
EM-42
EXIT
CYLINDER HEAD
Inspection (Cont’d)
CAMSHAFT JOURNAL CLEARANCE NFEM0019S05
1. Install camshaft bracket and tighten bolts to the specified
torque. GI
2. Measure inner diameter “A” of camshaft bearing.
Standard inner diameter:
MA
No. 1: 26.000 - 26.021 mm (1.0236 - 1.0244 in)
No. 2, 3, 4: 23.500 - 23.521 mm (0.9252 - 0.9260 in)
SEM862E LC
3. Measure outer diameter of camshaft journal.
Standard outer diameter:
EC
No. 1: 25.935 - 25.955 mm (1.0211 - 1.0218 in)
No. 2, 3, 4: 23.445 - 23.465 mm (0.9230 - 0.9238 in)
4. If clearance exceeds the limit, replace camshaft and/or cylin- FE
der head.
Camshaft journal clearance:
Standard
CL
No. 1: 0.045 - 0.086 mm (0.0018 - 0.0034 in)
SEM012A
No. 2, 3, 4: 0.035 - 0.076 mm (0.0014 - 0.0030 in) MT
Limit
0.15 mm (0.0059 in)
AT
AX
SU
BR
CAMSHAFT END PLAY

1. Install camshaft in cylinder head.
NFEM0019S06 ST
2. Measure camshaft end play.
Camshaft end play: RS
Standard
0.115 - 0.188 mm (0.0045 - 0.0074 in)
Limit
BT
0.24 mm (0.0094 in)
HA
SEM864E
CAMSHAFT SPROCKET RUNOUT NFEM0019S07

SC
1. Install sprocket on camshaft.
2. Measure camshaft sprocket runout.
EL
Less than 0.15 mm (0.0059 in)
3. If it exceeds the limit, replace camshaft sprocket. IDX
SEM865E
EM-43
EXIT
CYLINDER HEAD
VALVE GUIDE CLEARANCE NFEM0019S08
1. Measure valve deflection as shown in the figure. (Valve and
valve guide mostly wear in this direction.)
Valve deflection limit (Dial gauge reading):
Intake 0.24 mm (0.0094 in)
Exhaust 0.28 mm (0.0110 in)
SEM178F
2. 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.
Valve to valve guide clearance limit:
Intake 0.08 mm (0.0031 in)
Exhaust 0.1 mm (0.004 in)
c. If it exceeds the limit, replace valve or valve guide.
SEM938C
VALVE GUIDE REPLACEMENT NFEM0019S09

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):
10.185 - 10.196 mm (0.4010 - 0.4014 in)
SEM932C
EM-44
EXIT
CYLINDER HEAD
4. Heat cylinder head to 110 to 130°C (230 to 266°F) and press
service valve guide onto cylinder head.
Projection “L”: GI
12.6 - 12.8 mm (0.496 - 0.504 in)
5. Ream valve guide.
Finished size:
MA
6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM950E LC
VALVE SEATS NFEM0019S10
Check valve seats for any evidence of pitting at valve contact EC
surface, and reseat or replace if it has worn out excessively.
I Before repairing valve seats, check valve and valve guide
for wear. If they have worn, replace them. Then correct FE
valve seat.
I Use both hands to cut uniformly.
CL
SEM934C
MT
REPLACING VALVE SEAT FOR SERVICE PARTS NFEM0019S11
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 37.500 - 37.516 mm (1.4764 - 1.4770 in) SU
Exhaust 32.700 - 32.716 mm (1.2874 - 1.2880 in)
Be sure to ream in circles concentric to the valve guide
center. BR
SEM795A
This will enable valve seat to fit correctly.
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking
in heated oil. ST
4. Press fit valve seat until it seats on the bottom.
5. Cut or grind valve seat using suitable tool to the specified RS
dimensions as shown in SDS (EM-76).
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. BT
Seat face angle “α”: 45°
Contacting width “W”:
HA
Intake 1.09 - 1.31 mm (0.0429 - 0.0516 in)
SEM892B
Exhaust 1.29 - 1.51 mm (0.0508 - 0.0594 in)
SC
EL
IDX
EM-45
EXIT
CYLINDER HEAD
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 41.07 - 41.67 mm (1.6169 - 1.6405 in)
Exhaust 41.00 - 41.60 mm (1.6142 - 1.6378 in)
SEM621F
VALVE DIMENSIONS NFEM0019S12

Check dimensions of each valve. For dimensions, refer to SDS
(EM-73).
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.
SEM188A
VALVE SPRING NFEM0019S13

Squareness NFEM0019S1301
1. Measure dimension “S”.
Out-of-square “S”:
2. If it exceeds the limit, replace spring.
SEM288A
Pressure NFEM0019S1302
Check valve spring pressure at specified spring height.
Pressure:
Standard
202 N (20.6 kg, 45.4 lb) at height 37.0 mm (1.457 in)
Limit
More than 436 N (44.5 kg, 98.1 lb) at height 28.2
mm (1.110 in)
If it exceeds the limit, replace spring.
EM113
VALVE LIFTER NFEM0019S14

1. Check contact and sliding surfaces for wear or scratches.
SEM960E
EM-46
EXIT
CYLINDER HEAD
2. Check diameter of valve lifter and valve lifter guide bore.
Valve lifter outer diameter:
34.960 - 34.975 mm (1.3764 - 1.3770 in) GI
MA
SEM961E LC
Lifter guide bore diameter:
35.000 - 35.021 mm (1.3780 - 1.3788 in)
EC
FE
CL
SEM867E
MT
Assembly NFEM0020
1. Install valve component parts. AT
I Always use new valve oil seal. Refer to “VALVE OIL
SEAL”, EM-36.
AX
I Before installing valve oil seal, install valve spring seat.
I Install valve spring (uneven pitch type) with its narrow
pitch side toward cylinder head side (paint mark). SU
I After installing valve component parts, tap valve stem tip with
plastic hammer to assure a proper fit.
BR
SEM085D
Installation NFEM0021 ST
1. Before installing rear timing chain case, remove old liquid gas-
ket from mating surface using a scraper.
I Also remove old liquid gasket from mating surface of cylinder RS
block.
BT
HA
SEM891E
I Remove old liquid gasket from the bolt hole and thread. SC
EL
IDX
SEM161F
EM-47
EXIT
CYLINDER HEAD
2. Before installing cam bracket, remove old liquid gasket from
mating surface using a scraper.
3. Remove O-rings from cylinder block.
SEM892E
4. Turn crankshaft until No. 1 piston is set at approximately 240°

before TDC on compression stroke to prevent interference of
valves and pistons.
SEM875E
5. Install cylinder heads with new gaskets.

I Do not rotate crankshaft and camshaft separately, or
valves will strike piston heads.
SEM876E
CAUTION:
Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between d1 and d2
exceeds the limit, replace them with new ones.
Limit (d1 - d2):
0.11 mm (0.0043 in)
engine oil.
SEM957E
EM-48
EXIT
CYLINDER HEAD
I Tightening procedure:
a. Tighten all bolts to 98 N·m (10 kg-m, 72 ft-lb).
b. Completely loosen all bolts. GI
c. Tighten all bolts to 34 to 44 N·m (3.5 to 4.5 kg-m, 25 to 33
ft-lb).
d. Turn all bolts 90 to 95 degrees clockwise.
MA
e. Turn all bolts 90 to 95 degrees clockwise.
SEM877EA LC
EC
FE
CL
SEM878EA
MT
6. Install cylinder head outside bolts.
AT
AX
SU
BR
SEM879EA
7. Install camshaft chain tensioners on both sides of cylinder

head. ST
RS
BT
HA
SEM490F
8. Install exhaust and intake camshafts and camshaft brackets. SC

I Intake camshaft has a drill mark on camshaft sprocket
mounting flange. Install it on the intake side.
EL
IDX
SEM652F
EM-49
EXIT
CYLINDER HEAD
I Identification marks are present on camshafts.
Paint mark
Bank INT/EXH ID mark Drill mark
M1 M2
INT R3 Yes Yes No

RH
EXH R3 No No Yes
INT L3 Yes Yes No

LH
EXH L3 No No Yes
SEM653F
I Position camshaft
RH exhaust camshaft dowel pin at about 10 o’clock
LH exhaust camshaft dowel pin at about 2 o’clock
SEM888EA
9. Before installing camshaft brackets, apply sealant to mating

surface of No. 1 journal head.
I Use Genuine RTV silicone sealant Part No. 999MP-A7007
or equivalent.
EM-21.
I Install camshaft brackets in their original positions.
I Tighten camshaft bracket bolts gradually in two or three
stages.
I If any part of valve assembly or camshaft is replaced,
check valve clearance according to reference data.
After completing assembly check valve clearance. Refer
to “Checking” and “Adjusting” in “VALVE CLEARANCE”,
EM-52 and 54.
Reference data valve clearance (Cold):
Intake
0.26 - 0.34 mm (0.010 - 0.013 in)
Exhaust
0.29 - 0.37 mm (0.011 - 0.015 in)
I Lubricate threads and seat surfaces of camshaft bracket
bolts with new engine oil before installing them.
SEM884EB
I Align stamp mark as shown in the figure.
SEM188F
EM-50
EXIT
CYLINDER HEAD
I Tighten the camshaft brackets in the following steps.
Step Tightening torque Tightening order
GI
Tighten in the order of 7 to 10,
1 1.96 N·m (0.2 kg-m, 17 in-lb)
then tighten 1 to 6.
2 6 N·m (0.6 kg-m, 52 in-lb) Tighten in the numerical order.

MA
9.02 - 11.8 N·m (0.92 - 1.20 kg-m,
3 Tighten in the numerical order.
79.9 - 104.2 in-lb)
SEM885EA LC
EC
FE
CL
SEM886EA
MT
10. Install O-rings to cylinder block.
AT
AX
SU
BR
SEM887E
11. Apply sealant to the hatched portion of rear timing chain case.
I Apply continuous bead of liquid gasket to mating surface of
ST
rear timing chain case.
Refer to “POSITION FOR APPLYING LIQUID GASKET”,
EM-21.
RS
I Before installation, wipe off the protruding sealant.
BT
HA
SC
EL
IDX
EM-51
EXIT
CYLINDER HEAD
12. Align rear timing chain case with dowel pins, then install on
cylinder head and block.
13. Tighten rear chain case bolts.
a. Tighten bolts in numerical order shown in the figure.
b. Repeat above step a.
I This installation is the same procedure as that for timing chain.
Refer to “Installation”, EM-31.
SEM890EA
Valve Clearance NFEM0022

CHECKING NFEM0022S01
Check valve clearance while engine is cold and not running.
1. Remove intake manifold collector.
2. Remove rocker cover ornament.
3. Remove RH and LH rocker covers.
4. Remove all spark plugs.
5. Set No. 1 cylinder at TDC on its compression stroke.
I Align pointer with TDC mark on crankshaft pulley.
SEM868E I Check that valve lifters on No. 1 cylinder are loose and valve
lifters on No. 4 are tight.
If not, turn crankshaft one revolution (360°) and align as above.
EM-52
EXIT
CYLINDER HEAD
Valve Clearance (Cont’d)
6. Check only those valves shown in the figure.
Valve
GI
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Crank
position INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH
MA
No. 1 TDC q q q q
LC
EC
FE
CL
SEM893E
MT
I Using a feeler gauge, measure clearance between valve lifter
and camshaft. AT
I Record any valve clearance measurements which are out of
specification. They will be used later to determine the required
replacement adjusting shim. AX
Valve clearance for checking (Cold):
Intake
SU
0.26 - 0.34 mm (0.010 - 0.013 in)
Exhaust
0.29 - 0.37 mm (0.011 - 0.015 in) BR
SEM139D
7. Turn crankshaft 240° and align as above.

ST
Valve RS
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Crank
BT
No. 3 TDC q q q q
HA
SC
EL
IDX
SEM894E
EM-53
EXIT
CYLINDER HEAD
10. Turn crankshaft 240° and align as above.
Valve
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

Crank
No. 5 TDC q q q q
13. If all valve clearances are within specification, install the fol-
lowing parts.
I Intake manifold collector
I RH and LH rocker covers
I All spark plugs
I Rocker cover ornament
SEM958E
ADJUSTING NFEM0022S02
Adjust valve clearance while engine is cold.
1. Turn crankshaft, to position cam lobe on camshaft of valve that
must be adjusted upward.
2. Place Tool (A) around camshaft as shown in figure.
Before placing Tool (A), rotate notch toward center of cyl-
inder head (See figure.), to simplify shim removal later.
CAUTION:
Be careful not to damage cam surface with Tool (A).
SEM557EB
3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down.
SEM869E
4. Place Tool (B) 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).
SEM870E
EM-54
EXIT
CYLINDER HEAD
6. Blow air into the hole to separate adjusting shim from valve
lifter.
GI
MA
SEM871E LC
7. Remove adjusting shim using a small screwdriver and a mag-
netic finger.
8. Determine replacement adjusting shim size following formula.
EC
I Using a micrometer determine thickness of removed shim.
I Calculate thickness of new adjusting shim so valve clearance FE
comes within specified values.
R = Thickness of removed shim
N = Thickness of new shim CL
M = Measured valve clearance
Intake:
SEM872E N = R + [M − 0.30 mm (0.0118 in)] MT
Exhaust:
N = R + [M − 0.33 mm (0.0130 in)] AT
Shims are available in 64 sizes from 2.32 mm (0.0913 in)
to 2.95 mm (0.1161 in), in steps of 0.01 mm (0.0004 in).
I Select new shim with thickness as close as possible to calcu- AX
lated value.
SU
BR
SEM145D
ST
RS
BT
HA
SEM873E
9. Install new shim using a suitable tool. SC

I Install with the surface on which the thickness is stamped
facing down.
EL
IDX
SEM146D
EM-55
EXIT
CYLINDER HEAD
10. Place Tool (A) as mentioned in steps 2 and 3.
11. Remove Tool (B).
12. Remove Tool (A).
13. Recheck valve clearance.
Valve clearance:
Unit: mm (in)
Cold Hot* (reference data)
Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)

SEM874E
*: Approximately 80°C (176°F)
EM-56
EXIT
ENGINE ASSEMBLY
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
SEM306G
HA
1. Front upper engine slinger 4. Rear engine mounting (Fluid type) 7. LH engine mounting
2. RH engine mounting 5. Center member 8. Rear engine slinger SC
3. Mounting bracket 6. Front engine mounting (Fluid type) 9. Insulator
WARNING:
EL
I Situate vehicle on a flat and solid surface.
I Place chocks at front and back of rear wheels. IDX
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.
EM-57
EXIT
ENGINE ASSEMBLY
I Before disconnecting fuel hose, release fuel pressure
from fuel line.
I Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI-46, “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
crankshaft position sensor (POS) from the assembly.
I Always pay extra attention not to damage edge of crank-
shaft position sensor (POS) or ring gear teeth.
REMOVAL NFEM0023S01
1. Remove engine undercover and hood.
2. Drain coolant from both cylinder block and radiator. Refer to
MA-14, “Changing Engine Coolant”.
3. Remove vacuum hoses, fuel hoses, wires, harnesses, connec-
tors and so on.
4. Remove front exhaust tubes, ball joints and drive shafts.
5. Remove radiator and fans.
6. Remove drive belts.
7. Remove alternator, compressor and power steering oil pump
SEM971F
from engine.
8. Set a suitable transmission jack under transaxle. Hoist engine
with engine slinger.
9. Remove LH engine mounting.
10. Disconnect control rod and support rod from transaxle (M/T
model).
11. Disconnect control cable from transaxle (A/T model).
SEM835E
12. Remove RH engine mounting.
SEM836EA
EM-58
EXIT
ENGINE ASSEMBLY
13. Remove center member and then slowly lower transmission
jack.
GI
MA
SEM837E LC
14. Remove engine with transaxle as shown.
EC
FE
CL
MT
AT
AX
SU
BR
SEM972F
ST
RS
BT
HA
INSTALLATION NFEM0023S02
SC
Installation is in the reverse order of removal.
Install the electronically-controlled engine mount harness to match
the following values. (Models with electronically-controlled engine EL
mounts)
Front (A — B):
170 mm (6.69 in)
IDX
Rear (C — D):
130 mm (5.12 in)
SEM307G
EM-59
EXIT
CYLINDER BLOCK
Components
Components NFEM0024
SEM654FB
1. Rear oil seal retainer 9. Main bearing cap 16. Drive plate reinforcement
2. Cylinder block 10. Main bearing beam 17. Oil ring
3. Knock sensor 11. Crankshaft 18. Piston pin
4. Upper main bearing 12. Pilot bushing or pilot converter 19. Connecting rod bearing
5. Lower main bearing 13. Flywheel with signal plate (M/T 20. Connecting rod
6. Water drain plug (LH side) models) 21. Piston
7. Water drain plug (RH side) 14. Drive plate with signal plate (A/T 22. Top ring
8. Water drain plug (Water pump model) 23. 2nd ring
side) 15. Flywheel reinforcement
EM-60
EXIT
CYLINDER BLOCK

CAUTION:
I When installing bearings, pistons, or other sliding parts, GI
lubricate contacting surfaces with new engine oil.
I Place removed parts such as bearings and bearing caps
in their proper order and direction.
MA
I When installing connecting rod nuts, and main bearing
cap bolts, apply new engine oil to threads and seating
surfaces.
I Do not allow any magnetic materials to contact the signal
SEM180FA plate teeth of flywheel or drive plate. LC
Disassembly NFEM0026
PISTON AND CRANKSHAFT NFEM0026S01
EC
1. Remove engine. Refer to “Removal and Installation”, EM-57.
2. Place engine on a work stand.
3. Drain coolant and oil. FE
4. Remove oil pan. Refer to “Removal”, EM-13.
5. Remove timing chain. Refer to “Removal”, EM-23. CL
6. Remove cylinder head. Refer to “Removal”, EM-40.
SEM190FA
MT
7. Remove pistons with connecting rods.
I When disassembling piston and connecting rod, remove snap AT
ring first, then heat piston to 60 to 70°C (140 to 158°F).
8. Remove rear oil seal retainer.
CAUTION:
AX
I When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
SU
I When replacing piston rings, if there is no punchmark,
install with either side up.
BR
SEM965A
9. Loosen bolts in numerical order as shown and remove main

bearing beam, bearing cap and crankshaft. ST
I Before removing bearing beam and bearing cap, measure
crankshaft end play. Refer to EM-69.
RS
I Bolts should be loosened in two or three steps.
BT
HA
SEM842E
Inspection NFEM0027
SC
PISTON AND PISTON PIN CLEARANCE NFEM0027S01
1. Measure inner diameter of piston pin hole “dp”. EL
Standard diameter “dp”:
Grade No. 0
21.993 - 21.999 mm (0.8659 - 0.8661 in) IDX
Grade No. 1
21.999 - 22.005 mm (0.8661 - 0.8663 in)
AEM023
EM-61
EXIT
CYLINDER BLOCK
2. Measure outer diameter of piston pin “Dp”.
Standard diameter “Dp”:
Grade No. 0
21.989 - 21.995 mm (0.8657 - 0.8659 in)
Grade No. 1
21.995 - 22.001 mm (0.8659 - 0.8662 in)
3. Calculate interference fit of piston pin to piston.
Dp − dp = 0.002 - 0.06 mm (0.0001 - 0.0024 in)
If it exceeds the above value, replace piston assembly with pin.
AEM024
PISTON RING SIDE CLEARANCE NFEM0027S02

Side clearance:
Top ring
0.040 - 0.080 mm (0.0016 - 0.0031 in)
2nd ring
0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring
0.015 - 0.185 mm (0.0006 - 0.0073 in)
Max. limit of side clearance:
SEM024AA Top ring 0.11 mm (0.0043 in)
2nd ring 0.1 mm (0.004 in)
If out of specification, replace piston ring. If clearance exceeds
maximum limit with new ring, replace piston.
PISTON RING END GAP NFEM0027S03

End gap:
Top ring 0.22 - 0.32 mm (0.0087 - 0.0126 in)
2nd ring 0.32 - 0.47 mm (0.0126 - 0.0185 in)
Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 in)
Max. limit of ring gap:
Top ring 0.55 mm (0.0217 in)
2nd ring 0.85 mm (0.0335 in)
Oil ring 0.95 mm (0.0374 in)
SEM599A If out of specification, replace piston ring. If gap still exceeds the
limit even with a new ring, do the following. Rebore cylinder and
use oversized piston and piston rings.
Refer to SDS (EM-79).
I When replacing the piston, check the cylinder block surface for
scratches or seizure. If scratches or seizure is found, hone or
replace the cylinder block.
EM-62
EXIT
CYLINDER BLOCK
CONNECTING ROD BEND AND TORSION NFEM0027S04
Bend:
Limit 0.15 mm (0.0059 in) GI
per 100 mm (3.94 in) length
Torsion: MA
Limit 0.30 mm (0.0118 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
SEM038F LC
EC
FE
CL
SEM003F
MT
CYLINDER BLOCK DISTORTION AND WEAR NFEM0027S05
I Clean upper surface of cylinder block. AT
Use a reliable straightedge and feeler gauge to check the flat-
ness of cylinder block surface.
Check along six positions shown in the figure. AX
Distortion limit: 0.10 mm (0.0039 in)
I If out of specification, resurface it. The limit for cylinder block
resurfacing is determined by cylinder head resurfacing in
SU
engine.
Resurfacing limit: BR
SEM123C Amount of cylinder head resurfacing is “A”.
Amount of cylinder block resurfacing is “B”.
The maximum limit is as follows: ST
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height from crankshaft center:
214.95 - 215.05 mm (8.4626 - 8.4665 in) RS
I If necessary, replace cylinder block. BT
HA
SC
EL
IDX
EM-63
EXIT
CYLINDER BLOCK
PISTON-TO-BORE CLEARANCE NFEM0027S06
1. Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper.
Cylinder bore inner diameter
Grade No. Standard inner diameter Wear limit
No. 1 93.000 - 93.010 mm (3.6614 - 3.6618 in)
No. 2 93.011 - 93.020 mm (3.6618 - 3.6622 in) 0.20 mm (0.0079 in)
No. 3 93.021 - 93.030 mm (3.6622 - 3.6626 in)

SEM843E
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
Out-of-round (X − Y):
Limit 0.015 mm (0.0006 in)
Taper (A − B − C):
Limit 0.015 mm (0.0006 in)
2. Check for scratches and seizure. If seizure is found, hone it.
SEM321AA
I If both cylinder block and piston are replaced with new

ones, select piston of the same grade number punched on
cylinder block rear position. These numbers are punched
in either Arabic or Roman numerals.
SEM174F
3. Measure piston skirt diameter.

Piston diameter “A”: Refer to SDS (EM-79).
Measuring point “a” (Distance from the top):
45.4 mm (1.787 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance “B”:
0.010 - 0.032 mm (0.0004 - 0.0013 in)
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service.
SEM258C
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter “A”.
Rebored size calculation: D = A + B − C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified torque.
Otherwise, cylinder bores may be distorted in final assembly.
EM-64
EXIT
CYLINDER BLOCK
8. Cut cylinder bores.
I When any cylinder needs boring, all other cylinders must
also be bored. GI
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.
9. Hone cylinders to obtain specified piston-to-bore clearance. MA
10. Measure finished cylinder bore for out-of-round and taper.
I Measurement should be done after cylinder bore cools
down.
LC
CRANKSHAFT NFEM0027S07
1. Check crankshaft main and pin journals for score, wear or EC
cracks.
2. With a micrometer, measure journals for taper and out-of-
round. FE
Out-of-round (X − Y):
Standard
0.002 mm (0.0001 in) CL
Taper (A − B):
Standard MT
SEM316A
0.002 mm (0.0001 in)
AT
AX
SU
BR
3. Measure crankshaft runout.
ST
Limit 0.10 mm (0.0039 in)
RS
BT
HA
SEM346D
BEARING CLEARANCE NFEM0027S08

SC
I Use either of the following two methods, however, method “A”
gives more reliable results and is preferable.
Method A (Using bore gauge & micrometer) EL
Main bearing NFEM0027S0801
1. Set main bearings in their proper positions on cylinder block IDX
and main bearing cap.
SEM175F
EM-65
EXIT
CYLINDER BLOCK
2. Install main bearing cap and bearing beam to cylinder block.
Tighten all bolts in correct order.
3. Measure inner diameters “A” of each main bearing.
SEM845E
4. Measure outer diameters “Dm” of each crankshaft main jour-

nal.
5. Calculate main bearing clearance.
Main bearing clearance = A − Dm
Standard: 0.035 - 0.045 mm (0.0014 - 0.0018 in) (actual
clearance)
Limit: 0.065 mm (0.0026 in)
I If it exceeds the limit, replace bearing.
I If clearance cannot be adjusted using any standard bearing
grade, grind crankshaft journal and use undersized bearing.
AEM033
a. When grinding crankshaft journal, confirm that “L” dimension in

fillet roll is more than the specified limit.
“L”: 0.1 mm (0.004 in)
b. Refer to SDS for grinding crankshaft and available service
parts.
SEM964
6. If crankshaft or cylinder block is replaced with a new one,

select thickness of main bearings as follows:
a. Grade number of each cylinder block main journal is punched
on the respective cylinder block. These numbers are punched
in either Arabic or Alphabet. Refer to SDS, EM-78.
If measured diameter is out of grade punched, decide suitable
grade using table in SDS.
SEM176F
b. Grade number of each crankshaft main journal is punched on

the respective crankshaft. These numbers are punched in
either Arabic or Alphabet. Refer to SDS, EM-81.
If measured diameter is out of grade punched, decide suitable
grade using table in SDS.
c. Select main bearing with suitable thickness according to the
following table.
Refer to “SDS”, EM-82, for available main bearings.
SEM847E
EM-66
EXIT
CYLINDER BLOCK
GI
MA
LC
EC
FE
CL
MT
AT
SEM280G
AX
SU
BR
Connecting Rod Bearing (Big end)

1.
NFEM0027S0802
Install connecting rod bearing to connecting rod and cap.
ST
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque. RS
3. Measure inner diameter “C” of connecting rod.
BT
HA
AEM027
4. Measure outer diameter “Dp” of each crankshaft pin journal. SC

5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C − Dp
Standard: 0.034 - 0.059 mm (0.0013 - 0.0023 in) (actual EL
clearance)
Limit: 0.070 mm (0.0028 in)
IDX
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing.
Refer to “BEARING CLEARANCE — Main bearing”, EM-65.
AEM034
EM-67
EXIT
CYLINDER BLOCK
8. If crankshaft is replaced with a new one, select connecting rod
bearing according to the following table.
Connecting rod bearing grade number (Identification
color):
These numbers are punched in either Arabic or Roman numer-
als.
Crankshaft pin journal grade
Connecting rod bearing grade number
number
0 0 (Black)
SEM848E 1 1 (Brown)
2 2 (Green)
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
CONNECTING ROD BUSHING CLEARANCE (SMALL

END) NFEM0027S09
1. Measure inner diameter “C” of bushing.
2. Measure outer diameter “Dp” of piston pin.
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance = C − Dp
Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit: 0.030 mm (0.0012 in)
If it exceeds the limit, replace connecting rod assembly or
connecting rod bushing and/or piston set with pin.
SEM673E
REPLACEMENT OF CONNECTING ROD BUSHING

(SMALL END) NFEM0027S10
1. Drive in small end bushing until it is flush with end surface of
rod.
Be sure to align the oil holes.
2. After driving in small end bushing, ream the bushing. This is
to ensure the clearance between connecting rod bushing and
piston pin is the specified value.
Clearance between connecting rod bushing and piston
pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
SEM062A
FLYWHEEL/DRIVE PLATE RUNOUT NFEM0027S11

Flywheel (M/T model)★
Drive plate (A/T model)
★ Measurement position:
Approximately 145 mm (5.71 in) from the crankshaft center
CAUTION:
SEM849EA
I The signal plate is built into the flywheel assembly. Be
EM-68
EXIT
CYLINDER BLOCK
careful not to damage the signal plate, especially the
teeth.
I Check the drive plate and signal plate for deformation or GI
cracks.
I Never place the flywheel assembly with the signal plate
facing down. MA
I Keep any magnetized objects away from the signal plate.
I Do not allow any magnetic materials to contact the signal
plate teeth.
I Do not surface flywheel. Replace as necessary.
LC
Assembly NFEM0028
PISTON NFEM0028S01
EC
1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston,
piston pin, connecting rod and new snap ring. FE
I Align the direction of piston and connecting rod.
I Numbers stamped on connecting rod and cap correspond CL
to each cylinder.
I After assembly, make sure connecting rod swings
SEM838F
smoothly. MT
3. Set piston rings as shown.
CAUTION: AT
I When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
I When replacing piston rings, these without punchmarks, AX
present, piston rings can be mounted with either side up.
SU
BR
SEM965E
I Align piston rings so that end gaps are positioned as

shown in the figure. ST
RS
BT
HA
SEM160B
CRANKSHAFT NFEM0028S02
SC
1. Set main bearings in their proper positions on cylinder block
and main bearing beam.
I Confirm that correct main bearings are used. Refer to EL
“Inspection” of this section.
IDX
SEM175F
EM-69
EXIT
CYLINDER BLOCK
Assembly (Cont’d)
2. Instructions for re-use of main bearing cap bolts.
I A plastic zone tightening method is used for tightening
main bearing cap bolts. Measure d1 and d2 as shown in
the figure.
d2: Select minimum diameter in the measuring area.
If the difference between d1 and d2 exceeds the limit,
replace the bolts with new ones.
Limit (d1 - d2): 0.11 mm (0.0043 in)
SEM177F
3. After installing crankshaft, main bearing cap, main bearing

beam and bearing cap bolts, tighten bearing cap bolts in
numerical order as shown.
I Tightening procedure
a) Tighten all bolts to 32 to 38 N·m (3.3 to 3.9 kg-m, 24 to 28
ft-lb).
b) Turn all bolts 90 to 95 degrees clockwise with angle
wrench.
I Prior to tightening bearing cap bolts, place bearing beam
in its proper position by shifting crankshaft in the axial
SEM851E direction.
I After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
engine oil.
4. Measure crankshaft end play.
Crankshaft end play:
Standard
0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit
0.30 mm (0.0118 in)
SEM852E If beyond the limit, replace bearing with a new one.
5. Install connecting rod bearings in connecting rods and con-
necting rod caps.
I Confirm that correct bearings are used.
SEM973F
6. Install pistons with connecting rods.

a. Install them into corresponding cylinders with Tool.
I Be careful not to scratch cylinder wall with the connecting
rod.
I Arrange so that front mark on piston head faces toward
engine front.
SEM620
EM-70
EXIT
CYLINDER BLOCK
Assembly (Cont’d)
b. A plastic zone tightening method is used for tightening con-
necting rod bolts and nuts. Check the old bolts for deformation
before re-using them. GI
I Ensure that the connecting rod nut can be screwed
smoothly as far as the bolt thread end.
I If this is not possible, use slide calipers to measure the MA
outside diameter of the narrowest thread part of the bolt
at 16 mm (0.63 in) from the thread end. Replace the con-
necting rod bolt and nut, if under the limit.
Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 in)
SEM956E Limit: 7.75 mm (0.3051 in) LC
c. Install connecting rod caps.
I Lubricate threads and seat surfaces with new engine oil.
EC
Tighten connecting rod bearing cap nuts to the specified
torque.
Connecting rod bearing nut: FE
(1) Tighten nuts to 19 to 21 N·m (1.9 to 2.1 kg-m, 14
to 15 ft-lb).
(2) Turn nuts 90 to 95 degrees clockwise with angle CL
wrench.
SEM953E
MT
7. Measure connecting rod side clearance.
Connecting rod side clearance: AT
Standard
0.20 - 0.35 mm (0.0079 - 0.0138 in)
Limit
AX
0.40 mm (0.0157 in)
If beyond the limit, replace connecting rod and/or crankshaft. SU
8. Install rear oil seal retainer.
BR
SEM954E
REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT

CONVERTER (A/T) ST
NFEM0028S04
1. Remove pilot bushing or pilot converter using tool or suitable
tool. RS
BT
HA
SEM005G
2. Install pilot bushing or pilot converter as shown. SC
EL
IDX
SEM163B
EM-71
EXIT
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
General Specifications NFEM0029
Cylinder arrangement V-6
Displacement cm3 (cu in) 2,988 (182.33)
Bore and stroke mm (in) 93 x 73.3 (3.66 x 2.886)
Valve arrangement DOHC
Firing order 1-2-3-4-5-6
Compression 2
Number of piston rings
Oil 1
Number of main bearings 4
Compression ratio 10.0
Compression Pressure NFEM0030

Unit: kPa (kg/cm2, psi)/300 rpm
Standard 1,275 (13.0, 185)
Compression pressure Minimum 981 (10.0, 142)
Differential limit between cylinders 98 (1.0, 14)
Cylinder number
SEM713A
Cylinder Head NFEM0031

Unit: mm (in)
Standard Limit
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
SEM949E
EM-72
EXIT
Valve
Valve NFEM0032
VALVE NFEM0032S01
Unit: mm (in)
GI
MA
LC
SEM188
EC
Intake 36.0 - 36.3 (1.417 - 1.429)
Valve head diameter “D” FE
Exhaust 31.2 - 31.5 (1.228 - 1.240)
Intake 97.32 - 97.82 (3.8315 - 3.8512)

Valve length “L” CL
Exhaust 94.85 - 95.35 (3.7342 - 3.7539)
Intake 5.965 - 5.980 (0.2348 - 0.2354)

Valve stem diameter “d” MT
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
Intake
Valve seat angle “α” 45°15′ - 45°45′ AT
Exhaust
Intake 0.95 - 1.25 (0.0374 - 0.0492)

Valve margin “T” AX
Exhaust 1.15 - 1.45 (0.0453 - 0.0571)
Valve margin “T” limit More than 0.5 (0.020)

SU
Valve stem end surface grinding limit Less than 0.2 (0.008)
Intake 0.26 - 0.34 (0.010 - 0.013)

Valve clearance (Cold) BR
Exhaust 0.29 - 0.37 (0.011 - 0.015)
VALVE CLEARANCE NFEM0032S02

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

RS
Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)

BT
*: Approximately 80°C (176°F)
AVAILABLE SHIMS NFEM0032S03 HA

Thickness mm (in) Identification mark
2.32 (0.0913) 232 SC

2.33 (0.0917) 233
2.34 (0.0921) 234 EL

2.35 (0.0925) 235
2.36 (0.0929) 236 IDX

2.37 (0.0933) 237
2.38 (0.0937) 238
2.39 (0.0941) 239
EM-73
EXIT
Valve (Cont’d)
2.40 (0.0945) 240
2.41 (0.0949) 241
2.42 (0.0953) 242
2.43 (0.0957) 243
2.44 (0.0961) 244
2.45 (0.0965) 245
2.46 (0.0969) 246
2.47 (0.0972) 247
2.48 (0.0976) 248
2.49 (0.0980) 249
2.50 (0.0984) 250
2.51 (0.0988) 251
2.52 (0.0992) 252
2.53 (0.0996) 253
2.54 (0.1000) 254
2.55 (0.1004) 255
2.56 (0.1008) 256
2.57 (0.1012) 257
2.58 (0.1016) 258
2.59 (0.1020) 259
2.60 (0.1024) 260
2.61 (0.1028) 261
2.62 (0.1031) 262
2.63 (0.1035) 263
2.64 (0.1039) 264
2.65 (0.1043) 265
2.66 (0.1047) 266
2.67 (0.1051) 267
2.68 (0.1055) 268
2.69 (0.1059) 269
2.70 (0.1063) 270
2.71 (0.1067) 271
2.72 (0.1071) 272
2.73 (0.1075) 273
2.74 (0.1079) 274
2.75 (0.1083) 275
2.76 (0.1087) 276
2.77 (0.1091) 277
2.78 (0.1094) 278
2.79 (0.1098) 279
EM-74
EXIT
Valve (Cont’d)
2.80 (0.1102) 280 GI

2.81 (0.1106) 281
2.82 (0.1110) 282 MA

2.83 (0.1114) 283
2.84 (0.1118) 284
2.85 (0.1122) 285
2.86 (0.1126) 286 LC

2.87 (0.1130) 287
2.88 (0.1134) 288 EC

2.89 (0.1138) 289
2.90 (0.1142) 290 FE

2.91 (0.1146) 291
2.92 (0.1150) 292 CL

2.93 (0.1154) 293
2.94 (0.1157) 294 MT

2.95 (0.1161) 295
AT
AX
SU
BR
SEM966E
ST
VALVE SPRING NFEM0032S04
RS
Free height mm (in) 47.10 (1.8543)
Standard 202 (20.6, 45.4) at 37.0 (1.457)

Pressure N (kg, lb) at height mm (in) BT
Limit 436 (44.5, 98.1) at 28.2 (1.110)
Out-of-square mm (in) Less than 2.0 (0.079)

HA
VALVE LIFTER NFEM0032S05
Unit: mm (in)
SC
Valve lifter outer diameter 34.960 - 34.975 (1.3764 - 1.3770)
Lifter guide inner diameter 35.000 - 35.021 (1.3780 - 1.3788)

EL
Clearance between lifter and lifter guide 0.025 - 0.061 (0.0010 - 0.0024)
IDX
EM-75
EXIT
Valve (Cont’d)
VALVE GUIDE NFEM0032S06
Unit: mm (in)
SEM950E
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 9.960 - 9.978 (0.3921 - 0.3928) 10.185 - 10.196 (0.4010 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Standard Max. tolerance
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)
Intake — 0.24 (0.0094)

Valve deflection limit
Exhaust — 0.28 (0.0110)
Projection length “L” 12.6 - 12.8 (0.496 - 0.504)
Valve Seat NFEM0033

Unit: mm (in)
SEM021EA
EM-76
EXIT
Valve Seat (Cont’d)
GI
MA
LC
SEM621F
Standard Service
EC
Intake 37.000 - 37.016 (1.4567 - 1.4573) 37.500 - 37.516 (1.4764 - 1.4770)
Cylinder head seat recess diameter (D)
Exhaust 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880)
FE
Intake 0.081 - 0.113 (0.0032 - 0.0044)
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038)
CL
Intake 37.097 - 37.113 (1.4605 - 1.4611) 37.597 - 37.613 (1.4802 - 1.4808)
Valve seat outer diameter (d)
Exhaust 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2905 - 1.2912)
MT
Intake 5.9 - 6.0 (0.232 - 0.236) 5.05 - 5.15 (0.1988 - 0.2028)
Height (h)
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)
AT
Depth (H) 5.9 - 6.1 (0.232 - 0.240)
Intake 41.07 - 41.67 (1.6169 - 1.6405)

Depth (L) AX
Exhaust 41.00 - 41.60 (1.6142 - 1.6378)
Camshaft and Camshaft Bearing NFEM0034

SU
Unit: mm (in)
Standard Limit
BR
No. 1
0.045 - 0.086 (0.0018 - 0.0034)
Camshaft journal to bearing clearance 0.15 (0.0059)
No. 2, 3, 4 ST
0.035 - 0.076 (0.0014 - 0.0030)
No. 1
Inner diameter of camshaft bearing
26.000 - 26.021 (1.0236 - 1.0244)
—
RS
No. 2, 3, 4
23.500 - 23.521 (0.9252 - 0.9260)
No. 1 BT
25.935 - 25.955 (1.0211 - 1.0218)
Outer diameter of camshaft journal —
No. 2, 3, 4
23.445 - 23.465 (0.9230 - 0.9238) HA
Camshaft runout [TIR*] Less than 0.02 (0.0008) 0.05 (0.0020)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059) — SC

Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)
*: Total indicator reading EL
IDX
EM-77
EXIT
Camshaft and Camshaft Bearing (Cont’d)
EM671
Intake 43.940 - 44.130 (1.7299 - 1.7374)

Cam height “A”
Exhaust 44.465 - 44.655 (1.7506 - 1.7581)
Wear limit of cam height 0.2 (0.008)
Valve timing
Unit: degree
a b c d e f
232 224 3 41 3 49
Cylinder Block NFEM0035

Unit: mm (in)
SEM022EA
Standard Less than 0.03 (0.0012)

Surface flatness
Limit 0.10 (0.0039)
Grade No. 1 93.000 - 93.010 (3.6614 - 3.6618)
Standard Grade No. 2 93.011 - 93.020 (3.6618 - 3.6622)

Cylinder bore Inner diameter
Grade No. 3 93.021 - 93.030 (3.6622 - 3.6626)
Wear limit 0.20 (0.0079)
Out-of-round (X − Y) Less than 0.015 (0.0006)
Taper (A − B − C) Less than 0.015 (0.0006)
EM-78
EXIT
Cylinder Block (Cont’d)
Grade No. A 63.993 - 63.994 (2.5194 - 2.5194)

Grade No. B 63.994 - 63.995 (2.5194 - 2.5195)
Grade No. C 63.995 - 63.996 (2.5195 - 2.5195) GI
Grade No. D 63.996 - 63.997 (2.5195 - 2.5196)
Grade No. E 63.997 - 63.998 (2.5196 - 2.5196)
Grade No. F 63.998 - 63.999 (2.5196 - 2.5196)
Grade No. G 63.999 - 64.000 (2.5196 - 2.5197) MA
Grade No. H 64.000 - 64.001 (2.5197 - 2.5197)
Grade No. J 64.001 - 64.002 (2.5197 - 2.5198)
Grade No. K 64.002 - 64.003 (2.5198 - 2.5198)
Grade No. L 64.003 - 64.004 (2.5198 - 2.5198)
Main journal inner
Grade No. M 64.004 - 64.005 (2.5198 - 2.5199)
diameter grade
Grade No. N 64.005 - 64.006 (2.5199 - 2.5199)
(Without bearing)
Grade No. P 64.006 - 64.007 (2.5199 - 2.5200) LC
Grade No. R 64.007 - 64.008 (2.5200 - 2.5200)
Grade No. S 64.008 - 64.009 (2.5200 - 2.5200)
Grade No. T 64.009 - 64.010 (2.5200 - 2.5201) EC
Grade No. U 64.010 - 64.011 (2.5201 - 2.5201)
Grade No. V 64.011 - 64.012 (2.5201 - 2.5202)
Grade No. W 64.012 - 64.013 (2.5202 - 2.5202)
Grade No. X 64.013 - 64.014 (2.5202 - 2.5202) FE
Grade No. Y 64.014 - 64.015 (2.5202 - 2.5203)
Grade No. 4 64.015 - 64.016 (2.5203 - 2.5203)
Grade No. 7 64.016 - 64.017 (2.5203 - 2.5203)
CL
Difference in inner
diameter between Standard Less than 0.03 (0.0012)
cylinders MT
Piston, Piston Ring and Piston Pin
AVAILABLE PISTON
NFEM0036
AT
NFEM0036S01
Unit: mm (in)
AX
SU
BR
ST
SEM882E
RS
Grade No. 1 92.979 - 92.988 (3.6606 - 3.6609)
Grade No. 2 92.988 - 93.000 (3.6609 - 3.6614)

Piston skirt diameter “A” Standard BT
Grade No. 3 93.000 - 93.009 (3.6614 - 3.6618)
0.20 (0.0079) oversize (Service) 93.179 - 93.209 (3.6685 - 3.6696)

HA
“a” dimension 45.4 (1.787)
Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661)

Piston pin hole diameter SC
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663)
Piston clearance to cylinder block 0.010 - 0.032 (0.0004 - 0.0013)

EL
IDX
EM-79
EXIT
Piston, Piston Ring and Piston Pin (Cont’d)
PISTON RING =NFEM0036S02
Unit: mm (in)
Standard Limit
Top 0.040 - 0.080 (0.0016 - 0.0031) 0.11 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.1 (0.004)
Oil ring 0.015 - 0.185 (0.0006 - 0.0073) —
Top 0.22 - 0.32 (0.0087 - 0.0126) 0.55 (0.0217)
End gap 2nd 0.32 - 0.47 (0.0126 - 0.0185) 0.85 (0.0335)
Oil (rail ring) 0.20 - 0.60 (0.0079 - 0.0236) 0.95 (0.0374)
PISTON PIN NFEM0036S03

Unit: mm (in)
Grade No. 0 21.989 - 21.995 (0.8657 - 0.8659)

Piston pin outer diameter
Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662)
Interference fit of piston pin to piston 0.002 - 0.006 (0.0001 - 0.0002)
Standard 0.005 - 0.017 (0.0002 - 0.0007)

Piston pin to connecting rod bushing clearance
Limit 0.030 (0.0012)
*: Values measured at ambient temperature of 20°C (68°F)
Connecting Rod NFEM0037

Unit: mm (in)
Center distance 147.60 - 147.70 (5.8110 - 5.8149)
Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
Connecting rod small end inner diameter 23.980 - 24.000 (0.9441 - 0.9449)
Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664)

Piston pin bushing inner diameter*
Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666)
Connecting rod big end inner diameter 48.000 - 48.013 (1.8898 - 1.8903)
Standard 0.20 - 0.35 (0.0079 - 0.0138)

Side clearance
Limit 0.40 (0.0157)
*: After installing in connecting rod
EM-80
EXIT
Crankshaft
Crankshaft NFEM0038
Unit: mm (in)
GI
Grade No. A 59.975 - 59.974 (2.3612 - 2.3612)
Grade No. B 59.974 - 59.973 (2.3612 - 2.3611)
Grade No. C 59.973 - 59.972 (2.3611 - 2.3611)
Grade No. D 59.972 - 59.971 (2.3611 - 2.3611) MA
Grade No. E 59.971 - 59.970 (2.3611 - 2.3610)
Grade No. F 59.970 - 59.969 (2.3610 - 2.3610)
Grade No. G 59.969 - 59.968 (2.3610 - 2.3609)
Grade No. H 59.968 - 59.967 (2.3609 - 2.3609)
Grade No. J 59.967 - 59.966 (2.3609 - 2.3609)
Grade No. K 59.966 - 59.965 (2.3609 - 2.3608)
Grade No. L 59.965 - 59.964 (2.3608 - 2.3608) LC
Grade No. M 59.964 - 59.963 (2.3608 - 2.3607)
Main journal dia. “Dm” grade
Grade No. N 59.963 - 59.962 (2.3607 - 2.3607)
Grade No. P 59.962 - 59.961 (2.3607 - 2.3607)
Grade No. R 59.961 - 59.960 (2.3607 - 2.3606)
EC
Grade No. S 59.960 - 59.959 (2.3606 - 2.3606)
Grade No. T 59.959 - 59.958 (2.3606 - 2.3605)
Grade No. U 59.958 - 59.957 (2.3605 - 2.3605) FE
Grade No. V 59.957 - 59.956 (2.3605 - 2.3605)
Grade No. W 59.956 - 59.955 (2.3605 - 2.3604)
Grade No. X 59.955 - 59.954 (2.3604 - 2.3604)
Grade No. Y 59.954 - 59.953 (2.3604 - 2.3603)
CL
Grade No. 4 59.953 - 59.952 (2.3603 - 2.3603)
Grade No. 7 59.952 - 59.951 (2.3603 - 2.3603)
Grade No. 0 44.968 - 44.974 (1.7704 - 1.7706)

MT
Pin journal dia. “Dp” Grade No. 1 44.962 - 44.968 (1.7702 - 1.7704)
AT
Grade No. 2 44.956 - 44.962 (1.7699 - 1.7702)
Center distance “r” 36.61 - 36.69 (1.4413 - 1.4445)

AX
Out-of-round (X − Y) Standard Less than 0.002 (0.0001)
Taper (A − B) Standard Less than 0.002 (0.0001)

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

Free end play BR
Limit 0.30 (0.0118)
ST
RS
BT
HA
SEM645 EM715
SC
*: Total indicator reading
EL
IDX
EM-81
EXIT
Available Main Bearing
Available Main Bearing NFEM0039
SEM175F
Identification color
Grade number Thickness “T” mm (in) Width “W” mm (in) Remarks
(UPR/LWR)
0 2.000 - 2.003 (0.0787 - 0.0789) Black
1 2.003 - 2.006 (0.0789 - 0.0790) Brown
2 2.006 - 2.009 (0.0790 - 0.0791) Green
3 2.009 - 2.012 (0.0791 - 0.0792) Yellow Grade is the same for

upper and lower bearings.
4 2.012 - 2.015 (0.0792 - 0.0793) Blue
5 2.015 - 2.018 (0.0793 - 0.0794) Pink
6 2.018 - 2.021 (0.0794 - 0.0796) Purple
7 2.021 - 2.024 (0.0796 - 0.0797) White
UPP 2.003 - 2.006 (0.0789 - 0.0790)

01 Brown/Black
LWR 2.000 - 2.003 (0.0787 - 0.0789)
UPR 2.006 - 2.009 (0.0790 - 0.0791) 19.9 - 20.1

12 Green/Brown
(0.783 - 0.791)
LWR 2.003 - 2.006 (0.0789 - 0.0790)
UPR 2.009 - 2.012 (0.0791 - 0.0792)

23 Yellow/Green
LWR 2.006 - 2.009 (0.0790 - 0.0791)
UPR 2.012 - 2.015 (0.0792 - 0.0793)

Grade is different for upper
34 Blue/Yellow
LWR 2.009 - 2.012 (0.0791 - 0.0792) and lower bearings.
UPR 2.015 - 2.018 (0.0793 - 0.0794)

45 Pink/Blue
LWR 2.012 - 2.015 (0.0792 - 0.0793)
UPR 2.018 - 2.021 (0.0794 - 0.0796)

56 Purple/Pink
LWR 2.015 - 2.018 (0.0793 - 0.0794)
UPR 2.021 - 2.024 (0.0796 - 0.0797)

67 White/Purple
LWR 2.018 - 2.021 (0.0794 - 0.0796)
UNDERSIZE NFEM0039S01
Unit: mm (in)
Thickness Main journal diameter “Dm”
Grind so that bearing clearance is the specified

0.25 (0.0098) 2.132 - 2.140 (0.0839 - 0.0843)
value.
EM-82
EXIT
Available Connecting Rod Bearing
Available Connecting Rod Bearing NFEM0040

CONNECTING ROD BEARING NFEM0040S01
GI
Grade number Thickness “T” mm (in) Identification color (mark)
0 1.500 - 1.503 (0.0591 - 0.0592) Black

MA
1 1.503 - 1.506 (0.0592 - 0.0593) Brown
2 1.506 - 1.509 (0.0593 - 0.0594) Green
UNDERSIZE NFEM0040S02
Unit: mm (in) LC
Thickness Crank pin journal diameter “Dp”
0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643)

Grind so that bearing clearance is the specified EC
value.
Miscellaneous Components NFEM0041

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

CL
Drive plate runout [TIR]* Less than 0.15 (0.0059)
*: Total indicator reading MT

BEARING CLEARANCE NFEM0041S01
Unit: mm (in)
AT
Standard 0.035 - 0.045 (0.0014 - 0.0018)*
Main bearing clearance
Limit 0.065 (0.0026)
AX
Standard 0.034 - 0.059 (0.0013 - 0.0023)*
Connecting rod bearing clearance
Limit 0.070 (0.0028)
SU
*: Actual clearance
BR
ST
RS
BT
HA
SC
EL
IDX
EM-83
EXIT
NOTES

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EXIT

PRECAUTIONS ...............................................................3 CAMSHAFT SPROCKET RUNOUT ...........................43

Parts Requiring Angular Tightening NFEM0001

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

Special Service Tools NFEM0003

ST0501S000 Disassembling and assembling

KV10117000 KV10117000 has been replaced with KV10117001

KV10117001 Installing on the cylinder block

ST10120000 Loosening and tightening cylinder head bolt

KV10116200 Disassembling valve mechanism

KV101151S0 Changing shims

ST16610001 Removing crankshaft pilot bushing AT

Commercial Service Tools NFEM0004

Spark plug wrench Removing and installing spark plug

Valve seat cutter set Finishing valve seat dimensions

Piston ring expander Removing and installing piston ring

Valve guide drift Removing and installing valve guide

(J-43897-18) Reconditioning the exhaust system threads before

Anti-seize lubricant Lubricating oxygen sensor thread cleaning tool

NVH Troubleshooting — Engine Noise NFEM0005S01

Top of Ticking or Tappet

Piston and piston pin

Main bearing oil clear-

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

Removal and Installation NFEM0006

1. EGR valve 4. Thermostat with water inlet 8. Water control valve

Intake Manifold Collector NFEM0006S0107

7. Attach a compression tester to No. 1 cylinder.

Difference limit between

11. If compression in one or more cylinders is low:

4. Remove steel oil pan. SC

5. Remove oil strainer.

6. Remove front exhaust tube and its support.

13. Remove rear cover plate.

14. Remove aluminum oil pan bolts in numerical order. SC

16. Remove aluminum oil pan.

f. Install aluminum oil pan.

2. Install the four engine-to-transaxle bolts. For tightening torque, SC

8. Install crankshaft position sensors (POS and REF) and front

11. Install steel oil pan.

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

I Be sure liquid gasket is 4.5 to 5.5 mm (0.177 to 0.217 in)

7. Remove RH and LH ignition coils. SC

9. Remove intake manifold collector supports and intake manifold

10. Remove fuel tube assembly. Refer to EC-56, “Injector Removal

18. Set No. 1 piston at TDC on the compression stroke by rotat-

28. Remove front timing chain case bolts.

30. Remove internal chain guide.

I Remove timing chain tensioner. (Push piston and insert a suit-

36. Remove exhaust camshaft sprocket 2ND bolts on both sides.

38. Remove lower chain guide.

I Be careful not to confuse intake and exhaust camshaft

8. Remove RH and LH camshaft chain tensioner stopper pins.

20. Apply liquid gasket to water pump cover.

23. Install RH and LH rocker covers.

FRONT OIL SEAL

2. Remove front oil seal using a suitable tool. SC

5. Remove old liquid gasket using scraper.