Engine Mechanical: Section

ENGINE
SECTION
ENGINE MECHANICAL
EM EM
E
CONTENTS
SYMPTOM DIAGNOSIS ............................... 3 Inspection ................................................................14 F
NOISE, VIBRATION AND HARSHNESS AIR CLEANER FILTER ..................................... 15

(NVH) TROUBLESHOOTING ............................. 3 Removal and Installation .........................................15
G
NVH Troubleshooting - Engine Noise .................... 3
SPARK PLUG ................................................... 16
Use the Chart Below to Help You Find the C
Exploded View .........................................................16
ause of the Symptom .............................................. 3
Removal and Installation .........................................16 H
PRECAUTION ............................................... 5 Inspection ................................................................17
PRECAUTIONS ................................................... 5 CAMSHAFT VALVE CLEARANCE .................. 18

Inspection and Adjustment ......................................18 I
Precaution for Procedure without Cowl Top Cover...... 5
Precaution for Supplemental Restraint System COMPRESSION PRESSURE ........................... 23
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
Inspection ................................................................23 J
SIONER" ................................................................... 5
Service Procedure Precautions for Models with a REMOVAL AND INSTALLATION ............... 25
Pop-up Roll Bar ......................................................... 5
Precaution for Battery Service .................................. 6 ENGINE COVER ............................................... 25 K
Precaution Necessary for Steering Wheel Rota- Exploded View .........................................................25
tion after Battery Disconnect ..................................... 6 Removal and Installation .........................................25
Draining Engine Coolant .......................................... 6 L
Disconnecting Fuel Piping ....................................... 6 DRIVE BELT AUTO TENSIONER AND IDLER
Removal and Disassembly ...................................... 6 PULLEY ............................................................. 26
Inspection, Repair and Replacement ...................... 7 Exploded View .........................................................26
Removal and Installation .........................................26 M
Assembly and Installation ........................................ 7
Parts Requiring Angle Tightening ........................... 7
Liquid Gasket ........................................................... 7
AIR CLEANER AND AIR DUCT ....................... 27
Definitions of Bank Names ........................................ 8 Exploded View .........................................................27 N
Removal and Installation .........................................27
PREPARATION ............................................ 9 Inspection ................................................................28
INTAKE MANIFOLD COLLECTOR .................. 29 O

PREPARATION ................................................... 9
Special Service Tools .............................................. 9 Exploded View .........................................................29
Commercial Service Tools ..................................... 10 Removal and Installation .........................................29
P
PERIODIC MAINTENANCE ......................... 13 INTAKE MANIFOLD ......................................... 32
Exploded View .........................................................32
DRIVE BELT .......................................................13 Removal and Installation .........................................32
Exploded View ........................................................ 13 Inspection ................................................................33
Checking ................................................................. 13
Tension Adjustment ................................................ 13 EXHAUST MANIFOLD ...................................... 34
Removal and Installation ......................................... 13 Exploded View .........................................................34
Revision: 2010 March EM-1 2009 G37 Convertible

Removal and Installation ........................................ 34 OIL PAN (UPPER) AND OIL STRAINER .......... 76
Inspection ............................................................... 36 Exploded View ........................................................ 76
Disassembly and Assembly .................................... 76
FUEL INJECTOR AND FUEL TUBE ................. 37 Inspection ................................................................ 78
Exploded View ........................................................ 37
Removal and Installation ........................................ 37 REAR TIMING CHAIN CASE ............................ 79
Inspection ............................................................... 42 Exploded View ........................................................ 79
Disassembly and Assembly .................................... 80
OIL PAN (LOWER) ............................................ 43
Exploded View ........................................................ 43 CAMSHAFT ....................................................... 84
Removal and Installation ........................................ 43 Exploded View ........................................................ 84
Inspection ............................................................... 45 Disassembly and Assembly .................................... 85
Inspection ................................................................ 94
IGNITION COIL, SPARK PLUG AND ROCK-
ER COVER ......................................................... 46 CYLINDER HEAD ............................................. 101
Exploded View ........................................................ 46 Exploded View ...................................................... 101
Removal and Installation ........................................ 46 Disassembly and Assembly .................................. 102
Inspection .............................................................. 107
TIMING CHAIN .................................................. 49
Exploded View ........................................................ 49 CYLINDER BLOCK .......................................... 111
Removal and Installation ........................................ 50 Exploded View ...................................................... 111
Inspection ............................................................... 64 Disassembly and Assembly .................................. 112
Inspection .............................................................. 121
OIL SEAL ........................................................... 66
HOW TO SELECT PISTON AND BEARING .. 132
FRONT OIL SEAL ..................................................... 66 Description ............................................................ 132
FRONT OIL SEAL : Removal and Installation ........ 66 Piston .................................................................... 132
REAR OIL SEAL ....................................................... 66 Connecting Rod Bearing ..................................... 133
REAR OIL SEAL : Removal and Installation .......... 66 Main Bearing ........................................................ 136
UNIT REMOVAL AND INSTALLATION ..... 68 SERVICE DATA AND SPECIFICATIONS

(SDS) ......................................................... 138
ENGINE ASSEMBLY ......................................... 68
Exploded View ........................................................ 68 SERVICE DATA AND SPECIFICATIONS
Removal and Installation ........................................ 68 (SDS) ................................................................ 138
Inspection ............................................................... 71 General Specification ........................................... 138
Drive Belt .............................................................. 138
UNIT DISASSEMBLY AND ASSEMBLY ... 73 Spark Plug ............................................................ 138
Intake Manifold ...................................................... 139
ENGINE STAND SETTING ................................ 73 Exhaust Manifold .................................................. 139
Setting .................................................................... 73 Camshaft ............................................................... 139
ENGINE UNIT .................................................... 75 Cylinder Head ...................................................... 141
Cylinder Block ...................................................... 143
Disassembly ........................................................... 75
Main Bearing ........................................................ 147
Assembly ................................................................ 75
Connecting Rod Bearing ..................................... 148

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
NVH Troubleshooting - Engine Noise INFOID:0000000004924136
EM
JPBIA1048GB
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000004924137
1. Locate the area where noise occurs.

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

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-18
gine clicking noise
Rocker
cover Camshaft Camshaft runout
Cylinder Rattle C A — A B C bearing Camshaft journal oil EM-139
head noise clearance
Piston to piston pin oil

Slap or Piston pin clearance
— A — B B — EM-143
knock noise Connecting rod bushing
oil clearance
Piston to cylinder bore
Crank- clearance
shaft pul- Piston ring side clear-
Slap or Piston
ley A — — B B A ance EM-143
rap slap noise
Cylinder Piston ring end gap
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan EM-143
ing rod oil clearance
Knock A B C B B B
bearing Connecting rod bearing
EM-148
noise oil clearance
Main bearing oil clear- EM-147
Main bear-
Knock A B — A B C ance
ing noise
Crankshaft runout EM-143
Timing
Front of chain and Timing chain cracks
EM-64
engine Tapping or timing and wear
A A — B B B
Timing ticking chain ten- Timing chain tensioner
EM-50
chain case sioner operation
noise
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-13
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water CO-17,
Squall
A B — B A B pump Water pump operation "Exploded
Creak
noise View"
A: Closely related B: Related C: Sometimes related —: Not related

PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Procedure without Cowl Top Cover INFOID:0000000005158185
EM
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
C
PIIB3706J
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT F
PRE-TENSIONER" INFOID:0000000005158193
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along G
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
H
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this
Service Manual.
WARNING: I
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. J
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIR BAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this K
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
L
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) M
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the N
battery, and wait at least 3 minutes before performing any service.
Service Procedure Precautions for Models with a Pop-up Roll Bar INFOID:0000000005158182
O
WARNING:
• Risk of passenger injury or death may increase if the pop-up roll bar does not deploy during a roll
over collision. In order to reduce the chance of an incident where the pop-up roll bar is inoperative, P
all maintenance must be performed by a NISSAN or INFINITI dealer.
• Before removing and installing the pop-up roll bar component parts and harness, always turn the
ignition switch OFF, disconnect the battery negative terminal, and wait for 3 minutes or more. (The
purpose of this operation is to discharge electricity that is accumulated in the auxiliary power supply
circuit in the air bag diagnosis sensor unit.)
• When repairing, removing, and installing a pop-up roll bar, always refer to SRS AIR BAG and SRS
AIR BAG CONTROL warnings in the Service Manual.

PRECAUTIONS
< PRECAUTION >
Precaution for Battery Service INFOID:0000000005158189
Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect
INFOID:0000000005158190
NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi-
tion, then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the push-button ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT-III.
Draining Engine Coolant INFOID:0000000004924142
Drain engine coolant and engine oil when the engine is cooled.
Disconnecting Fuel Piping INFOID:0000000004924143
• Before starting work, chack that no fire or spark producing items are in the work area.
• Release fuel pressure before disconnecting and disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.
Removal and Disassembly INFOID:0000000004924144
• When instructed to use SST, use the specified tools. Always be careful to work safely, and avoid forceful or
uninstructed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Dowel pins are used for the alignment of several parts. When replacing and reassembling parts with dowel
pins, check that dowel pins are installed in the original position.
• Cover openings of engine system with tape or equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.

PRECAUTIONS
< PRECAUTION >
Inspection, Repair and Replacement INFOID:0000000004924145
A
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Assembly and Installation INFOID:0000000004924146
EM
• Use torque wrench to tighten bolts or nuts to specification.

• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the C
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for D
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well. E
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
F
Parts Requiring Angle Tightening INFOID:0000000004924147
• Use the angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts: G
- Cylinder head bolts
- Lower cylinder block bolts
- Connecting rod cap bolts
• Do not use a torque value for final tightening. H
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Liquid Gasket INFOID:0000000004924148
I
REMOVAL OF LIQUID GASKET SEALING

• After removing mounting nuts and bolts, separate the mating sur- J
face using the seal cutter [SST: KV10111100 (J-37228)] (A) and
remove old liquid gasket sealing.
CAUTION: K
Be careful not to damage the mating surfaces.
• Tap the seal cutter [SST: KV10111100 (J-37228)] to insert it (B),
and then slide it (C) by tapping on the side as shown in the figure.
L
• In areas where the seal cutter [SST: KV10111100 (J-37228)] is dif-
ficult to use, lightly tap the parts using a plastic hammer to remove
it.
CAUTION: M
JPBIA0052ZZ
If for some unavoidable reason a tool such as a screwdriver is
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE N
1. Using a scraper (A), remove old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
• Remove liquid gasket completely from the groove of the liquid O
gasket application surface, mounting bolts and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove P
adhering moisture, grease and foreign materials.
JPBIA0053ZZ

PRECAUTIONS
< PRECAUTION >
3. Attach liquid gasket tube to the tube presser (commercial ser-
vice tool).
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-17, "Recommended Chemical Products and Sealants".
4. Apply liquid gasket without gaps to the specified location accord-
ing to the specified dimensions.
• If there is a groove for liquid gasket application, apply liquid
gasket to the groove.
EMA0622D
• As for bolt holes (B), normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Check to read the text of this manual.
A : Groove
: Inside
• Within five minutes of liquid gasket application, install the mat-

ing component.
• If liquid gasket protrudes, wipe it off immediately.
• Do not retighten mounting bolts or nuts after the installation.
JPBIA0010ZZ
• After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe them.
Definitions of Bank Names INFOID:0000000004924149
• In this manual, each bank name is defined as follows:
A : Bank 1 (The conventional right bank)

B : Bank 2 (The conventional left bank)
: Engine front
• For cylinder numbers and bank layout, refer to the illustration.
Bank 1 : The bank side including cylinder No. 1

(odd-numbered cylinder side)
Bank 2 : The other bank side of the above JPBIA1135ZZ
(even-numbered cylinder side)

PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000004924152
EM
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description C
Tool name
KV10116200 Disassembling valve mechanism
(J-26336-A) Part (1) is a component of KV10116200 (J- D
Valve spring compressor 26336-A), but Part (2) is not so.
1. KV10115900
(J-26336-20)
Attachment E
2. KV10109220
( — )
Adapter PBIC1650E
F
KV10107902 Replacing valve oil seal
(J-38959)
Valve oil seal puller
G
H
NT011
KV10115600 Installing valve oil seal

(J-38958) Use side A (G).
I
Valve oil seal drift a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421)
c: 10.3 (0.406) dia. f: 5 (0.20)
H: side B J
Unit: mm (in)
JPBIA0396ZZ
EM03470000 Installing piston assembly into cylinder bore K

(J-8037)
Piston ring compressor
NT044 M
ST16610001 Removing pilot converter
(J-23907)
Pilot bushing puller N
O
NT045
KV10111100 Removing oil pan (lower and upper), front and

(J-37228) rear timing chain case, etc. P
Seal cutter
NT046

PREPARATION
< PREPARATION >
Tool number
(Kent-Moore No.) Description
Tool name
KV10112100 Tightening bolts for connecting rod bearing
(BT8653-A) cap, cylinder head, etc. at an angle
Angle wrench
NT014
KV10114400 Loosening or tightening air fuel ratio sensor 1

(J-38365) a: 22 mm (0.87 in)
Heated oxygen sensor wrench
JPBIA0397ZZ
KV10118600 Removing and installing crankshaft pulley

(J-48641)
Ring gear stopper
JPBIA0409ZZ
Commercial Service Tools INFOID:0000000004924153
(Kent-Moore No.)
Description
Tool name
( — ) Pressing the tube of liquid gasket
Tube presser
NT052
( — ) Loosening nuts and bolts

Power tool
PBIC0190E
( — ) Removing and installing flywheel

TORX socket Size: T55
PBIC1113E

PREPARATION
< PREPARATION >
(Kent-Moore No.)
Description
Tool name A
( — ) Removing and installing engine
Manual lift table caddy
EM
C
ZZA1210D
(J-24239-01) Loosening and tightening cylinder head bolt,

Cylinder head bolt wrench and used with the angle wrench [SST: D
KV10112100 (BT8653-A)]
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
E
Unit: mm (in)
JPBIA0398ZZ
F
( — ) Checking compression pressure
1. Compression gauge
2. Adapter
G
H
ZZA0008D
( — ) Removing and installing spark plug

Spark plug wrench a: 14 mm (0.55 in)
I
JPBIA0399ZZ
( — ) Finishing valve seat (EXH) dimensions K

Valve seat cutter set
NT048 M
( — ) Removing and installing piston ring
Piston ring expander
N
O
NT030
( — ) Removing and installing valve guide (EXH)

Valve guide drift Exhaust: P
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
JPBIA0400ZZ

PREPARATION
< PREPARATION >
(Kent-Moore No.)
Description
Tool name
( — ) A: Reaming valve guide (EXH) inner hole
Valve guide reamer B: Reaming hole for oversize valve guide
(EXH)
Exhaust:
c: 6.0 mm (0.236 in) dia.
d: 10.2 mm (0.402 in) dia.
JPBIA0401ZZ
(J-43897-18) Reconditioning the exhaust system threads

(J-43897-12) before installing a new air fuel ratio sensor and
Oxygen sensor thread cleaner heated oxygen sensor (Use with anti-seize lu-
bricant shown below.)
A: J-43897-18 [18 mm (0.71 in) dia.] for zir-
conia heated oxygen sensor and air fuel
ratio sensor
B: J-43897-12 [12 mm (0.47 in) dia.] for tita-
nia heated oxygen sensor
JPBIA0238ZZ C: Mating surface shave cylinder
D: Flutes
( — ) Lubricating oxygen sensor thread cleaning
Anti-seize lubricant (Permatex 133AR tool when reconditioning exhaust system
or equivalent meeting MIL specifica- threads
tion MIL-A-907)
AEM489
( — ) Inspection valve clearance (Use a curved-tip

Feeler gauge gauge)
JPBIA1362ZZ

DRIVE BELT
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE A
DRIVE BELT
Exploded View INFOID:0000000004924155
EM
JPBIA1060ZZ
H
1. Power steering oil pump 2. Alternator 3. Drive belt auto-tensioner
4. Idler pulley 5. Crankshaft pulley 6. A/C compressor
7. Idler pulley 8. Drive belt 9. Idler pulley I
A. Possible use range B. Range when new drive belt is installed C. Indicator
D. View D
J
Checking INFOID:0000000004924156
WARNING:
K
Be sure to perform the this step when engine is stopped.
• Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range
(A).
NOTE: L
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the fig-
ure. M
• Visually check the entire drive belt for wear, damage or crack.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
Tension Adjustment INFOID:0000000004924157 N
Refer to EM-138, "Drive Belt".

Removal and Installation INFOID:0000000004924158 O
REMOVAL
1. Remove engine undercover with power tool. P

DRIVE BELT
2. While securely holding the square hole (A) in pulley center of
auto tensioner (1) with a spinner handle, move spinner handle in
the direction of arrow (loosening direction of drive belt).
CAUTION:
Never place hand in a location where pinching may occur if
the holding tool accidentally comes off.
: Loosening direction of drive belt
3. Under the above condition, insert a metallic bar of approximately

6 mm (0.24 in) in diameter [hexagonal wrench (C) shown as
JPBIA0003ZZ
example in the figure] through the holding boss (B) to lock auto-
tensioner pulley arm.
4. Remove drive belt.

INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Check drive belt is securely installed around all pulleys.
• Check drive belt is correctly engaged with the pulley groove.
• Check for engine oil and engine coolant are not adhered drive belt and pulley groove.
Inspection INFOID:0000000004924159
INSPECTION AFTER INSTALLATION

• Turn crankshaft pulley clockwise several times to equalize tension between each pulley, and then confirm
tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to EM-13,
"Exploded View".

AIR CLEANER FILTER
AIR CLEANER FILTER
A
Removal and Installation INFOID:0000000004924163
REMOVAL EM
1. Unhook clips (A).
1 : Holder C
2 : Air cleaner case
E
JPBIA1597ZZ
2. Remove holder (3) from air cleaner case (2), and then remove F
air cleaner filter (1) from holder.
JPBIA1598ZZ I
INSTALLATION
Note the following, and install in the reverse order of removal. J
• Install the air cleaner filter by aligning the seal with the notch of air cleaner case.

SPARK PLUG
SPARK PLUG
JPBIA2803GB
1. PCV hose 2. Clamp 3. PCV valve

4. O-ring 5. Clamp 6. PCV hose
7. Ignition coil 8. Spark plug 9. Rocker cover (bank 1)
10. Oil filler cap 11. Rocker cover gasket (bank 1) 12. Clamp
13. PCV hose 14. PCV hose 15. Rocker cover gasket (bank 2)
16. Rocker cover (bank 2)
A. To intake manifold collector B. To air duct C. VVEL ladder assembly side
Tightening must be done following
D. the installation procedure.
Refer to EM-46
Refer to GI-4, "Components" for symbols in the figure.
REMOVAL
1. Remove engine cover with power tool. Refer to EM-25, "Exploded View".
2. Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View".
3. Remove electric throttle control actuator. Refer to EM-29, "Exploded View".
4. Remove ignition coil. Refer to EM-46, "Removal and Installation".

SPARK PLUG
5. Remove spark plug with a spark plug wrench (commercial ser-
vice tool). A
a : 14 mm (0.55 in)
EM
JPBIA0030ZZ
D
INSTALLATION
Installation is the reverse order of removal.
E
INSPECTION AFTER REMOVAL

Use the standard type spark plug for normal condition. F
Spark plug (Standard type) : Refer to EM-138, "Spark Plug".

G
CAUTION:
• Never drop or shock spark plug.
• Never use a wire brush for cleaning.
• If plug tip is covered with carbon, use spark plug cleaner to H
clean.
Cleaner air pressure I

2
: Less than 588 kPa (6 kg/cm , 85 psi)
Cleaning time
J
: Less than 20 seconds
SMA773C
• Spark plug gap adjustment is not required between replace- K

ment intervals.
• Measure spark plug gap. When it exceeds the limit, replace
spark plug even if it is within the specified replacement mile- L
age. Refer to EM-138, "Spark Plug".
JPBIA0031ZZ
N

CAMSHAFT VALVE CLEARANCE
Inspection and Adjustment INFOID:0000000004924169
INSPECTION
Check valve clearance if applicable to the following cases:
Intake side:
• At the removal and installation of VVEL ladder assembly or valve-related parts, or at the occurrence of mal-
function (poor starting, idle malfunction, unusual noise) due to aged deterioration in valve clearance.
CAUTION:
Valve clearance check on the intake side is not required after replacing the VVEL ladder assembly and
cylinder head assembly with a new one. (Install new VVEL ladder assembly and cylinder head assem-
bly in factory-shipped condition because it is factory-adjusted and inspected.)
NOTE:
VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder
head assembly.
Exhaust side:
• At the removal, installation, and replacement of camshaft (EXH) or valve-related parts, or at the occurrence
of malfunction (poor starting, idle malfunction, unusual noise) due to aged deterioration in valve clearance.
1. Remove rocker covers (bank 1 and bank 2). Refer to EM-46, "Removal and Installation".
2. Measure the valve clearance as follows:
• Use the feeler gauge (commercial service tool) of curved-tip. This allows the feeler gauge to access the
clearance between camshaft and valve lifter with ease.
Valve clearance : Refer to EM-139, "Camshaft".

NOTE:
Be sure to note the following points when measuring valve clearance on the intake side.
• Before measuring, check that the position of drive shaft nose
is within the angle shown in the figure.
A : Bank 1
B : Feeler gauge (commercial service tool)
D : View D
c : 45 degrees (drive shaft nose angle)
: Insertion direction of feeler gauge on the bank 1
: Insertion direction of feeler gauge on the bank 2
• Refer to the illustration for the insertion direction of the feeler

gauge since the direction depends on the bank.
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a. Set No. 1 cylinder at TDC of its compression stroke.

• Rotate crankshaft pulley clockwise to align timing mark
(grooved line without color) with timing indicator. A
: Timing mark (grooved line without color)

EM
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D
• Check that exhaust cam nose on No. 1 cylinder (engine front
side of bank 1) is located as shown in the figure.
E
1 : Camshaft (EXH) (bank 1)
: Engine front
• If not, turn crankshaft one revolution (360 degrees) and align F

as shown in the figure.
G
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• By referring to the figure, measure the valve clearances at H

locations marked “×” as shown in the table below (locations
indicated in the figure).
I
: Engine front
• No. 1 cylinder at compression TDC

J
Measuring position [bank 1 (A)] No. 1 CYL. No. 3 CYL. No. 5 CYL.
No. 1 cylinder at com- EXH × (C)

pression TDC
K
INT × (D)
Measuring position [bank 2 (B)] No. 2 CYL. No. 4 CYL. No. 6 CYL.
No. 1 cylinder at com- INT × (E) L

pression TDC EXH × (F)
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b. Rotate crankshaft 240 degrees clockwise (when viewed from engine front) to align No. 3 cylinder at TDC O
its compression stroke.
NOTE:
P

Mark a position 240 degrees (b) from a corner of the hexagonal
part of crankshaft pulley mounting bolt as shown in the figure.
Use the hexagonal part as a guide.
1 : Crankshaft pulley
A : Paint mark
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• By referring to the figure, measure the valve clearances at

locations marked “×” as shown in the table below (locations
: Engine front
Measuring position [bank 1 (A)] No. 1 CYL. No. 3 CYL. No. 5 CYL.
No. 3 cylinder at com- EXH × (C)

pression TDC INT × (D)
No. 3 cylinder at com- INT × (E)

pression TDC EXH × (F)
JPBIA1335ZZ
c. Rotate crankshaft 240 degrees clockwise (when viewed from engine front) to align No. 5 cylinder at TDC
of compression stroke.
NOTE:
Mark a position 240 degrees (b) from a corner of the hexagonal
part of crankshaft pulley mounting bolt as shown in the figure.
Use the hexagonal part as a guide.
A : Paint mark
JPBIA0166ZZ

• By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below (locations A
: Engine front
EM
Measuring position [bank 1 (A)] No. 1 CYL. No. 3 CYL. No. 5 CYL. C
No. 5 cylinder at EXH × (C)

compression TDC INT × (D)
D
No. 5 cylinder at INT × (E)

compression TDC EXH × (F) E
G
JPBIA1336ZZ
3. Perform adjustment or replacement if the measured value is out of the standard.

• If a valve clearance on the exhaust side is out of specification, adjust the valve clearance. H
• If a valve clearance on the intake side is out of specification, replace VVEL ladder assembly and cylin-
der head assembly. Refer to EM-84, "Exploded View" and EM-101, "Exploded View".
CAUTION:
I
Never adjust valve clearance on the intake side.
NOTE:
Since the valve lifter (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head
assembly replacement are required. J
CAMSHAFT (EXH) VALVE CLEARANCE ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter (EXH).
K
1. Measure the valve clearance. Refer to “INSPECTION”.
2. Remove VVEL ladder assembly and camshaft (EXH). Refer to EM-85, "Disassembly and Assembly".
CAUTION:
Never loosen adjusting bolts and mounting bolts (black color) of VVEL ladder assembly. L
3. Remove valve lifter (EXH) at the locations that are out of the standard.
4. Measure the center thickness of the removed valve lifters (EXH)
with a micrometer (A). M
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P
5. Use the equation below to calculate valve lifter (EXH) thickness for replacement.
Valve lifter (EXH) thickness calculation: t = t1 + (C1 – C2)

t = Valve lifter (EXH) thickness to be replaced
t1 = Removed valve lifter (EXH) thickness

C1 = Measured valve clearance
C2 = Standard valve clearance:
Exhaust : 0.33 mm (0.013 in)
• Thickness of new valve lifter (EXH) can be identified by stamp
marks on the reverse side (inside the cylinder).
Stamp mark 788 indicates 7.88 mm (0.3102 in) in thickness.
A : Stamp
B : Thickness of valve lifter (EXH)
JPBIA0170ZZ
Available thickness of valve lifter (EXH): 27 sizes with range 7.88 to 8.40 mm (0.3102 to 0.3307 in) in
steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-139, "Camshaft".
6. Install selected valve lifter (EXH).
7. Install VVEL ladder assembly and camshaft (EXH). Refer to EM-85, "Disassembly and Assembly".
8. Manually turn crankshaft pulley a few turns.
9. Check that the valve clearances for cold engine are within the specifications by referring to the specified
values. Refer to EM-18, "Inspection and Adjustment".
10. Install all removed parts in the reverse order of removal.
11. Warm up the engine, and check for unusual noise and vibration.

COMPRESSION PRESSURE
A
1. Warm up engine thoroughly. Then, stop it. EM

2. Release fuel pressure. Refer to EC-607, "Inspection".
3. Disconnect fuel pump fuse (1) from IPDM E/R (2) to avoid fuel
injection during measurement. C
JMBIA0021ZZ
F
5. Remove ignition coil and spark plug from each cylinder. Refer to EM-46, "Exploded View".
6. Connect engine tachometer (not required in use of CONSULT-III). G
7. Install compression gauge with an adapter (commercial service
tool) onto spark plug hole.
H
J
PBIC0900E
• Use the adapter whose picking up end inserted to spark plug K

hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.
L
a : 20 mm (0.79 in)
N
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8. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each O
cylinder.
Compression pressure : Refer to EM-138, "General Specification".

P
CAUTION:
• Measure a six-cylinder under the same conditions since a measurement depends on measure-
ment conditions (engine water temperature, etc.).
• Always use a fully charged battery to obtain the specified engine speed.
• If the engine speed is out of the specified range, check battery liquid for proper gravity. Check the
engine speed again with normal battery gravity.

• If compression pressure is below the minimum value, check valve clearances and parts associated with
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, and cylinder
head gasket). After checking, measure compression pressure again.
• If a cylinder has low compression pressure, pour a small amount of engine oil into the spark plug hole of
the cylinder to recheck it for compression.
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-
ton rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
• If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
9. After inspection is completed, install removed parts.
10. Start the engine, and check that the engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-132, "Description".

ENGINE COVER
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION A
ENGINE COVER
EM
1 : Engine cover C
JPBIA1049GB I
J
REMOVAL
Loosen mounting bolts and nuts in the reverse order as shown in the
figure, and then remove engine cover.
CAUTION: K
Never damage or scratch engine cover when installing or
removing.
L
JPBIA1785ZZ
INSTALLATION N
Install engine cover, and then tighten mounting bolts and nuts in
numerical order as shown in the figure.
CAUTION: O
Never damage or scratch engine cover when installing or
removing.
JPBIA1785ZZ

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
JPBIA1059GB
1. Front timing chain case 2. Idler pulley 3. Drive belt auto-tensioner

4. Idler pulley 5. Idler pulley
REMOVAL
1. Remove drive belt. Refer to EM-13, "Exploded View".
• Keep auto-tensioner pulley arm locked after drive belt is removed.
2. Remove auto-tensioner and idler pulley.
• Keep auto-tensioner pulley arm locked to install or remove auto-tensioner.
INSTALLATION
Install in the reverse order of removal.
CAUTION:
If there is damage greater than peeled paint, replace drive belt auto-tensioner.

AIR CLEANER AND AIR DUCT
A
EM
I
JPBIA2730GB
1. Mass air flow sensor (bank 1) 2. Air cleaner filter 3. Holder J

4. Bracket 5. Air dust side duct (RH) 6. Resonator (RH)
7. Bracket 8. Grommet 9. Clamp
10. PCV hose 11. Grommet 12. Air cleaner case (RH) K
13. Clamp 14. Air duct (RH) 15. Air duct (LH)
16. Clamp 17. PCV hose 18. Air cleaner case (LH)
19. Air dust side duct (LH) 20. Bracket 21. Resonator (LH) L
22. Bracket 23. Mass air flow sensor (bank 2)
A. To electric throttle control actuator B. To rocker cover (bank 1) C. To rocker cover (bank 2)
Refer to GI-4, "Components" for symbols in the figure. M
N
REMOVAL
NOTE:
Mass air flow sensor is removable under the car-mounted condition.
O
1. Disconnect mass air flow sensor harness connector.
2. Disconnect PCV hose.
3. Remove air cleaner case and mass air flow sensor assembly and air duct and air hose by disconnecting P
their joints.
• Add marks if necessary for easier installation.
4. Remove mass air flow sensor from air cleaner case, if necessary.
CAUTION:
Handle mass air flow sensor according to the following instructions.
• Never shock the mass air flow sensor.
• Never disassemble the mass air flow sensor.

• Never touch the sensor of the mass air flow sensor.
INSTALLATION
• Align marks. Attach each joint. Screw clamps firmly.

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

INTAKE MANIFOLD COLLECTOR
A
EM
J
JPBIA1356GB
EVAP canister purge control solenoid K

1. 2. Clamp 3. EVAP hose
valve
4. EVAP hose 5. Clamp 6. Water hose
7. Water hose 8. Electric throttle control actuator (bank 1) 9. Gasket L
10. PCV hose 11. Clamp 12. PCV hose
13. Intake manifold collector 14. Gasket 15. Water hose
16. Water hose 17. Electric throttle control actuator (bank 2) 18. EVAP hose M
Manifold absolute Pressure (MAP) sen-
19. 20. EVAP tube assembly 21. EVAP hose
sor
A. To vacuum pipe B. To brake booster C. To water outlet (rear) N
D. To PCV valve E. To heater pipe
O
REMOVAL
P
WARNING:
Never drain engine coolant when the engine is hot to avoid the danger of being scalded.
3. Remove electric throttle control actuator as follows:
a. Drain engine coolant. When water hoses are disconnected, attach plug to prevent engine coolant leak-
age.

CAUTION:
• Perform this step when engine is cold.
• Never spill engine coolant on drive belt.
b. Disconnect water hoses from electric throttle control actuator. When engine coolant is not drained from
radiator, attach plug to water hoses to prevent engine coolant leakage.
c. Disconnect harness connector.
d. Loosen mounting bolts in reverse order as shown in the figure.
NOTE:
• When removing only intake manifold collector, move electric
throttle control actuator without disconnecting the water hose.
• The figure shows the electric throttle control actuator (bank 1)
viewed from the air duct side.
• Viewed from the air duct side, the order of loosening mounting
bolts of electric throttle control actuator (bank 2) is the same
as that of the electric throttle control actuator (bank 1).
CAUTION:
Handle carefully to avoid any shock to electric throttle con-
JPBIA0011ZZ
trol actuator.
4. Disconnect vacuum hose, PCV hose, and EVAP hose from intake manifold collector.
5. Remove EVAP canister purge volume control solenoid valve and EVAP tube assembly from intake mani-
fold collector.
6. Loosen mounting bolts and nuts with power tool in the reverse
order as shown in the figure to remove intake manifold collector.
: Engine front
JPBIA1353ZZ
INSTALLATION
• If stud bolts were removed, install them and tighten to the torque specified below.
: 10.8 N·m (1.1 kg-m, 8 ft-lb)

• Tighten mounting bolts and nuts in numerical order as shown in the
figure.
: Engine front
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WATER HOSE
• Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.
• Clamp hose at location of 3 to 7 mm (0.12 to 0.28 in) from hose end.
ELECTRIC THROTTLE CONTROL ACTUATOR (BANK 1 AND BANK 2)

• Tighten in numerical order as shown in the figure.
NOTE: A
• The figure shows the electric throttle control actuator (bank 1)
viewed from the air duct side.
• Viewed from the air duct side, the order of tightening mounting
EM
bolts of electric throttle control actuator (bank 2) is the same as
that of the electric throttle control actuator (bank 1).
• Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is disconnected. C
Refer to EC-18, "THROTTLE VALVE CLOSED POSITION
LEARNING : Description".
JPBIA0011ZZ
• Perform the “Idle Air Volume Learning” and “Throttle Valve Closed D
Position Learning” when electric throttle control actuator is replaced. Refer to EC-19, "IDLE AIR VOLUME
LEARNING : Description" and EC-18, "THROTTLE VALVE CLOSED POSITION LEARNING : Description".

INTAKE MANIFOLD
INTAKE MANIFOLD
JPBIA1350GB
1. Intake manifold 2. Gasket

A. the installation procedure.
Refer to EM-32
REMOVAL
2. Remove intake manifold collector. Refer to EM-29, "Exploded View".
3. Remove fuel tube and fuel injector assembly. Refer to EM-37, "Exploded View".
4. Loosen mounting bolts in reverse order as shown in the figure to
remove intake manifold with power tool.
: Engine front
CAUTION:
• Cover engine openings to avoid entry of foreign materi-
als.
• Put a mark on the intake manifold and the cylinder head
with paint before removal because they need to be
installed in the specified direction.
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5. Remove gaskets.
INSTALLATION
INTAKE MANIFOLD
: 10.8 N·m (1.1 kg-m, 8 ft-lb)

INTAKE MANIFOLD
• Tighten all mounting bolts to the specified torque in two or more
steps in numerical order as shown in the figure. A
: Engine front
CAUTION: EM
• Install intake manifold with the marks (put on the intake
manifold and the cylinder head before removal) aligned.
C
1st step:
: 7.4 N·m (0.75 kg-m, 5 ft-lb) JPBIA1352ZZ
2nd step and after: D

: 25.5 N·m (2.6 kg-m, 19 ft-lb)
E
INSPECTION AFTER REMOVAL F

Surface Distortion
• Check the surface distortion of the intake manifold mating surface
with a straightedge (A) and a feeler gauge (B). G
Limit : Refer to EM-139, "Intake Manifold".

• If it exceeds the limit, replace intake manifold. H
JPBIA1348ZZ

EXHAUST MANIFOLD
EXHAUST MANIFOLD
JPBIA2812GB
1. Heated oxygen sensor 2 (bank 1) 2. Air fuel ratio sensor 1 (bank 1) 3. Exhaust manifold cover (upper)
4. Exhaust manifold (bank 1) 5. Exhaust manifold cover (lower) 6. Gasket
7. Ring gasket 8. Three way catalyst (bank 1) 9. Gasket
10. Heated oxygen sensor 2 (bank 2) 11. Gasket 12. Three way catalyst (bank 2)
13. Ring gasket 14. Exhaust manifold (bank 2) 15. Exhaust manifold cover (lower)
16. Gasket 17. Air fuel ratio sensor 1 (bank 2) 18. Exhaust manifold cover (upper)
REMOVAL
WARNING:
Perform the work when the exhaust and cooling system have completely cooled down.
NOTE:
When removing bank 1 side parts only, steps 1, 4, and 7 are unnecessary.
1. Drain engine coolant. Refer to CO-7, "Draining".
4. Remove water pipe and water hose. Refer to CO-22, "Exploded View".
5. Remove engine undercover with power tool.
6. Remove exhaust front tube and three way catalysts (bank 1 and bank 2). Refer to EX-5, "Exploded View".

EXHAUST MANIFOLD
7. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.
Refer to ST-21, "Exploded View". A
8. Disconnect air fuel ratio sensor 1 (bank 1 and bank 2) harness connectors and remove harness clip.
9. Using the heated oxygen sensor wrench [SST: KV10114400 (J-
38365)] (C), remove air fuel ratio sensor 1 (bank 1 and bank 2). EM
A : Bank 1
B : Bank 2 C
CAUTION:
• Be careful not to damage air fuel ratio sensor 1.
• Discard any air fuel ratio sensor 1 that has been dropped D
onto a hard surface such as a concrete floor. Replace with
a new sensor.
JPBIA2176ZZ
E
10. Remove exhaust manifold cover (upper) (bank 1 and bank 2).
11. Loosen mounting nuts in the reverse order as shown in the fig-
ure to remove exhaust manifold. F
A : Bank 1
B : Bank 2
G
: Engine front
NOTE:
Disregard the numerical order No. 7 and 8 in removal. H
L
JPBIA0017ZZ
12. Remove gaskets. M

CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSTALLATION N
EXHAUST MANIFOLD GASKET
• Install exhaust manifold gasket in direction shown in the figure. O
(Follow the same procedure for both banks.)
A : Bank 1
P
B : Triangle press
C : Bank 2
: Engine front
JPBIA0019ZZ

EXHAUST MANIFOLD
EXHAUST MANIFOLD
Tightening torque : Refer to EM-34, "Exploded View".

• Install exhaust manifold and tighten mounting bolts in numerical
order as shown in the figure.
A : Bank 1
B : Bank 2
: Engine front
NOTE:
Tighten nuts the No. 1 and 2 in two steps. The numerical order No.
7 and 8 shows the second step.
JPBIA0017ZZ
AIR FUEL RATIO SENSOR 1

CAUTION:
• Before installing a new air fuel ratio sensor 1, clean exhaust system threads using heated oxygen
sensor thread cleaner tool (commercial service tool: J-43897-18 or J-43897-12) and apply anti-seize
lubricant.
• Never apply excessive torque to air fuel ratio sensor 1. Doing so may cause damage to air fuel ratio
sensor 1, resulting in the “MIL” illuminating.

Surface Distortion
• Check the surface distortion of the exhaust manifold mating sur-
face with a straightedge (A) and a feeler gauge (B).
Limit : Refer to EM-139, "Exhaust Manifold".

• If it exceeds the limit, replace exhaust manifold.
JPBIA0018ZZ

FUEL INJECTOR AND FUEL TUBE
A
EM
I
JPBIA1169GB
1. Quick connector cap 2. Fuel feed hose (with damper) 3. O-ring J

4. Fuel sub tube 5. O-ring 6. Clip
7. Fuel damper 8. O-ring 9. Fuel tube
10. O-ring (black) 11. Fuel injector 12. Clip K
13. O-ring (green)
A. the installation procedure. L
Refer to EM-37
CAUTION: M
Never remove or disassemble parts unless instructed as shown in the figure.
N
REMOVAL
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop. O
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
• Never drain engine coolant when the engine is hot to avoid the danger of being scalded. P
2. Disconnect battery cable from the negative terminal. Refer to PG-100, "Exploded View".

6. Remove fuel feed hose (with damper) (1) from fuel sub-tube (2)
and remove harness bracket (3).
: Engine front
NOTE:
There is no fuel return route.
CAUTION:
• While hoses are disconnected, plug them to prevent fuel
from draining.
• Never separate damper and hose.
JPBIA0032ZZ
7. When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect
quick connector as follows:
a. Remove quick connector cap (2) from quick connector connec-
tion on right member side.
b. Disconnect fuel feed hose (with damper) (1) from bracket hose
clamp.
JPBIA0254ZZ
c. Push in retainer tabs (2).

d. Draw and pull out quick connector (1) straight from centralized
under-floor piping (3).
CAUTION:
• Pull quick connector holding (A) position as shown in the
figure.
• Never pull with lateral force applied. O-ring inside quick
connector may be damaged.
• Prepare container and cloth beforehand because fuel will
leakage out.
• Avoid fire and sparks. JPBIA1854ZZ
• Keep parts away from heat source. Especially, be careful
when welding is performed around them.
• Never expose parts to battery electrolyte or other acids.
• Never bend or twist connection between quick connector and fuel feed hose (with damper) dur-
ing installation/removal.
• To keep the connecting portion clean and to avoid dam-
age and foreign materials, cover them completely with
plastic bags, etc. (A) or a similar item.
JPBIA0035ZZ
8. Remove fuel sub tube mounting bolt.

9. Disconnect harness connector from fuel injector.

10. Loosen mounting bolts in reverse order as shown in the figure,
and remove fuel tube and fuel injector assembly. A
: Engine front
CAUTION: EM
Never tilt it, or remaining fuel in pipes may flow out from
pipes.
C
JPBIA1170ZZ
D
11. Remove fuel injector (2) from fuel tube (4) as follows:
3 : O-ring E
A : Installed condition
B : Clip mounting groove
a. Open and remove clip (1). F
b. Remove fuel injector from fuel tube by pulling straight.
CAUTION:
• Be careful with remaining fuel that may go out from fuel G
tube. JPBIA1359ZZ
• Be careful not to damage injector nozzles during removal.
• Never bump or drop fuel injector. H
• Never disassemble fuel injector.
12. Remove fuel sub-tube and fuel damper, if necessary.

I
INSTALLATION
1. Install fuel damper (4) as follows:
J
2 : Cup
5 : Clip
C : Cut-out
K
a. Install new O-ring (1) to fuel tube as shown. When handling new
O-ring, pay attention to the following caution items:
CAUTION: L
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign M
material.
• When installing O-ring, be careful not to scratch it with
tool or fingernails. Also be careful not to twist or stretch N
O-ring. If O-ring was stretched while it was being
attached, never insert it quickly into fuel tube.
• Insert new O-ring straight into fuel tube. Never twist it.
O
b. Install spacer (3) to fuel damper.
c. Insert fuel damper straight into fuel tube.
CAUTION:
• Insert straight, checking that the axis is lined up. P
JPBIA1171ZZ
• Never pressure-fit with excessive force.
Reference value : 130 N (13.3 kg, 29.2 lb)

• Insert fuel damper until (A) is touching (B) of fuel tube.

d. Install the cut-out (A) of the clip (2) to the projection (B), which
ensures that the fuel tube does not move or rotate.
1 : Fuel tube
e. Unlock the clip after checking that the rib of the cup and the brim
of the fuel damper are mated each other and positioned in the
holes (C) of the clip.
JPBIA1172ZZ
f. Check that the opening (B) and the slit (C) of the clip are posi-
tioned and fixed properly so it does not rotate or pull out.
A : Under view
JPBIA1173ZZ
2. Install fuel sub-tube.

• When handling new O-rings, be careful of the following caution items:
CAUTION:
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not
to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it
quickly into fuel tube.
• Insert new O-ring straight into fuel tube. Never decenter or twist it.
• Insert fuel sub-tube straight into fuel tube.
• Tighten mounting bolts evenly in turn.
• After tightening mounting bolts, Check that there is no gap between flange and fuel tube.
3. Install new O-rings to fuel injector, paying attention to the following items.
CAUTION:
• Upper and lower O-ring are different. Be careful not to confuse them.
Fuel tube side : Black

Nozzle side : Green
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly
into fuel tube.
• Insert O-ring straight into fuel injector. Never decenter or twist it.

4. Install fuel injector to fuel tube as follows:
A
2 : O-ring (Black)
4 : O-ring (Green)
a. Insert clip (3) into clip mounting groove (F) on fuel injector (5). EM
CAUTION:
• Never reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If C
interference occurs, replace O-ring.
• Insert clip so that protrusion (E) of fuel injector matches
cut-out (C) of clip.
D
b. Insert fuel injector into fuel tube (1) with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (A) of fuel tube matches
cutout (B) of clip. E
• Check that fuel tube flange (G) is securely fixed in flange fixing
groove (D) on clip.
c. Check that installation is complete by checking that fuel injector F
does not rotate or come off.
• Check that protrusions of fuel injectors and fuel tube are
aligned with cutouts of clips after installation.
G
JPBIA1358ZZ
5. Install fuel tube and fuel injector assembly to intake manifold.

CAUTION: H
Be careful not to let tip of injector nozzle come in contact with other parts.
• Tighten mounting bolts in two steps in numerical order as
shown in the figure. I
: Engine front
J
1st step: 10.1 N·m (1.0 kg-m, 7 ft-lb)
2nd step: 23.6 N·m (2.4 kg-m, 17 ft-lb)
K
JPBIA1170ZZ
L
6. Connect injector sub-harness.
7. Install fuel sub tube mounting bolt.
8. Connect fuel feed hose (with damper). M
• Handling procedure of O-ring is the same as that of fuel damper and fuel sub-tube.
• Insert fuel damper straight into fuel sub-tube.
• Tighten mounting bolts evenly in turn.
• After tightening mounting bolts, check that there is no gap between flange and fuel sub-tube. N
9. Connect quick connector between fuel feed hose (with damper) and centralized under-floor piping con-
nection as follows:
a. Check that no foreign substances are deposited in and around centralized under-floor piping and quick O
connector, and that there is no damage to them.
b. Thinly apply new engine oil around centralized under-floor piping from tip end to spool end.
c. Align center to insert quick connector straightly into centralized under-floor piping. P
• Insert quick connector to centralized under-floor piping until top spool is completely inside quick connec-
tor and 2nd level spool exposes right below quick connector.
CAUTION:
• Hold align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.
• Insert until you hear a “click” sound and actually feel the engagement.
• To avoid misidentification of engagement with a similar sound, be sure to perform the next step.

d. Pull quick connector by hand holding position (A). Check it is
completely engaged (connected) so that it does not come out
from centralized under-floor piping (1).
PBIC3795E
e. Install quick connector cap (3) to quick connector connection.
1 : Centralized under-floor piping

2 : Fuel feed hose
B : Under view
• Install quick connector cap with arrow (A) on surface facing in
direction of quick connector (fuel feed hose side).
CAUTION:
If quick connector cap cannot be installed smoothly, quick
connector may have not been installed correctly. Check the
connection again. JPBIA0039ZZ
10. Install in the reverse order of removal after this step.


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

OIL PAN (LOWER)
OIL PAN (LOWER)
A
EM
L
JPBIA1401GB
1. Oil level gauge 2. Oil level gauge guide 3. O-ring M

4. O-ring 5. Connector bolt 6. Oil filter
7. Relief valve 8. Oil pressure switch 9. Oil strainer
10. Oil temperature sensor 11. Washer 12. Oil pan (upper) N
13. Drain plug 14. Drain plug washer 15. Oil pan (lower)
16. Rear plate cover 17. Rear cover plate (M/T models)
A. Refer to LU-9 B. To oil pump C. Oil pan side O

P
REMOVAL
CAUTION:
Never drain engine oil when the engine is hot to avoid the danger of being scalded.
2. Remove oil pan (lower) as follows:

OIL PAN (LOWER)
a. Loosen mounting bolts in reverse order as shown in the figure to
remove.
: Engine front
JPBIA0021ZZ
b. Insert the seal cutter [SST: KV10111100 (J-37228)] (A) between

oil pan (upper) and oil pan (lower).
CAUTION:
• Be careful not to damage the mating surfaces.
• Never insert a screwdriver. This damages the mating sur-
faces.
c. Slide the seal cutter by tapping on the side of tool with a ham-
mer. Remove oil pan (lower).
JPBIA0276ZZ
INSTALLATION
1. Install oil pan (lower) as follows:
a. Use scraper (A) to remove old liquid gasket from mating sur-
faces.
• Remove old liquid gasket from the bolt holes and thread.
CAUTION:
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
JPBIA0025ZZ
b. Apply a continuous bead of liquid gasket with the tube presser

(commercial service tool) to the oil pan (lower) as shown in the
figure.
a : φ4.0 - 5.0 mm (0.157 - 0.197 in)

: Engine front

CAUTION:
Attaching should be done within 5 minutes after coating.
JPBIA1556ZZ
c. Install oil pan (lower).

OIL PAN (LOWER)
• Tighten mounting bolts in numerical order as shown in the fig-
ure. A
: Engine front
EM
JPBIA0021ZZ
D
2. Install oil pan drain plug.
• Refer to the figure of the components of on the prior page for installation direction of drain plug washer.
Refer to EM-43, "Exploded View". E
NOTE:
Wait at least 30 minutes after oil pan is installed before pouring engine oil.
F
INSPECTION AFTER REMOVAL G

Clean oil strainer if any object is attached.
H
1. Check the engine oil level and adjust engine oil. Refer to LU-6, "Inspection".
2. Start engine, and check there is no leakage of engine oil.
3. Stop engine and wait for 10 minutes. I
4. Check the engine oil level again. Refer to LU-6, "Inspection".

IGNITION COIL, SPARK PLUG AND ROCKER COVER
JPBIA2803GB
1. PCV hose 2. Clamp 3. PCV valve

4. O-ring 5. Clamp 6. PCV hose
7. Ignition coil 8. Spark plug 9. Rocker cover (bank 1)
10. Oil filler cap 11. Rocker cover gasket (bank 1) 12. Clamp
13. PCV hose 14. PCV hose 15. Rocker cover gasket (bank 2)
16. Rocker cover (bank 2)
A. To intake manifold collector B. To air duct C. VVEL ladder assembly side
D. the installation procedure.
Refer to EM-46
REMOVAL
1. Remove the following parts:
• Engine cover: Refer to EM-25, "Exploded View".
• Air cleaner case and air duct (RH and LH): Refer to EM-27, "Exploded View".
• Intake manifold collector: Refer to EM-29, "Exploded View".
2. Disconnect PCV hose from rocker cover.
3. Remove PCV valve and O-ring from rocker cover, if necessary.
4. Remove oil filler cap from rocker cover, if necessary.
5. Remove ignition coil.
CAUTION:
Never shock ignition coil.
6. Remove harness clips on the rocker cover.

7. Loosen mounting bolts with power tool in reverse order as
shown in the figure. A
A : Bank 1
B : Bank 2 EM
: Engine front
G
JPBIA2423ZZ
8. Remove rocker cover gasket from rocker cover.

9. Use scraper to remove all traces of liquid gasket from cylinder head and VVEL ladder assembly. H
CAUTION:
Never scratch or damage the mating surface when cleaning off old liquid gasket.
INSTALLATION I
1. Apply liquid gasket to the position shown in the figure with the
following procedure:
J
2 : Actuator bracket (rear)
3 : VVEL actuator sub assembly
A : Liquid gasket application point K
F : View F
I : End surface of VVEL ladder assembly
b : 4 mm (0.16 in) L
c : φ2.5 - 3.5 mm (0.098 - 0.138 in)
d : 5 mm (0.20 in)
g : 10 mm (0.39 in) M
: Engine front
a. Refer to figure (E) to apply liquid gasket to joint part of VVEL lad- N
der assembly (1) and cylinder head.
b. Refer to figure (H) to apply liquid gasket in 90 degrees to figure.
O
JPBIA1347ZZ P
2. Install rocker cover gasket to rocker cover.

3. Install rocker cover.
• Check that rocker cover gasket does not drop from the installation groove of rocker cover.

4. Tighten bolts in two steps separately in numerical order as
shown in the figure.
A : Bank 1
B : Bank 2
: Engine front
1st step: 2.0 N·m (0.20 kg-m, 18 in-lb)

2nd step: 8.3 N·m (0.85 kg-m, 73 in-lb)
JPBIA2423ZZ

TIMING CHAIN
TIMING CHAIN
A
EM
JPBIA1101GB
1. Timing chain (secondary) (bank 1) 2. Camshaft sprocket (EXH) (bank 1) 3. O-ring

4. Timing chain (secondary) (bank 2) 5. Camshaft sprocket (EXH) (bank 2) 6. Internal chain guide
7. Timing chain (primary) 8. Camshaft sprocket (INT) (bank 1) 9. Timing chain tensioner (primary)

TIMING CHAIN
10. Slack guide 11. Crankshaft sprocket 12. Camshaft sprocket (INT) (bank 2)
Intake valve timing control cover
13. Tension guide 14. 15. Seal ring
gasket (bank 1)
Intake valve timing control cover Camshaft position sensor (PHASE)
16. 17. O-ring 18.
(bank 1) (bank 1)
19. Oil level gauge 20. Oil level gauge guide 21. O-ring
Intake valve timing control solenoid Intake valve timing control cover Camshaft position sensor (PHASE)
22. 23. 24.
valve (bank 2) (bank 2) (bank 2)
25. 26. Front oil seal 27. Crankshaft pulley
gasket (bank 2)
Intake valve timing control solenoid
28. Crankshaft pulley bolt 29. 30. Power steering oil pump bracket
valve (bank 1)
31. Idler pulley bracket 32. Alternator bracket 33. Water outlet (front)
34. Front timing chain case 35. Rear timing chain case 36. O-ring
37. O-ring 38. O-ring
Tightening must be done following Tightening must be done following
A. the installation procedure. B. the assembly procedure. C. Oil filter
Refer to EM-50 Refer to EM-80
REMOVAL
1. Release the fuel pressure. Refer to EC-607, "Inspection".
2. Disconnect the battery cable from the negative terminal.
4. Remove radiator reservoir tank. Refer to CO-12, "Exploded View".
5. Remove air duct and air cleaner case assembly (RH and LH). Refer to EM-27, "Exploded View".
7. Drain engine coolant from radiator. Refer to CO-7, "Draining".
CAUTION:
• Perform this step when the engine is cold.
8. Remove radiator hose (upper and lower). Refer to CO-12, "Exploded View".
9. Drain engine oil. Refer to LU-7, "Draining".
CAUTION:
Perform this step when the engine is cold.
10. Remove radiator cooling fan assembly. Refer to CO-12, "Exploded View".
11. Remove drive belt. Refer to EM-13, "Removal and Installation".
12. Separate engine harnesses by removing their brackets from front timing chain case.
14. Remove fuel sub tube mounting bolt. Refer to EM-37, "Exploded View".
15. Remove oil level gauge and oil level gauge guide.
16. Remove A/C compressor from bracket with piping connected, and temporarily secure it aside. Refer to
HA-38, "Exploded View".
17. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
Refer to ST-31, "EXCEPT FOR SPORT MODELS : Exploded View" or ST-36, "SPORT MODELS :
Exploded View".
18. Remove power steering oil pump bracket.
19. Remove idler pulley, drive belt auto-tensioner and bracket. Refer to EM-26, "Exploded View".
20. Remove alternator and alternator bracket. Refer to CHG-26, "Exploded View".
21. Remove water pipe. Refer to CO-22, "Exploded View".

TIMING CHAIN
22. Remove camshaft position sensor (PHASE).
A
A : Keep free from magnetic materials
CAUTION:
• Handle carefully to avoid dropping and shocks. EM
• Never disassemble.
• Never allow metal powder to adhere to magnetic part at
sensor tip.
C
• Never place sensors in a location where they are exposed
to magnetism.
JPBIA0454ZZ
D
23. Remove intake valve timing control covers and gasket as follows:
a. Disconnect intake valve timing control solenoid valve harness connector.
b. Loosen mounting bolts in reverse order as shown in the figure. E
A : Bank 1
B : Bank 2 F
C : Dowel pin hole
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) cen- G
ter hole. When removing, keep it horizontal until it is com-
pletely disconnected.
JPBIA1333ZZ H
c. Shaft is engaged with camshaft sprocket (INT) center hole on inside. Pull straight out so that it does not tilt
until the joint is disengaged. I
24. Remove intake valve timing control solenoid valve, if necessary.
CAUTION:
Intake valve timing control solenoid valve is nonreusable. Never remove it unless required.
J
25. Remove rocker covers (bank 1 and bank 2). Refer to EM-46, "Exploded View".
26. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
a. Rotate crankshaft pulley clockwise to align timing mark (grooved K
line without color) with timing indicator.
: Timing mark (grooved line without color)

L
JPBIA0043ZZ N
b. Check that exhaust cam noses on No. 1 cylinder (engine front

side of bank 1) is located as shown in the figure.
O
: Engine front
P
• If not, turn crankshaft one revolution (360 degrees) and align
JPBIA1127ZZ
27. Remove crankshaft pulley as follows:

TIMING CHAIN
a. Remove rear cover plate and set the ring gear stopper [SST:
KV10118600 (J-48641)] (A) as shown in the figure.
1 : Oil pan (upper)

2 : Flywheel (M/T models) or drive plate (A/T models)
: Vehicle front
JPBIA0408ZZ
b. Loosen crankshaft pulley bolt and rotate bolt seating surface at

10 mm (0.39 in) from its original position.
CAUTION:
Never remove crankshaft pulley bolt because it is used as a
supporting point for suitable puller.
JPBIA1364ZZ
c. Place suitable puller tab on holes of crankshaft pulley, and pull

crankshaft pulley through.
CAUTION:
Never put suitable puller tab on crankshaft pulley periphery,
because this damages internal damper.
JPBIA1368ZZ
28. Remove oil pan (lower). Refer to EM-43, "Exploded View".

29. Loosen two mounting bolts in front of oil pan (upper) with power
tool in reverse order as shown in the figure.
: Engine front
JPBIA0047ZZ
30. Remove front timing chain case as follows:

TIMING CHAIN
a. Loosen mounting bolts in reverse order as shown in the figure.
A
EM
JPBIA0046ZZ
D
b. Insert a suitable tool (A) into the notch at the top of front timing
chain case as shown.
c. Pry off case by moving the suitable tool as shown. E
• Use the seal cutter [SST: KV10111100 (J-37228)] to cut liquid
gasket for removal.
CAUTION:
• Never use a screwdriver or a similar item. F
• After removal, handle front timing chain case carefully so
it does not tilt, cant, or warp under a load.
G
JPBIA0048ZZ
31. Remove front oil seal from front timing chain case using a suit- H
able tool.
• Use a screwdriver for removal.
CAUTION:
I
Be careful not to damage front timing chain case.
JPBIA0049ZZ K
32. Remove O-ring (1) from rear timing chain case. L

A : Bank 1
B : Bank 2
M
JPBIA1111ZZ
O

TIMING CHAIN
33. Remove timing chain tensioner (primary) (1) as follows:
a. Remove lower mounting bolt (A).
b. Loosen upper mounting bolt (B) slowly, and then turn timing
chain tensioner (primary) on the upper mounting bolt so that
plunger (C) is fully expanded.
NOTE:
Even if plunger is fully expanded, it does not drop from the body
of timing chain tensioner (primary).
c. Remove upper mounting bolt, and then remove timing chain ten-
sioner (primary).
JPBIA1537ZZ
34. Remove internal chain guide (1), slack guide (2) and tension
guide (3).
JPBIA1104ZZ
35. Remove timing chain (primary) and crankshaft sprocket.

CAUTION:
After removing timing chain (primary), never turn crankshaft and camshaft separately, or valves
strike the piston heads.
36. Remove timing chain (secondary) and camshaft sprockets as follows:
a. Attach suitable stopper pin (C) to the timing chain tensioners
(secondary) (1), (2).
A : Bank 1
B : Bank 2
NOTE:
• Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a
stopper pin.
• For removal of timing chain tensioners (secondary), refer to
EM-84, "Exploded View". (Removing VVEL ladder assembly is
required.) JPBIA1105ZZ
b. Remove camshaft sprocket (EXH) mounting bolt.

• Secure the hexagonal portion of camshaft (EXH) using a wrench to loosen mounting bolt.
CAUTION:
Never loosen the mounting bolt by securing anything other than the camshaft (EXH) hexagonal
portion or with tensioning the timing chain.

TIMING CHAIN
c. Remove camshaft sprocket (INT) mounting bolt.
• Secure the hexagonal portion (located in between journal No. A
1 and journal No. 2) of drive shaft (A) using a wrench to loosen
mounting bolt.
EM
: Engine front
CAUTION: C
• Never loosen the mounting bolt by securing anything
other than the drive shaft hexagonal portion or with ten-
sioning the timing chain.
JPBIA1332ZZ D
• When holding the hexagonal part of drive shaft on the
intake side with a wrench, be careful not to allow the wrench to cause interference with other
parts.
• Never disassemble camshaft sprocket (INT). [Never E
loosen bolts (A) as shown in the figure.]
JPBIA1106ZZ H
d. Remove timing chain (secondary) together with camshaft sprockets.

37. Use a scraper to remove all traces of old liquid gasket from front I
and rear timing chain cases and oil pan (upper), and liquid gas-
ket mating surfaces.
CAUTION:
Be careful not to allow gasket fragments to enter oil pan. J
JPBIA0050ZZ L
38. Remove old liquid gasket from bolt hole and thread.
M
A : Remove old liquid gasket that is stuck
B : Bolt hole
JPBIA0051ZZ
INSTALLATION P
NOTE:
The figure below shows the relationship between the matching mark on each timing chain and that on the cor-
responding sprocket with the components installed.

TIMING CHAIN
JPBIA1107ZZ
1. Internal chain guide 2. Camshaft sprocket (INT) 3. Timing chain (secondary)

4. Camshaft sprocket (EXH) 5. Timing chain tensioner (primary) 6. Slack guide
7. Timing chain (primary) 8. Crankshaft sprocket 9. Water pump
Timing chain tensioner (secondary) Timing chain tensioner (secondary)
10. Tension guide 11. 12.
(bank 2) (bank 1)
A. Matching mark [punched (back side)] B. Matching mark (yellow link) C. Matching mark (punched)
D. Matching mark (orange link) E. Matching mark (notched) F. Crankshaft key
G. Matching mark (punched)
1. Check that dowel pin (A) and crankshaft key (1) are located as
shown in the figure. (No. 1 cylinder at compression TDC)
NOTE:
Though camshaft does not stop at the position as shown in the
figure, for the placement of cam noses, it is generally accepted
that camshaft is placed in the same direction as that of the fig-
ure.
Camshaft dowel pin

: At cylinder head upper face side in each bank.
JPBIA0094ZZ
Crankshaft key
: At cylinder head side of bank 1.
2. Install timing chains (secondary) and camshaft sprockets as follows:
CAUTION:
Matching marks between timing chain and sprockets slip easily. Confirm all matching mark posi-
tions repeatedly during the installation process.

TIMING CHAIN
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with a stopper pin (A). A
EM
JPBIA0095ZZ
D
b. Install timing chains (secondary) and camshaft sprockets.
A : Camshaft sprocket (INT) back face

E
B : Orange link
C : Dowel groove
D : Matching mark (oval)
F
E : Matching mark (2 oval: on front face)
F : Matching mark (circle)
G : Camshaft sprocket (EXH) back face
G
H : Matching mark (2 circle: on front face)
I : Timing chain (secondary)
NOTE: H
Figure shows bank 1 (rear view).
• Align the matching marks on timing chain (secondary) (orange
link) with the ones on intake and exhaust camshaft sprockets
I
(punched), and install them.
NOTE:
• Matching marks for camshaft sprockets (INT) are on the
back side of camshaft sprockets (secondary). J
• There are two types of matching marks, the circle and oval
types. They should be used for the bank 1 and bank 2,
respectively. JPBIA1109ZZ
K
Bank 1 : Use circle type

Bank 2 : Use oval type L
• Shape (orientation of signal plate) of camshaft sprocket (INT)
varies depending on the bank position. See the right figure to
install. M
A : Bank 1
B : Bank 2
N
O
JPBIA1516ZZ
• Align dowel pin camshafts with the pin groove on sprockets, and install them. P
• In case that positions of each matching mark and each dowel pin do not fit with matching parts, make
fine adjustment to the position holding the hexagonal portion on camshaft (EXH) or drive shaft with
wrench or equivalent tool.
• Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is
sufficient to prevent the dislocation of dowel pins.

TIMING CHAIN
• It may be difficult to visually check the dislocation of matching
marks during and after installation. To make the matching eas-
ier, make a matching mark on the top of sprocket teeth and its
extended line in advance with paint.
A : Matching mark (painted)

B : Matching mark (orange link)
JPBIA1110ZZ
c. Tighten camshaft sprocket (EXH) mounting bolt.

• Secure camshaft (EXH) using a wrench at the hexagonal portion to tighten mounting bolt.
d. After confirming the matching marks are aligned, tighten camshaft sprocket (INT) mounting bolt.
• Secure the hexagonal portion (located in between journal No.
1 and journal No. 2) of drive shaft (A) using a wrench to tighten
mounting bolt.

: Engine front
CAUTION:
When holding the hexagonal part of drive shaft on the
intake side with a wrench, be careful not to allow the
wrench to cause interference with other parts.
JPBIA1332ZZ
e. Pull stopper pins (C) out from timing chain tensioners (second-
ary) (1), (2).
A : Bank 1
B : Bank 2
JPBIA1105ZZ
3. Install timing chain (primary) as follows:

a. Install crankshaft sprocket (1).
A : Matching mark (front side)

: Engine front
• Check that the matching marks on crankshaft sprocket face

the front of the engine.
JPBIA1108ZZ
b. Install timing chain (primary).

TIMING CHAIN
• Install timing chain (primary) so that the matching mark
(punched) (B) on camshaft sprocket (INT) (1) is aligned with A
the yellow link (A) on timing chain, while the matching mark
(notched) (C) on crankshaft sprocket (2) is aligned with the
orange link (D) one on timing chain, as shown in the figure.
EM
3 : Water pump
• When it is difficult to align matching marks of timing chain (pri-
C
mary) with each sprocket, gradually turn drive shaft using
wrench on the hexagonal portion to align it with the matching
marks.
D
G
JPBIA1601ZZ
4. Install internal chain guide (1), slack guide (2), and tension guide H
(3).
N
JPBIA1104ZZ
CAUTION: O

TIMING CHAIN
Never overtighten slack guide mounting bolt (2). It is nor-
mal for a gap (A) to exist under the bolt seats when mount-
ing bolt are tightened to the specification.
1 : Slack guide
3 : Cylinder block
JPBIA0117ZZ
5. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab (A) up (or turn lever downward) so as to
remove plunger stopper tab from the ratchet of plunger (D).
NOTE:
Plunger stopper tab and lever (C) are synchronized.
b. Push plunger into the inside of tensioner body.
c. Hold plunger in the fully compressed position by engaging
plunger stopper tab with the tip of ratchet.
d. To secure lever, insert stopper pin (E) through hole of lever into
tensioner body hole (B).
• The lever parts and the plunger stopper tab are synchronized.
Therefore, the plunger is secured under this condition. JPBIA0118ZZ
NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
e. Install timing chain tensioner (primary) (1).
• Remove any dirt and foreign materials completely from the
back and the mounting surfaces of timing chain tensioner (pri-
mary).
f. Pull out stopper pin (A) after installing, and then release plunger.
JPBIA0119ZZ
6. Check again that the matching marks on sprockets and timing chain have not slipped out of alignment.
7. Install new O-rings (1) on rear timing chain case.
A : Bank 1
B : Bank 2
JPBIA1111ZZ

TIMING CHAIN
8. Install new front oil seal on front timing chain case.
A
: Engine inside
: Engine outside
EM
• Apply new engine oil to both oil seal lip (A) and dust seal lip
(B).
• Install it so that each seal lip is oriented as shown in the figure.
C
JPBIA0054ZZ
D
• Using a suitable drift [outer diameter: 60 mm (2.36 in)] (A),
press-fit oil seal until it becomes flush with front timing chain
case end face. E
• Check that the garter spring is in position and seal lip is not
inverted.
F
G
JPBIA0055ZZ
9. Install front timing chain case as follows: H

• Check that O-rings stay in place during installation to rear timing chain case.
a. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to front timing chain case back side as I
B : Protrusion
J
c : φ3.4 - 4.4 mm (0.134 - 0.173 in)
d : φ2.6 - 3.6 mm (0.102 - 0.142 in)
e : 4.0 - 5.6 mm (0.157 - 0.220 in)
K
L
O
JPBIA1138ZZ

TIMING CHAIN
b. Apply liquid gasket to top surface of oil pan (upper) as shown in
the figure.
A : φ4.0 - 5.0 mm (0.157 - 0.197 in)

Use Genuine RTV Silicone Sealant or equivalent. Refer
toGI-17, "Recommended Chemical Products and Sealants".
JPBIA0056ZZ
c. Assemble front timing chain case.
1 : Front timing chain case

2 : Oil pan (upper)
3 : Cylinder block
: Engine front
CAUTION:
• Be careful not to damage front oil seal by interference
with front end of crankshaft.
• Attaching should be done within 5 minutes after liquid JPBIA0058ZZ
gasket application.
d. Install front timing chain case fitting its dowel pin hole together with dowel pin on rear timing chain case.
e. Tighten mounting bolts to the specified torque in numerical order
• There are two types of mounting bolts. Refer to the following
for locating bolts.
M10 bolts : 1, 2, 3, 4, 5, 6, 7
: 55.0 N·m (5.6 kg-m, 41 ft-lb)
M6 bolts : Except the above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
JPBIA0046ZZ
f. After all bolts are tightened, retighten them to the specified
torque in numerical order shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).
g. Install two mounting bolts in front of oil pan (upper) in numerical
order shown in the figure.
: Engine front
Tightening torque : Refer to EM-76, "Exploded View".
JPBIA0047ZZ
10. Install intake valve timing control covers as follows:

TIMING CHAIN
a. Install new seal rings (1) in shaft grooves.
A
A : Bank 2
CAUTION:
When replacing seal ring, replace all rings with new ones. EM
NOTE:
The figure shows an example of bank 2.
C
JPBIA1113ZZ
D
b. Install intake valve timing control cover with new gasket to front timing chain case.
CAUTION:
• Align the center of both shaft holes of the shaft and the intake side camshaft sprocket, and then
E
insert them.
• Be careful not to drop the seal ring from the shaft groove.
c. Being careful not to move seal ring from the installation groove,
align dowel pins on front timing chain case with dowel pin holes F
(C) to install intake valve timing control covers.
A : Bank 1 G
B : Bank 2
d. Tighten mounting bolts in numerical order as shown in the fig-
ure. H
• After all bolts are tightened, tighten No. 1 bolt to the specified
torque again.
JPBIA1333ZZ
I
11. Install oil pan (lower). Refer to EM-43, "Exploded View".

12. Install rocker covers (bank 1 and bank 2). Refer to EM-46, "Exploded View". J
13. Install crankshaft pulley as follows:
a. Fix crankshaft using the ring gear stopper [SST: KV10118600 (J-48641)].
b. Install crankshaft pulley, taking care not to damage front oil seal. K
• When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference).
c. Tighten crankshaft pulley bolt.
L
: 44.1 N·m (4.5 kg-m, 33 ft-lb)
d. Tighten the bolt 90 degrees (one mark) (b).
• Place a matching mark (A) on crankshaft pulley (2) aligning M
with the matching (C) of crankshaft pulley bolt (1).
JPBIA0120ZZ
P
e. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns
smoothly.
14. Install power steering oil pump bracket and idler pulley bracket as follows:

TIMING CHAIN
a. Tighten mounting bolts in numerical order as shown in the fig-
ure. (temporarily)
1 : Idler pulley bracket

2 : Power steering oil pump bracket
A : Engine front side
B : Engine right side
: Engine front
b. Tighten mounting bolts to specified torque in numerical order as

JPBIA1786ZZ
15. For the following operations, perform steps in the reverse order of removal.

Timing Chain
Check for cracks and any excessive wear at link plates and roller
links of timing chain. Replace timing chain if necessary.
A : Crack
B : Wear
JPBIA0091ZZ

Inspection for Leakage
The following are procedures for checking fluid leakage, lubricant leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the
required quantity, fill them to the specified level. Refer to MA-10, "Fluids and Lubricants".
• Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping,
check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises.
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.

TIMING CHAIN
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary. A
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level EM
Engine oil Level Leakage Level
Other oils and fluids* Level Leakage Level
C
Fuel Leakage Leakage Leakage
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
D

OIL SEAL
OIL SEAL
FRONT OIL SEAL
FRONT OIL SEAL : Removal and Installation INFOID:0000000004924203
REMOVAL
• Engine undercover with power tool.
• Drive belt: Refer to EM-13, "Exploded View".
• Crankshaft pulley: Refer to EM-49, "Exploded View".
2. Remove front oil seal using a suitable tool.
CAUTION:
Be careful not to damage front timing chain case and crank-
shaft.
PBIC2931E
INSTALLATION
1. Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal.
2. Install front oil seal.
• Install front oil seal so that each seal lip is oriented as shown in
the figure.
A : Oil seal lip

B : Dust seal lip
: Engine inside
: Engine outside
JPBIA0054ZZ
• Using a suitable drift, press-fit until the height of front oil seal is
level with the mounting surface.
- Suitable drift: outer diameter 60 mm (2.36 in), inner diameter
50 mm (1.97 in).
• Check that the garter spring is in position and seal lips are not
inverted.
CAUTION:
• Be careful not to damage front timing chain case and
crankshaft.
• Press-fit straight and avoid causing burrs or tilting oil
seal.
PBIC2931E
REAR OIL SEAL
REAR OIL SEAL : Removal and Installation INFOID:0000000004924204
REMOVAL
1. Remove transmission assembly. Refer to TM-31, "Exploded View" (M/T models) or TM-270, "Exploded
View" (A/T models).

OIL SEAL
2. Remove drive plate (A/T models) or fly wheel (M/T models). Refer to EM-111, "Exploded View".
3. Remove rear oil seal with a suitable tool. A
CAUTION:
Be careful not to damage crankshaft and cylinder block.
EM
PBIC2932E
D
INSTALLATION
1. Install rear oil seal. E
• Install rear oil seal so that each seal lip is oriented as shown in
the figure.
A : Oil seal lip

F
B : Dust seal lip
: Engine inside
G
: Engine outside
H
JPBIA0054ZZ
• Press in rear oil seal (1) to the position as shown in the figure.
I
B : Cylinder block rear end face
a : 0 - 0.5 mm (0 - 0.020 in)
J
JPBIA0152ZZ
L
• Using a suitable drift (A), press-fit until the height of rear oil seal is
level with the mounting surface.
- Suitable drift: outer diameter 100 mm (3.94 in), inner diameter 85 M
mm (3.35 in).
CAUTION:
• Be careful not to damage crankshaft and cylinder block. N
• Press-fit straight and avoid causing burrs or tilting oil seal.
JPBIA0153ZZ
P

ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >
UNIT REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
JPBIA2869GB
1. Engine mounting bracket (RH) 2. Engine mounting insulator (RH) 3. Engine mounting bracket (LH)
4. Engine mounting insulator (LH) 5. Rear engine mounting member 6. Engine mounting insulator (rear)
7. Dynamic damper (RH) (M/T models) 8. Dynamic damper (LH) (M/T models) 9. Dynamic damper (A/T models)
A. Front mark
WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at the front and back of rear wheels.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• Always be careful to work safely, and avoid forceful or uninstructed operations.
• Never start working until exhaust system and engine coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as much as possible. If board-on type is used for
unavoidable reasons, support at rear axle jacking point with transmission jack or similar tool before
starting work, in preparation for the backward shift of the center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-28, "Garage Jack and
Safety Stand and 2-Pole Lift".
REMOVAL
Outline

ENGINE ASSEMBLY
At first, remove the engine and the transmission assembly with front suspension member facing downward.
Then separate the engine from transmission. A
Preparation
EM
2. Disconnect both battery cables. Refer to PG-100, "Exploded View".
3. Drain engine coolant from radiator. Refer to CO-7, "Draining".
CAUTION:
• Perform this step when engine is cold. C
• Radiator reservoir tank: Refer to CO-12, "Exploded View". D
• Engine cover: Refer to EM-25, "Exploded View".
• Front road wheel and tires (power tool)
• Engine undercover (power tool) E
• Cowl top cover: Refer to EXT-21, "Exploded View"
• Air duct and air cleaner case assembly (RH and LH): Refer to EM-27, "Exploded View".
• Cooling fan assembly: Refer to CO-12, "Exploded View".
F
5. Discharge refrigerant from A/C circuit. Refer to HA-25, "Collection and Charge".
6. Remove radiator hoses (upper and lower). Refer to CO-12, "Exploded View".
Engine Room LH G
1. Disconnect heater hose at vehicle side, and fit a plug onto hose end to prevent engine coolant leakage.
2. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to HA-
41, "Exploded View". H
3. Disconnect brake booster vacuum hose.
4. Disconnect ground cable.
I
Engine Room RH
1. Disconnect battery positive cable at vehicle side and temporarily fasten it on engine.
2. Disconnect all clips and connectors of the engine room harness from engine back side. J
3. Disconnect fuel feed hose (with damper) and EVAP hose. Refer to EM-37, "Exploded View".
CAUTION:
Fit plugs onto disconnected hoses to prevent fuel leakage.
K
4. Remove reservoir tank of power steering oil pump and piping from vehicle, and temporarily secure them
on engine. Refer to ST-42, "Exploded View".
CAUTION:
When temporarily securing, keep the reservoir tank upright to avoid fluid leakage. L
Vehicle Inside
Follow the procedure below to disconnect engine room harness connectors at passenger room side, and tem-
porarily secure them on engine. M
1. Remove passenger-side kicking plate and dash side finisher. Refer to INT-15, "Exploded View".
2. Disconnect engine room harness connectors at unit sides TCM, ECM and other locations.
N
3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily
secure them on engine.
CAUTION:
• When pulling out harnesses, take care not to damage harnesses and connectors. O
• After temporarily securing, cover connectors with vinyl or similar material to protect against
adhesion of foreign materials.
Vehicle Underbody P
1. Remove A/T fluid cooler hoses (A/T models) and power steering oil pump oil cooler hoses.
• Install plug to avoid leakage of A/T fluid and power steering fluid.
2. Disconnect heated oxygen sensor 2 harness. Refer to EX-5, "Exploded View".
3. Remove three way catalyst and exhaust front tube. Refer to EX-5, "Exploded View".
4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.
Refer to ST-21, "Exploded View".

ENGINE ASSEMBLY
5. Remove rear propeller shaft. Refer to DLN-6, "Exploded View" (M/T models) or DLN-14, "Exploded View"
(A/T models).
6. Disengage control rod and remove clutch tube. Refer to TM-31, "Exploded View" (M/T models).
7. Disengage A/T control rod at A/T shift selector side. Then, temporarily secure it on the transmission
assembly, so that it does not sag. Refer to TM-260, "Exploded View" (A/T models).
8. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter.
Refer to EM-43, "Exploded View" (A/T models).
9. Remove transmission joint bolts that pierce at oil pan (upper) lower rear side. Refer to EM-76, "Exploded
View".
10. Remove front stabilizer connecting rod from transverse link. Refer to FSU-16, "Exploded View".
11. Remove lower ends of left and right steering knuckle from transverse link. Refer to FAX-7, "Exploded
View".
12. Separate steering outer sockets from steering knuckle. Refer to ST-23, "Exploded View".
13. Remove transverse links mounting bolts at suspension member side. Refer to FSU-12, "Exploded View".
Removal Work
1. Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a transmission jack. Securely support
bottom of suspension member and the transmission assembly.
CAUTION:
Use a piece of wood or a similar item as the supporting sur-
face to secure a completely stable condition.
PBIC0804E
2. Remove rear engine mounting member bolts.

3. Remove front suspension member mounting bolts and nuts. Refer to FSU-17, "Exploded View".
4. Carefully lower jack, or raise lift, to remove the engine, the transmission assembly and front suspension
member. When performing work, observe the following caution items:
CAUTION:
• Confirm there is no interference with the vehicle.
• Check that all connection points have been disconnected.
• Keep in mind that the center of gravity of the vehicle changes. If necessary, use jack(s) to sup-
port the vehicle at rear jacking point(s) to prevent it from falling off the lift.
Separation Work
1. Install engine slingers into front of cylinder head (bank 1) and
rear of cylinder head (bank 2).
1 : Engine front slinger

2 : Engine rear slinger
A : Bank 1
B : Bank 2
: Engine front
Slinger bolts: JPBIA1385ZZ
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
2. Remove power steering oil pump from engine side. Refer to ST-31, "EXCEPT FOR SPORT MODELS :
Exploded View"or ST-36, "SPORT MODELS : Exploded View".
3. Remove engine mounting insulators (RH and LH) under side nuts with power tool.
4. Lift with hoist and separate the engine and the transmission assembly from front suspension member.
CAUTION:

ENGINE ASSEMBLY
• Before and during this lifting, always check that any harnesses are left connected.
• Never damage engine mounting insulator and avoid oil/grease smearing or spills onto engine A
mounting insulator.
5. Remove crankshaft positon sensor. Refer to EM-111, "Exploded View".
CAUTION: EM
• Handle crankshaft position sensor carefully and avoid impacts.
• Never disassemble.
• Never place crankshaft position sensor in a location where it is exposed to magnetism.
C
6. Remove alternator. Refer to CHG-26, "Exploded View".
7. Remove starter motor. Refer to .STR-16, "Exploded View"
8. Separate the engine from the transmission assembly. Refer to TM-31, "Exploded View" (M/T models) or D
TM-270, "Exploded View" (A/T models).
9. Remove each engine mounting insulator and each engine mounting bracket from the engine with power
tool.
E
INSTALLATION
• Do not damage engine mounting insulator and do not spill oil on it. F
• For a location with a positioning pin, insert it securely into hole of mating part.
• For a part with a specified installation orientation, refer to component figure in EM-68, "Exploded View".
• When installing engine mounting bracket (RH and LH) on cylinder
block, tighten two upper bolts [shown as (B) in the figure] first. G
Then tighten two lower bolts [shown as (C) in the figure].
A : Example Left H
JPBIA0159ZZ
J
• Check that all engine mounting insulators are seated properly, then tighten mounting nuts.
• Tighten rear engine mounting member bolts in numerical order as
shown in the figure. K
: Vehicle front
L
JPBIA0160ZZ
N

O
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the P
NOTE:

ENGINE ASSEMBLY
engine coolant.
the specified level, if necessary.
Engine coolant Level Leakage Level
Exhaust gases — Leakage —

ENGINE STAND SETTING
< UNIT DISASSEMBLY AND ASSEMBLY >
UNIT DISASSEMBLY AND ASSEMBLY A
Setting INFOID:0000000004924211
EM
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using a differ-
ent type of engine stand, note the difference in the steps, etc. C
1. Remove the engine assembly from the vehicle. Refer to EM-68, "Exploded View".
2. Remove the parts that may restrict installation of engine to a widely use engine stand.
NOTE: D
The procedure is described assuming that you use a widely use engine stand holding the surface, to
which transmission is installed.
• Remove clutch cover and clutch disc. Refer to CL-21, "Exploded View" (M/T models). E
• Remove drive plate (A/T models) or flywheel (M/T models) with power tool. Fix crankshaft with a ring
gear stopper [SST: KV10118600 (J-48641)], and remove mounting bolts.
• Loosen mounting bolts in diagonal order.
• Check for deformation or damage of drive plate (A/T models) or flywheel (M/T models). F
CAUTION:
• Never disassemble drive plate (A/T models) or flywheel (M/T models).
• Never place drive plate (A/T models) or flywheel (M/T models) with signal plate facing down. G
• When handling signal plate, take care not to damage or scratch it.
• Handle signal plate in a manner that prevents it from becoming magnetized.
H
3. Remove pilot converter (A/T models) using the pilot bushing
puller [SST: ST16610001 (J-23907)] (A) if necessary.
K
JPBIA0193ZZ
4. Lift the engine with hoist to install it onto the widely use engine stand.
L
CAUTION:
Use an engine stand that has a load capacity [220 kg (485 lb) or more] large enough for supporting
the engine weight.
• If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the M
potential risk of overturning the stand.
- Remove intake manifold collector. Refer to EM-29, "Exploded View".
- Remove fuel injector and fuel tube assembly. Refer to EM-37, "Exploded View".
N
- Remove intake manifold. Refer to EM-32, "Exploded View".
- Remove ignition coil. Refer to EM-46, "Exploded View".
- Remove rocker cover. Refer to EM-46, "Exploded View".
- Remove exhaust manifold. Refer to EM-34, "Exploded View". O
- Other removable brackets.
NOTE:
P

The figure shows an example of widely use engine stand (A)
that can hold mating surface of transmission with drive plate
(A/T models) or flywheel (M/T models) removed.
CAUTION:
Before removing the hanging chains, check the engine
stand is stable and there is no risk of overturning.
JPBIA0190ZZ
5. Drain engine oil. Refer to LU-7, "Draining".

6. Drain engine coolant by removing water drain plug (1) from both
sides of the cylinder block as shown in the figure.
2 : Washer
3 : Plug
4 : Drain plug
: Engine front
JPBIA0191ZZ

ENGINE UNIT
ENGINE UNIT
A
Disassembly INFOID:0000000004924212
1. Remove intake manifold collector. Refer to EM-29, "Exploded View". EM

2. Remove fuel injector and fuel tube. Refer to EM-37, "Exploded View".
3. Remove intake manifold. Refer to EM-32, "Exploded View".
4. Remove exhaust manifold. Refer to EM-34, "Exploded View". C
6. Remove ignition coil, spark plug, and rocker cover. Refer to EM-46, "Exploded View".
D
7. Remove timing chain. Refer to EM-49, "Exploded View".
8. Remove rear timing chain case. Refer to EM-79, "Exploded View".
9. Remove camshaft (EXH) and VVEL ladder assembly. Refer to EM-84, "Exploded View". E
10. Remove cylinder head. Refer to EM-101, "Exploded View".
Assembly INFOID:0000000004924213
F
Assemble in the reverse order of disassembly.

OIL PAN (UPPER) AND OIL STRAINER
JPBIA1401GB

4. O-ring 5. Connector bolt 6. Oil filter
7. Relief valve 8. Oil pressure switch 9. Oil strainer
10. Oil temperature sensor 11. Washer 12. Oil pan (upper)
13. Drain plug 14. Drain plug washer 15. Oil pan (lower)
16. Rear plate cover 17. Rear cover plate (M/T models)
A. Refer to LU-9 B. To oil pump C. Oil pan side
Disassembly and Assembly INFOID:0000000004924215
REMOVAL
CAUTION:
Never drain engine oil when the engine is hot to avoid the danger of being scalded.
1. Remove oil level gauge, oil pressure switch and oil temperature sensor.
3. Remove oil strainer.

4. Loosen mounting bolts in the reverse order as shown in the fig-
ure with power tool to remove. A
: Engine front
• Insert the seal cutter [SST: KV10111100 (J-37228)] between EM

oil pan (upper) and lower cylinder block. Slide seal cutter by
tapping on the side of tool with a hammer. Remove oil pan
(upper).
C
CAUTION:
• Be careful not to damage the mating surfaces.
• Never insert a screwdriver, because this damages the JPBIA0022ZZ
mating surfaces. D
5. Remove O-rings (2) from bottom of lower cylinder block (1) and
oil pump (3). E
: Engine front
JPBIA1330ZZ
INSTALLATION H
1. Install oil pan (upper) as follows:

a. Use a scraper (A) to remove old liquid gasket from mating sur-
I
faces.
CAUTION:
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket. J
• Also remove old liquid gasket from mating surface of lower cyl-
inder block.
• Remove old liquid gasket from the bolt holes and threads. K
JPBIA0027ZZ
L
b. Install new O-rings (2) on the bottom of lower cylinder block (1)
and oil pump (3).
M
: Engine front
O
JPBIA1330ZZ

c. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to the cylinder block mating surface of
oil pan (upper) to a limited portion as shown in the figure.
a : φ4.0 - 5.0 mm (0.157 - 0.197 in)

: Engine front

CAUTION:
• For bolt holes with marks (7 locations), apply liquid JPBIA0388ZZ
gasket outside the holes.
• Attaching should be done within 5 minutes after coating.
d. Install oil pan (upper).
CAUTION:
Never misalign both O-rings during installation.
• Tighten mounting bolts in numerical order as shown in the fig-
ure.
: Engine front
• There are two types of mounting bolts. Refer to the following

for locating bolts.
M8 × 90 mm (3.54 in) : 7, 10, 13

M8 × 25 mm (0.98 in) : Except the above
JPBIA0022ZZ
2. Install oil strainer to oil pump.

3. Install oil pan (lower). Refer to EM-43, "Exploded View".
4. Install oil pan drain plug.
• Refer to the figure of components on the prior page for installation direction of drain plug washer. Refer
to EM-43, "Exploded View".
NOTE:
Wait at least 30 minutes after oil pan is installed before pouring engine oil.

Clean oil strainer if any object is attached.
1. Check the engine oil level and adjust engine oil. Refer to LU-6, "Inspection".
2. Start engine, and check there is no leakage of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check the engine oil level again. Refer to LU-6, "Inspection".

REAR TIMING CHAIN CASE
A
EM
JPBIA1101GB
1. Timing chain (secondary) (bank 1) 2. Camshaft sprocket (EXH) (bank 1) 3. O-ring

4. Timing chain (secondary) (bank 2) 5. Camshaft sprocket (EXH) (bank 2) 6. Internal chain guide
7. Timing chain (primary) 8. Camshaft sprocket (INT) (bank 1) 9. Timing chain tensioner (primary)

10. Slack guide 11. Crankshaft sprocket 12. Camshaft sprocket (INT) (bank 2)
13. Tension guide 14. 15. Seal ring
gasket (bank 1)
Intake valve timing control cover Camshaft position sensor (PHASE)
16. 17. O-ring 18.
(bank 1) (bank 1)
Intake valve timing control solenoid Intake valve timing control cover Camshaft position sensor (PHASE)
22. 23. 24.
valve (bank 2) (bank 2) (bank 2)
25. 26. Front oil seal 27. Crankshaft pulley
gasket (bank 2)
Intake valve timing control solenoid
28. Crankshaft pulley bolt 29. 30. Power steering oil pump bracket
valve (bank 1)
31. Idler pulley bracket 32. Alternator bracket 33. Water outlet (front)
34. Front timing chain case 35. Rear timing chain case 36. O-ring
37. O-ring 38. O-ring
Tightening must be done following Tightening must be done following
A. the installation procedure. B. the assembly procedure. C. Oil filter
Refer to EM-50 Refer to EM-80
DISASSEMBLY
1. Remove front timing chain case and timing chain. Refer to EM-50, "Removal and Installation".
2. Remove water pump. Refer to CO-17, "Exploded View".
3. Remove oil pan (upper). Refer to EM-76, "Exploded View".
4. Remove rear timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
b. Cut liquid gasket using the seal cutter [SST: KV10111100 (J-
37228)] and remove rear timing chain case.
JPBIA0089ZZ
CAUTION:
• Never remove plate metal cover (1) of oil passage.
• After removal, handle rear timing chain case carefully so
it does not tilt, cant, or warp under a load.
JPBIA0088ZZ

5. Remove O-rings (1) from cylinder block.
A
: Engine front
EM
JPBIA0090ZZ
D
6. Use a scraper to remove all traces of liquid gasket from rear timing chain cases and opposite mating sur-
faces.
7. Remove old liquid gasket from bolt hole and thread. E
A : Remove old liquid gasket that is stuck

B : Bolt hole F
JPBIA0051ZZ H
ASSEMBLY
I
1. Install rear timing chain case as follows:
a. Install new O-rings (1) onto cylinder block.
J
: Engine front
JPBIA0090ZZ
M
b. Apply liquid gasket with the tube presser (commercial service tool) to rear timing chain case back side as
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Prod-
ucts and Sealants". N
CAUTION:
• For in the figure, completely wipe off liquid gasket extended on a portion touching at engine
coolant. O
• Apply liquid gasket on installation position of water pump and cylinder head completely.

JPBIA0092ZZ
C. Protrusion D. Clearance 1 mm (0.04 in) E. Do not protrude in this area

Protrusions at beginning and end of
F. Run along bolt hole inner side G.
gasket
h. φ3.4 - 4.4 mm (0.134 - 173 in) i. φ2.6 - 2.8 mm (0.102 - 0.110 in)
c. Align rear timing chain case with dowel pins (bank 1 and bank 2) on cylinder block and install rear timing
chain case.
• Check that O-rings stay in place during installation to cylinder block.
d. Tighten mounting bolts in numerical order as shown in the fig-
ure.
• There are three types of mounting bolts. Refer to the following
for locating bolts.
Bolt length: Bolt position

20 mm (0.79 in) : 1, 2, 3, 6, 7, 8, 9, 10
16 mm (0.63 in) : Except the above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
JPBIA0089ZZ
e. After all bolts are tightened, retighten them to the specified

torque in numerical order shown in the figure.
• If liquid gasket protrudes, wipe it off immediately.

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

EM
2 : Lower cylinder block
Standard C
Rear timing chain case to lower cylinder block:
–0.24 to 0.14 mm (–0.0094 to 0.0055 in) JPBIA1363ZZ
• If not within the standard, repeat the installation procedure. D

2. Install water pump with new O-rings. Refer to CO-17, "Exploded View".
3. Install timing chains, camshaft sprockets and front timing chain case. Refer to EM-50, "Removal and
E
Installation".
• After installing front timing chain case, check the surface
height difference between the following parts on the oil pan
(upper) mounting surface. F
1 : Front timing chain case

2 : Rear timing chain case G
3 : Lower cylinder block
Standard H
Front timing chain case to rear timing chain case: JPBIA0093ZZ
–0.14 to 0.14 mm (–0.0055 to 0.0055 in)

I
• If not within the standard, repeat the installation procedure.
4. Install oil pan (upper). Refer to EM-76, "Exploded View".
5. Install in the reverse order of removal after this step. J

CAMSHAFT
CAMSHAFT
JPBIA1102GB
VVEL control shaft position sensor

1. 2. VVEL actuator sub assembly (bank 1) 3. Actuator bracket (rear) (bank 1)
(bank 1)
4. Washer 5. VVEL ladder assembly (bank 1) 6. Washer
Timing chain tensioner (secondary)
7. 8. Camshaft (EXH) (bank 1) 9. Valve lifter (EXH)
(bank 1)
10. Valve lifter (INT) 11. Oil filter 12. Cylinder head (bank 1)
Timing chain tensioner (secondary)
13. 14. Cylinder head (bank 2) 15. Camshaft (EXH) (bank 2)
(bank 2)
VVEL control shaft position sensor
16. VVEL ladder assembly (bank 2) 17. VVEL actuator sub assembly (bank 2) 18.
(bank 2)
19. Actuator bracket (rear) (bank 2)
Tightening must be done following the
A. assembly procedure.
Refer to EM-85
CAUTION:
A high degree of precision is required for a valve on the intake side. Never remove the valve related-
parts unless necessary.

CAMSHAFT
NOTE:
• As for replacement of parts on the intake side as shown in the exploded view, replace VVEL ladder assem- A
bly and cylinder head assembly.
• VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder
head assembly.
EM
VVEL Ladder Assembly and Cylinder Head Assembly Features
JPBIA1508ZZ
H
Hexagonal part of drive shaft
A. Control shaft B. Drive shaft C.
(for holding)
Hexagonal part of camshaft (EXH) Two flat area of control shaft
D. E. Stopper of control shaft F.
(for holding) (for holding) I
: Engine front
NOTE: J
The figure shows an example of bank 2.
K
DISASSEMBLY
JPBIA1128ZZ P
CAUTION:
Never loosen adjusting bolts (A) and mounting bolts (black color) (B) of VVEL ladder assembly. If loos-
ened, the stroke of cam lift becomes out of adjustment. In such case, replacement of VVEL ladder
assembly and cylinder head assembly is required.
NOTE:
head assembly.

CAMSHAFT
1. Remove rocker covers (bank 1 and bank 2). Refer to EM-46, "Exploded View".
2. Remove VVEL actuator sub assembly as follows:
CAUTION:
VVEL actuator sub assembly and VVEL control shaft position sensor are nonreusable. Never
remove them unless they are required.
a. Remove VVEL control shaft position sensor.
b. Turn control shaft to the large lift side and fix it in order to prevent the interference of the stopper surface.
• If control shaft cannot be moved, set crankshaft in position referring to the information below. (To dis-
place cam nose)
Bank 1 : Turn 120 degrees from no. 1 cylinder at TDC

Bank 2 : No. 1 cylinder at TDC
c. Fix two flat areas (C) of control shaft with a wrench to remove
mounting bolts of control shaft.
A : Bank 1
B : Bank 2
: Engine front
CAUTION:
• During the operation, never allow a wrench to interfere
with other parts.
• Fix control shaft to prevent the interference of the stopper
surface.
JPBIA1331ZZ
d. Remove VVEL actuator sub assembly.

• Loosen mounting bolts in the reverse order as shown in the
figure.
A : Bank 2
B : Bank 1
CAUTION:
• When removing, prepare wastes because oil spills.
• When installing, be careful with VVEL actuator sub
assembly (bank 2) mounting bolt No. 1 because its length
is different.
JPBIA1114ZZ
e. Remove actuator bracket (rear).

CAMSHAFT
• Loosen mounting bolts in the reverse order as shown in the
figure. A
A : Bank 1
B : Bank 2 EM
: Engine front
JPBIA1131ZZ
D
3. Remove front timing chain case, camshaft sprockets, and timing chain. Refer to EM-49, "Exploded View".
4. Remove rear timing chain case. Refer to EM-79, "Exploded View".
5. Remove VVEL ladder assembly. E
• Loosen mounting bolts (gold color) in the reverse order as
A : Bank 1 F
B : Bank 2
: Engine front
G
CAUTION:
• Never loosen adjusting bolts and mounting bolts (black
color).
H
• When removing VVEL ladder assembly, hold the drive
shaft from below so as not to drop it.
JPBIA1103ZZ
L
6. Remove camshaft (EXH).
7. Remove valve lifter.
• Identify installation positions, and store them without mixing them up. M
8. Remove timing chain tensioners (secondary) (1) from cylinder
head.
N
A : Bank 1
B : Bank 2
• Remove timing chain tensioners (secondary) with its stopper O
pin (C) attached.
NOTE:
Stopper pin should be attached when timing chain (secondary)
is removed. P
JPBIA0121ZZ
9. Remove oil filter from cylinder head, if necessary.

ASSEMBLY

CAMSHAFT
1. Install timing chain tensioners (secondary) (1) on both sides of
cylinder head.
A : Bank 1
B : Bank 2
• Install timing chain tensioner with its stopper pin (C) attached.
• Install timing chain tensioner with sliding part facing downward
on cylinder head (bank 1), and with sliding part facing upward
on cylinder head (bank 2).
JPBIA0121ZZ
2. Install oil filter (1), if removed.

• Do not project from the cylinder head (2) surface.
JPBIA1390ZZ
3. Install valve lifter.

• Install it in the original position.
4. Install camshaft (EXH).
• Distinction between camshaft (EXH) (bank 1 and bank 2) is
performed with the identification mark.
: Engine front
Paint marks Identification mark

Bank
M1 (C) M2 (D) M3 (E) (F)
Bank 1 (A) No Blue Light blue 1N

Bank 2 (B) No Blue Light blue 1P
JPBIA1129ZZ
5. Install VVEL ladder assembly as follows:

CAMSHAFT
a. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to the cylinder head as shown in the A
figure.
A : Bank 1
EM
B : Bank 2
c : φ3.4 - 4.4 mm (0.134 - 0.173 in)
: Engine front C
D
G
JPBIA1123ZZ
b. Tighten mounting bolts in the following step, in numerical order

as shown in the figure. H
A : Bank 1
B : Bank 2 I
: Engine front
i. Tighten bolts in numerical order as shown in the figure.

J
: 1.96 N·m (0.20 kg-m, 1 ft-lb)

ii. Tighten bolts in numerical order as shown in the figure. K
: 5.88 N·m (0.60 kg-m, 4 ft-lb)

L
iii. Tighten bolts in numerical order as shown in the figure.
: 10.4 N·m (1.1 kg-m, 8 ft-lb) M
N
JPBIA1103ZZ
6. Measure difference in levels between front end faces of VVEL

ladder assembly and cylinder head. O
Standard : −0.14 to 0.14 mm (−0.0055 to 0.0055 in)

• Measure two positions (both intake and exhaust side) for a P
single bank.
• If the measured value is out of the standard, reinstall VVEL
ladder assembly.
EMQ0044D

CAMSHAFT
7. Install rear timing chain case. Refer to EM-79, "Exploded View".
8. Install camshaft sprockets and timing chains. Refer to EM-49, "Exploded View".
9. Install actuator bracket (rear) as follows:
a. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to the actuator bracket (rear) as
A : Bank 1
B : Bank 2
c : φ3.4 - 4.4 mm (0.134 - 0.173 in)
: Engine front

GI-17, "Recommended Chemical Products and Sealants". JPBIA1130ZZ
CAUTION:
Never apply gasket to the oil passage.
b. Tighten mounting bolts in the following steps, in numerical order

A : Bank 1
B : Bank 2
: Engine front
i. Tighten bolts in numerical order as shown in the figure.
: 1.96 N·m (0.20 kg-m, 1 ft-lb)

JPBIA1131ZZ
ii. Tighten bolts in numerical order as shown in the figure.
: 5.88 N·m (0.60 kg-m, 4 ft-lb)

iii. Tighten bolts in numerical order as shown in the figure.
: 31.4 N·m (3.2 kg-m, 23 ft-lb)

10. Install new VVEL actuator sub assembly as follows:
CAUTION:
Regarding replacement, because VVEL actuator sub assembly and VVEL control shaft position
sensor are controlled on a one-on-one basis, replace them as a set.
NOTE:
• VVEL actuator arm (B) is factory-fixed at 5.5 degrees from the
small lift with a holding jig (A).
• The holding jig is supplied in the new VVEL actuator sub
assembly.
JPBIA1137ZZ
CAUTION:

CAMSHAFT
• Never disassemble VVEL actuator sub assembly. [Never
loosen actuator motor mounting bolts (A) shown in the A
figure]
• Never shock VVEL actuator sub assembly.
EM
JPBIA1120ZZ
D
a. Move control shaft to the position of small lift stopper.
• The position where a part of the stopper of control shaft con-
tacts VVEL ladder bracket. E
1 : VVEL ladder assembly (bank 2)

2 : VVEL ladder assembly (bank 1)
F
A : Stopper of control shaft
: Small lift side
CAUTION: G
Be careful not to damage the stopper surface.
K
JPBIA1122ZZ
• If control shaft cannot be moved, set crankshaft in position referring to the information below. (To dis- L
place cam nose)
Bank 1 : Turn 120 degrees from No. 1 cylinder at TDC

M
Bank 2 : No. 1 cylinder at TDC

CAMSHAFT
b. Hold two flat areas of control shaft with a wrench, and rotate the
control shaft (5.5 degrees from the stopper) to the large lift side.
(This is for aligning the bolt hole of control shaft and the hole of
VVEL actuator arm.)
1 : VVEL actuator sub assembly (bank 1)

A : Control shaft
b : 5.5 degrees
: Large lift side
JPBIA1132ZZ
c. Apply a continuous bead of liquid gasket with tube presser

(commercial service tool) to the VVEL actuator sub assembly as

a : 4.0 - 5.6 mm (0.157 - 0.220 in)
b : φ3.4 - 4.4 mm (0.134 - 0.173 in)
CAUTION:
Never apply gasket to the oil passage.
JPBIA1125ZZ
d. Install new VVEL actuator sub assembly.

• Tighten mounting bolts in the following step, in numerical order
A : Bank 2
B : Bank 1
CAUTION:
• When installing, be careful with VVEL actuator sub
assembly (bank 2) mounting bolt No. 1 because its length
is different.
JPBIA1114ZZ

CAMSHAFT
• Be sure to check that the VVEL actuator sub assembly is in contact with the cylinder head before
tightening the mounting bolts. A
e. Remove holding jig.
f. Check that VVEL actuator arm bolt hole is aligned with control shaft tapped hole. If it is not aligned, turn
control shaft for alignment. EM
g. Fix two flat areas (C) of control shaft with a wrench to install
mounting bolts of control shaft.
C
A : Bank 1
B : Bank 2
: Engine front D
CAUTION:
• During the operation, never allow a wrench to interfere
with other parts. E
• Fix control shaft to prevent the interference of the stopper
surface.
F
JPBIA1331ZZ
I
11. Install new VVEL control shaft position sensor as follows:
CAUTION:
Regarding replacement, because VVEL actuator sub assembly and VVEL control shaft position J
sensor are controlled on a one-on-one basis, replace them as a set.
a. Apply engine oil to O-ring or contact surface of O-ring.
b. Align matching marks (B) of VVEL control shaft position sensor K
and upper housing.
C : Bank 2 L
• Face connector toward matching mark (A).
JPBIA1124ZZ
c. Temporarily tighten bolt.

CAMSHAFT
d. Adjust VVEL control shaft position sensor after setting the engine assembly in the vehicle. Refer to EC-21,
"VVEL CONTROL SHAFT POSITION SENSOR ADJUSTMENT : Description".
CAUTION:
Be sure to adjust VVEL control shaft position sensor.
e. After adjusting VVEL control shaft position sensor, tighten bolts to the specified torque.
12. Inspect the valve clearance. Refer to EM-18, "Inspection and Adjustment".
INSPECTION AFTER REMOVAL (EXHAUST SIDE)

Camshaft (EXH) Runout
1. Put V-block on precise flat table, and support No. 2 and 4 jour-
nals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft
sprocket) because it has a different diameter from the other
three locations.
2. Set a dial indicator vertically to No. 3 journal.
3. Turn camshaft (EXH) to one direction with hands, and measure
the camshaft runout on a dial indicator. (Total indicator reading)
PBIC0929E
Standard and limit : Refer to EM-139, "Camshaft".
4. If it exceeds the limit, replace camshaft (EXH).
Camshaft (EXH) Cam Height
• Measure the camshaft (EXH) cam height with a micrometer.
Standard : Refer to EM-139, "Camshaft".

• If wear exceeds the limit, replace camshaft (EXH).
EMQ0072D
Camshaft (EXH) Journal Oil Clearance
CAMSHAFT (EXH) JOURNAL DIAMETER

• Measure the outer diameter of camshaft (EXH) journal with a
micrometer (A).
JPBIA0122ZZ
VVEL LADDER ASSEMBLY (EXHAUST SIDE) INNER DIAMETER

• Tighten VVEL ladder assembly bolts to the specified torque. Refer to “INSTALLATION” for the tightening
procedure.

CAMSHAFT
• Measure inner diameter (A) of VVEL ladder assembly (Exhaust
side) with a bore gauge. A

EM
PBIC1645E
D
CAMSHAFT (EXH) JOURNAL OIL CLEARANCE
• (Oil clearance) = [VVEL ladder assembly (Exhaust side) inner diameter] – [Camshaft (EXH) journal diame-
ter]. E

• If the calculated value exceeds the limit, replace either or both camshaft (EXH) and VVEL ladder assembly F
and cylinder head assembly.
NOTE:
head assembly. G
Camshaft (EXH) End Play

• Install a dial indicator in thrust direction on front end of camshaft.
H
Measure the end play of a dial indicator when camshaft (EXH) is
moved forward/backward (in direction of axis).
Standard and limit : Refer to EM-139, "Camshaft". I
SEM864E
K
• Measure the following parts if out of the limit.
- Dimension “A” for camshaft (EXH) No. 1 journal
L
Standard : 27.500 - 27.548 mm (1.0827 - 1.0846 in)
- Dimension “B” for cylinder head No. 1 journal bearing
M
Standard : 27.360 - 27.385 mm (1.0772 - 1.0781 in)
• Refer to the standards above, and then replace camshaft (EXH) N
and/or VVEL ladder assembly and cylinder head assembly.
NOTE:
Cylinder head assembly cannot be replaced as a single part, KBIA2404J
because it is machined together with VVEL ladder assembly. O
Camshaft Sprocket (EXH) Runout
1. Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft (EXH).
P
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other three locations.

CAMSHAFT
2. Measure the camshaft sprocket (EXH) runout with a dial indica-
tor. (Total indicator reading)
Limit : Refer to EM-139, "Camshaft".

3. If it exceeds the limit, replace camshaft sprocket (EXH).
PBIC0930E
Valve Lifter (EXH)

• Check if surface of valve lifter has any wear or crack.
• If wear or crack is found, replace valve lifter (EXH). Refer to EM-
139, "Camshaft".
KBIA0182E
Valve Lifter Clearance (EXH)
VALVE LIFTER OUTER DIAMETER

• Measure the outer diameter at 1/2 height of valve lifter with a
micrometer (A) since valve lifter is in barrel shape.
JPBIA0125ZZ
VALVE LIFTER HOLE DIAMETER

• Measure the inner diameter of valve lifter hole of cylinder head with
an inside micrometer.
SEM867E
VALVE LIFTER CLEARANCE

• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)

• If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and
valve lifter hole diameter, replace either or both valve lifter and VVEL ladder assembly and cylinder head
assembly.

CAMSHAFT
NOTE:
Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL lad- A
der assembly.
INSPECTION AFTER REMOVAL (INTAKE SIDE)
EM
Drive Shaft End Play
• Install a dial indicator in thrust direction on front end of drive shaft.
Measure the end play of a dial indicator when drive shaft is moved
forward/backward (in direction of axis). C

D
JPBIA1337ZZ
• Measure the following parts if out of the limit. F

- Dimension “A” for drive shaft No. 1 journal
Standard : 27.500 - 27.548 mm (1.0827 - 1.0846 in) G

- Dimension “B” for cylinder head No. 1 journal bearing
Standard : 27.360 - 27.385 mm (1.0772 - 1.0781 in) H
• If it exceeds the limit, replace VVEL ladder assembly and cylinder

head assembly.
NOTE: I
Cylinder head assembly cannot be replaced as a single part, KBIA2404J
because it is machined together with VVEL ladder assembly.
J
Camshaft Sprocket (INT) Runout
1. Put V-block on precise flat table, and support No. 2 and 4 journals of drive shaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter K
from the other three locations.
2. Measure the camshaft sprocket (INT) runout with a dial indicator. (Total indicator reading)
L
Limit : Refer to EM-139, "Camshaft".
3. If it exceeds the limit, replace camshaft sprocket (INT). M
Valve Lifter (INT)
• Check if surface of valve lifter has any wear or crack.
• If wear or crack is found, replace VVEL ladder assembly and cylin- N
der head assembly. Refer to EM-139, "Camshaft".
NOTE:
Since the valve lifter (INT) cannot be replaced by the piece, VVEL
ladder assembly and cylinder head assembly replacement are O
required.
KBIA0182E
Valve Lifter Clearance (INT)
VALVE LIFTER OUTER DIAMETER

CAMSHAFT
• Measure the outer diameter at 1/2 height of valve lifter (INT) with a
micrometer (A) since valve lifter is in barrel shape.
JPBIA0125ZZ
VALVE LIFTER HOLE DIAMETER

• Measure the inner diameter of valve lifter hole of cylinder head with
an inside micrometer.
SEM867E
VALVE LIFTER CLEARANCE

• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)

• If the calculated value is out of the standard, replace VVEL ladder assembly and cylinder head assembly.
NOTE:
Since the valve lifter (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head
assembly replacement are required.
VVEL Ladder Assembly
DRIVE SHAFT OPERATIONAL CHECK

• Hold the both ends of the drive shaft (A) and rotate it to check that
it rotates smoothly.
CAUTION:
Turn VVEL ladder assembly upside down to prevent the drive
shaft from dropping off.
JPBIA1327ZZ
CONTROL SHAFT OPERATIONAL CHECK

CAMSHAFT
• Move control shaft (A) to the small stopper and large stopper to
check that the control shaft functions smoothly. A
CAUTION:
Turn VVEL ladder assembly upside down to prevent the drive
shaft from dropping off.
EM
JPBIA1328ZZ
D
LINK CHECK FOR BACK-LASH (BONDING)
• Check that the link and the shaft of drive shaft and control shaft are
not fixed. E
• Check this by moving drive shaft and control shaft in the axial and
rotation directions.
F
JPBIA1509ZZ
H
• If there is an unusualness related to the above three, replace VVEL ladder assembly and cylinder head
assembly.
NOTE: I
head assembly.
INSPECTION AFTER INSTALLATION J
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011, P0012 is detected in self-diagnostic results of CON- K
SULT-III and it is directed according to inspection procedure of EC section. Refer to EC-107, "Diag-
nosis Description".
• Check when engine is cold to prevent burns from the splashing engine oil. L
1. Check engine oil level. Refer to LU-6, "Inspection".
2. Perform the following procedure to prevent the engine from being unintentionally started while checking.
a. Release the fuel pressure. Refer to EC-607, "Inspection". M
b. Disconnect ignition coil and injector harness connectors. Refer to EM-46, "Exploded View".
3. Remove intake valve timing control solenoid valve. Refer to EM-49, "Exploded View".
N
4. Crank engine, and then check that engine oil comes out from
intake valve timing control solenoid valve hole (A). End crank
after checking.
O
1 : Intake valve timing control cover (bank 1)
: Engine front
WARNING: P
Be careful not to touch rotating parts (drive belt, idler pul-
ley, and crankshaft pulley, etc.).
CAUTION:
JPBIA0410ZZ
• Prevent splashing by using a shop cloth to prevent the
worker from injury from engine oil and to prevent engine oil contamination.

CAMSHAFT
• Prevent splashing by using a shop cloth to prevent engine oil from being splashed to engine and
vehicle. Especially, be careful no to apply engine oil to rubber parts of drive belt, engine mount-
ing insulator, etc. Wipe engine oil off immediately if it is splashed.
5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
• Remove oil filter, and then clean it. Refer to EM-49, "Exploded View".
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-2,
"Engine Lubrication System".
6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-2, "Engine Lubrication System".
7. After inspection, install removed parts in the reverse order.
NOTE:
engine coolant.

CYLINDER HEAD
CYLINDER HEAD
A
EM
L
JPBIA1126GB
1. Valve lifter (EXH) 2. Valve collet (EXH) 3. Valve spring retainer (EXH) M
4. Valve oil seal (EXH) 5. Valve spring (EXH) 6. Valve spring seat (EXH)
7. Valve guide (EXH) 8. Spark plug 9. Valve lifter (INT)
10. Valve collet (INT) 11. Valve spring retainer (INT) 12. Valve oil seal (INT) N
13. Valve spring (INT) 14. Valve spring seat (INT) 15. Cylinder head bolt
16. Cylinder head (bank 1) 17. Valve seat (EXH) 18. Valve (EXH)
19. Cylinder head gasket (bank 1) 20. Valve (INT) 21. Cylinder head gasket (bank 2) O
22. Cylinder head (bank 2) 23. Engine rear lower slinger
A. the assembly procedure.
P
Refer to EM-102
CAUTION:
A high degree of precision is required for a valve on the intake side. Never remove the valve related-
parts unless necessary.
NOTE:

CYLINDER HEAD
• As for replacement of parts on the intake side as shown in the exploded view, replace VVEL ladder assem-
bly and cylinder head assembly. (Only valve oil seals are replaceable as a single part.)
• VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder
head assembly.
DISASSEMBLY
• Intake manifold collector: Refer to EM-29, "Exploded View".
• Rocker cover: Refer to EM-46, "Exploded View".
• Fuel tube and fuel injector assembly: Refer to EM-37, "Exploded View".
• Intake manifold: Refer to EM-32, "Exploded View".
• Exhaust manifold: Refer to EM-34, "Exploded View".
• Water inlet and thermostat assembly: Refer to CO-20, "Exploded View".
• Water outlet, water pipe and heater pipe: Refer to CO-22, "Exploded View".
• Timing chain: Refer to EM-49, "Exploded View".
• Rear timing chain case: Refer to EM-79, "Exploded View".
• Camshaft (EXH) and VVEL ladder assembly: Refer to EM-84, "Exploded View".
2. Remove cylinder head.
• Loosen mounting bolts in reverse order as shown in the figure.
A : Bank 1
B : Bank 2
: Engine front
• Use the cylinder head bolt wrench [commercial service tool:

— (J-24239-01)] and power tool.
JPBIA0172ZZ
3. Remove cylinder head gaskets.

4. Remove spark plug with spark plug wrench (commercial service tool).
5. Remove valve lifter.
• Identify installation positions, and store them without mixing them up.
6. Remove valve collet.

CYLINDER HEAD
• Compress valve spring with the valve spring compressor [SST:
KV10116200 (J-26336-A)] (A), the attachment [SST: A
KV10115900 (J-26336-20)] (C), and the adapter [SST:
KV10109220 ( — )] (B). Remove valve collet with a magnet
hand.
EM
CAUTION:
When working, take care not to damage valve lifter holes.
JPBIA1365ZZ
D
7. Remove valve spring retainer, valve spring and valve spring seat.
8. Push valve stem to combustion chamber side, and remove valve.
• Identify installation positions, and store them without mixing them up. E
9. Remove valve oil seal using the valve oil seal puller [SST:
KV10107902 (J-38959)] (A).
F
H
JPBIA1366ZZ
10. Remove valve seat (EXH), if valve seat (EXH) must be replaced. I
• Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat
recess in cylinder head. Set the machine depth stop to ensure this. Refer to EM-141, "Cylinder Head".
CAUTION:
Prevent to scratch cylinder head by excessive boring. J
11. Remove valve guide (EXH), if valve guide (EXH) must be replaced.
a. To remove valve guide (EXH), heat cylinder head to 110 to
130°C (230 to 266°F) by soaking in heated oil (A). K
JPBIA0184ZZ
N
b. Drive out valve guide (EXH) with a press [under a 20 kN (2 ton,
2.2 US ton, 2.0 lmp ton) pressure] or a hammer and the valve
guide drift (commercial service tool). O
WARNING:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
P
SEM931C
ASSEMBLY

CYLINDER HEAD
1. If valve guide (EXH) is removed in step 11 (DISASSEMBLY), install it.
Replace with oversized [0.2 mm (0.008 in)] valve guide (EXH).
a. Using the valve guide reamer (commercial service tool) (A),
ream cylinder head valve guide (EXH) hole.
Oversize (service) [0.2 mm (0.008 in)]

: Refer to EM-141, "Cylinder Head".
JPBIA0185ZZ
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil (A).
JPBIA0184ZZ
c. Using the valve guide drift (commercial service tool), press valve
guide (EXH) from camshaft side to the dimensions as shown in
the figure.
Projection (A)
: Refer to EM-141, "Cylinder Head".
WARNING:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
JPBIA0186ZZ
d. Using the valve guide reamer (commercial service tool) (A),

apply reamer finish to valve guide (EXH).
Standard : Refer to EM-141, "Cylinder Head".
JPBIA0185ZZ
2. If valve seat (EXH) is removed in step 10 (DISASSEMBLY), install it.

Replace with oversize [0.5 mm (0.020 in)] valve seat (EXH).

CYLINDER HEAD
a. Ream cylinder head recess diameter (a) for service valve seat
(EXH). A
Oversize (service) [0.5 mm (0.020 in)]

: Refer to EM-141, "Cylinder Head". EM
• Be sure to ream in circles concentric to valve guide center.
This will enable valve to fit correctly.
C
JPBIA0188ZZ
D
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A).
E
G
JPBIA0184ZZ
c. Provide valve seats (EXH) cooled well with dry ice. Force fit valve seat (EXH) into cylinder head. H
WARNING:
Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
CAUTION: I
Avoid directly touching cold valve seats.
d. Using the valve seat cutter set (commercial service tool) or valve
seat grinder, finish seat to the specified dimensions. Refer to J
EM-141, "Cylinder Head".
CAUTION:
When using the valve seat cutter, firmly grip cutter handle
with both hands. Then, press on the contacting surface all K
around the circumference to cut in a single drive. Improper
pressure on cutter or cutting many different times may
result in staged valve seat. L
SEM934C
M
e. Using compound, grind to adjust valve fitting.
f. Check again for normal contact. Refer to "VALVE SEAT CONTACT".
3. Install new valve oil seals as follows. N
a. Apply new engine oil on new valve oil seal joint and seal lip.
b. Using the valve oil seal drift [SST: KV10115600 (J-38958)] (A),
press fit valve seal to height (b) shown in figure. O
NOTE:
Dimension: Height measured before valve spring seat installa-
tion
P
Height (b) : 14.3 - 14.9 mm (0.563 - 0.587 in)
JPBIA1367ZZ
4. Install valve spring seat.

CYLINDER HEAD
5. Install valve.
NOTE:
Larger diameter valves are for intake side.
6. Install new cylinder head gaskets.
7. Turn crankshaft until No. 1 piston is set at TDC.
• Crankshaft key should line up with the cylinder center line
(bank 1) as shown in the figure.
1 : Crankshaft key
: Bank 1 side
JPBIA0174ZZ
8. Install cylinder head, and tighten cylinder head bolts in numeri-

cal order as shown in figure as follows:
A : Bank 1
B : Bank 2
: Engine front
• Use the cylinder head bolt wrench [commercial service tool:

— (J-24239-01)] and power tool.
CAUTION:
• If cylinder head bolts are reused, check their outer diame-
ters before installation. Refer to EM-107, "Inspection".
• Before installing cylinder head, inspect cylinder head dis-
tortion. Refer to EM-107, "Inspection".
a. Apply new engine oil to threads and seat surfaces of cylinder
head bolts.
b. Tighten all cylinder head bolts.
: 105 N·m (11 kg-m, 77 ft-lb)

c. Completely loosen all cylinder head bolts.
JPBIA0172ZZ
: 0 N·m (0 kg-m, 0 ft-lb)
CAUTION:
In step “c”, loosen bolts in the reverse order of that indicated in the figure.
d. Tighten all cylinder head bolts.
: 40.0 N·m (4.1 kg-m, 30 ft-lb)
e. Turn all cylinder head bolts 95 degrees clockwise (angle tightening).

CAUTION:

CYLINDER HEAD
Check the tightening angle using the angle wrench [SST:
KV10112100 (BT8653-A)] (A). Never make judgment by A
visual inspection.
• Check tightening angle indicated on the angle wrench indica-
tor plate.
EM
f. Turn all cylinder head bolts 95 degrees clockwise again (angle
tightening).
C
JPBIA0175ZZ
D
9. After installing cylinder head, measure distance between front
end faces of cylinder block and cylinder head (bank 1 and bank
2).
E
Standard : 14.1 - 14.9 mm (0.555 - 0.587 in)
• If measured value is out of the standard, reinstall cylinder F
head.
G
EMQ0662D
10. Install valve spring (uneven pitch type).

H
• Install narrow pitch (B) end [paint mark (C)] to cylinder head
side (valve spring seat side).
A : Wide pitch I
: Cylinder head side
J
Paint mark color
Intake : Purple
Exhaust : Yellowish green K
JPBIA0179ZZ
11. Install valve spring retainer.

12. Install valve collet. L
• Compress valve spring with the valve spring compressor [SST:
KV10116200 (J-26336-A)] (A), the attachment [SST:
KV10115900 (J-26336-20)] (C) and the adapter [SST: M
KV10109220 ( — )] (B). Install valve collet with a magnet
hand.
CAUTION:
When working, take care not to damage valve lifter holes. N
• Tap valve stem edge lightly with plastic hammer after installa-
tion to check its installed condition.
O
JPBIA1365ZZ
13. Install valve lifter. P

• Install it in the original position.
14. Install spark plug with spark plug wrench (commercial service tool).
INSPECTION AFTER DISASSEMBLY

CYLINDER HEAD
Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between (B) and (A)
exceeds the limit, replace them with new one.
c : 48 mm (1.89 in)
d : 11 mm (0.43 in)
Limit [(B) - (A)] : 0.18 mm (0.0071 in)

• If reduction of outer diameter appears in a position other than (A),
use it as (A) point. JPBIA1134ZZ
Cylinder Head Distortion

NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-121, "Inspec-
tion".
1. Using a scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.
CAUTION:
Never allow gasket fragments to enter engine oil or engine coolant passages.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions (A), (B), (C), (D), (E), and
(F).
Limit : Refer to EM-141, "Cylinder Head".

• If it exceeds the limit, replace VVEL ladder assembly and cylinder
head assembly.
NOTE:
Cylinder head assembly cannot be replaced as a single part,
because it is machined together with VVEL ladder assembly.
JPBIA0176ZZ
Valve Dimensions
• Check the dimensions of each valve. For the dimensions, refer to EM-141, "Cylinder Head".
• If dimensions are out of the standard.
- Replace valve (EXH) and check valve seat contact. Refer to "VALVE SEAT CONTACT". (Exhaust side)
- Replace VVEL ladder assembly and cylinder head assembly. Refer to EM-84, "Exploded View". (Intake side)
NOTE:
Since the valve (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly
replacement are required.
Valve Guide Clearance
Valve Stem Diameter

• Measure the diameter of valve stem with micrometer (A).
Valve Guide Inner Diameter

• Measure the inner diameter of valve guide with bore gauge.
Valve Guide Clearance

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve
stem diameter) JPBIA0183ZZ

• If the calculated value exceeds the limit.
- Replace valve (EXH) and/or valve guide (EXH). Refer to EM-101, "Exploded View". (Exhaust side)
- Replace VVEL ladder assembly and cylinder head assembly. Refer to EM-84, "Exploded View". (Intake side)

CYLINDER HEAD
NOTE:
Since the valve (INT) and valve guide (INT) cannot be replaced by the piece, VVEL ladder assembly and A
cylinder head assembly replacement are required.
Valve Seat Contact
• After confirming that the dimensions of valve guides and valves are within the specifications, perform this EM
procedure.
• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve
contact on the surface. C
• Check if the contact area band is continuous all around the circum-
ference.
A : OK D
B : NG
- If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions even after the recheck, replace E
valve seat (EXH). Refer to EM-101, "Exploded View". (Exhaust
side)
- If not, replace VVEL ladder assembly and cylinder head assembly. F
Refer to EM-84, "Exploded View". (Intake side) JPBIA0187ZZ
NOTE:
Since the valve seat (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head
assembly replacement are required. G
Valve Spring Squareness

• Set a try square (A) along the side of valve spring and rotate H
spring. Measure the maximum clearance between the top of spring
and try square.
B : Contact I
Limit : Refer to EM-141, "Cylinder Head".

J
• If it exceeds the limit.
- Replace valve spring (EXH). Refer to EM-101, "Exploded View".
(Exhaust side)
JPBIA0189ZZ
- Replace VVEL ladder assembly and cylinder head assembly. K
Refer to EM-84, "Exploded View". (Intake side)
NOTE:
Since the valve spring (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head L
Valve Spring Dimensions and Valve Spring Pressure Load
• Check the valve spring pressure at specified spring height. M
Standard
: Refer to EM-141, "Cylinder Head". N
• If the installation load or load with valve open is out of the stan-
dard.
- Replace valve spring (EXH). Refer to EM-101, "Exploded View". O
(Exhaust side)
- Replace VVEL ladder assembly and cylinder head assembly.
Refer to EM-84, "Exploded View". (Intake side)
NOTE:
SEM113 P
Since the valve spring (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head

CYLINDER HEAD
NOTE:
engine coolant.

CYLINDER BLOCK
CYLINDER BLOCK
A
EM
JPBIA1771GB
N
1. Sub harness 2. Knock sensor 3. Crankshaft position sensor
4. Cylinder block heater (for Canada) 5. Cylinder block 6. Thrust bearing
7. Main bearing (upper) 8. Crankshaft 9. Crankshaft key O
10. Main bearing (lower) 11. O-ring 12. Lower cylinder block bolt
13. Baffle plate 14. Lower cylinder block 15. Pilot bush (M/T models)
16. Pilot converter (A/T models) 17. Reinforcement plate (A/T models) 18. Drive plate (A/T models) P
19. Rear oil seal 20. Flywheel (M/T models) 21. Oil jet
22. Top ring 23. Second ring 24. Oil ring
25. Piston 26. Piston pin 27. Snap ring
28. Connecting rod 29. Connecting rod bearing 30. Connecting rod bearing cap
31. Connecting rod bolt

CYLINDER BLOCK
A. the assembly procedure. B. Chamfered C. Front mark
Refer to EM-112
: Crankshaft side
DISASSEMBLY
• Oil pans (upper and lower): Refer to EM-43, "Exploded View" and EM-76, "Exploded View".
• Front and rear timing chain case: Refer to EM-49, "Exploded View" and EM-79, "Exploded View".
• Cylinder head: Refer to EM-101, "Exploded View".
2. Remove knock sensor.
CAUTION:
Carefully handle sensor avoiding shocks.
3. Remove baffle plate from lower cylinder block.
4. Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-121, "Inspection".
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod bearing cap.
c. Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.
PBIC2940E
5. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
• Be careful not to drop connecting rod bearing, and to scratch the surface.
6. Remove piston rings from piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-121, "Inspection".
• Use a piston ring expander (commercial service tool) (A).
CAUTION:
• When removing piston rings, be careful not to damage
piston.
• Be careful not to damage piston rings by expanding them
excessively.
JPBIA0194ZZ
7. Remove piston from connecting rod as follows:

CYLINDER BLOCK
a. Using snap ring pliers (A), remove snap rings.
A
EM
JPBIA0195ZZ
D
b. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use
dryer (A) or equivalent.
E
G
JPBIA0196ZZ
c. Push out piston pin using a stick than has an outer diameter of
H
approximately 20 mm (0.79 in).
PBIC0262E
K
8. Remove lower cylinder block bolts.
• Before loosening lower cylinder block bolts, measure the crankshaft end play. Refer to EM-121, "Inspec-
tion". L
• Loosen lower cylinder block bolts in the reverse order shown
in the figure in several different steps.
M
: Engine front
O
JPBIA0197ZZ
9. Remove lower cylinder block as follows:

P

CYLINDER BLOCK
Screw M8 bolt [pitch: 1.25 mm (0.049 in) length: approximately
50 mm (1.97 in)] into bolt holes (A). Then equally tighten each
bolt, and remove lower cylinder block.
: Engine front
CAUTION:
• Be careful not to damage the mounting surfaces.
• Never tighten bolts excessively.
• Never insert screwdriver, this will damage the mating sur-
face.
10. Remove crankshaft. JPBIA0414ZZ
11. Pull rear oil seal out from rear end of crankshaft.
12. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
• Be careful not to drop main bearing, and to scratch the surface.
13. Remove oil jet.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use goggles to protect your eyes.
2. Install each plug to cylinder block as shown in the figure.
3 : Plug
: Engine front
• Apply sealant to the thread of water drain plug (1).

• Apply sealant to the thread of plug (4).
Use Genuine High Strength Thread Locking Sealant or
equivalent. Refer to GI-17, "Recommended Chemical
Products and Sealants".
• Replace washers (2) with new ones.
JPBIA0191ZZ
• Tighten each plug as specified below.

Unit: N·m (kg-m, ft-lb)
Part Washer Tightening torque
1 No 19.6 (2.0, 14)
3 Yes 78.0 (8.0, 58)
4 Yes 12.3 (1.3, 9)
3. Install oil jet.

CYLINDER BLOCK
• Insert oil jet dowel pin (A) into cylinder block dowel pin hole,
and tighten mounting bolts. A
: Engine front
EM
JPBIA0198ZZ
D
4. Install main bearings and thrust bearings as follows:
CAUTION:
Be careful not to drop main bearing, and to scratch the surface.
E
a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block.
b. Install thrust bearings (1) to both sides of the No. 3 journal hous-
ing on cylinder block.
F
A : No. 1
B : No. 2
C : No. 3 G
D : No. 4
F : Thrust bearing installation position
: Engine front H
• Install thrust bearings with the oil groove (E) facing crankshaft JPBIA0199ZZ
arm (outside).
I
c. Install main bearings paying attention to the direction.
A : Cylinder block side J

D : Lower cylinder block side
: Engine front
K
• Main bearing with oil hole (B) and groove (C) goes on cylinder
block. The one without them goes on lower cylinder block.
• Before installing main bearings, apply engine oil to the bearing
surface (inside). Do not apply engine oil to the back surface, L
but thoroughly clean it. JPBIA0200ZZ
• When installing, align main bearing stopper protrusion to cut-
out of cylinder block and lower cylinder block. M
• Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
5. Install crankshaft to cylinder block.

• While turning crankshaft by hand, check that it turns smoothly. N
6. Install lower cylinder block.
NOTE:
Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder O
block.

CYLINDER BLOCK
• Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to lower cylinder block as shown in
the figure.
B : Apply to end
a : φ4.0 - 5.0 mm (0.157 - 0.197 in)
JPBIA1354ZZ
7. Inspect the outer diameter of lower cylinder block bolt. Refer to EM-121, "Inspection".
8. Install lower cylinder block bolts in numerical order as shown in the figure as follows:
a. Apply new engine oil to threads and seat surfaces of lower cylinder block bolts.
b. Tighten bolts (No. 17 to 26) in numerical order as shown in the
figure.
: Engine front
: 25.0 N·m (2.6 kg-m, 18 ft-lb)

c. Repeat step b.
JPBIA0197ZZ
d. Tighten bolts (No. 1 to 16) in numerical order as shown in the

figure.
: Engine front
NOTE:
Use TORX socket for bolts No. 1 to 16.
: 35.3 N·m (3.6 kg-m, 26 ft-lb)
JPBIA0197ZZ
e. Turn bolts (No. 1 to 16) 90 degrees clockwise (angle tightening).

CAUTION:
Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to
check tightening angle. Never make judgment by visual
inspection.
JPBIA0202ZZ
• After installing lower cylinder block bolts, check that crankshaft can be rotated smoothly by hand.
• Check the crankshaft end play. Refer to EM-121, "Inspection".
9. Install piston to connecting rod as follows:
a. Using snap ring pliers, install new snap ring to the groove of piston rear side.
• Insert it fully into groove to install.

CYLINDER BLOCK
b. Install piston to connecting rod.
• Using an industrial use dryer or similar tool, heat piston until piston pin can be pushed in by hand without A
excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into
piston and connecting rod.
• Assemble so that the front mark on the piston head and the
EM
cylinder number on connecting rod are positioned as shown in
the figure.
A : Example RH C
B : Piston grade number
C : Front mark
D : Pin grade number D
E : Cylinder number
F : Front mark JPBIA1213ZZ
E
: Engine front
c. Install new snap ring to the groove of the piston front side.
• Insert it fully into groove to install. F
• After installing, check that connecting rod moves smoothly.
10. Using a piston ring expander (commercial service tool) (A),

install piston rings. G
CAUTION:
• When installing piston rings, be careful not to damage
piston. H
• Be careful not to damage piston rings by expending them
excessively.
I
JPBIA0194ZZ
J
• If there is stamped mark on ring, mount it with marked side up.
Stamped mark: K
Top ring (A) : 1 N
Second ring (B) : 2 N L
JPBIA1720ZZ
• Position each ring with the gap as shown in the figure referring N
to the piston front mark (D).
C : Top ring gap O

E : Oil ring upper or lower rail gap (either of them)
F : Second ring and oil ring spacer gap
a : 90 degrees P
b : 45 degrees
JPBIA0205ZZ
• Check the piston ring side clearance. Refer to EM-121, "Inspection".

11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.

CYLINDER BLOCK
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
• Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply
engine oil to the back surface, but thoroughly clean it.
• When installing, align connecting rod bearing stopper protru-
sion (B) with cutout (C) of connecting rods and connecting rod
bearing caps to install.
• Ensure the oil hole (A) on connecting rod and that on the cor-
responding bearing are aligned.
JPBIA0206ZZ
12. Install piston and connecting rod assembly to crankshaft.

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
• Match the cylinder position with the cylinder number on connecting rod to install.
• Be sure that front mark on piston crown is facing the front of the engine.
• Using a piston ring compressor [SST: EM03470000 (J-8037)]
(A) or suitable tool, install piston with the front mark on the pis-
ton crown facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.
JPBIA0207ZZ
13. Install connecting rod bearing cap.

• Match the stamped cylinder number marks on connecting rod
with those on connecting rod bearing cap to install.
A : Sample codes
B : Bearing stopper groove
C : Small-end diameter grade
D : Big-end diameter grade
E : Weight grade
F : Cylinder No.
G : Management code
JPBIA0208ZZ
I : Management code
• Be sure that front mark (H) on connecting rod bearing cap is facing the front of the engine.
14. Tighten connecting rod bolt as follows:
a. Inspect the outer diameter of connecting rod bolt. Refer to EM-121, "Inspection".
b. Apply engine oil to the threads and seats of connecting rod bolts.
c. Tighten connecting rod bolts.
: 28.4 N·m (2.9 kg-m, 21 ft-lb)

d. Completely loosen connecting rod bolts.
: 0 N·m (0 kg-m, 0 ft-lb)

e. Tighten connecting rod bolts.

CYLINDER BLOCK
: 24.5 N·m (2.5 kg-m, 18 ft-lb) A
f. Then turn connecting rod bolts 90 degrees clockwise (angle tightening).

CAUTION:
Always use the angle wrench [SST: KV10112100 (BT8653- EM
A)] (A). Never make judgment by visual inspection.
• After tightening connecting rod bolts, check that crankshaft
rotates smoothly. C
• Check the connecting rod side clearance. Refer to EM-121,
"Inspection".
D
E
JPBIA0209ZZ
15. Install baffle plate.

16. Install new rear oil seal. Refer to EM-66, "REAR OIL SEAL : Removal and Installation". F
• Apply new engine oil to both oil seal lip and dust seal lip.
17. Install pilot converter (A/T models) or pilot bushing (M/T mod- G
els).
• With a drift of the following outer diameter, press-fit as far as it
will go.
H
Pilot bushing : Approximately. 17 mm (0.67 in)
Pilot converter : Approximately. 33 mm (1.30 in)
I
PBIC2947E J
• Press-fit pilot converter with its chamfer facing crankshaft as

shown in the figure. (A/T models)
K
: Crankshaft side
JPBIA0210ZZ
N
• Press-fit pilot bushing (1) as the dimension shown in the fig-
ure. (M/T models)
O
A : Crankshaft (rear end surface)
: 10.20 – 10.85 mm (0.402 – 0.427 in)
b
[Target: 10.20 mm (0.402 in)]
P
JPBIA0415ZZ

CYLINDER BLOCK
18. Install knock sensors.
A : Bank 1
B : Bank 2
: Engine front
• Install knock sensor so that connector faces the rear of the

engine.
• After installing knock sensor, connect harness connector, and
lay it out to rear of the engine.
CAUTION:
• Never tighten mounting bolts while holding connector.
• If any impact by dropping is applied to knock sensor,
replace it with new one.
NOTE:
• Check that there is no foreign material on the cylinder block
mating surface and the back surface of knock sensor.
• Check that knock sensor does not interfere with other parts.
JPBIA0211ZZ
19. Note the following, assemble in the reverse order of disassembly after this step.
Flywheel (M/T models)
• Ensure the dowel pin (1) is installed in the crankshaft.
4 : Rear oil seal

• When installing flywheel (3) to crankshaft (2), be sure to cor-
rectly align crankshaft side dowel pin and flywheel side dowel
pin hole (A).
JPBIA0322ZZ
• There is a matching mark (B) on the clutch cover side of fly-

wheel (4). Refer it during installation.
1 : Dowel pin
2 : Rear oil seal
3 : Crankshaft
A : Hole
JPBIA0323ZZ
Drive plate (A/T models)

• When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive
plate side dowel pin hole.
CAUTION:
If these are not aligned correctly, engine runs roughly and “MIL” illuminates.

CYLINDER BLOCK
• Install drive plate (2) and reinforcement plate (3) as shown in
the figure. A
1 : Ring gear
4 : Pilot converter EM
5 : Crankshaft
A : Rounded
: Engine front C
• Holding ring gear with the ring gear stopper [SST:
KV10118600 (J-48641)]. JPBIA0212ZZ
• Tighten the mounting bolts crosswise over several times. D
E
CRANKSHAFT END PLAY
• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial F
indicator.
Standard and limit : Refer to EM-143, "Cylinder Block". G

• If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft
also. H
PBIC2953E
I
CONNECTING ROD SIDE CLEARANCE
• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge.
J
Standard and limit : Refer to EM-143, "Cylinder Block".
• If the measured value exceeds the limit, replace connecting rod, K
and measure again. If it still exceeds the limit, replace crankshaft
also.
PBIC2954E
PISTON TO PISTON PIN OIL CLEARANCE M

Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer (A). N
Standard : Refer to EM-143, "Cylinder Block".

O
JPBIA0217ZZ
Piston Pin Outer Diameter

CYLINDER BLOCK
Measure the outer diameter of piston pin with a micrometer (A).
JPBIA0218ZZ
Piston to Piston Pin Oil Clearance

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

• If the calculated value is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly, refer to EM-132, "Description".
NOTE:
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
piston pin grades can be selected. (Only “0” grade is available.)
PISTON RING SIDE CLEARANCE
• Measure the side clearance of piston ring (1) and piston ring
groove with a feeler gauge (C).
A : NG
B : OK

• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also.
JPBIA0219ZZ
PISTON RING END GAP

• Check that the cylinder bore inner diameter is within the specification. Refer to EM-112, "Disassembly and
Assembly".
• Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert piston ring until middle of cylinder with piston, and mea-
sure the piston ring end gap with a feeler gauge (B).
A : Press-fit
C : Measuring point

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

CYLINDER BLOCK
• Check with a connecting rod aligner.
A
A : Bend
B : Torsion
C : Feeler gauge EM
Bend limit
: Refer to EM-143, "Cylinder Block".
Torsion limit C
• If it exceeds the limit, replace connecting rod assembly.
D
G
JPBIA0221ZZ
CONNECTING ROD BIG END DIAMETER

• Install connecting rod bearing cap without installing connecting rod H
bearing, and tighten connecting rod bolts to the specified torque.
Refer to EM-112, "Disassembly and Assembly" for the tightening
procedure.
I
1 : Connecting rod
• Measure the inner diameter of connecting rod big end with an
J
inside micrometer.

JPBIA0222ZZ K
• If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
L
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).
M
O
JPBIA0223ZZ
Piston Pin Outer Diameter P

CYLINDER BLOCK
Measure the outer diameter of piston pin with a micrometer (A).
JPBIA0218ZZ
Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)

• If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly, refer to EM-132, "Description".
• If replacing connecting rod assembly, refer to EM-133,
"Connecting Rod Bearing" to select the connecting rod bearing.
A : Sample codes
B : Bearing stopper groove
D : Big-end diameter grade
E : Weight grade
F : Cylinder No.
G : Management code
JPBIA0208ZZ
H : Front mark
I : Management code
Factory installed parts grading:

• Service parts apply only to grade “0”.
A : RH
B : LH
C : Piston pin grade number
D : Piston grade number
E : Front mark
F : Identification code
Unit: mm (in)
Grade 0 1
Connecting rod bushing 22.000 - 22.006 22.006 - 22.012
inner diameter * (0.8661 - 0.8664) (0.8664 - 0.8666)
21.993 - 21.999 21.999 - 22. 005
Piston pin hole diameter
(0.8659 - 0.8661) (0.8661 - 0.8663)
21.989 - 21.995 21.995 - 22.001
Piston pin outer diameter
(0.8657 - 0.8659) (0.8659 - 0.8662)
*: After installing in connecting rod
JPBIA1212ZZ
CYLINDER BLOCK DISTORTION

CYLINDER BLOCK
• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination. A
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
• Measure the distortion on the cylinder block upper face at some
EM
different points in six directions (C), (D), (E), (F), (G), and (H) with a
straightedge (A) and a feeler gauge (B).
Limit : Refer to EM-143, "Cylinder Block". C

• If it exceeds the limit, replace cylinder block.
D
JPBIA0224ZZ
E
MAIN BEARING HOUSING INNER DIAMETER
• Install lower cylinder block (2) without installing main bearings, and
tighten lower cylinder block bolts to the specified torque. Refer to F
EM-112, "Disassembly and Assembly" for the tightening proce-
dure.
• Measure the inner diameter of main bearing housing with a bore
gauge. G

H
• If out of the standard, replace cylinder block (1) and lower cylinder
block as assembly.
NOTE: JPBIA0225ZZ
Cylinder block cannot be replaced as a single part, because it is I

machined together with lower cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
J
Cylinder Bore inner Diameter
• Using a bore gauge, measure cylinder bore for wear, out-of-round
and taper at six different points on each cylinder. [(A) and (B) direc-
tions at (C), (D) and (E)] is in longitudinal direction of engine. K
f : 10 mm (0.39 in)
L
g : 60 mm (2.36 in)
h : 125 mm (4.92 in)
M
JPBIA0226ZZ
N
• If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or rebore the inner
wall.
• Oversize piston is provided. When using oversize piston, rebore O
cylinder so that the clearance of the piston-to-cylinder bore satis-
fies the standard.
CAUTION: P
When using oversize piston, use oversize pistons for all cylin-
ders with oversize piston rings.
Oversize (O/S) : 0.2 mm (0.008 in) SEM843E
Piston Skirt Diameter

CYLINDER BLOCK
Measure the outer diameter of piston skirt with a micrometer (A).
Measure point
: Refer to EM-143, "Cylinder Block".
Standard
JPBIA0227ZZ
Piston-to-Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter
[direction (B), position (D)].
A : Direction A
C : Position C
E : Position E
f : 10 mm (0.39 in)
g : 60 mm (2.36 in)
h : 125 mm (4.92 in)
JPBIA0226ZZ
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter).

• If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to EM-143,
"Cylinder Block".
Reboring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
Rebored size calculation: D = A + B – C

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

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

• If out of the standard, measure the connecting rod bearing oil C
clearance. Then use undersize bearing. Refer to EM-133,
"Connecting Rod Bearing".
D
JPBIA0228ZZ
E
CRANKSHAFT OUT-OF-ROUND AND TAPER
• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in the dimensions F
between (d) and (c) at (a) and (b).
• Taper is indicated by the difference in the dimensions between.
G
Limit : Refer to EM-143, "Cylinder Block".
• If the measured value exceeds the limit, correct or replace crank-
shaft. H
• If corrected, measure the bearing oil clearance of the corrected
main journal and/or pin journal. Then select the main bearing and/ JPBIA0229ZZ
or connecting rod bearing. Refer to EM-136, "Main Bearing" and/ I

or EM-133, "Connecting Rod Bearing".
CRANKSHAFT RUNOUT
• Place V-block on precise flat table, and support the journals on J
both ends of crankshaft.
• Place a dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on a
K
dial indicator. (Total indicator reading)

L
• If it exceeds the limit, replace crankshaft.
SEM346D M
CONNECTING ROD BEARING OIL CLEARANCE
Method by Calculation N
• Install connecting rod bearings (1) to connecting rod (2) and con-
necting rod cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-112, "Disassembly and Assembly" for the
tightening procedure. O
JPBIA0230ZZ
• Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter)

CYLINDER BLOCK
Standard and limit : Refer to EM-148, "Connecting Rod Bearing".

• If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to
EM-132, "Description".
Method of Using Plastigage
• Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting
rod bolts to the specified torque. Refer to EM-112, "Disassembly and Assembly" for the tightening proce-
dure.
CAUTION:
Never rotate crankshaft.
• Remove connecting rod bearing cap and bearings, and using the
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is the
same as that described in the “Method by Calculation”.
JPBIA0231ZZ
MAIN BEARING OIL CLEARANCE

Method by Calculation
• Install main bearings (3) to cylinder block (1) and lower cylinder
block (2), and tighten lower cylinder block bolts to the specified
torque. Refer to EM-112, "Disassembly and Assembly" for the
tightening procedure.
• Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main
journal diameter)
Standard and limit : Refer to EM-147, "Main Bearing".

• If the calculated value exceeds the limit, select proper main bear-
ing according to main bearing inner diameter and crankshaft main JPBIA0232ZZ
journal diameter to obtain the specified bearing oil clearance.

Refer to EM-132, "Description".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install main bearing to cylinder block and lower cylinder block, and tighten lower cylinder block bolts with
lower cylinder block to the specified torque. Refer to EM-112, "Disassembly and Assembly" for the tightening
procedure.
CAUTION:
Never rotate crankshaft.

CYLINDER BLOCK
• Remove lower cylinder block and bearings, and using the scale on
the plastigage bag, measure the plastigage width. A
NOTE:
The procedure when the measured value exceeds the limit is the
same as that described in the “Method by Calculation”.
EM
JPBIA0231ZZ
D
MAIN BEARING CRUSH HEIGHT
• When lower cylinder block is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of
bearing must protrude. Refer to EM-112, "Disassembly and E
Assembly" for the tightening procedure.
A : Crush height F
Standard : There must be crush height.

• If the standard is not met, replace main bearings. G
JPBIA0233ZZ
CONNECTING ROD BEARING CRUSH HEIGHT H

• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings (1) installed,
the tip end of bearing must protrude. Refer to EM-112, "Disassem-
I
bly and Assembly" for the tightening procedure.
A : Crush height
J
Standard : There must be crush height.
• If the standard is not met, replace connecting rod bearings. K
JPBIA0233ZZ
LOWER CYLINDER BLOCK BOLT OUTER DIAMETER

• Measure the outer diameters (c), (d) at two positions as shown in L
the figure.
a : 20 mm (0.79 in) M
b : 30 mm (1.18 in)
e : 10 mm (0.39 in)
• If reduction appears in (a) range, regard it (c). N
Limit [(d) – (c)] : 0.11 mm (0.0043 in)

• If it exceeds the limit (large difference in dimensions), replace JPBIA0234ZZ
O
lower cylinder block bolt with new one.
CONNECTING ROD BOLT OUTER DIAMETER P

CYLINDER BLOCK
1. Measure the outer diameters [(a), (b) and (c)] at the position
a : Value at the end of the smaller diameter of the bolt

b : Value at the end of the smaller diameter of the bolt [opposite side of (a)]
c : Value of the smallest diameter of the smaller of the bolt
2. Obtain a mean value (d) of (a) and (b).
3. Subtract (c) from (d).
Limit [(d) – (c)] : 0.09 mm (0.0035 in) JPBIA0262ZZ
4. If it exceeds the limit (large difference in dimensions), replace the bolt with new one.
FLYWHEEL DEFLECTION (M/T models)
• Measure the deflection of flywheel contact surface to clutch with a
dial indicator (A).
• Measure the deflection at 210 mm (8.27 in) dia.
Standard : 0.45 mm (0.0177 in) or less.

• If measured value is out of the standard, replace flywheel.
JPBIA0236ZZ
MOVEMENT AMOUNT OF FLYWHEEL (M/T models)

CAUTION:
Never disassemble double mass flywheel.
Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.
• Tighten bolt at a force of 9.8 N·m (1.00 kg-m, 87 in-lb) to keep it from loosening.
2. Put a matching mark on circumferences of the two flywheel
masses without applying any load (measurement standard
points).
1 : Clutch cover mounting bolt

2 : Flywheel (transaxle side)
A : Torque wrench
b : 9.8 N·m (1.00 kg-m, 87 in-lb)
3. Apply a force of 9.8 N·m (1.00 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transaxle JPBIA0237ZZ
side.
4. Measure the dimensions of movement amounts (C) and (D) on circumference of the flywheel on the tran-
saxle side.
Standard: Less than 29.9 mm (1.177 in)

• If measured value is out of the standard, replace flywheel.
DRIVE PLATE (A/T models)

CYLINDER BLOCK
• Check drive plate and signal plate for deformation or damage.
CAUTION: A
• Never disassemble drive plate.
• Never place drive plate with signal plate facing down.
• When handling signal plate, take care not to damage or
EM
scratch it.
• Handle signal plate in a manner that prevents it from becom-
ing magnetized.
• If anything is found, replace drive plate. C
JPBIA0192ZZ
D
OIL JET
• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs.
• If it is not satisfied, clean or replace oil jet. E
OIL JET RELIEF VALVE

• Using a clean plastic stick, press check valve in oil jet relief valve.
Check that valve moves smoothly with proper reaction force. F
• If it is not satisfied, replace oil jet relief valve.
EMU0468D
I

HOW TO SELECT PISTON AND BEARING
Description INFOID:0000000004924230
Selection points Selection parts Selection items Selection methods

Determined by match of cylin-
der block bearing housing
Between cylinder block and Main bearing grade grade (inner diameter of hous-
Main bearing
crankshaft (bearing thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block and pis- Piston grade Piston grade = cylinder bore
(Piston is available together
ton (piston skirt diameter) grade (inner diameter of bore)
with piston pin as assembly.)
Between piston and connecting
— — —
rod*
*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is available.) The
information at the shipment from the plant is described as a reference.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
Piston INFOID:0000000004924231
WHEN NEW CYLINDER BLOCK IS USED

Check the cylinder bore grade (“1”, “2” or “3”) on rear side of cylinder
block, and select piston of the same grade.
A : Bearing housing grade No. 1

B : Bearing housing grade No. 2
C : Bearing housing grade No. 3
D : Bearing housing grade No. 4
E : Cylinder bore grade No. 1
F : Cylinder bore grade No. 2
G : Cylinder bore grade No. 3
JPBIA0268ZZ
H : Cylinder bore grade No. 4
I : Cylinder bore grade No. 5
J : Cylinder bore grade No. 6
K : Identification
: Engine front
NOTE:
Piston is available with piston pin as a set for the service part. (Only “0” grade piston pin is available.)
WHEN NEW CYLINDER BLOCK IS REUSED

1. Measure the cylinder bore inner diameter. Refer to EM-121, "Inspection".

2. Determine the bore grade by comparing the measurement with
the values under the cylinder bore inner diameter of the “PIS- A
TON SELECTION TABLE”.
A : RH
EM
B : LH
C : Piston pin grade number
D : Piston grade number
C
E : Front mark
F : Identification code
G
JPBIA1212ZZ
3. Select piston of the same grade.

H
PISTON SELECTION TABLE
Unit: mm (in)
Grade 1 2 3
I
95.500 - 95.510 95.510 - 95.520 95.520 - 95.530
Cylinder bore inner diameter
(3.7598 - 3.7602) (3.7602 - 3.7606) (3.7606 - 3.7610)
95.480 - 95.490 95.490 - 95.500 95.500 - 95.510 J
Piston skirt diameter
(3.7590 - 3.7594) (3.7594 - 3.7598) (3.7598 - 3.7602)
NOTE:
• Piston is available together with piston pin as assembly. K
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no pis-
ton pin grades can be selected. (Only “0” grade is available.)
• No second grade mark is available on piston.
L
Connecting Rod Bearing INFOID:0000000004924232
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED M

1. Apply connecting rod big end diameter grade stamped (D) on
connecting rod side face to the row in the “CONNECTING ROD
BEARING SELECTION TABLE”. N
A : Sample codes
B : Bearing stopper groove O
E : Weight grade
F : Cylinder No. P
G : Management code JPBIA0208ZZ
H : Front mark
I : Management code

2. Apply crankshaft pin journal diameter grade stamped on crank-
shaft front side to the column in the “CONNECTING ROD
BEARING SELECTION TABLE”
A : Journal diameter grade No. 1

B : Journal diameter grade No. 2
C : Journal diameter grade No. 3
D : Journal diameter grade No. 4
E : Pin diameter grade No. 1
F : Pin diameter grade No. 2 JPBIA0269ZZ
G : Pin diameter grade No. 3
H : Pin diameter grade No. 4
I : Pin diameter grade No. 5
J : Pin diameter grade No. 6
K : Identification
3. Read the symbol at the cross point of selected row and column in the “CONNECTING ROD BEARING
SELECTION TABLE”.
4. Apply the symbol obtained to the “CONNECTING ROD BEARING GRADE TABLE” to select connecting
rod bearing.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
1. Measure connecting rod big end diameter and crankshaft pin journal diameter. Refer to EM-121, "Inspec-
tion".
2. Correspond the measured dimension in “connecting rod big end diameter” row of “CONNECTING ROD
BEARING SELECTION TABLE”.
3. Correspond the measured dimension in “crankshaft pin diameter” column of “CONNECTING ROD BEAR-
ING SELECTION TABLE”.
4. Follow step 3 and later in “WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED”.
CONNECTING ROD BEARING SELECTION TABLE

EM
PBIC5435E
K
CONNECTING ROD BEARING GRADE TABLE

L
Connecting rod bearing grade table : Refer to EM-148, "Connecting Rod Bearing".
UNDERSIZE BEARING USAGE GUIDE

• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod M
bearings, use undersize (US) bearings.
• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard. N
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the
fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)].
O
JPBIA0216ZZ

Bearing undersize table : Refer to EM-148, "Connecting Rod Bearing".
Main Bearing INFOID:0000000004924233
WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED

1. “MAIN BEARING SELECTION TABLE” rows correspond to
bearing housing grade on rear side of cylinder block.
A : Bearing housing grade No. 1

B : Bearing housing grade No. 2
C : Bearing housing grade No. 3
D : Bearing housing grade No. 4
E : Cylinder bore grade No. 1
F : Cylinder bore grade No. 2
G : Cylinder bore grade No. 3
JPBIA0268ZZ
H : Cylinder bore grade No. 4
I : Cylinder bore grade No. 5
J : Cylinder bore grade No. 6
K : Identification code
: Engine front
2. “MAIN BEARING SELECTION TABLE” columns correspond to

journal diameter grade on front side of crankshaft.
A : Journal diameter grade No. 1

B : Journal diameter grade No. 2
C : Journal diameter grade No. 3
D : Journal diameter grade No. 4
E : Pin diameter grade No. 1
F : Pin diameter grade No. 2
G : Pin diameter grade No. 3
JPBIA0269ZZ
H : Pin diameter grade No. 4
I : Pin diameter grade No. 5
J : Pin diameter grade No. 6
K : Identification code
3. Select main bearing grade at the point where selected row and column meet in “MAIN BEARING SELEC-
TION TABLE”.
4. Apply sign at crossing in above step 3 to “MAIN BEARING GRADE TABLE”.
NOTE:
• “MAIN BEARING GRADE TABLE” applies to all journals.
• Service parts are available as a set of both upper and lower.
WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED
1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer
to EM-121, "Inspection".
2. Correspond the measured dimension in “Cylinder block main bearing housing inner diameter” row of
“MAIN BEARING SELECTION TABLE”.
3. Correspond the measured dimension in “Crankshaft main journal diameter” column of “MAIN BEARING
SELECTION TABLE”.
4. Follow step 3 and later in “When New Cylinder Block and Crankshaft are Used”.

MAIN BEARING SELECTION TABLE
A
EM
K
JPBIA0264ZZ
MAIN BEARING GRADE TABLE (ALL JOURNALS)

L
Main bearing grade table (All journals) : Refer to EM-147, "Main Bearing".
UNDERSIZE BEARING USAGE GUIDE

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under- M
size (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard. N
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)].
O
Bearing undersize table : Refer to EM-147,
"Main Bearing".
P
JPBIA0216ZZ

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000004924235
GENERAL SPECIFICATIONS
Cylinder arrangement V-6

3 3,696 (225.53)
Displacement cm (cu in)
Bore and stroke mm (in) 95.5×86.0 (3.760×3.386)
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 11
Standard 1,667 - 2,354 (17 - 24, 242 - 341)
Compression pressure
Minimum 1,226 (12.5, 178)
kPa (kg/cm2, psi)/200 rpm
Differential limit between cylinders 98 (1.0, 14)
Cylinder number
SEM713A
Unit: degree
Intake valve open (BTDC) 63 - −64
Intake valve close (ABDC) −73 - 82
Valve timing
Exhaust valve open (BBDC) 64
Exhaust valve close (ATDC) 12
Drive Belt INFOID:0000000004924236
DRIVE BELT
Tension of drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Spark Plug INFOID:0000000004924356
SPARK PLUG
Unit: mm (in)
Make DENSO
Standard type FXE24HR11

Standard 1.1 (0.043)
Gap (Nominal) A
Limit 1.4 (0.055)
Intake Manifold INFOID:0000000004924238
EM
INTAKE MANIFOLD
Unit: mm (in)
Items Limit C
Surface distortion Intake manifold 0.1 (0.004)
Exhaust Manifold INFOID:0000000004924239 D
EXHAUST MANIFOLD
Unit: mm (in) E
Items Limit
Surface distortion Exhaust manifold 0.7 (0.028)
F
Camshaft INFOID:0000000004924240
CAMSHAFT (EXH) G
Unit: mm (in)
Items Standard Limit

No. 1 0.045 - 0.086 (0.0018 - 0.0034)
H
Camshaft (EXH) journal oil clearance 0.150 (0.0059)
No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030)
No. 1 26.000 - 26.021 (1.0236 - 1.0244) —
VVEL ladder assembly bracket inner diameter (EXH) I
No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) —
No. 1 25.935 - 25.955 (1.0211 - 1.0218) —
Camshaft (EXH) journal diameter
No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) — J
Camshaft (EXH) end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)
Bank 1 45.015 - 45.205 (1.7722 - 1.7797)
Camshaft (EXH) cam height “A” 0.2 (0.008)*1 K
Bank 2 46.735 - 46.925 (1.8400 - 1.8474)
Camshaft (EXH) runout [TIR*2] Less than 0.02 (0.0008) 0.05 (0.0020)
L
Camshaft sprocket (EXH) runout [TIR*2] — 0.15 (0.0059)
SEM671
P
*1: Cam wear limit
*2: Total indicator reading
CAMSHAFT (INT)

Unit: mm (in)

Drive shaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)
Camshaft sprocket (INT) runout [TIR*1] — 0.15 (0.0059)
*1: Total indicator reading
VALVE LIFTER
Unit: mm (in)
Items Standard
Valve lifter outer diameter 33.980 - 33.990 (1.3378 - 1.3382)
Valve lifter hole diameter 34.000 - 34.016 (1.3386 - 1.3392)
Valve lifter clearance 0.010 - 0.036 (0.0004 - 0.0014)
VALVE CLEARANCE
Unit: mm (in)
Items Cold Hot* (reference data)

Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)
AVAILABLE VALVE LIFTER

Unit: mm (in)
Identification (stamped) mark Thickness

788 7.88 (0.3102)
790 7.90 (0.3110)
792 7.92 (0.3118)
794 7.94 (0.3126)
796 7.96 (0.3134)
798 7.98 (0.3142)
800 8.00 (0.3150)
802 8.02 (0.3157)
804 8.04 (0.3165)
806 8.06 (0.3173)
808 8.08 (0.3181)
810 8.10 (0.3189)
812 8.12 (0.3197)
814 8.14 (0.3205)
816 8.16 (0.3213)
818 8.18 (0.3220)
820 8.20 (0.3228)
822 8.22 (0.3236)
824 8.24 (0.3244)
826 8.26 (0.3252)
828 8.28 (0.3260)
830 8.30 (0.3268)
832 8.32 (0.3276)
834 8.34 (0.3283)
836 8.36 (0.3291)

Identification (stamped) mark Thickness
A
838 8.38 (0.3299)
840 8.40 (0.3307)
EM
E
SEM758G
Cylinder Head INFOID:0000000004924241
F
CYLINDER HEAD
Unit: mm (in)

G
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)

Normal cylinder head height “H” 126.4 (4.98) — H
PBIC0924E
VALVE DIMENSIONS L
Unit: mm (in)
SEM188
P
Intake 36.6 - 36.9 (1.441 - 1.453)
Valve head diameter “D”
Exhaust 30.2 - 30.5 (1.189 - 1.201)
Intake 100.11 (3.94)
Valve length “L”
Exhaust 94.67 (3.7272)

Intake 5.965 - 5.980 (0.2348 - 0.2354)
Valve stem diameter “d”
Exhaust 5.962 - 5.970 (0.2347 - 0.2350)
Intake
Valve seat angle “α” 45°15′ - 45°45′
Exhaust
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 1.3 (0.051)
Valve margin “T” limit 0.5 (0.020)
Valve stem end surface grinding limit 0.2 (0.008)
VALVE GUIDE
Unit: mm (in)
SEM950E
Items Standard Oversize (Service) [0.2 (0.008)]*

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)
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.003)
Valve guide clearance
Exhaust 0.030 - 0.056 (0.0012 - 0.0022) 0.09 (0.004)
Projection length “L” 12.6 - 12.8 (0.496 - 0.504)
*: Parts settings are for exhaust side only
VALVE SEAT
Unit: mm (in)
PBIC2745E
Items Standard Oversize (Service) [0.5 (0.02)] *4

Intake 38.000 - 38.016 (1.4961 - 1.4967) —
Cylinder head seat recess diameter “D”
Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)*4

Intake 38.097 - 38.113 (1.4999 - 1.5005) —
Valve seat outer diameter “d” A
Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676)*4
Intake 0.081 - 0.113 (0.0032 - 0.0044)
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038) EM
Intake 34.6 (1.362)
Diameter “d1”*1
Exhaust 27.7 (1.091)
C
Intake 35.9 - 36.4 (1.413 - 1.433)
Diameter “d2”*2
Exhaust 29.3 - 29.8 (1.154 - 1.173)
Intake 60° D
Angle “α1”
Exhaust 60°
Intake 88°45′ - 90°15′
Angle “α2” E
Exhaust 88°45′ - 90°15′
Intake 120°
Angle “α3”
Exhaust 120°
F
Intake 1.0 - 1.4 (0.039 - 0.055)
Contacting width “W”*3
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Intake 5.9 - 6.0 (0.232 - 0.236) — G
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)*4
Depth “H” 6.0 (0.236) H
*1: Diameter made by intersection point of conic angles “α1” and “α2”
*2: Diameter made by intersection point of conic angles “α2” and “α3”
*3: Machining data
I
*4: Parts settings are for exhaust side only
VALVE SPRING J
Standard
Items
Intake Exhaust K
Free height 45.66 mm (1.7976 in) 43.85 mm (1.7264 in)
191.1 - 215.5 N (19.5 - 22 kg, 43 - 48 lb) 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)
Installation L
at 40.90 mm (1.6102 in) at 37.00 mm (1.4567 in)
Pressure
830.9 - 936.9 N (84.8 - 95.6 kg, 187 - 211 lb) 502 - 566 N (51.2 - 57.7 kg, 113 - 127 lb)
Valve open
at 28.07 mm (1.1051 in) at 26.80 mm (1.0551 in)
Identification color Purple Yellowish green M
Limit
Items N
Intake Exhaust
Out-of-square 2.0 mm (0.079 in) 1.9 mm (0.075 in)
Cylinder Block INFOID:0000000004924242

O
CYLINDER BLOCK
P

Unit: mm (in)
JPBIA1050GB
Standard Less than 0.03 (0.0012)

Surface flatness
Limit 0.1 (0.004)
Main bearing housing inner diameter Standard 69.993 - 70.017 (2.7556 - 2.7566)
Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602)
Standard Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606)
Cylinder bore Inner diameter
Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610)
Wear limit 0.2 (0.008)
Out-of-round 0.015 (0.0006)
Limit
Taper 0.010 (0.0004)
Grade No. A 69.993 - 69.994 (2.7556 - 2.7557)
Grade No. B 69.994 - 69.995 (2.7557 - 2.7557)
Grade No. C 69.995 - 69.996 (2.7557 - 2.7557)
Grade No. D 69.996 - 69.997 (2.7557 - 2.7558)
Grade No. E 69.997 - 69.998 (2.7558 - 2.7558)
Grade No. F 69.998 - 69.999 (2.7558 - 2.7559)
Grade No. G 69.999 - 70.000 (2.7559 - 2.7559)
Grade No. H 70.000 - 70.001 (2.7559 - 2.7559)
Grade No. J 70.001 - 70.002 (2.7559 - 2.7560)
Grade No. K 70.002 - 70.003 (2.7560 - 2.7560)
Grade No. L 70.003 - 70.004 (2.7560 - 2.7561)
Grade No. M 70.004 - 70.005 (2.7561 - 2.7561)
Main bearing housing inner diameter grade (Without bearing)
Grade No. N 70.005 - 70.006 (2.7561 - 2.7561)
Grade No. P 70.006 - 70.007 (2.7561 - 2.7562)
Grade No. R 70.007 - 70.008 (2.7562 - 2.7562)
Grade No. S 70.008 - 70.009 (2.7562 - 2.7563)
Grade No. T 70.009 - 70.010 (2.7563 - 2.7563)
Grade No. U 70.010 - 70.011 (2.7563 - 2.7563)
Grade No. V 70.011 - 70.012 (2.7563 - 2.7564)
Grade No. W 70.012 - 70.013 (2.7564 - 2.7564)
Grade No. X 70.013 - 70.014 (2.7564 - 2.7565)
Grade No. Y 70.014 - 70.015 (2.7565 - 2.7565)
Grade No. 4 70.015 - 70.016 (2.7565 - 2.7565)
Grade No. 7 70.016 - 70.017 (2.7565 - 2.7566)
Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)
AVAILABLE PISTON

Unit: mm (in)
A
EM
D
SEM882E
Items Standard Oversize (Service) [0.2 (0.008)]

E
Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) —
Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) —
Piston skirt diameter “A”
Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602) —
F
Service — 95.680 - 95.710 (3.7669 - 3.7681)
“a” dimension 38.8 (1.528) — G
Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) —
Piston pin hole diameter
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) —
H
Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)
PISTON RING
Unit: mm (in) I
Top 0.040 - 0.080 (0.0016 - 0.0031) 0.11 (0.0043)
J
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.055 - 0.155 (0.0022 - 0.0061) 0.19 (0.0075)
Top 0.23 - 0.33 (0.0091 - 0.0130) 0.42 (0.0169) K
End gap 2nd 0.23 - 0.33 (0.0091 - 0.0130) 0.57 (0.0224)
Oil (rail ring) 0.17 - 0.47 (0.0067 - 0.0185) 0.63 (0.0248)
L
PISTON PIN
Unit: mm (in)
Items Standard Limit M

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) —
N
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
Connecting rod bushing oil clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.030 (0.0012)
CONNECTING ROD O
Unit: mm (in)

P
Center distance 149.45 - 149.55 (5.88 - 5.89) —
Bend [per 100 (3.94)] — 0.15 (0.0059)
Torsion [per 100 (3.94)] — 0.30 (0.0118)
Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664) —
Connecting rod bushing inner diameter*
Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666) —

Grade No. A 57.000 - 57.001 (2.2441 - 2.2441) —
Grade No. B 57.001 - 57.002 (2.2441 - 2.2442) —
Grade No. C 57.002 - 57.003 (2.2442 - 2.2442) —
Grade No. D 57.003 - 57.004 (2.2442 - 2.2442) —
Grade No. E 57.004 - 57.005 (2.2442 - 2.2443) —
Grade No. F 57.005 - 57.006 (2.2443 - 2.2443) —
Connecting rod big end diameter (Without
Grade No. G 57.006 - 57.007 (2.2443 - 2.2444) —
bearing)
Grade No. H 57.007 - 57.008 (2.2444 - 2.2444) —
Grade No. J 57.008 - 57.009 (2.2444 - 2.2444) —
Grade No. K 57.009 - 57.010 (2.2444 - 2.2445) —
Grade No. L 57.010 - 57.011 (2.2445 - 2.2445) —
Grade No. M 57.011 - 57.012 (2.2445 - 2.2446) —
Grade No. N 57.012 - 57.013 (2.2446 - 2.2446) —
Side clearance 0.20 - 0.35 (0.0079 - 0.0138) 0.40 (0.0157)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
SEM645 SBIA0535E
Grade No. A 64.975 - 64.974 (2.5581 - 2.5580)

Grade No. B 64.974 - 64.973 (2.5580 - 2.5580)
Grade No. C 64.973 - 64.972 (2.5580 - 2.5579)
Grade No. D 64.972 - 64.971 (2.5579 - 2.5579)
Grade No. E 64.971 - 64.970 (2.5579 - 2.5579)
Grade No. F 64.970 - 64.969 (2.5579 - 2.5578)
Grade No. G 64.969 - 64.968 (2.5578 - 2.5578)
Grade No. H 64.968 - 64.967 (2.5578 - 2.5578)
Grade No. J 64.967 - 64.966 (2.5578 - 2.5577)
Grade No. K 64.966 - 64.965 (2.5577 - 2.5577)
Grade No. L 64.965 - 64.964 (2.5577 - 2.5576)
Grade No. M 64.964 - 64.963 (2.5576 - 2.5576)
Main journal diameter. “Dm” grade Standard
Grade No. N 64.963 - 64.962 (2.5576 - 2.5576)
Grade No. P 64.962 - 64.961 (2.5576 - 2.5575)
Grade No. R 64.961 - 64.960 (2.5575 - 2.5575)
Grade No. S 64.960 - 64.959 (2.5575 - 2.5574)
Grade No. T 64.959 - 64.958 (2.5574 - 2.5574)
Grade No. U 64.958 - 64.957 (2.5574 - 2.5574)
Grade No. V 64.957 - 64.956 (2.5574 - 2.5573)
Grade No. W 64.956 - 64.955 (2.5573 - 2.5573)
Grade No. X 64.955 - 64.954 (2.5573 - 2.5572)
Grade No. Y 64.954 - 64.953 (2.5572 - 2.5572)
Grade No. 4 64.953 - 64.952 (2.5572 - 2.5572)
Grade No. 7 64.952 - 64.951 (2.5572 - 2.5571)

Grade No. A 53.974 - 53.973 (2.1250 - 2.1249)
A
Grade No. B 53.973 - 53.972 (2.1249 - 2.1249)
Grade No. C 53.972 - 53.971 (2.1249 - 2.1248)
Grade No. D 53.971 - 53.970 (2.1248 - 2.1248) EM
Grade No. E 53.970 - 53.969 (2.1248 - 2.1248)
Grade No. F 53.969 - 53.968 (2.1248 - 2.1247)
Grade No. G 53.968 - 53.967 (2.1247 - 2.1247) C
Grade No. H 53.967 - 53.966 (2.1247 - 2.1246)
Grade No. J 53.966 - 53.965 (2.1246 - 2.1246)
Pin journal diameter. “Dp” grade Standard D
Grade No. K 53.965 - 53.964 (2.1246 - 2.1246)
Grade No. L 53.964 - 53.963 (2.1246 - 2.1245)
Grade No. M 53.963 - 53.962 (2.1245 - 2.1245) E
Grade No. N 53.962 - 53.961 (2.1245 - 2.1244)
Grade No. P 53.961 - 53.960 (2.1244 - 2.1244)
F
Grade No. R 53.960 - 53.959 (2.1244 - 2.1244)
Grade No. S 53.959 - 53.958 (2.1244 - 2.1243)
Grade No. T 53.958 - 53.957 (2.1243 - 2.1243) G
Grade No. U 53.957 - 53.956 (2.1243 - 2.1242)
Center distance “r” 42.96 - 43.04 (1.6913 - 1.6945)
H
Taper (Difference between “A” and “B”) 0.0025 (0.0001)
Limit
Out-of-round (Difference between “X” and “Y”) 0.0025 (0.0001)
Standard Less than 0.05 (0.0020) I
Crankshaft runout [TIR*]
Limit 0.10 (0.0039)
Standard 0.10 - 0.25 (0.0039 - 0.0098)
Crankshaft end play J
Limit 0.30 (0.0118)
*: Total indicator reading
Main Bearing INFOID:0000000004924243 K
MAIN BEARING
Unit: mm (in) L
PBIC2969E
Grade number Thickness Width Identification color Remarks P

0 2.500 - 2.503 (0.0984 - 0.0985) Black
1 2.503 - 2.506 (0.0985 - 0.0987) Brown
2 2.506 - 2.509 (0.0987 - 0.0988) Green
3 2.509 - 2.512 (0.0988 - 0.0989) Yellow Grade is the same
for upper and lower
4 2.512 - 2.515 (0.0989 - 0.0990) Blue bearings.
5 2.515 - 2.518 (0.0990 - 0.0991) Pink
6 2.518 - 2.521 (0.0991 - 0.0993) Purple
7 2.521 - 2.524 (0.0993 - 0.0994) White
UPR 2.503 - 2.506 (0.0985 - 0.0987) Brown
01
LWR 2.500 - 2.503 (0.0984 - 0.0985) Black
UPR 2.506 - 2.509 (0.0987 - 0.0988) 19.9 - 20.1 Green
12
LWR 2.503 - 2.506 (0.0985 - 0.0987) (0.783 - 0.791) Brown
UPR 2.509 - 2.512 (0.0988 - 0.0989) Yellow
23
LWR 2.506 - 2.509 (0.0987 - 0.0988) Green
UPR 2.512 - 2.515 (0.0989 - 0.0990) Blue Grade and color are
34 different for upper
LWR 2.509 - 2.512 (0.0988 - 0.0989) Yellow and lower bearings.
UPR 2.515 - 2.518 (0.0990 - 0.0991) Pink
45
LWR 2.512 - 2.515 (0.0989 - 0.0990) Blue
UPR 2.518 - 2.521 (0.0991 - 0.0993) Purple
56
LWR 2.515 - 2.518 (0.0990 - 0.0991) Pink
UPR 2.521 - 2.524 (0.0993 - 0.0994) White
67
LWR 2.518 - 2.521 (0.0991 - 0.0993) Purple
UNDERSIZE
Unit: mm (in)
Items Thickness Main journal diameter

0.25 (0.0098) 2.633 - 2.641 (0.1037 - 0.1040) Grind so that bearing clearance is the specified value.
MAIN BEARING OIL CLEARANCE

Unit: mm (in)

Main bearing oil clearance 0.035 - 0.045 (0.0014 - 0.0018)* 0.065 (0.0026)
*: Actual clearance
Connecting Rod Bearing INFOID:0000000004924244
CONNECTING ROD BEARING

Unit: mm (in)
Grade number Thickness Identification color (mark)

0 1.497 - 1.500 (0.0589 - 0.0591) Black
1 1.500 - 1.503 (0.0591 - 0.0592) Brown
2 1.503 - 1.506 (0.0592 - 0.0593) Green
3 1.506 - 1.509 (0.0593 - 0.0594) Yellow
4 1.509 - 1.512 (0.0594 - 0.0595) Blue
UNDERSIZE
Unit: mm (in)
Items Thickness Crank pin journal diameter

0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643) Grind so that bearing clearance is the specified value.

CONNECTING ROD BEARING OIL CLEARANCE
Unit: mm (in) A
Connecting rod bearing oil clearance 0.040 - 0.053 (0.0016 - 0.0021)* 0.070 (0.0028)
EM
*: Actual clearance

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ENGINE

NOISE, VIBRATION AND HARSHNESS AIR CLEANER FILTER ..................................... 15

PRECAUTIONS ................................................... 5 CAMSHAFT VALVE CLEARANCE .................. 18

INTAKE MANIFOLD COLLECTOR .................. 29 O

Revision: 2010 March EM-1 2009 G37 Convertible

UNIT REMOVAL AND INSTALLATION ..... 68 SERVICE DATA AND SPECIFICATIONS

Revision: 2010 March EM-2 2009 G37 Convertible

1. Locate the area where noise occurs.

Revision: 2010 March EM-3 2009 G37 Convertible

Operating condition of engine

Piston to piston pin oil

Revision: 2010 March EM-4 2009 G37 Convertible

Revision: 2010 March EM-5 2009 G37 Convertible

Revision: 2010 March EM-6 2009 G37 Convertible

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

REMOVAL OF LIQUID GASKET SEALING

Revision: 2010 March EM-7 2009 G37 Convertible

• Within five minutes of liquid gasket application, install the mat-

• In this manual, each bank name is defined as follows:

A : Bank 1 (The conventional right bank)

• For cylinder numbers and bank layout, refer to the illustration.

Bank 1 : The bank side including cylinder No. 1

(even-numbered cylinder side)

Revision: 2010 March EM-8 2009 G37 Convertible

KV10115600 Installing valve oil seal

EM03470000 Installing piston assembly into cylinder bore K

KV10111100 Removing oil pan (lower and upper), front and

Revision: 2010 March EM-9 2009 G37 Convertible

KV10114400 Loosening or tightening air fuel ratio sensor 1

KV10118600 Removing and installing crankshaft pulley

Commercial Service Tools INFOID:0000000004924153

( — ) Loosening nuts and bolts

( — ) Removing and installing flywheel

Revision: 2010 March EM-10 2009 G37 Convertible

(J-24239-01) Loosening and tightening cylinder head bolt,

( — ) Removing and installing spark plug

( — ) Finishing valve seat (EXH) dimensions K

( — ) Removing and installing valve guide (EXH)

Revision: 2010 March EM-11 2009 G37 Convertible

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

( — ) Inspection valve clearance (Use a curved-tip

Revision: 2010 March EM-12 2009 G37 Convertible

Refer to EM-138, "Drive Belt".

Revision: 2010 March EM-13 2009 G37 Convertible

: Loosening direction of drive belt

3. Under the above condition, insert a metallic bar of approximately

4. Remove drive belt.

INSPECTION AFTER INSTALLATION

Revision: 2010 March EM-14 2009 G37 Convertible

Revision: 2010 March EM-15 2009 G37 Convertible

1. PCV hose 2. Clamp 3. PCV valve

Removal and Installation INFOID:0000000004924165

Revision: 2010 March EM-16 2009 G37 Convertible

INSPECTION AFTER REMOVAL

Spark plug (Standard type) : Refer to EM-138, "Spark Plug".

Cleaner air pressure I

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

Revision: 2010 March EM-17 2009 G37 Convertible

Valve clearance : Refer to EM-139, "Camshaft".