Nissan-Murano 2015 EN Motor E137da4f0c

ENGINE
EM
A
EM
SECTION
ENGINE MECHANICAL C
E
CONTENTS
PRECAUTION ............................................... 3 AIR CLEANER FILTER ..................................... 17 F
Exploded View .........................................................17
PRECAUTIONS ................................................... 3 Removal and Installation .........................................17
Precaution for Supplemental Restraint System G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- SPARK PLUG ................................................... 18
SIONER" ................................................................... 3 Exploded View .........................................................18
Precaution for Drain Coolant and Engine Oil ............ 3 Removal and Installation .........................................18
H
Precaution for Procedure without Cowl Top Cover...... 3
Parts Requiring Angular Tightening .......................... 3 CAMSHAFT VALVE CLEARANCE .................. 20
Precaution for Disconnecting Fuel Piping ................. 4 Valve Clearance ......................................................20
Precaution for Inspection, Repair and Replace- I
COMPRESSION PRESSURE ........................... 24
ment .......................................................................... 4
On-Vehicle Service ..................................................24
Precaution for Removal and Disassembly ................ 4
Precaution for Assembly and Installation .................. 4 REMOVAL AND INSTALLATION ............... 25 J
Special Cautions to Ensure the Safe Disposal of
Sodium-filled Exhaust Valves .................................... 4 ENGINE ROOM COVER ................................... 25
Precaution for Liquid Gasket ..................................... 5 Exploded View .........................................................25
K
Removal and Installation .........................................25
PREPARATION ............................................ 7
AIR CLEANER AND AIR DUCT ....................... 26
PREPARATION ................................................... 7 Exploded View .........................................................26 L
Special Service Tools .............................................. 7 Removal and Installation .........................................26
Commercial Service Tool .......................................... 8
INTAKE MANIFOLD COLLECTOR .................. 28
SYSTEM DESCRIPTION ............................. 12 Exploded View .........................................................28 M
Removal and Installation .........................................28
NOISE, VIBRATION, AND HARSHNESS
(NVH) TROUBLESHOOTING ............................12 INTAKE MANIFOLD ......................................... 31 N
NVH Troubleshooting - Engine Noise ..................... 12 Exploded View .........................................................31
Use the Chart Below to Help You Find the Cause Removal and Installation .........................................31
of the Symptom ....................................................... 13
EXHAUST MANIFOLD AND THREE WAY O
PERIODIC MAINTENANCE ......................... 14 CATALYST ........................................................ 33
Exploded View .........................................................33
DRIVE BELT .......................................................14 Removal and Installation (bank 2) ...........................33 P
Exploded View ........................................................ 14 Removal and Installation (bank 1) ...........................35
Checking Drive Belt ................................................. 14
Tension Adjustment ................................................ 14 OIL PAN AND OIL STRAINER ......................... 38
Removal and Installation ......................................... 14 Exploded View .........................................................38
Removal and Installation of Drive Belt Auto-ten- Removal and Installation (Lower Oil Pan) ...............38
sioner ...................................................................... 16 Removal and Installation (Upper Oil Pan) ...............39
Revision: October 2014 EM-1 2015 Murano

IGNITION COIL .................................................. 44 Disassembly and Assembly .................................... 94
Exploded View ........................................................ 44 Inspection After Disassembly .................................. 96
Removal and Installation (bank 2) .......................... 44
Removal and Installation (bank 1) .......................... 44 ENGINE MOUNT .............................................. 101
ROCKER COVER .............................................. 45 ENGINE MOUNT (FRONT) ..................................... 101

Exploded View ........................................................ 45 ENGINE MOUNT (FRONT) : Removal and Instal-
lation ..................................................................... 101
Removal and Installation (bank 2) .......................... 45
Removal and Installation (bank 1) .......................... 47 UNIT REMOVAL AND INSTALLATION ... 104
FUEL INJECTOR AND FUEL TUBE ................. 49 ENGINE ASSEMBLY ....................................... 104
Exploded View ........................................................ 49
Removal and Installation ........................................ 49 FWD ......................................................................... 104
Inspection ............................................................... 53 FWD : Exploded View ........................................... 104
FWD : Removal and Installation ........................... 104
VALVE TIMING CONTROL ............................... 54
Exploded View ........................................................ 54 AWD ........................................................................ 108
Valve Timing Control Cover (bank 1) ..................... 54 AWD : Exploded View ........................................... 108
Valve Timing Control Cover (bank 2) ..................... 55 AWD : Removal and Installation ........................... 109
FRONT TIMING CHAIN CASE .......................... 57 UNIT DISASSEMBLY AND ASSEMBLY .. 113
Exploded View ........................................................ 57
Removal and Installation ........................................ 57 CYLINDER BLOCK .......................................... 113
Exploded View ...................................................... 113
TIMING CHAIN .................................................. 65 Disassembly and Assembly .................................. 114
Exploded View ........................................................ 65 Inspection .............................................................. 124
Removal and Installation ........................................ 65 Dowel Pin Alignment ............................................. 134
REAR TIMING CHAIN CASE ............................ 73 SERVICE DATA AND SPECIFICATIONS
Exploded View ........................................................ 73 (SDS) ......................................................... 136
Removal and Installation ........................................ 73
SERVICE DATA AND SPECIFICATIONS
CAMSHAFT ....................................................... 78 (SDS) ................................................................ 136
Exploded View ........................................................ 78
General Specification ........................................... 136
Removal and Installation ........................................ 78
Drive Belt .............................................................. 136
Inspection after Installation ..................................... 86
Spark Plug ............................................................ 137
OIL SEAL ........................................................... 87 Intake Manifold ...................................................... 137
Removal and Installation of Valve Oil Seal ............. 87 Exhaust Manifold .................................................. 137
Removal and Installation of Front Oil Seal ............. 87 Camshaft ............................................................... 137
Removal and Installation of Rear Oil Seal .............. 89 Cylinder Head ...................................................... 139
Cylinder Block ...................................................... 142
CYLINDER HEAD .............................................. 91 Main Bearing ........................................................ 145
Exploded View ........................................................ 91 Connecting Rod Bearing ..................................... 146
Removal and Installation ........................................ 91 Drive Plate ............................................................ 147

PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
PRE-TENSIONER" INFOID:0000000011536741
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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. Information necessary to service the system safely is included in the SR and SB section of
this Service Manual.
WARNING: D
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. E
• 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 SR section.
F
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni- H
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) 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 I
battery and wait at least three minutes before performing any service.
Precaution for Drain Coolant and Engine Oil INFOID:0000000011220614
J
• Drain engine coolant and engine oil after the engine has cooled completely.
Precaution for Procedure without Cowl Top Cover INFOID:0000000011220613
K
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield. L
N
PIIB3706J
Parts Requiring Angular Tightening INFOID:0000000011220619 O
• Use an angle wrench for the final tightening of the following engine parts:
- Cylinder head bolts
- Main bearing cap bolts P
- Connecting rod cap nuts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.

PRECAUTIONS
< PRECAUTION >
Precaution for Disconnecting Fuel Piping INFOID:0000000011220615
• Before starting work, make sure no fire or spark producing items are in the work area.
• Release fuel pressure before disassembly.
• After disconnecting pipes, plug openings to stop fuel leaks.
Precaution for Inspection, Repair and Replacement INFOID:0000000011220617
• Thoroughly inspect parts before repairing or replacing them, even if they are new. Replace as necessary.
Precaution for Removal and Disassembly INFOID:0000000011220616
• When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
• 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
where noted in the step.
Precaution for Assembly and Installation INFOID:0000000011220618
• 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
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.
• Dowel pins are used in several critical parts for correct alignment. When replacing and reassembling parts
with dowel pins, check that dowel pins are installed in their original positions.
• Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for 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.
• Release air within route when refilling after draining coolant.
• Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped).
Then make sure that there are no leaks at fuel line connections.
• After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for
leaks.
Special Cautions to Ensure the Safe Disposal of Sodium-filled Exhaust Valves
INFOID:0000000011536743
Handling and disposal of sodium-filled exhaust valves requires spe-

cial care and consideration. Under conditions such as breakage with
subsequent contact with water, metal sodium which lines the inner
portion of exhaust valve will react violently, forming sodium hydrox-
ide and hydrogen which may result in an explosion. Sodium-filled
exhaust valve is identified on the top of its stem as shown in illustra-
tion.
(A) : Identification mark of sodium-filled exhaust valve
AWBIA2343ZZ
DEALER DISPOSAL INSTRUCTIONS

CAUTION:
• Use approved shatter-resistant eye protection when performing this procedure.
• Perform this and all subsequent disposal work procedures in an open room, away from flammable
liquids. Keep a fire extinguisher, rated at least 10 ABC, in close proximity to the work area.
• Be sure to wear rubber gloves when performing the following operations.
• Make sure the resultant (high alkalinity) waste water does not contact your skin. If the waste water
does contact you, wash the contacted area immediately with large quantities of water.
PRECAUTIONS
< PRECAUTION >
• Dealers should check their respective state and local regulations concerning any chemical treatment
or waste water discharge permits which may be required to dispose of the resultant (high alkalinity) A
waste water.
1. Clamp valve stem in a vice.
2. The valve has a specially-hardened surface. To cut through it, EM
first remove a half-round section, approximately 30 mm (1.18 in)
long using air-powered grinder until black color is removed and
silver color appears.
C
(A) : Black color
(B) : Silver color
(c) : 47 mm (1.85 in)
D
(d) : 17 mm (0.67 in)
JPBIA4964ZZ
E
3. Use hacksaw to cut through approximately half the diameter of
valve stem. Make the serration at a point 40 mm (1.57 in) from
the end of valve stem.
F
(a) : 40 mm (1.57 in)
H
JPBIA4965ZZ
4. Cover the serrated end of the valve with a large shop towel (A).
Strike the valve face end with a hammer, separating it into two I
pieces.
5. Fill a bucket, such as a 20 (5-1/4 US gal, 4-3/8 Imp gal) oil
can, with at least 10 (2-5/8 US gal, 2-1/4 lmp gal) of water. J
Carefully place the already cut (serrated) valves into the water
one-at-a-time using a set of large tweezers and quickly move
away at least 2.7 m (9 ft).
K
JPBIA4966ZZ
L
6. The valves should be placed in a standing position as shown in
the illustration to allow complete reaction. After the bubbling
action has subsided, additional valves can be placed into the
bucket allowing each subsequent chemical reaction to subside. M
However, no more than eight valves should be placed in the
same 10 (2-5/8 US gal, 2-1/4 lmp gal) amount of water. The
complete chemical reaction may take as long as four to five N
hours. Remove the valves using a set of large tweezers after the
chemical reaction has stopped. Afterwards, valves can be dis-
posed as ordinary scrap.
O
JPBIA4967ZZ
(A) : Bucket [Such as 20 (5-1/4 US gal, 4-3/8 Imp gal) oil can]
Precaution for Liquid Gasket INFOID:0000000011607899

P
REMOVAL OF LIQUID GASKET SEALING

PRECAUTIONS
< PRECAUTION >
• After removing the bolts and nuts, separate the mating surface and
remove the liquid gasket using Tool (A).
Tool Number : KV10111100 (J-37228)

CAUTION:
Be careful not to damage the mating surfaces.
• In areas where the cutter is difficult to use, use a plastic hammer to
lightly tap (1) the cutter where the liquid gasket is applied. Use a
plastic hammer to slide (2) the cutter by tapping on the side.
CAUTION:
Do not damage the mating surfaces. AWBIA1249GB
LIQUID GASKET APPLICATION PROCEDURE

1. Using suitable tool (A), remove old liquid gasket adhering to the
liquid gasket application surface and the mating surface.
• Remove liquid gasket completely from the groove of the liquid
gasket application surface, mounting bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign materials.
JPBIA0053ZZ
3. Attach liquid gasket tube to the suitable tool.

Use Genuine Silicone RTV Sealant, or equivalent. Refer to
GI-22, "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.
• After 30 minutes or more have passed from the installation, fill JPBIA0010ZZ
engine oil and engine coolant. Refer to LU-9, "Changing Engine Oil" and CO-9, "Changing Engine Cool-
ant".
CAUTION:
If there are more specific instructions in the procedures contained in this manual concerning liq-
uid gasket application, observe them.

PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000011538118
EM
The actual shape of the tools may differ from those illustrated here.
Tool number C
(TechMate No.) Description
Tool name
(J-43897-18) Reconditioning the exhaust system threads D
Oxygen sensor thread cleaner before installing a new oxygen sensor (Use
with anti-seize lubricant shown below.)
J-43897-18 (18 mm dia.) for zirconia oxy-
gen sensor E
AWBIA2076ZZ F
— Removing and installing crankshaft pulley
(J-50288)
Ring gear stopper G
H
ALBIA0675ZZ
16441 6N210 Removing fuel tube quick connectors in en-

(J-45488) gine room I
Quick connector release (Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)
J
PBIC0198E
K
— Removing and installing spark plug
(J-48891)
Spark plug socket
L
M
AWBIA1785ZZ
KV10111100 Removing oil pan and timing chain case

(J-37228)
Seal cutter N
S-NT046
KV991J0050 Loosening or tightening air fuel ratio A/F sen- P

(J-44626) sor
Air fuel sensor Socket a: 22 mm (0.87 in)
LBIA0444E

PREPARATION
< PREPARATION >
Tool number
Tool name
KV10114400 Loosening or tightening rear heated oxygen
(J-38365) sensor
Heated oxygen sensor wrench a: 22 mm (0.87 in)
NT636
— Installing front main seal

(J-37066)
Seal installer
AWBIA2081ZZ
— Installing rear main seal

(J-47128)
Seal installer
AWBIA2551ZZ
KV10112100 Tightening bolts for bearing cap, cylinder

(BT-8653-A) head, etc.
Torque angle meter
S-NT014
Commercial Service Tool INFOID:0000000011538119
Tool number
Tool name
KV10116200 Disassembling valve mechanism
(J-26336-A) Part (1) is a component of KV10116200 (J-
Valve spring compressor 26336-A), but part (2) is not.
1. KV10115900
(J-26336-20)
Attachment
2. KV10109220
( — )
Adapter PBIC1650E
Manual lift table caddy Removing and installing engine
ZZA1210D

PREPARATION
< PREPARATION >
Tool number
(TechMate No.) Description A
Tool name
ST16610001 Removing crankshaft pilot converter
(J-23907) EM
Pilot converter puller
S-NT045
Tube presser Pressing the tube of liquid gasket D
S-NT052 F
Piston ring compressor Installing piston assembly into cylinder bore
H
S-NT044
Pulley holder Crankshaft pulley removing and installing

I
ZZA1010D
K
Pulley puller Removing crankshaft pulley
M
NT676
Valve seat cutter set Finishing valve seat dimensions

N
S-NT048
Piston ring expander Removing and installing piston ring P
S-NT030

PREPARATION
< PREPARATION >
Tool number
Tool name
— Installing valve oil seal
(J-39386)
Valve oil seal drift
NT024
Valve guide drift Removing and installing valve guide

Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
S-NT015
Valve guide reamer 1: Reaming valve guide inner hole

2: Reaming hole for oversize valve guide
Intake & Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia.
S-NT016
Anti-seize lubricant (Permatex 133AR Lubricating oxygen sensor thread cleaning

or equivalent meeting MIL specifica- tool when reconditioning exhaust system
tion MIL-A-907) threads
AEM489
KV10115600 Installing valve oil seal

(J-38958) Use side A.
Valve oil seal drift a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421) dia.
c: 10.3 (0.406) dia. f: 5 (0.20) dia.
Unit: mm (in)
S-NT603
Power tool Loosening nuts, screws, and bolts
PIIB1407E
KV10107902 Removing valve oil seal

(J-38959)
Valve oil seal puller with adapter (1)
S-NT605

PREPARATION
< PREPARATION >
Tool number
(TechMate No.) Description A
Tool name
ST0501S000 Disassembling and assembling
Engine stand assembly EM
( — )
1. ST05011000
( — )
Engine stand C
2. ST05012000
( — )
Base NT042
D
KV10106500 Engine supporting
( — )
Engine stand shaft
E
F
NT028
KV10115300 Disassembling and assembling

( — )
Engine sub-attachment G
ZZA1078D
(J-45816) Removing and installing CVT drive plate bolts I

E20 ®Socket
LBIA0285E K

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
< SYSTEM DESCRIPTION >
SYSTEM DESCRIPTION
NVH Troubleshooting - Engine Noise INFOID:0000000011220623
AWBIA1176GB
1. Camshaft bearing noise 2. Piston pin noise 3. Piston slap noise

4. Main bearing noise 5. Connecting rod bearing noise 6. Water pump noise

< SYSTEM DESCRIPTION >
Timing chain and chain
7. 8. Drive belt noise (Sticking/Slipping) 9. Tappet noise
tensioner noise A
A. Valve B. Valve mechanism C. Rotation mechanism
D. Drive belt E. Timing chain
EM
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000011220624
1. Locate the area where noise occurs. C

2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source. Repair or replace the identified part as necessary. D
Operating condition of engine

Location Type of Before After When Source of Refer- E
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 F
C A — A B — Valve clearance EM-20
gine clicking noise
Rocker
cover Camshaft Camshaft journal clear-
Cylinder Rattle C A — A B C bearing ance EM-137
G
head noise Camshaft runout
Piston and piston pin

Slap or Piston pin clearance H
— A — B B — EM-24
knock noise Connecting rod bushing
clearance
Piston-to-bore clear-
Crank- ance I
shaft pul- Piston ring side clear-
Slap or Piston
ley A — — B B A ance EM-142
rap slap noise
Cylinder Piston ring end gap
J
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod clearance (Small end) K
Knock A B C B B B EM-146
bearing Connecting rod bearing
noise clearance (Big end)
Main bear-
Main bearing oil clear- L
Knock A B — A B C ance EM-145
ing noise
Crankshaft runout
Front of Timing
Timing chain cracks M
engine chain and
Tapping or and wear
Timing A A — B B B chain ten- EM-65
ticking Timing chain tensioner
chain cov- sioner
operation
er noise N
Drive belts
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belts deflection
or slip-
ing
ping) EM-14 O
Front of
Drive belts Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
P
Water
Squall
A B — B A B pump Water pump operation CO-17
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related

DRIVE BELT
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE
DRIVE BELT
Exploded View INFOID:0000000011220625
AWBIA1225GB
1. Drive belt auto-tensioner 2. Generator 3. A/C compressor

4. Drive belt 5. Crankshaft pulley A. Indicator
B. Range when new drive belt is installed C. Possible use range D. View D
Engine front
Checking Drive Belt INFOID:0000000011220626
WARNING:
Inspect and check the drive belt with the engine off.
1. Inspect drive belt for cracks, wear, fraying, or oil adhesion. If necessary, replace with a new one.
2. Rotate the crankshaft pulley two times, then ensure the drive belt auto-tensioner is within the possible use
range.
3. Visually check entire drive belt for wear, damage or cracks.
4. Check that the drive belt auto-tensioner indicator is within the possible use range.
NOTE:
• When new drive belt is installed, the drive belt auto-tensioner indicator should be within the new drive
belt range.
• Check the drive belt auto-tensioner indicator when the engine is cold.
5. If the drive belt auto-tensioner indicator is out of the possible use range or belt is damaged, replace drive
belt.
Tension Adjustment INFOID:0000000011220627
• Drive belt tension is automatically adjusted by the drive belt auto-tensioner.

• Drive belt tension is not manually adjustable.
Removal and Installation INFOID:0000000011220628
REMOVAL
1. Remove the front wheel and tire (RH) using a power tool. Refer to WT-68, "Removal and Installation".
2. Remove the fender protector side cover (RH). Refer to EXT-36, "FENDER PROTECTOR : Exploded
View".

DRIVE BELT
3. While securely holding the hexagonal part in pulley center of
drive belt auto-tensioner, move in the direction of arrow (loosen- A
ing direction of drive belt auto-tensioner) using suitable tool.
WARNING:
Avoid placing hand in a location where pinching may occur EM
if the holding tool accidentally comes off.
CAUTION:
Do not loosen the drive belt auto-tensioner pulley bolt. (Do
not turn it counterclockwise. If turned counterclockwise, C
the complete drive belt auto-tensioner must be replaced as
a unit, including pulley.) AWBIA1204GB
4. Insert a rod approximately 6 mm (0.24 in) in diameter through D

the rear of drive belt auto-tensioner into retaining boss to lock drive belt auto-tensioner pulley.
NOTE:
Leave drive belt auto-tensioner pulley arm locked until belt is installed. E
5. Remove drive belt from crankshaft pulley and then remove it from the other pulleys.
INSTALLATION
1. Install the drive belt onto all of the pulleys. F
CAUTION:
Confirm belt is completely set on the pulleys.
2. Release drive belt auto-tensioner, and apply tension to drive belt. G
WARNING:
Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes
off. H
CAUTION:
Do not loosen the drive belt auto-tensioner pulley bolt. (Don't turn it counterclockwise. If turned
counterclockwise, the complete drive belt auto-tensioner must be replaced as a unit, including I
pulley.)
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm drive belt auto-tensioner indicator is within the possible use range. Refer to EM-14, "Checking J
Drive Belt".
5. Install the fender protector side cover (RH). Refer to EXT-36, "FENDER PROTECTOR : Exploded View".
6. Install the front wheel and tire (RH). Refer to WT-68, "Removal and Installation". K

DRIVE BELT
Removal and Installation of Drive Belt Auto-tensioner INFOID:0000000011220629
AWBIA1220GB
1. Drive belt auto-tensioner
REMOVAL
CAUTION:
The complete drive belt auto-tensioner must be replaced as a unit, including the pulley.
1. Remove the drive belt. Refer to EM-14, "Removal and Installation".
2. Remove the drive belt auto-tensioner.
CAUTION:
Do not loosen the drive belt auto-tensioner pulley bolt. (Don't turn it counterclockwise. If turned coun-
terclockwise, the complete drive belt auto-tensioner must be replaced as a unit, including pulley).
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• If there is damage greater than peeled paint, replace drive belt auto-tensioner.
• Do not swap the pulley between the new and old drive belt auto-tensioner.
• The complete drive belt auto-tensioner must be replaced as a unit, including the pulley.

AIR CLEANER FILTER
AIR CLEANER FILTER
A
EM
I
AWBIA2344ZZ
1. Air duct hose and resonator assembly 2. Front air duct 3. Grommet J
4. Air cleaner case (lower) 5. Grommets 6. Air cleaner case mounting bracket
7. Bracket 8. Air cleaner filter 9. Air cleaner case (upper)
10. Mass air flow sensor A. Air cleaner case side B. To electric throttle control actuator K
clips
Front
L
REMOVAL M
CAUTION:
It is not necessary to remove the front air duct to replace the air cleaner filter.
NOTE:
Replace the air cleaner filter per the periodic maintenance schedule or as necessary. Refer to MA-7, "Introduc- N
tion of Periodic Maintenance".
1. Unhook air cleaner case side clips and lift air cleaner case (upper).
2. Remove the air cleaner filter. O
INSTALLATION
P

SPARK PLUG
SPARK PLUG
AWBIA2345ZZ
1. Ignition coil 2. Spark plug 3. Rocker cover (RH)

4. Rocker cover (LH) Front
REMOVAL
1. Remove the ignition coil. Refer to EM-44, "Removal and Installation (bank 2)" and EM-44, "Removal and
Installation (bank 1)".
2. Remove the spark plug with a suitable spark plug wrench.
ALBIA0672GB
INSPECTION AFTER REMOVAL

SPARK PLUG
Use the standard type spark plug for normal condition.
A
Spark plug : Refer to EM-137, "Spark Plug".
CAUTION:
• Do not drop or shock spark plug. Discard spark plug if EM
dropped.
• Do not use a wire brush for cleaning.
• If plug is covered with carbon, a spark plug cleaner may be C
used.
Cleaner air pressure : less than 588 kPa (6 kg/cm2,

SMA773C
D
85 psi)
Cleaning time : less than 20 seconds
• Spark plug gap adjustment is not required between replacement E
intervals.
• Measure spark plug gap. When it exceeds the limit, replace spark
plug even if it is within the specified replacement mileage. Refer to F
EM-137, "Spark Plug".
SMA806CA
H
INSTALLATION
I
Make DENSO
Standard type* FXE22HR11
J
Gap (nominal) 1.1 mm (0.043 in)
*: Always check with the Parts Department for the latest parts information.
K

CAMSHAFT VALVE CLEARANCE
Valve Clearance INFOID:0000000011220634
CHECKING
CAUTION:
Check valve clearance while engine is cold and not running.
NOTE:
Perform valve clearance inspection after removal, installation or replacement of camshaft or valve parts, or as
necessary.
1. Remove the air duct with air cleaner case, collectors, hoses, wires, harnesses, and connectors. Refer to
EM-26, "Removal and Installation".
2. Remove the intake manifold collector. Refer to EM-28, "Removal and Installation".
3. Remove the ignition coils and spark plugs. Refer to EM-44, "Exploded View".
4. Remove the rocker covers. Refer to EM-45, "Exploded View".
5. Set No.1 cylinder at TDC on its compression stroke.
: Engine front
AWBIA2445ZZ
a. Align pointer with TDC mark (A) on crankshaft pulley.
AWBIA1219GB
b. Check that the valve lifters on No.1 cylinder, bank 1 (A) are
loose and valve lifters on No.4 are tight. If not, turn the crank-
shaft one full revolution (360°) and align as shown.
: Engine front
AWBIA2446ZZ

6. Check only the valves as shown.
A
Crank Position Valve No. 1 Valve No. 2 Valve No. 3 Valve No. 6
No. 1 TDC Intake Exhaust Exhaust Intake
EM
(A). : Bank 1 cylinder head
(B). : Bank 2 cylinder head
(C). : Bank 2 exhaust camshaft C
(D). : Bank 2 intake camshaft
(E). : Bank 1 intake camshaft
(F). : Bank 1 exhaust camshaft D
: Engine front
G
AWBIA2447ZZ
a. Using a feeler gauge, measure the clearance between the valve

lifter and camshaft. H
Valve clearance : Refer to EM-136,

"General Specification". I
b. Record any valve clearance measurements which are out of

specification. They will be used later to determine the required
J
replacement lifter size.
SEM139D
K
(A). : Camshaft
L
(B). : Valve lifter
(C). : Suitable tool
7. Turn crankshaft 240°. M
AWBIA2448ZZ

9. Check only those valves as shown.
No. 3 TDC Intake Intake Exhaust Exhaust

(C). : Bank 2 exhaust camshaft
(F). : Bank 1 exhaust camshaft
: Engine front
AWBIA2449ZZ
10. Turn the crankshaft 240° and align as above.

12. Check only those valves as shown.
No. 5 TDC Exhaust Intake Intake Exhaust

(C). : Bank 2 exhaust camshaft
(F). : Bank 1 exhaust camshaft
: Engine front
AWBIA2450ZZ
13. Perform adjustment if the measured values are out of the specification range.
14. Installation of components is in the reverse order of removal.
VALVE ADJUSTING
CAUTION:
Adjust valve clearance while engine is cold.
NOTE:
• Perform adjustment by selecting the correct head thickness of the valve lifter (adjusting shims are not used).

• The specified valve lifter thickness dimension is measured at room temperature.
• Use specifications for hot engine for hot engine condition to confirm valve clearances. A
1. Remove the camshaft.
2. Remove the valve lifter that was measured as being outside the standard specifications.
3. Measure the center thickness of the removed lifter with suitable EM
tool (A) as shown.
AWBIA2451ZZ
E
4. Use the equation below to calculate the replacement valve lifter thickness.
F
Valve lifter thickness calculation: (C1 – C2) + t1=t
C1 = measured valve clearance
C2 = standard valve clearance G
t1 = thickness of the removed lifter
t = thickness of the replacement lifter
H
a. The thickness of the new valve lifter can be identified by the
stamp mark (A) on the reverse side (inside the lifter).
NOTE:
I
Available thicknesses of the valve lifters (B) are: 3.00 - 3.50 mm
(0.1181 - 0.1378 in), in 0.02 mm (0.0008 in) increments. Refer to
EM-137, "Camshaft"
J
K
JPBIA0170ZZ
5. Install the selected replacement valve lifter. L

6. Install the camshaft.
7. Rotate the crankshaft a few turns by hand.
8. Confirm that the valve clearances are within specification. M
9. After the engine has been run to full operating temperature, confirm that the valve clearances are within
specification.
N
Standard Valve Clearance Cold1 (reference data) Hot2 (reference data)
Intake 0.26 - 0.34 mm (0.010 - 0.013 in) 0.304 - 0.416 mm (0.012 - 0.016 in)
Exhaust 0.29 - 0.37 mm (0.011 - 0.015 in) 0.308 - 0.432 mm (0.012 - 0.017 in) O
1
: Approximately 20°C (68°F)
2 : Approximately 80°C (176°F)
P

COMPRESSION PRESSURE
COMPRESSION PRESSURE
On-Vehicle Service INFOID:0000000011220635
CHECKING COMPRESSION PRESSURE

1. Run the engine until it reaches normal operating temperature.
2. Turn the ignition switch to OFF.
3. Release fuel pressure and leave the fuel pump electrically disconnected.
Refer to EC-166, "Work Procedure".
4. Remove all six spark plugs.
Refer to EM-18, "Removal and Installation".
5. Attach a compression tester to No. 1 cylinder.
SBIA0533E
6. Depress accelerator pedal fully to keep the electric throttle control actuator butterfly-valve wide open to
maximize air intake flow.
7. Crank the engine and record the highest gauge indication.
CAUTION:
Always use a fully charged battery to obtain specified engine speed.
8. Repeat the test for each cylinder (steps 5 - 7).
Unit: kPa (kg/cm2, psi) /rpm
Standard Minimum Differential limit between cylinders

1,275 (13.0, 185) / 300 981 (10.0, 142) / 300 98 (1.0, 14) / 300
• If the engine speed is out of the specified range, check the battery and recharge as necessary. Check
the engine speed again with the battery properly charged.
• If some cylinders have 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 the
piston rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, the valves may be
malfunctioning. Check the valves for damage. Replace the 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 may be leaking, or a valve in adjacent
cylinders may be damaged. Inspect and repair as required.
• If the compression pressure is below the minimum value, check the valve clearances and parts associ-
ated with the combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head,
cylinder head gasket). After the checking, measure the compression pressure again.
9. Installation of the remaining components is in the reverse order of removal.

ENGINE ROOM COVER
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION A
ENGINE ROOM COVER
EM
AWBIA1239GB
H
1. Engine cover

I
CAUTION:
Do not damage or scratch engine room cover when installing or removing.
J
REMOVAL
1. Remove front air duct. Refer to EM-26, "Removal and Installation".
2. Remove engine cover bolts. K
3. Remove engine cover.
INSTALLATION
L

AIR CLEANER AND AIR DUCT
AWBIA2344ZZ
1. Air duct hose and resonator assembly 2. Front air duct 3. Grommet
4. Air cleaner case (lower) 5. Grommets 6. Air cleaner case mounting bracket
7. Bracket 8. Air cleaner filter 9. Air cleaner case (upper)
10. Mass air flow sensor A. To electric throttle con- B. To electric throttle control actuator
trol actuator
Front
REMOVAL
1. Remove front air duct.
2. Remove brake fluid level sensor harness connector from brake fluid level sensor.
3. Remove sub tank bracket from cowl top extension.
4. Disconnect the tube clamp at the electric throttle control actuator and at the air duct hose and resonator
assembly.
5. Disconnect the blow-by hose. Refer to EM-45, "Exploded View"
6. Remove air duct hose and resonator assembly.
7. Disconnect mass air flow sensor.
8. Remove mass air flow sensor from air cleaner case (upper), (if necessary).
CAUTION:
Handle mass air flow sensor with care.
• Do not shock it.
• Do not disassemble it.
• Do not touch its sensor.
9. Disconnect the transaxle air breather hose. Refer to TM-200, "Removal and Installation"

10. Remove bolts and pull air cleaner case (lower) upward to remove from the grommets.
11. Remove air cleaner assembly. A

Inspect air cleaner case (upper), air cleaner case (lower), front air duct, air duct and resonator assembly for
cracks or tears. Replace as necessary. EM
INSTALLATION
Installation is in the reverse order of removal. C

INTAKE MANIFOLD COLLECTOR
AWBIA2348ZZ
1. Intake manifold collector 2. Intake manifold collec- 3. Bracket clip

tor gasket
4. Electric throttle control actuator 5. Electric throttle control A. Refer to INSTALLATION
actuator gasket
Front
WARNING:
Do not drain the engine coolant when the engine is hot to avoid the danger of being scalded.
CAUTION:
Do not remove the power valves.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing.
REMOVAL
CAUTION:
Cover engine openings to avoid the entry of any foreign material.

1. Remove the cowl top cover and the cowl top extension. Refer to EXT-34, "Exploded View".
2. Remove the engine room cover. Refer to EM-25, "Removal and Installation". A
3. Remove the air cleaner case (upper), air cleaner case (lower), and air duct and resonator assembly. Refer
to EM-26, "Removal and Installation".
4. Disconnect the power brake booster vacuum hose. EM
5. Disconnect the engine mount control valve solenoid harness connector.
6. Disconnect VIAS control solenoid valve harness connector.
C
7. Disconnect the PCV hose.
8. Disconnect the electric throttle control actuator electrical harness connector.
9. Disconnect the EVAP canister purge volume control solenoid valve hose. D
10. Remove the electric throttle control actuator bolts and remove
the electric throttle control actuator and position aside. Loosen-
ing is done in reverse order of torquing.
E
CAUTION:
• Handle carefully to avoid any shock to the electric throttle
control actuator.
• Do not disassemble. F
G
SEM711G
11. Remove the VIAS control solenoid valve as necessary.

H
12. Remove the EVAP canister purge volume control solenoid valve.
13. Loosen the intake manifold collector bolts and remove the intake
manifold collector and gasket. Loosening is done in reverse
I
order of torquing.
ALBIA0240ZZ
L
INSTALLATION
• Tighten intake manifold collector bolts in the order as shown. M
Intake manifold collector : 11.0 N·m (1.1 kg-m, 8 ft-lb)
bolts
N
CAUTION:
Do not reuse intake manifold collector gasket.
O
ALBIA0240ZZ
P
• Tighten electric throttle control actuator bolts in the order shown.
Electric throttle control : 8.4 N·m (0.86 kg-m, 74 in-

actuator bolts lb)
CAUTION:

Do not reuse electric throttle control actuator gasket.
SEM711G
NOTE:
After installation, recalibrate the electric throttle control actuator as follows:
1. Perform the ″Throttle Valve Closed Position Learning″ when harness connector of the electric throttle con-
trol actuator is disconnected. Refer to EC-157, "Work Procedure".
2. Perform the ″Idle Air Volume Learning″ when the electric throttle control actuator is replaced. Refer to EC-
158, "Work Procedure".
3. Perform the ″Accelerator Pedal Released Position Learning″ when the electric throttle control actuator is
replaced. Refer to EC-156, "Work Procedure".

INTAKE MANIFOLD
INTAKE MANIFOLD
A
EM
I
ALBIA0231ZZ
1. Intake manifold 2. Intake manifold gasket A. Refer to INSTALLATION J
K
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain the coolant when the engine is hot. L
NOTE:
ing.
1. Remove fuel injectors and fuel tube. Refer to EM-49, "Removal and Installation". M
2. Remove the intake manifold and the intake maniold gaskets. Loosen nuts and bolts in reverse order as
shown.
CAUTION: N
Cover the engine openings to avoid the entry of foreign
materials.
O
ALBIA0233ZZ

Surface Distortion

INTAKE MANIFOLD
• Using straightedge and feeler gauge, inspect the surface distortion
of the intake manifold.
Standard : 0.1 mm (0.004 in)
AWBIA2535ZZ
INSTALLATION
Installation is in the reverse order of removal. Follow the procedure below for specific tightening sequences
and procedures.
CAUTION:
Do not reuse intake manifold gaskets.
• Install intake manifold nuts and bolts in two steps in the numerical
order as shown.
Step 1 : 7.4 N·m (0.75 kg-m, 65 in-lb)

Step 2 : 25.5 N·m (2.6 kg-m, 19 ft-lb)
ALBIA0233ZZ
INSPECTION AFTER INSTALLATION

Make sure there are no fuel leaks at the connections as follows:
1. Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel
leaks at connections.
2. Start the engine and rev it up and check for fuel leaks at connections.
WARNING:
Do not touch engine immediately after stopping as engine is extremely hot.
NOTE:
Use mirrors for checking on connections out of the direct line of sight.

EXHAUST MANIFOLD AND THREE WAY CATALYST
A
EM
L
AWBIA2353ZZ
1. Gasket 2. Exhaust manifold (bank 1) 3. Exhaust manifold cover (bank 1) M

4. Air fuel ratio sensor 1 (bank 1) 5. Ring gasket 6. Three way catalyst (bank 1)
7. Three way catalyst support (bank 1) 8. Heated oxygen sensor 2 (bank 1) 9. Three way catalyst (bank 2)
10. Three way catalyst support (bank 2) 11. Heated oxygen sensor 2 (bank 2) 12. Ring gasket N
13. Exhaust manifold (bank 2) 14. Exhaust manifold cover (bank 2) 15. Air fuel ratio sensor 1 (bank 2)
A. To oil pan (upper) B. Upper mark Engine front
O
Removal and Installation (bank 2) INFOID:0000000011220645
REMOVAL P
WARNING:
• Perform the work when the exhaust system has completely cooled down.
• When removing the front and rear engine mounting through bolts and nuts, lift the engine up slightly
for safety.
NOTE:
ing.

1. Remove the air cleaner case (upper), air cleaner case (lower), and air duct hose and resonator assembly.
Refer to EM-26, "Removal and Installation".
2. Remove the battery and battery tray assembly. Refer to PG-88, "Removal and Installation".
3. Remove the front wheels and tires using power tool. Refer to WT-68, "Removal and Installation".
4. Remove the engine under cover. Refer to EXT-40, "FRONT UNDER COVER : Removal and Installation".
5. Remove the fender protector side covers (LH and RH). Refer to EXT-36, "FENDER PROTECTOR :
Exploded View".
6. Remove the radiator assembly. Refer to CO-13, "Removal and Installation".
7. Remove the engine cooling fan shroud and motor assembly. Refer to CO-15, "Removal and Installation".
8. Remove the front exhaust tube. Refer to EX-5, "Exploded View".
9. Support the engine with a suitable tool.
10. Remove the engine mount bracket (front). Refer to EM-104, "FWD : Exploded View" (FWD) or EM-108,
"AWD : Exploded View" (AWD).
11. Remove the three way catalyst support (bank 2).
12. Remove heated oxygen sensor 2 (bank 2), air fuel ratio (A/F) sensor 1 (bank 2).
a. Remove harness connector of each sensor, and disconnect the harness from the bracket and middle
clamp.
b. Remove both heated oxygen sensor and air fuel ratio (A/F) sensor using Tool.
Tool numbers : KV10114400 (J-38365)

: KV991J0050 (J-44626)
CAUTION:
• Be careful not to damage heated oxygen sensors or air fuel ratio (A/F) sensors.
• Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m
(19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor.
13. Remove exhaust manifold and three way catalyst heat shields with power tool.
14. Remove the three way catalyst (bank 2) by loosening the bolts first and then removing the nuts and
through bolts.
15. Loosen and remove the exhaust manifold nuts in the reverse
order as shown.
: Engine front
NOTE:
Number 7 and 8 are not applicable to removal.
16. Remove the exhaust manifold (LH) and gasket.
: Engine front
AWBIA1208GB

Surface Distortion
• Use suitable tools (A/B) to check the flatness of the exhaust mani-
fold mating surfaces.
Limit : 0.3 mm (0.012 in)

• Replace the exhaust manifold if the measurement exceeds specifi-
cations.
AWBIA2452ZZ
INSTALLATION

1. Install the studs in the exhaust manifold (if removed), and tighten to specification. A
Exhaust manifold studs : 15.4 N·m (1.6 kg-m, 11 ft-lb)

EM
2. Install the exhaust manifold gasket in the direction shown.
CAUTION:
Do not reuse exhaust manifold gasket.
C
(A) : Bank 1
(B) : Triangle press
(C) : Bank 2 D
: Engine front
PBIC4954E
F
3. Install the exhaust manifold (bank 2) nuts and tighten to specifi-
cation in the order shown.
G
: Engine front
NOTE:
Number 7 and 8 are tightened a second time. H
I
AWBIA1208GB
CAUTION: J
• Before installing a heated oxygen sensor or air fuel ratio (A/F) sensor, clean the exhaust mani-
fold threads using the oxygen sensor thread cleaner tool and apply anti-seize lubricant.
K
Oxygen sensor thread cleaner : (J-43897-18)
• Do not over-tighten the air fuel ratio (A/F) sensor or heated oxygen sensors. Doing so may cause
damage. L

: KV991J0050 (J-44626) M
NOTE:
After installation, it is necessary to re-calibrate the electric throttle control actuator as follows:
• Perform the "Throttle Valve Closed Position Learning" when harness connector of the ECM is disconnected. N
Refer to EC-157, "Work Procedure".
• Perform the "Accelerator Pedal Released Position Learning" when harness connector of the ECM is discon-
nected. Refer to EC-156, "Work Procedure". O
REMOVAL P
WARNING:
• Perform the work when the exhaust system has completely cooled down.
• When removing the front and rear engine mounting through bolts and nuts, lift the engine up slightly
for safety.
NOTE:
ing.

1. Remove the cowl top and the lower cowl top extension. Refer to EXT-34, "Exploded View".
2. Remove the front wheel and tire (RH) (AWD models only) using a power tool. Refer to WT-68, "Removal
and Installation".
4. Remove the fender protector side cover (RH) (AWD models only). Refer to EXT-36, "FENDER PROTEC-
TOR : Exploded View".
5. Remove transmission air breather hose. Refer to TM-200, "Exploded View".
6. Remove the front exhaust tube, hanger and heat insulator. Refer to EX-5, "Exploded View".
7. Remove the propeller shaft and propeller shaft center bearing (AWD models only). Refer to RAX-11,
"Removal and Installation".
8. Remove the RH front axle shaft (AWD models only). Refer to FAX-21, "Removal and Installation (RH)".
9. Remove the three way catalyst support (bank 1).
10. Remove heated oxygen sensor 2 (bank 1), air fuel ratio (A/F) sensor 1 (bank 1).
a. Remove harness connector of each sensor, and disconnect the harness from the bracket and middle
clamp.
b. Remove both heated oxygen sensors and air fuel ratio (A/F) sensors using Tool.

: KV991J0050 (J-44626)
CAUTION:
• Be careful not to damage heated oxygen sensors or air fuel ratio (A/F) sensors.
• Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m
(19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor.
11. Remove exhaust manifold and three way catalyst heat shields with power tool.
12. Remove the three way catalyst (bank 1) by loosening the bolts first and then removing the nuts and
through bolts.
13. Loosen the exhaust manifold nuts in the reverse order as
shown.
: Engine front
NOTE:
Number 7 and 8 are not applicable to removal.
AWBIA1209GB
14. Remove the exhaust manifold (bank 1).

Surface Distortion
• Use suitable tools (A/B) to check the flatness of the exhaust mani-
fold mating surfaces.
Limit : 0.3 mm (0.012 in)

• Replace the exhaust manifold if the measurement exceeds specifi-
cations.
AWBIA2452ZZ
INSTALLATION

1. Install the studs in the exhaust manifold (if removed), and tighten to specification.
A
Exhaust manifold studs : 15.4 N·m (1.6 kg-m, 11 ft-lb)
2. Install the exhaust manifold gasket in the direction shown.
CAUTION: EM
Do not reuse exhaust manifold gasket.
(A) : Bank 1 C
(B) : Triangle press
(C) : Bank 2
: Engine front D
E
PBIC4954E
3. Install the exhaust manifold (bank 1) nuts and tighten to specifi- F

cation in the order shown.
: Engine front
G
NOTE:
Number 7 and 8 are tightened a second time.
H
AWBIA1209GB I
CAUTION:
• Before installing a heated oxygen sensor or air fuel ratio (A/F) sensor, clean the exhaust mani- J
fold threads using the oxygen sensor thread cleaner tool and apply anti-seize lubricant.
Oxygen sensor thread cleaner : (J-43897-18)

K
• Do not over-tighten the air fuel ratio (A/F) sensor or heated oxygen sensors. Doing so may cause
damage.
L
: KV991J0050 (J-44626)
M

OIL PAN AND OIL STRAINER
AWBIA2354ZZ
1. Oil pan baffle 2. O-ring 3. Upper oil pan gasket

4. Blind plug O-ring 5. Blind plug 6. Oil cooler O-ring
7. Relief valve 8. Oil cooler 9. Oil cooler connector
10. Oil filter 11. Oil pressure sensor 12. Lower oil pan
13. Oil strainer 14. Rear cover plate 15. Crankshaft position sensor (POS)
16. O-ring 17. Upper oil pan Front
Removal and Installation (Lower Oil Pan) INFOID:0000000011545081
REMOVAL
WARNING:
• You should not remove the oil pan until the exhaust system and cooling system have completely
cooled off.
1. Drain the engine oil. Refer to LU-9, "Changing Engine Oil".
2. Loosen the lower oil pan bolts in reverse order as shown.
AWBIA1211GB
3. Remove the lower oil pan.

• After removing the bolts, separate the mating surface and
remove the old liquid gasket using Tool. A
Tool number : KV10111100 (J-37228)

CAUTION: EM
Do not damage the mating surfaces.
• In areas where the Tool is difficult to use, use a plastic hammer
to lightly tap (1) the Tool where the liquid gasket is applied. C
Use a plastic hammer to slide (2) the Tool by tapping on the
side.
AWBIA1249GB
D
4. Remove the old sealant from the bolt holes and threads.
Clean debris from the oil strainer. E
INSTALLATION
1. Apply a continuous bead of sealant to the lower oil pan. F
• Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-
22, "Recommended Chemical Products and Sealants".
• Be sure the sealant is 4.5 - 5.5 mm (0.177 - 0.217 in) wide.
CAUTION: G
• Installation should be done within 5 minutes after apply-
ing liquid gasket.
• Do not fill the engine with engine oil for at least 30 min- H
utes after the components are installed to allow the seal-
ant to cure.
JPBIA0010ZZ I
Front
2. Install the lower oil pan. Tighten the lower oil pan bolts in order
as shown. J
CAUTION:
ing liquid gasket.
K
• Do not fill the engine with engine oil for at least 30 min-
utes after the components are installed to allow the seal-
ant to cure.
3. Refill the engine with oil. Refer to LU-9, "Changing Engine Oil". L
AWBIA1211GB
M
1. Inspect the engine oil level. Refer to LU-8, "Inspection".
2. Start the engine and check for leaks. Refer to LU-8, "Inspection". Repair as necessary. N
Removal and Installation (Upper Oil Pan) INFOID:0000000011545082
REMOVAL O
WARNING:
• Do not remove the oil pan until the exhaust system and cooling system have completely cooled off.
• When removing the front and rear engine through bolts and nuts, lift the engine up slightly for safety. P
CAUTION:
When removing the upper oil pan from the engine, first remove the crankshaft position sensor (POS).
Be careful not to damage sensor edges or signal plate teeth.
NOTE:
ing.

1. Remove the engine from the vehicle. Refer to EM-104, "FWD : Removal and Installation" (FWD) or EM-
109, "AWD : Removal and Installation" (AWD).
2. Install the engine on engine stand (A). Any commercially avail-
able engine stand (A) can be used.
CAUTION:
• Use an engine stand (A) that has a load capacity [approxi-
mately 240kg (529 lb) or more] large enough for support-
ing the engine weight.
• Before removing the hanging chains, make sure the
engine stand (A) is stable and there is no risk of overturn-
ing.
AWBIA2413ZZ
3. Remove the oil dipstick.

5. Disconnect the A/C compressor harness connector.
6. Remove the A/C compressor bolts and remove the A/C compressor. Refer to HA-29, "COMPRESSOR :
Removal and Installation".
7. Remove water pipe bolts.
8. Disconnect the water hoses from the engine oil cooler.
9. Remove the oil filter and engine oil cooler from the upper oil pan. Refer to EM-39, "Removal and Installa-
tion (Upper Oil Pan)".
10. Remove the oil pressure switch, and the crankshaft position sensor (POS) from the upper oil pan.
11. Remove the lower oil pan. Refer to EM-38, "Removal and Installation (Lower Oil Pan)".
12. Remove the oil strainer.
13. Remove the upper oil pan.
a. Loosen the bolts in the reverse order shown.
AWBIA1212GB
b. Insert a suitable tool (A) into the notch (B) of the upper oil pan
(1) as shown.
c. Pry off the upper oil pan (1) by moving the suitable tool up and
down (2) as shown.
AWBIA2048ZZ
14. Remove rear engine mount buffer bracket.

15. Remove the O-rings (2) from the bottom of the cylinder block (1)
and oil pump housing. Use new O-rings for installation. A
: Engine front
CAUTION: EM
Do not reuse O-rings.
AWBIA2049ZZ
D
16. Remove front cover gasket (A) and rear oil seal retainer gasket
(B).
E
: Engine front
G
AWBIA2050ZZ
17. If reinstalling the original oil pan, remove the old sealant from the H
mating surfaces using a suitable tool (A).
• Also remove the old sealant from mating surface of the cylin-
der block. I
• Remove the old sealant from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surfaces when clean-
ing off the old sealant. J
AWBIA2051ZZ
K
Clean debris from oil strainer.
L
INSTALLATION
1. Install oil strainer and tighten bolt to specified torque.
M
Oil strainer bolts : 21.1 N·m (2.2 kg-m, 16 ft-lb)
2. Apply Genuine Silicone RTV Sealant or equivalent (A) to the

front cover gasket and the rear oil seal retainer gasket as N
shown. Refer to GI-22, "Recommended Chemical Products and
Sealants".
CAUTION: O
ing liquid gasket.
• Do not fill the engine with oil for at least 30 minutes after
P
the components are installed to allow the sealant to cure.
AWBIA2052ZZ

3. Install the front cover gasket (A) and rear oil seal retainer gasket
(B) as shown.
CAUTION:
Do not reuse front cover gasket or rear oil seal retainer gas-
ket.
: Engine front
AWBIA2050ZZ
4. Apply a bead of sealant to the cylinder block mating surface of

the upper oil pan as shown.
CAUTION:
ing liquid gasket.
NOTE:
• Apply liquid gasket to the outside of bolt holes 5, 6, 10, 11 and
12.
• Apply liquid gasket to the inside of the other bolt holes.
AWBIA2053ZZ
a. Be sure the sealant is applied 5.0 mm (0.197 in) as shown (A).
Increase the bead to 4.5 - 5.5 mm (0.177 - 0.217 in) at the four places indicated (B).
b. Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-
: Engine front
JPBIA0010ZZ
5. Install new O-rings (2) on the cylinder block (1) and oil pump
body.
CAUTION:
: Engine front
AWBIA2049ZZ
6. Install the upper oil pan.

• Tighten bolts (1) and (2) to specification within 5 minutes of
applying the liquid gasket.
• Tighten the remaining upper oil pan bolts to specification in the
order shown.
CAUTION:
ing liquid gasket.
AWBIA1212GB

7. Install the lower oil pan. Refer to EM-38, "Removal and Installation (Lower Oil Pan)".
A
CAUTION:
• Do not allow crankshaft position sensor (POS) to contact magnet.
• Do not allow foreign material to contact tip of crankshaft position sensor (POS). EM
• Do not allow foreign material to contact crankshaft position sensor (POS) O-ring.
• Do not use a crankshaft position sensor (POS) that has been dropped.
• Do not use an oil pressure sensor that has been dropped.
C

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If there is less than D
required quantity, fill to the specified level. Refer to MA-11, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points. E
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE: F
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop
after hydraulic pressure rises.
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including G
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec- H
ified level, if necessary.
• Summary of the inspection items:
I
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level J
Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage
transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage
K
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gas — Leakage — L
*Power steering fluid, brake fluid, etc.

IGNITION COIL
IGNITION COIL
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1. Ignition coil 2. Spark plug 3. Rocker cover (Bank 1)

4. Rocker cover (Bank 2) Front
REMOVAL
1. Remove engine room cover. Refer to EM-25, "Removal and Installation".
2. Disconnect ignition coil harness connector.
3. Remove the ignition coil.
CAUTION:
Do not shock ignition coil.
INSTALLATION
REMOVAL
2. Disconnect ignition coil harness connector.
3. Remove the ignition coil.
CAUTION:
Do not shock ignition coil.
INSTALLATION

ROCKER COVER
ROCKER COVER
A
EM
I
AWBIA0856GB
1. Camshaft position sensor (Bank 2) 2. O-rings 3. Camshaft position sensor (Bank 1) J

4. O-rings 5. Rocker cover (Bank 1) 6. Rocker cover gasket (Bank 1)
7. Rocker cover gasket (Bank 2) 8. Rocker cover (Bank 2) A. Refer to INSTALLATION
Engine front K
L
REMOVAL
1. Remove the engine room cover. Refer to EM-25, "Removal and Installation".
2. Disconnect air fuel ratio sensor 1 (bank 2) harness connector from air fuel ratio sensor 1 (bank 2). M
3. Remove blow by hose from rocker cover.
4. Remove camshaft position sensors.
CAUTION: N
• Handle carefully to avoid dropping and shocks.
• Do not disassemble.
• Do not allow metal powder to adhere to magnetic part at O
sensor tip (A).
• Do not place sensors in a location where they are
exposed to magnetism.
P
ALBIA0258ZZ
5. Unclip the camshaft position sensor harness retainers.

6. Remove the ignition coils. Refer to EM-44, "Removal and Installation (bank 2)".
CAUTION:

ROCKER COVER
Do not shock ignition coils.
7. Remove rocker cover bolts from cylinder head in the reverse
order shown.
: Engine front
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8. Remove the rocker cover and gasket.

9. Remove the oil filler cap from the rocker cover, (if necessary).
INSTALLATION
CAUTION:
• Do not reuse rocker cover gasket.
• Blow by hose clamps should be installed facing upwards.
• Install press fit hoses so that the white mark faces the rib of the connector.
• Apply sealant to the areas on the front corners using Tool.
• Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-22,
"Recommended Chemical Products and Sealants".
Tool number : WS39930000 ( — )

CAUTION:
• Installation should be done within 5 minutes after applying
liquid gasket.
• Do not fill the engine with engine oil for at least 30 minutes
after the components are installed to allow the sealant to
cure.
PBIC2474E
• Tighten the rocker cover bolts to specification in two steps in order

shown.
: Engine front
Rocker cover bolts

Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb)
Step 2 : 8.33 N·m (0.85 kg-m, 74 in-lb)
AWBIA0703ZZ

ROCKER COVER
A
REMOVAL
EM
2. Disconnect air fuel ratio sensor 1 (bank 1) harness connector from air fuel ratio sensor 1 (bank 1).
3. Remove the front air duct and air duct hose and resonator assembly. Refer to EM-26, "Removal and
Installation".
C
5. Remove camshaft position sensors.
CAUTION:
• Handle carefully to avoid dropping and shocks. D
• Do not allow metal powder to adhere to magnetic part at
sensor tip (A). E
• Do not place sensors in a location where they are
exposed to magnetism.
F
ALBIA0258ZZ
6. Disconnect the PCV hose from the rocker cover. G

7. Disconnect the ignition coil harness connectors.
8. Remove ignition coils. Refer to EM-44, "Removal and Installation (bank 2)" and EM-44, "Removal and H
Installation (bank 1)".
CAUTION:
Do not shock ignition coils.
9. Remove rocker cover bolts from cylinder head in the reverse I
order shown.
: Engine front J
L
AWBIA0705ZZ
10. Remove the rocker cover and gasket.

INSTALLATION M
CAUTION:
• Do not reuse rocker cover gasket. N
• Blow by hose clamps should be installed facing upwards.
• Install press fit hoses so that the white mark faces the rib of the connector.
O

ROCKER COVER
• Apply sealant to the areas on the front corners using Tool.
• Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-22,
"Recommended Chemical Products and Sealants".
Tool number : WS39930000 ( — )

CAUTION:
• Installation should be done within 5 minutes after applying
liquid gasket.
• Do not fill the engine with engine oil for at least 30 minutes
after the components are installed to allow the sealant to
cure.
PBIC2474E
• Tighten the rocker cover bolts in two steps in order as shown.
: Engine front
Rocker cover bolts

Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb)
Step 2 : 8.33 N·m (0.85 kg-m, 74 in-lb)
AWBIA0705ZZ

FUEL INJECTOR AND FUEL TUBE
A
EM
J
AWBIA2358ZZ
1. Fuel feed hose 2. Quick connector cap 3. Fuel tube K

4. O-ring 5. Fuel damper 6. Fuel damper cap
7. Clip 8. O-ring (black) 9. Fuel injector
10. O-ring (green) A. Refer to INSTALLATION Engine front L
M
REMOVAL
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop. N
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
• Do not drain engine coolant when engine is hot to avoid the danger of being scalded. O
CAUTION:
• Apply new engine oil when installing the parts as specified to do so.
• Do not remove or disassemble parts unless instructed.
NOTE: P
ing.
2. Release the fuel pressure. Refer to EC-166, "Work Procedure".
3. Disconnect the battery negative terminal. Refer to PG-86, "Exploded View".
4. Remove intake manifold collector. Refer to EM-28, "Removal and Installation".

5. When separating fuel feed hose and fuel tube connection, disconnect quick connector using tool as fol-
lows:
Tool number : 16441 6N210 (J-45488)

a. Remove quick connector cap from quick connector.
b. Disconnect quick connector from fuel tube as follows:
CAUTION:
Disconnect quick connector by using the special service tool, not by prying out retainer tabs.
i. With the sleeve side of tool facing toward the quick connector, install the tool onto fuel tube.
ii. Insert the tool (A) into quick connector (2) until sleeve (B) con-
tacts and goes no further. Hold tool in that position.
(C) : Insert and retain

CAUTION:
Inserting tool with excess force will not disconnect quick
connector. Hold quick connector release where it contacts
and goes no further.
iii. Draw and pull out quick connector straight from fuel tube (1).
CAUTION:
• Pull quick connector (E) holding position (D) as shown. JPBIA0033ZZ
• Do not pull with lateral force applied. O-ring inside quick

connector may be damaged.
• Prepare container and cloth beforehand as fuel will leak out.
• Avoid fire and sparks.
• Keep parts away from heat source. Be especially careful when welding is performed around
them.
• Do not expose parts to battery electrolyte or other acids.
• Do not 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 (A) or something similar.
JPBIA0035ZZ
6. Disconnect harness connector from fuel injector.

7. Loosen bolts in reverse order as shown, and remove fuel tube
and fuel injector assembly.
: Engine front
CAUTION:
Do not tilt fuel tube or remaining fuel in pipes may flow out
from pipes.
AWBIA2225ZZ
8. Remove fuel injector from fuel tube as follows:
Revision: October 2014 E M -5 0 2015 Murano

a. Open and remove clip (1).
A
(3) : O-ring (green)
(4) : O-ring (black)
(A) : Installed condition EM
(B) : Clip mounting groove
b. Remove fuel injector (2) from fuel tube (5) by pulling straight.
CAUTION: C
• Be careful or the remaining fuel in the fuel tube may spill.
• Be careful not to damage injector nozzle during removal. JPBIA1958ZZ
• Do not bump or drop fuel injector. D
• Do not disassemble fuel injector.
• Do not reuse O-rings.
9. Remove fuel damper from fuel tube. E
INSTALLATION
1. Install fuel damper as follows:
a. Install new O-ring (2) to fuel tube (1) as shown. When handling F
new O-ring, be careful of the following caution:
CAUTION:
• Do not reuse O-rings. G
• Handle O-ring with bare hands. Do not wear gloves.
• Lubricate O-ring with new engine oil.
• Do not clean O-ring with solvent.
H
• Check that O-ring and its mating part are free of foreign
material.
• When installing O-ring, be careful not to scratch, nick or
damage it. Also be careful not to twist or stretch O-ring. I
• Insert new O-ring straight into fuel tube. Be sure O-ring is
centered and not twisted.
b. Install spacer (3) to fuel damper (4). J
c. Insert fuel damper straight into fuel tube.
CAUTION:
• Insert fuel damper until (B) is touching (A) of fuel tube. K
• Insert straight, checking that the axis is lined up.
• Do not pressure-fit with excessive force.
L
Reference value : 130 N (13.3 kg, 29.2 lb)
d. Tighten bolts evenly in turn. JPBIA0316ZZ
• After tightening bolts, check that there is no gap between fuel M

damper cap (5) and fuel tube.
2. Install new O-rings to fuel injector paying attention to the following.
CAUTION:
N
• Upper and lower O-ring are different. Be careful to install them in the correct location.
• Handle O-ring with bare hands. Do not wear gloves.
• Lubricate O-ring with new engine oil. O
• Do not clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch or nick it. Also be careful not to twist or stretch
P
O-ring.
• Insert O-ring straight into fuel injector. Be sure that the O-ring is centered and not twisted.
3. Install fuel injector to fuel tube as follows:

a. Insert clip (3) into clip groove (F) on fuel injector (5).
(2) : O-ring (black)

(4) : O-ring (green)
• Insert clip so that protrusion (E) of fuel injector matches cutout
(C) of clip.
CAUTION:
• Do not reuse clip. Replace it with new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube (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.
• Check that fuel tube flange (G) is securely fixed in flange
groove (D) on clip.
CAUTION:
Do not pressure-fit with excessive force.
Reference value : 147 N (15.0 kg, 33.0 lb)

JPBIA1959ZZ
c. Check that installation is complete by checking that fuel injector does not rotate or come off.
• Check that protrusions of fuel injectors and fuel tubes are aligned with cutouts of clips after installation.
4. Install fuel tube and fuel injector assembly to intake manifold.

CAUTION:
Be careful not to let tip of injector nozzle come in contact with other parts.
• Tighten bolts in two steps in numerical order as shown.
: Engine front
1st step : 10.1 N·m (1.0 kg-m, 7 ft-lb)

2nd step : 22.0 N·m (2.2 kg-m, 16 ft-lb)
AWBIA2225ZZ
5. Connect fuel injector harness.

6. Install intake manifold collector. Refer to EM-28, "Removal and Installation".
7. Connect quick connector between fuel feed hose and fuel tube connection with the following procedure:
a. Check no foreign substances are on the fuel tube or quick connector and that they are not damaged.
b. Apply a light coating of new engine oil around fuel tube from tip end to spool end.
c. Align center to insert quick connector straightly into fuel tube.
• Insert quick connector (1) to fuel tube until top spool (2) is
completely inside quick connector, and 2nd level spool (3)
exposes right below quick connector.
(B) : Installed condition

: Upright insertion
CAUTION:
• Hold (A) position as shown when inserting fuel tube into
quick connector.
• Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector. JPBIA0275ZZ

• 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. A
d. Pull quick connector by hand holding position. Check it is completely engaged (connected) so that it does
not come out from fuel tube.
e. Install quick connector cap (3) to quick connector. EM
(1) : Fuel feed hose

(2) : Fuel tube C
(B) : Upper view
• Install quick connector cap with arrow (A) on surface facing in
direction of quick connector (fuel feed hose side). D
CAUTION:
If quick connector cap cannot be installed smoothly, quick
connector may have not been installed correctly. Check
E
connection again. JPBIA0039ZZ
f. Secure fuel feed hose to clamp of quick connector cap.

F
Inspection INFOID:0000000011220658
INSPECTION AFTER INSTALLATION G

Check For Fuel Leaks
1. Turn ignition switch ON with the engine stopped. With fuel pressure applied to fuel piping, check for fuel H
leaks at connection points. Repair as necessary.
NOTE:
Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, check again for fuel leaks at connection points. Repair as I
necessary.
WARNING:
Do not touch the engine immediately after stopped, as the engine becomes extremely hot. J
NOTE:
Use mirrors for checking on connections out of the direct line of sight.
• Perform procedures for “Throttle Valve Closed Position Learning” after finishing repairs. Refer to EC- K
157, "Work Procedure".
• If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” after
finishing repairs. Refer to EC-158, "Work Procedure".
L

VALVE TIMING CONTROL
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1. Front timing chain case 2. Valve timing control cover gas- 3. O-ring
ket (bank 1)
4. O-ring 5. Intake valve timing intermediate 6. Exhaust valve timing control sole-
lock control solenoid valve (bank noid valve (bank 1)
1)
7. Intake valve timing control sole- 8. Valve timing control cover (bank 9. Valve timing control cover (bank
noid valve (bank 1) 1) 2)
10. Intake valve timing control sole- 11. Exhaust valve timing control so- 12. Intake valve timing intermediate
noid (bank 2) lenoid (bank 2) lock control solenoid valve (bank
2)
13. Valve timing control cover gas- A. Refer to INSTALLATION
ket (bank 2)
Valve Timing Control Cover (bank 1) INFOID:0000000011545381
REMOVAL
1. Disconnect battery negative terminal. Refer to PG-90, "Exploded View".
2. Remove core support cover. Refer to EXT-30, "Exploded View".

3. Remove front air duct. Refer to EM-26, "Exploded View".
4. Remove cowl top and cowl top extension. Refer to EXT-34, "Exploded View". A
5. Remove reservoir tank. Refer to CO-13, "Exploded View".
6. Remove power steering oil pump. Refer to ST-38, "Removal and Installation".
EM
7. Support engine (1) and transaxle (2) using suitable jack (A).
CAUTION:
• Position a suitable jack under the engine and transaxle
assembly as shown. C
• Do not damage the front exhaust tube or transaxle oil pan
with the jack.
D
E
ALBIA0894GB
8. Remove upper torque rod, engine mounting insulator (RH), and engine mounting bracket (RH). Refer to
EM-104, "FWD : Exploded View" (FWD) or EM-108, "AWD : Exploded View" (AWD). F
9. Disconnect intake valve timing intermediate lock control solenoid valve (bank 1) harness connector..
10. Disconnect exhaust valve timing control solenoid valve (bank 1) harness connector.
11. Disconnect intake valve timing control solenoid valve (bank 1) harness connector. G
12. Remove intake valve timing intermediate lock control solenoid valve (bank 1), exhaust valve timing control
solenoid valve (bank 1), and intake valve timing control solenoid valve (bank 1) from valve timing control
cover (bank 1). H
CAUTION:
INSTALLATION I
• Install valve timing control cover (bank 1). Refer to EM-54, "Exploded View".
• Installation of remaining components is in the reverse order of removal.
CAUTION: J
• Do not reuse valve timing control cover gasket.
• Lubricate O-rings with clean engine oil prior to installation. K
Valve Timing Control Cover (bank 2) INFOID:0000000011545382
REMOVAL L
1. Remove core support cover. Refer to EXT-30, "Exploded View".
2. Remove front air duct. Refer to EM-26, "Removal and Installation".
M
3. Remove reservoir tank. Refer to CO-13, "Exploded View".
4. Remove power steering oil pump. Refer to ST-38, "Removal and Installation".
5. Disconnect intake valve timing intermediate lock control solenoid valve (bank 2) harness connector.. N
6. Disconnect exhaust valve timing control solenoid valve (bank 2) harness connector.
7. Disconnect intake valve timing control solenoid valve (bank 2) harness connector.
8. Remove intake valve timing intermediate lock control solenoid valve (bank 2), exhaust valve timing control O
solenoid valve (bank 2), and intake valve timing control solenoid valve (bank 2) from valve timing control
cover (bank 2).
CAUTION:
P
9. Remove valve timing control cover and valve timing control cover gasket.
INSTALLATION
• Install valve timing control cover (bank 2). Refer to EM-54, "Exploded View".
• Installation of remaining components is in the reverse order of removal.
CAUTION:
• Do not reuse valve timing control cover gasket.

• Lubricate O-rings with clean engine oil prior to installation.

FRONT TIMING CHAIN CASE
A
EM
L
AWBIA2246ZZ
1. Engine assembly 2. Water pump cover 3. Crankshaft pulley M

4. Front oil seal 5. Front timing chain case A. To Valve timing control cover
(bank 1/ bank 2). Refer to EM-
54, "Exploded View"
B. Refer to INSTALLATION Front N
O
NOTE:
• This section describes the procedure for removal/installation of the front timing chain case without removing
the engine from the vehicle. P
• When rear timing chain case must be removed, remove the engine from the vehicle. Refer to EM-104, "FWD
: Removal and Installation" (FWD) or EM-109, "AWD : Removal and Installation" (AWD). Then remove front
timing chain case, timing chain related parts, and rear timing chain case in this order, and install in reverse
order of removal.
• When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from
spilling.
REMOVAL

1. Remove engine under cover. Refer to EM-25, "Removal and Installation".
2. Drain the engine coolant from the radiator. Refer to CO-9, "Changing Engine Coolant".
3. Drain the engine oil. Refer to LU-9, "Changing Engine Oil".
4. Drain the power steering fluid. Refer to ST-30, "Draining and Refilling".
6. Remove front air duct. Refer to EM-26, "Exploded View".
7. Remove battery tray. Refer to PG-88, "Removal and Installation".
8. Remove cowl top. Refer to EXT-34, "Exploded View".
9. Remove upper radiator hose.
10. Disconnect engine coolant reservoir hose from the radiator and remove engine coolant reservoir.
11. Remove cooling fan assembly. Refer to CO-15, "Removal and Installation".
12. Disconnect lower radiator hose from engine.
13. Remove the radiator. Refer to CO-13, "Removal and Installation".
14. Disconnect the power steering fluid reservoir tank hose from the power steering pump and fluid cooler and
remove the power steering fluid reservoir tank.
15. Remove the front wheel and tire (RH) using a power tool. Refer to WT-68, "Removal and Installation".
16. Remove the fender protector side cover (RH). Refer to EXT-36, "FENDER PROTECTOR : Exploded
View".
18. Remove the rocker covers, if necessary. Refer to EM-45, "Removal and Installation (bank 2)" (bank 2) and
EM-47, "Removal and Installation (bank 1)" (bank 1).
NOTE:
Necessary only when removing timing chains.
19. If removing the timing chains, obtain compression TDC of No. 1
cylinder as follows:
a. Rotate crankshaft pulley clockwise to align timing mark (grooved
line without color) with timing indicator (A).
AWBIA2359ZZ
b. Check that intake and exhaust camshaft lobes on No. 1 cylinder

(bank 1) (A) are located as shown.
• If not, turn the crankshaft one revolution (360°) and align as
shown.
Engine front
AWBIA2360ZZ
20. Remove the access plate and lock the ring gear using Tool.
Tool number : — (J-50288)

CAUTION:
Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when installing
Tool.
21. Remove the crankshaft pulley as follows:
a. Loosen crankshaft pulley and locate bolt seating surface at 10 mm (0.39 in) from its original position.

b. Position a pulley puller at recess hole of crankshaft pulley to
remove crankshaft pulley. A
CAUTION:
Do not use a puller claw on crankshaft pulley periphery.
EM
EMQ0477D
D
22. Remove the power steering pump. Refer to ST-38, "Removal and Installation".
23. Remove the lower oil pan. Refer to EM-38, "Removal and Installation (Lower Oil Pan)".
24. Remove upper oil pan bolts (1) and (2) as shown. Refer to EM- E
39, "Removal and Installation (Upper Oil Pan)".
Engine front F
AWBIA2361ZZ H
25. Remove the generator. Refer to CHG-29, "Removal and Installation".

26. Disconnect the A/C tubes from the A/C compressor and position aside. Refer to HA-22, "Recycle Refriger- I
ant".
27. Remove the A/C compressor bolts and the A/C compressor. Refer to HA-29, "COMPRESSOR : Removal
and Installation".
J
28. Remove the generator bracket. Refer to CHG-29, "Exploded View".
29. Support the engine with suitable jack and remove the RH engine insulator, mount and torque rod. Refer to
EM-104, "FWD : Removal and Installation" (FWD) and EM-109, "AWD : Removal and Installation" (AWD).
K
30. Disconnect the oil pressure switch harness connector.
31. Disconnect the intake valve timing control solenoid valve harness connector.
32. Remove the valve timing control cover (bank 1) (A) and valve L
timing control cover (bank 2) (B).
(C) : Dowel pin hole

M
• Loosen the intake valve timing control solenoid valve cover
bolts in the reverse order as shown.
CAUTION:
N
The shaft in the intake valve timing control solenoid valve
cover is inserted into the center hole of the intake cam-
shaft sprocket. Remove the intake valve timing control
solenoid valve cover by pulling straight out until the JPBIA1639ZZ O
intake valve timing control solenoid valve cover disen-
gages from the camshaft sprocket.
33. Remove the drive belt auto-tensioner. Refer to EM-16, "Removal and Installation of Drive Belt Auto-ten- P
sioner".
34. If necessary, remove the water pump cover.

35. Remove the front timing chain case.
a. Loosen the front timing chain case bolts in reverse order as
shown.
AWBIA0708ZZ
b. Insert the appropriate size suitable tool into the notch (A) at the
top of the front timing chain case as shown.
c. Pry off the case by moving the suitable tool (B) as shown.
• Cut liquid gasket for removal using Tool.
Tool number: KV10111100 (J-37228)

CAUTION:
• Do not use a screwdriver or similar tool.
• After removal, handle carefully so it does not bend, or
warp under a load.
ALBIA0251ZZ
36. Remove O-rings (1) from rear timing chain case.
(A) : Bank 1 (RH)

(B) : Bank 2 (LH)
CAUTION:
AWBIA2247ZZ
37. Remove the front oil seal from the front timing chain case using
suitable tool.
CAUTION:
Do not damage the front cover.
SEM829E
38. Remove all old Silicone RTV Sealant (A) from all the bolt holes
(B) and bolts.
CAUTION:
Do not damage the threads or mating surfaces.
AWBIA2362ZZ

39. Use a suitable tool (A) to remove all of the old Silicone RTV
Sealant from the front timing chain case (B) and opposite mating A
surfaces.
CAUTION:
Do not damage the mating surfaces. EM
AWBIA2363ZZ
D
INSTALLATION
1. Install dowel pins (right and left) (A) into front timing chain case
E
up to a point close to taper in order to shorten protrusion length.
NOTE:
Be sure to place the dowel pins in original hole locations in the
front timing chain case (B). F
AWBIA2364ZZ
H
2. Install the new front oil seal on the front timing chain case. Apply
new engine oil to the oil seal edges.
NOTE: I
Install it so that each seal lip is oriented as shown.
K
AWBIA2365ZZ
L
a. Install the new front oil seal so that it becomes flush with the
face with front timing chain case using Tool (A). Refer to EM-87,
"Removal and Installation of Front Oil Seal".
CAUTION: M
Press fit straight and avoid causing burrs or tilting the oil
seal.
NOTE: N
Make sure the garter spring is in position and seal lip is not
inverted.
O
AWBIA2366ZZ

3. Install new O-rings (1) on rear timing chain case.
(A) : Bank 1 (RH)

(B) : Bank 2 (LH)
CAUTION:
AWBIA2247ZZ
4. Apply Silicone RTV Sealant to front timing chain case as shown.

• Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-
• Before installation, wipe off the protruding sealant.
• (C): 2.6 - 3.6 mm (0.102 - 0.142 in) dia.
ALBIA0252ZZ
5. Install dowel pin on the front timing chain case into dowel pin hole in the rear timing chain case.
6. Loosely install the front timing chain case bolts.
Bolt position Bolt diameter

1, 2 : 8 mm (0.31 in)
3 – 22 : 6 mm (0.24 in)
7. Tighten the front timing chain case bolts in the order as shown.
• Retighten the front timing chain case bolts in the order as
shown.
Bolt position Tightening specification AWBIA0708ZZ
1, 2 : 28.4 N·m (2.9 kg-m, 21 ft-lb)

3 – 22 : 12.7 N·m (1.3 kg-m, 9 ft-lb)

8. Install upper oil pan bolts (1) and (2) as shown. Refer to EM-39,
"Removal and Installation (Upper Oil Pan)". A
Engine front
EM
AWBIA2361ZZ
D
9. Install lower oil pan. Refer to EM-38, "Removal and Installation (Lower Oil Pan)".
10. Install intake valve timing control solenoid valve covers as follows:
a. Install new O-rings in shaft grooves. E
CAUTION:
b. Being careful not to move O-rings from the installation grooves, align dowel pins on front timing chain
F
case with the holes to install valve timing control covers.
c. Tighten intake valve timing control solenoid valve cover bolts in
numerical order as shown.
G
(A) : Bank 1 (RH)
(B) : Bank 2 (LH)
(C) : Dowel pin hole H
Intake valve timing control : 11.3 N·m (1.2 kg-m, 8 ft-lb)

I
solenoid valve cover bolts
JPBIA1639ZZ
11. Apply liquid gasket and install the water pump cover, if removed. J
• Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-22, "Recommended Chemical Products
and Sealants".
K
12. Install crankshaft pulley and tighten the bolt in two steps.
• Lubricate thread and seat surface of the bolt with new engine
oil.
• Apply a paint mark for the second step of angle tightening. L
Step 1 : 44 N·m (4.5 kg-m, 32 ft-lb)

Step 2 : 84° - 90° degrees clockwise M
Tool Number : KV10112100 (BT-8653-A)

N
AWBIA2367ZZ
13. Remove Tool and install the access plate.

O
CAUTION:
Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when removing P
the Tool.
14. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns
smoothly.

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-11, "Fluids and Lubricants".
age at connection points.
NOTE:
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec-

Engine oil Level Leakage Level

Exhaust gas — Leakage —

TIMING CHAIN
TIMING CHAIN
A
EM
I
AWBIA2248ZZ
1. Timing chain tensioner (secondary) 2. Internal chain guide 3. Timing chain tensioner (secondary) J
(bank 2) (bank 1)
4. Camshaft sprocket (bank 1) (EXH) 5. Timing chain (secondary) 6. Timing chain (primary)
7. Camshaft sprocket (bank 1) (INT) 8. Slack guide 9. Timing chain tensioner (primary)
K
10. Crankshaft sprocket 11. Camshaft sprocket (bank 2) 12. Timing chain (secondary)
(INT)
13. Camshaft sprocket (bank 2) (EXH) 14. Tension guide
L
CAUTION: M
• After removing timing chains, do not turn the crankshaft and camshaft separately or the valves will
strike the pistons.
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil. N
• Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets, camshaft
brackets, and crankshaft pulley.
O
REMOVAL
1. Remove front timing chain case. Refer to EM-57, "Removal and Installation".
2. Remove the intake manifold collector. Refer to EM-28, "Removal and Installation". P
3. Remove the spark plugs. Refer to EM-18, "Removal and Installation".
4. Place paint marks on the timing chain and sprockets to indicate the correct position of the components for
installation.
5. Disconnect the camshaft position sensor harness connectors.
6. Remove the timing chain tensioner (primary).

TIMING CHAIN
a. Pull lever down and release plunger stopper tab. Plunger stop-
per tab can be pushed up to release (coaxial structure with
lever).
AWBIA2368ZZ
b. Insert stopper pin (D) into timing chain tensioner (primary) body
hole to hold lever, and keep the tab released. An allen wrench
[1.2 mm (0.047 in)] is used for a stopper pin (D) as an example.
c. Insert plunger (A) into tensioner body by pressing the slack
guide (B).
d. Keep the slack guide (B) pressed and hold it by pushing the
stopper pin (D) through the lever hole and body hole.
e. Remove the bolts and remove the timing chain tensioner (pri-
mary).
AWBIA2369ZZ
7. Remove internal chain guide (A), tension guide (C) and slack
guide (B).
NOTE:
Tension guide (C) can be removed after removing timing chain
(primary).
AWBIA2370ZZ
8. Remove timing chain (primary) and crankshaft sprocket.

CAUTION:
After removing timing chains, do not turn the crankshaft and camshaft separately or the valves
will strike the pistons.
9. Remove timing chain (secondary) and camshaft sprockets as follows:

TIMING CHAIN
a. Attach a suitable stopper pin (B) to the bank 1 [RH (A)] and bank
2 [LH (C)] timing chain tensioners (secondary) (1). A
NOTE:
• Use approximately 0.5 mm (0.02 in) diameter hard metal pin
as a stopper pin.
EM
• Removal of camshaft bracket (No. 1) is required prior to
removing the timing chain tensioner (secondary).
AWBIA2250ZZ
D
b. Remove camshaft sprockets (INT/EXH) bolts.
• Secure the hexagonal portion of camshaft using a suitable tool
to loosen bolts.
E
CAUTION:
Do not loosen bolts using anything other than the cam-
shaft hexagonal portion. Do not apply tension to the tim-
ing chain. F
KBIA1698J
H
c. Remove timing chain (secondary) together with camshaft sprockets.
• Turn camshaft slightly to keep the chain tight when removing the timing chain (secondary).
• Insert 0.5 mm (0.020 in) thick metal or resin plate between tim-
ing chain and timing chain tensioner plunger (guide) (E). I
Remove timing chain (secondary) (2) together with camshaft
sprockets with timing chain loose from guide groove.
J
(1) : Timing chain tensioner (secondary)
(A) : Bank 1 (RH)
(B) : View B
K
(C) : Stopper pin
(D) : Plate
JPBIA2527ZZ
(F) : Timing chain tensioner (body)
L
CAUTION:
Be careful of plunger coming off when removing timing chain (secondary). The plunger of timing
chain tensioner (secondary) moves during operation, which could cause the stopper pin to fall M
out.
• Bank 1 shown.
d. Camshaft sprocket (INT) is two-for-one structure of sprockets for timing chain (primary) and for timing
chain (secondary). N
CAUTION:
• Handle camshaft sprocket (INT) carefully to avoid any
shock to camshaft sprocket. O
• Do not disassemble. [Do not loosen bolts (A) as shown].
PBIC2980E
INSPECTION
TIMING CHAIN
Check for cracks and any excessive wear of the timing chain. Replace the timing chain as necessary.
INSTALLATION
AWBIA2251ZZ
1. Internal chain guide 2. Camshaft sprocket (INT) 3. Mating mark (pink link)
4. Mating mark (punched) 5. Timing chain tensioner (secondary) 6. Mating mark (orange link)
7. Timing chain (secondary) 8. Camshaft sprocket (EXH) 9. Tension guide
10. Water pump 11. Crankshaft sprocket 12. Mating mark (notched)
13. Timing chain (primary) 14. Slack guide 15. Timing chain tensioner (primary)
16. Mating mark (back side) 17. Crankshaft key
NOTE:
This illustration shows the relationship between the mating mark on each timing chain and on the correspond-
ing sprocket with the components installed.
1. Install timing chain tensioners (secondary) with a new O-ring and the stopper pin attached.
CAUTION:
Do not reuse O-ring.
2. Check that dowel pin (A) and crankshaft key (1) are located as
shown. (No. 1 cylinder at compression TDC)
NOTE:
Though camshaft does not stop at the position as shown, for the
placement of cam nose, it is generally accepted camshaft is
placed in the same direction.
Camshaft dowel pin

: At cylinder head upper face side in each bank
Crankshaft key AWBIA1221GB
: At cylinder head side of bank 1

3. Install timing chain (secondary) and camshaft sprockets (INT and EXH) as follows:
CAUTION:
Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions
repeatedly during the installation process.

TIMING CHAIN
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with stopper pin (A). A
EM
JPBIA0095ZZ
D
b. Install timing chain (secondary) (2) and camshaft sprockets [INT
(1) and EXH (3)].
E
(A) : Dowel pin groove
(B) : Mating mark (2 oblong on rear face)
(C) : Orange link
F
(D) : Mating mark (2 circles on rear face)
(E) : Mating mark (Oblong on rear face)
(F) : Dowel pin groove
G
(G) : Mating mark (Circle on rear face)
(H) : Orange link
NOTE: H
Bank 1 shown (rear view).
• Align the mating marks on timing chain (secondary) (orange
link) with the mating marks on camshaft sprockets (INT and
EXH), and install them. I
• Align dowel pin on camshafts with the groove on sprockets,
and install them.
• Tighten the bolts for the camshaft sprockets by hand, enough J
to prevent the dowel pins from falling out of the grooves.
AWBIA2252ZZ
K
• It may be difficult to visually check the dislocation of mating
marks during and after installation. To make the matching eas-
ier, make a mating mark (A) on the top of sprocket teeth and L
its extended line with paint.
(B) : Mating mark (orange link) M
JPBIA2260ZZ
O
4. After confirming the mating marks are aligned, tighten the cam-
shaft sprocket bolts.
• Secure the camshaft using a wrench at the hexagonal portion
to tighten the bolts. P
KBIA1698J

TIMING CHAIN
5. Pull stopper pins (B) out from timing chain tensioners (second-
ary) (1).
(A) : Bank 1 (RH)

(C) : Bank 2 (LH)
JPBIA1727ZZ
6. Install the crankshaft sprocket (C) on the crankshaft.

• Make sure the mating marks (D) on the crankshaft sprocket
(C) face the front of the engine.
• The flat side of the crankshaft sprocket (C) is on the crankshaft
side (A)
AWBIA2371ZZ
7. Install the timing chain (primary).

• Install timing chain (primary) so the mating mark (punched) (B)
on camshaft sprocket (C) is aligned with the pink link (A) on
the timing chain, while the mating mark (notched) (E) on the
crankshaft sprocket (D) is aligned with the orange one (F) on
the timing chain, as shown.
• When it is difficult to align mating marks of the timing chain
(primary) with each sprocket, gradually turn the camshaft
using a wrench on the hexagonal portion to align it with the
mating marks.
• During alignment, be careful to prevent dislocation of mating
mark alignments of the secondary timing chains.
(G) : Water pump
AWBIA2253ZZ

TIMING CHAIN
8. Install the internal chain guide (1) and slack guide (2).
A
(3) : Tension guide
EM
G
AWBIA2254ZZ
CAUTION:
Do not over tighten slack guide mounting bolt (2). It is nor- H
mal for a gap (A) to exist under the bolt seat when bolt is
tightened to specification.
I
(1) : Slack guide
(3) : Cylinder block
J
K
JPBIA0117ZZ
9. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab (A) up (or turn lever downward) so as to L
remove plunger stopper tab from the ratchet of plunger (D).
NOTE:
Plunger stopper tab and lever (C) are synchronized.
M
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. N
d. To secure lever, insert stopper pin (E) through hole of lever into
tensioner body hole (B).
• The lever parts and the tab are synchronized. Therefore, the
plunger will be secured under this condition. JPBIA0118ZZ O
NOTE:
Illustration shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper
pin. P

TIMING CHAIN
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
10. Reconfirm that the matching marks on the sprockets and the timing chain have not slipped out of align-
ment.
11. Install the spark plugs. Refer to EM-18, "Removal and Installation".
12. Install the intake manifold collector. Refer to EM-28, "Removal and Installation".
13. Install the front timing chain case. Refer to EM-57, "Removal and Installation".

REAR TIMING CHAIN CASE
A
EM
I
AWBIA2373ZZ
1. Rear timing chain case 2. O-ring 3. Cylinder block J
CAUTION: K
• After removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will
strike the pistons.
• Before removing the upper oil pan, remove the crankshaft position sensor (POS). L
• Be careful not to damage sensor edges.
REMOVAL
1. Remove the engine assembly. Refer to EM-104, "FWD : Removal and Installation" (FWD) or EM-109, M
"AWD : Removal and Installation" (AWD).
2. Remove upper oil pan. Refer to EM-39, "Removal and Installation (Upper Oil Pan)".
3. Remove the front timing chain case. Refer to EM-57, "Removal and Installation". N
4. Remove the timing chains (primary) and (secondary). Refer to EM-65, "Removal and Installation".
5. Remove the rear timing chain case.
CAUTION: O
• Do not remove the plate metal cover for the oil passage.
• After removing the chain case, do not apply any load to
the case that might bend it. P
KBIA1307E

a. Loosen and remove the rear timing chain case bolts in the reverse order shown.
AWBIA0710ZZ
b. Cut the sealant using Tool and remove the rear timing chain case.
• After removing the bolts, separate the mating surface and
remove the old liquid gasket using Tool.
Tool number : KV10111100 (J-37228)

CAUTION:
• Tap the seal cutter to insert it (1).
• In areas where the Tool is difficult to use, lightly tap to slide it
(2).
AWBIA1249GB
6. Remove O-rings (1) from cylinder block.
: Engine front
CAUTION:
JPBIA0090ZZ

7. Use a scraper to remove all of the old Silicone RTV Sealant from
the front and rear timing chain case and opposite mating sur- A
faces.
CAUTION:
EM
SEM428G
D
8. Remove all old Silicone RTV Sealant from all the bolt holes and
bolts.
CAUTION:
E
Do not damage the threads or mating surfaces.
G
SEM161F
INSTALLATION
H
1. Install O-rings (1) on cylinder block.
: Engine front
I
CAUTION:
J
K
JPBIA0090ZZ
2. Apply Genuine Silicone RTV Sealant or equivalent, to the rear timing chain case using suitable tool as
shown. Refer to GI-22, "Recommended Chemical Products and Sealants". L
CAUTION:
• Installation should be done within 5 minutes after applying liquid gasket.
• Do not fill the engine with engine oil for at least 30 minutes after the components are installed to M
allow the sealant to cure.
• Wipe off liquid gasket where it touches the engine coolant passage at point (A).
• Follow the installation instructions for applying the liquid gasket. Pay particular attention to the
water pump and cylinder area. N

AWBIA2374ZZ
3. Align the rear timing chain case and water pump assembly with the dowel pins (RH and LH) on the cylin-
der block and install the case. Make sure the O-rings stay in place during installation.
a. Tighten the bolts in the numerical order as shown. There are two bolt lengths used. Follow the chart below
for proper bolt length specifications.
AWBIA0710ZZ

Bolt length Bolt position Torque specification A

20 mm (0.79 in) 1, 2, 3, 6, 7, 8, 9, 10 12.7 N·m (1.3 kg-m, 9 ft-lb)
16 mm (0.63 in) All except the 12.7 N·m (1.3 kg-m, 9 ft-lb)
EM
above
b. After all bolts are initially tightened, retighten them to the specification in the numerical order as shown.
NOTE:
C
If liquid gasket protrudes, wipe it off immediately.
4. Install the timing chains (primary and secondary). Refer to EM-65, "Removal and Installation".
5. Install the front timing chain case. Refer to EM-57, "Removal and Installation". D
6. Install the upper oil pan. Refer to EM-39, "Removal and Installation (Upper Oil Pan)".
7. Install the engine assembly. Refer to EM-104, "FWD : Removal and Installation" (FWD) or EM-109, "AWD
: Removal and Installation" (AWD). E

CAMSHAFT
CAMSHAFT
AWBIA0840GB
1. Camshaft position sensor bracket 2. Camshaft brackets 3. No. 1 camshaft bracket (bank 1)
(bank 1)
4. Camshaft (EXH) (bank 1) 5. Camshaft (INT) 6. Cylinder head (bank 1)
(bank 1)
7. Cylinder head (bank 2) 8. Camshaft (EXH) 9. Camshaft (INT) (bank 2)
(bank 2)
10. No. 1 camshaft bracket (bank 2) 11. Camshaft brackets 12. Camshaft position sensor bracket (bank
2)
A. Refer to INSTALLATION
CAUTION:
Apply new engine oil to parts marked in illustration before installation.

CAMSHAFT
REMOVAL
1. Remove the timing chains. Refer to EM-65, "Removal and Installation". A
2. Remove camshaft position sensor brackets (RH shown LH simi-
lar).
EM
D
ALBIA0259ZZ
E
3. Remove the intake and exhaust camshaft brackets (bank 1) (C)
and the camshafts (bank 1) (A/B).
• Mark the camshafts (bank 1) (A/B), camshaft brackets (bank
1) (C), and bolts so they are placed in the same position and F
direction for installation.
• Equally loosen the camshaft bracket bolts in several steps in
the numerical order as shown. G
:Engine front
H
AWBIA2379ZZ
4. Remove the intake and exhaust camshaft brackets (bank 2) (B) I

and the camshafts (bank 2) (A/C).
• Mark the camshafts (bank 2) (A/C), camshaft brackets (bank
2) (B), and bolts so they are placed in the same position and J
direction for installation.
• Equally loosen the camshaft bracket bolts in several steps in
the numerical order as shown.
K
:Engine front
AWBIA2380ZZ
L
5. Remove valve lifters, if necessary.

NOTE: M
Identify installation positions to ensure proper installation.
6. Remove secondary timing chain tensioner (2/5) from bank 1/
bank 2 (A/B)
• Remove secondary tensioner (2/5) with its stopper pin (4) N
attached.
NOTE:
• Stopper pin (4) was attached when secondary timing chain (2/ O
5) was removed.
• Do not reuse O-rings (1/3).
P
AWBIA2381ZZ
INSTALLATION

CAMSHAFT
1. Before installation, remove any old Silicone RTV Sealant (A)
from component mating surfaces using a suitable tool.
• Remove the old Silicone RTV Sealant (A) from the bolt holes
(B) and threads.
• Do not scratch or damage the mating surfaces.
AWBIA2362ZZ
2. Before installing the front cam bracket, remove the old Silicone
RTV Sealant (B) from the mating surface using a suitable tool
(A).
• Do not scratch or damage the mating surface.
AWBIA2382ZZ
3. Turn the crankshaft until No. 1 piston is set at TDC on the com-
pression stroke.
• The crankshaft key (A) should line up with the right bank cylin-
der center line (B) as shown.
AWBIA2383ZZ
4. Install camshaft chain tensioners (1/2) at bank 1 (A) and bank 2

(B) . Refer to EM-65, "Exploded View".
CAUTION:
AWBIA2384ZZ
5. Install valve lifters, if removed.

NOTE:
Install them in original positions.

CAMSHAFT
6. Install exhaust camshaft (A) and intake camshaft (B) and cam-
shaft brackets. A
• Intake camshaft has a drill mark (C) on camshaft sprocket
mounting flange.
EM
AWBIA2385ZZ
D
• Follow your identification marks made during removal, or fol-
low the identification marks that are present on the new cam-
shafts components for proper placement and direction of the E
components.
:Engine front
F
ID mark Paint marks G

Bank INT/EXH Drill mark
(A)
M1 (E) M2 (F) M3 (D) AWBIA1352ZZ
INT 1A Yes Purple No Light blue

1 (B) H
EXH 1C No No Brown Light blue
INT 1B Yes Purple No Light blue
2 (C)
EXH 1D No No Brown Light blue I
• Position the camshaft dowel pins (A) as shown.
(1) :Crankshaft key J
L
AWBIA1221GB

CAMSHAFT
7. Apply sealant to mating surface of camshaft brackets (1) of bank
1 (A) and bank 2 (B) cylinder heads.
• Use Genuine Silicone RTV Sealant, or equivalent. Refer to
• Before installation, wipe off any protruding sealant from front
face of camshaft bracket.
• Refer to EM-5, "Precaution for Liquid Gasket".
:Engine front
AWBIA2386ZZ
• Install bank 1 (B) and bank 2 (C) camshaft brackets in their

original positions and direction. Align the stamp marks (A) as
shown.
• If checking and adjusting any part of valve assembly or
camshaft, check valve clearance according to the refer-
ence data. Refer to EM-20, "Valve Clearance".
:Engine front
Valve clearance (cold) Intake : 0.26 - 0.34 mm

(0.010 - 0.013 in) AWBIA2390ZZ
Valve clearance (cold) Exhaust : 0.29 - 0.37 mm

(0.011 - 0.015 in)
• Locate the camshaft (EXH) (bank 1) (A) and camshaft (INT)

(bank 1) (B). Tighten the camshaft brackets (C) in the three
steps, in numerical order as shown.
AWBIA2388ZZ

CAMSHAFT
• Locate the camshaft (EXH) (bank 2) (B) and camshaft (INT)
(bank 2) (A). Tighten the camshaft brackets (C) in the three A
steps, in numerical order as shown.
Tighten No. 7 - 10, then EM

1 1.96 N·m (0.20 kg-m, 17 in-lb) tighten 1 - 6 in numerical
order as shown.
Tighten all in numerical or- C
2 5.88 N·m (0.60 kg-m, 52 in-lb)
der as shown.
Tighten No. 1 - 10 in nu- AWBIA2389ZZ
AWBIA2388ZZ
3 10.41 N·m (1.1 kg-m, 8 ft-lb) D

merical order as shown.
8. Measure difference in levels between front end faces of No. 1 E

camshaft bracket and cylinder head.
Standard : – 0.14 (– 0.0055 in) F

• If measurement is outside the specified range, reinstall cam-
shaft and camshaft bracket.
G
H
EMQ0044D
9. Install camshaft position sensor bracket (PHASE) (RH and LH bank.)

I
10. Install the timing chains. Refer to EM-65, "Exploded View".
Camshaft Visual Check J
Check camshaft for scratches, seizure and wear. Replace if necessary.
Camshaft Runout
K
1. Put V-block on precise flat bed and support No. 2 and No. 4 jour-
nal of camshaft as shown.
2. Set dial gauges vertically to No. 3 journal as shown. L
3. Turn camshaft in one direction slowly by hand, measure the
camshaft runout on the dial gauges.
• Runout is the largest indicator reading after one full revolution.
M
Refer to EM-137, "Camshaft".
4. If actual runout exceeds the limit, replace the camshaft.
N
PBIC0929E
Camshaft Cam Lobe Height

1. Measure camshaft cam lobe height as shown. Refer to EM-137, O
"Camshaft".
2. If wear has reduced the lobe height below specifications,
replace the camshaft. P
SEM549A

CAMSHAFT
Camshaft Journal Clearance
Outer Diameter of Camshaft Journal
• Measure outer diameter of camshaft journal as shown. Refer to
EM-137, "Camshaft".
SEM012A
Inner Diameter of Camshaft Bracket

1. Tighten camshaft bracket bolt with specified torque.
2. Using inside micrometer, measure inner diameter (A) of cam-
shaft bearing. Refer to EM-137, "Camshaft".
SEM862E
Calculation of Camshaft Journal Clearance

(Journal clearance) = (inner diameter of camshaft bracket) – (outer diameter of camshaft journal). Refer to
EM-137, "Camshaft".
• When out of the specified range, replace either or both camshaft and cylinder head.
NOTICE:
Inner diameter of camshaft bracket is manufactured together with cylinder head. Replace the whole cylinder
head assembly.
Camshaft End Play
1. Install the camshaft in the cylinder head.
2. Install dial gauge in thrust direction on front end of camshaft.
Measure end play when camshaft is moved forward/backward
(in direction to axis) as shown. Refer to EM-137, "Camshaft".
• If out of the specified range, replace with new camshaft and mea-
sure again.
• If out of the specified range again, replace with new cylinder head.
SEM864E
Camshaft Sprocket Runout

CAMSHAFT
1. Put V-block on precise flat bed and support No. 2 and No. 4 jour-
nal of camshaft as shown. A
2. Install camshaft sprocket on camshaft.
3. Measure camshaft sprocket runout. Refer to EM-137, "Cam-
shaft". EM
4. If sprocket runout exceeds the limit, replace camshaft sprocket.
PBIC0930E
D
Valve Lifter
• Check if the surface of the valve lifter has any excessive wear or
cracks, replace as necessary.
E
G
KBIA0182E
Valve Lifter Clearance H

Outer Diameter of Valve Lifter
• Measure the outer diameter of the valve lifter with a suitable tool
(A). Refer to EM-137, "Camshaft".
• If out of the specified range, replace the valve lifter. I
AWBIA2391ZZ
L
Valve Lifter Bore Diameter
• Using inside micrometer, measure diameter of valve lifter bore of
cylinder head. Refer to EM-137, "Camshaft".
• If out of the specified range, replace the cylinder head assembly. M
SEM867E
P
Calculation of Valve Lifter Clearance
• (Valve lifter clearance) = (hole diameter for valve lifter) – (outer diameter of valve lifter) Refer to EM-137,
"Camshaft".
• If out of specified range, replace either or both valve lifter and cylinder head assembly.

CAMSHAFT
Inspection after Installation INFOID:0000000011552721
INSPECTION OF CAMSHAFT SPROCKET (INT) OIL GROOVE

WARNING:
• Check when engine is cold so as to prevent burns from any splashing engine oil.
CAUTION:
• Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT and
it is directed according to inspection procedure of EC section. Refer to EC-202, "Diagnosis Proce-
dure".
1. Check engine oil level. Refer to LU-8, "Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release fuel pressure. Refer to EC-166, "Work Procedure".
b. Disconnect ignition coil and injector harness connectors, if practical.
3. Remove intake valve timing control solenoid valve.
4. Crank engine, and then make sure that engine oil comes out from intake valve timing control solenoid
valve cover oil hole. End cranking after checking.
WARNING:
Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.).
CAUTION:
• Engine oil may squirt from intake valve timing control solenoid valve installation hole during
cranking. Use a shop cloth to prevent engine oil from splashing on worker, engine components
and vehicle.
• Do not allow engine oil to get on rubber components such as drive belts or engine mount insula-
tors. Immediately wipe off any splashed engine oil.
5. Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not
come out from intake valve timing control solenoid valve cover oil hole.
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.
7. After inspection, installation of the remaining components is in the reverse order of removal.

OIL SEAL
OIL SEAL
A
Removal and Installation of Valve Oil Seal INFOID:0000000011557860
REMOVAL EM
1. Turn crankshaft until the cylinder requiring new oil seals is at TDC. This will prevent valve from dropping
into cylinder.
CAUTION: C
When rotating crankshaft, be careful to avoid scarring the front cover with the timing chain.
2. Remove camshaft relating to valve oil seal to be removed. Refer to EM-78, "Removal and Installation".
3. Remove valve lifters. D
4. Remove valve collet, valve spring retainer and valve spring
using suitable tool (A).
CAUTION: E
When working, take care not to damage valve lifter bore.
• Compress valve spring using Tool, attachment and adapter.
Remove valve collet with magnet hand.
F
G
AWBIA1760ZZ
H
5. Remove valve oil seal using suitable tool (A).
K
ALBIA0863GB
INSTALLATION
L
1. Apply new engine oil to new valve oil seal joint surface and seal lip.
2. Press in valve oil seal to height (H) using suitable tool (A).
NOTE: M
Dimension (H): height measured before valve spring seat instal-
lation.
N
Intake and exhaust (H) : 14.3 - 14.9 mm (0.563 - 0.587 in)
3. Installation of the remaining components is in the reverse order
of removal. O
ALBIA0864GB
Removal and Installation of Front Oil Seal INFOID:0000000011557861

P
REMOVAL
1. Remove drive belt. Refer to EM-14, "Removal and Installation".
2. Lock the drive plate using Tool.

OIL SEAL
CAUTION:
Do not damage the ring gear teeth or the signal plate teeth behind the ring gear when setting the
Tool.
3. Remove the crankshaft pulley as follows:
a. Loosen crankshaft pulley and locate bolt seating surface at 10 mm (0.39 in) from its original position.
b. Position a pulley puller at recess hole of crankshaft pulley to
remove crankshaft pulley.
CAUTION:
Do not use a puller claw on the outer diameter of the crank-
shaft pulley.
EMQ0477D
4. Remove front oil seal from front cover using a suitable tool.
CAUTION:
Be careful not to damage front cover or crankshaft.
WBIA0680E
INSTALLATION
1. Apply new engine oil to oil seal lip (C) and dust seal (D) and
install.
• Install new oil seal towards the engine inside (B) as shown.
CAUTION:
Press fit straight and avoid causing burrs to engine inside
(C) or engine outside (A) or tilting the oil seal.
AWBIA2396ZZ
• Press-fit oil seal until it becomes flush with the timing chain case
end face, using Tool (A).

• Make sure the garter spring in the oil seal is in position and seal lip
is not inverted.
AWBIA2397ZZ
2. Install crankshaft pulley and tighten the bolt in two steps.

• Lubricate thread and seat surface of the bolt with new engine oil.
• For the second step angle tighten using Tool.
CAUTION:

OIL SEAL
• Do not damage the front oil seal when inserting crankshaft pulley.
• Use only brass or plastic hammer if tapping on the crankshaft pulley. A
• Do not hammer on pulley grooves.
Step 1 : 44.1 N·m (4.5 kg-m, 33 ft-lb) EM

Step 2 : 90°(+0°/-6°) degrees clockwise
Tool number : KV10112100 (BT-8653-A) C

3. Remove the Tool to unlock the drive plate.
Tool number : — (J-50288) D
CAUTION:
Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when removing
E
the Tool.
Removal and Installation of Rear Oil Seal INFOID:0000000011557862 F
REMOVAL
1. Remove the upper oil pan. Refer to EM-39, "Removal and Installation (Upper Oil Pan)". G
2. Remove drive plate. Refer to EM-113, "Exploded View".
3. Remove rear oil seal retainer using Tool (A).
H
Tool Number : KV10111100 (J-37228)
CAUTION:
I
• Be careful not to damage mating surface.
• If rear oil retainer is removed, replace it with a new one
NOTE:
Rear oil seal and retainer form a single part and are replaced as J
an assembly.
AWBIA2398ZZ
K
INSTALLATION
1. Remove old liquid gasket material from mating surface of cylinder block and oil pan using a suitable
scraper. L
2. Install the rear oil seal using Tool (A).
Tool number : — (J-47128) M

a. Loosen the wing nut (B) on the end of the Tool (A).
b. Insert the arbor (D) into the crankshaft pilot hole until the outer
lip (C) of the Tool (A) covers the edge of the crankshaft sealing N
surface.
c. Tighten the wing nut (B) to secure the Tool (A) to the crankshaft.
O
ALBIA0652ZZ

OIL SEAL
d. Apply sealant to rear oil seal retainer as shown.
Use Genuine Silicone RTV Sealant or equivalent. Refer to
CAUTION:
ing liquid gasket.
the components are installed to allow the liquid gasket to
cure.
AWBIA0028ZZ
e. Lubricate the sealing surface of the new rear main seal with new engine oil.
f. Slide the new rear main seal (1) over the Tool (A) and onto the
crankshaft.
g. Loosen the wing nut and push the threaded rod into the handle
to remove the Tool (A).
h. Tighten the rear oil seal retainer bolts to specification.
Rear oil seal retainer bolts : 8.8 N·m (0.9 kg-m, 78 in-lb)
ALBIA0653ZZ

CAUTION:
• When replacing an engine or transmission you must make sure the dowels are installed cor-
rectly during reassembly.
• Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of
drivetrain components.

CYLINDER HEAD
CYLINDER HEAD
A
EM
G
ALBIA0260ZZ
1. Cylinder head bolt 2. Cylinder head 3. Cylinder head gasket

4. Engine block A. Refer to INSTALLATION
H
I
REMOVAL
1. Remove the engine from the vehicle. Refer to EM-104, "FWD : Removal and Installation" (FWD) or EM-
109, "AWD : Removal and Installation" (AWD). J
2. Remove the rear timing chain case. Refer to EM-73, "Removal and Installation".
3. Remove the intake manifold. Refer to EM-31, "Removal and Installation".
4. Remove the exhaust manifold and three way catalyst (bank 1/bank 2). Refer to EM-33, "Exploded View". K
5. Remove the intake and exhaust camshafts. Refer to EM-78, "Removal and Installation".
6. Remove the water outlet housing. Refer to CO-24, "Exploded View".
L
7. Remove the bolts from bank 1 cylinder head (A) and bank 2 cylinder head (B).
• The bolts should be loosened gradually in three stages.
• Loosen the bolts in the reverse tightening sequence as shown.
M
:Engine front
AWBIA2401ZZ
P

CYLINDER HEAD
AWBIA2402ZZ
8. Remove cylinder head (A) and cylinder head gasket.

CAUTION:
Do not reuse cylinder head gaskets.
:Engine front
AWBIA2399ZZ
INSTALLATION
1. Turn the crankshaft until No. 1 piston is set at TDC on the com-
pression stroke.
• The crankshaft key (A) should line up with the bank 1 cylinder
head center line (B) as shown.
AWBIA2383ZZ
2. Install new cylinder head gaskets.

CAUTION:
Do not reuse cylinder head gaskets.
3. Inspect the cylinder head bolts (B) before installing the cylinder heads.
CAUTION:
Cylinder head bolts (B) are tightened by degree rotation
tightening method. Observing measuring points (A), when-
ever the size difference between d1 and d2 exceeds the
limit, replace the bolts with new ones.
Limit (d1 - d2) : 0.11 mm (0.0043 in)

• Lubricate threads and seat surfaces of the bolts with new
engine oil.
:Engine front
AWBIA2400ZZ
4. Install the bank 1 cylinder head (A) and bank 2 cylinder head (B) on the cylinder block. Tighten the cylin-
der head bolts in the five steps in the numerical order as shown using Tool.
CAUTION:
Do not rotate crankshaft and camshaft separately or valves will strike piston heads.

CYLINDER HEAD
Tool Number : KV10112100 (BT-8653-A) A

• Tightening procedure:
EM
Cylinder head bolts
Step 1 : 98.1 N·m (10 kg-m, 72 ft-lb) in order
C
Step 2 : Loosen bolts in the reverse order of tighten-
ing.
Step 3 : 39.2 N·m (4.0 kg-m, 29 ft-lb) in order
D
Step 4 : 103° degrees rotation in order
Step 5 : 103° degrees rotation in order
E
AWBIA2401ZZ
:Engine front
AWBIA2402ZZ
I

CYLINDER HEAD
Disassembly and Assembly INFOID:0000000011557865
AWBIA1353ZZ
1. Valve collet 2. Valve spring retainer 3. Valve spring

4. Valve oil seal 5. Valve spring seat 6. Valve guide
7. Spark plug tube 8. Lifter (INT) 9. Lifter (EXH)
10. Cylinder head 11. Valve seat (EXH) 12. Valve seat (INT)
13. Valve (EXH) 14. Valve (INT)
CAUTION:
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
• Apply new engine oil to threads and seat surface when installing cylinder head, camshaft sprocket,
crankshaft pulley, and camshaft bracket.

CYLINDER HEAD
• Attach tags to valve lifters so as not to mix them up.
A
DISASSEMBLY
1. Remove spark plug.
2. Remove valve lifter. EM
• Identify installation positions and store them without mixing them up.
3. Remove valve collet.
• Compress valve spring and remove valve collet with magnet
C
hand using suitable tool (A)
CAUTION:
D
AWBIA1760ZZ
F
4. Remove valve spring retainer, valve spring and valve spring seat.
5. Push valve stem to combustion chamber side and remove valve.
• Identify installation positions, and store them without mixing them up.
G
6. Remove valve oil seals using suitable tool (A).
J
ALBIA0863GB
7. If valve seat must be replaced, refer to EM-96, "Inspection After Disassembly".

8. If valve guide must be replaced, refer to EM-96, "Inspection After Disassembly". K
9. Remove spark plug tube, as necessary.
• Using pair of pliers, pull spark plug tube out of cylinder head.
CAUTION: L
• Take care not to damage cylinder head.
• Once removed, spark plug tube will be deformed and cannot be reused. Do not remove it unless
absolutely necessary. M
ASSEMBLY
1. When valve guide is removed, install it. Refer to EM-96, "Inspection After Disassembly".
N
2. When valve seat is removed, install it. Refer to EM-96, "Inspection After Disassembly".
3. Install valve oil seals using suitable tool (A).
O
Height (H) (Without valve spring seat installed)
Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
4. Install valve spring seat. P
5. Install valves.
• Install it in the original position.
NOTE:
Larger diameter valves are for intake side.
ALBIA0864GB

CYLINDER HEAD
6. Install valve spring (uneven pitch type) with narrow pitch (C) end
(paint mark) (B) facing cylinder head side (A). Wide pitch (D)
end should face away from cylinder head.
AWBIA2403ZZ
7. Install valve spring retainer.

8. Install valve collet.
• Compress valve spring using suitable tool (A), attachment and
adapter. Install valve collet with magnet hand.
CAUTION:
• Tap valve stem edge lightly with plastic hammer after installa-
tion to check its installed condition.
AWBIA1760ZZ
9. Install valve lifter.

• Install it in the original position.
10. Install spark plug tube.
• Press-fit spark plug tube as follows:
a. Remove old liquid gasket adhering to cylinder head mounting hole.
b. Apply sealant to area (A) within approximately 12 mm (0.47 in)
from edge of spark plug tube press-fit side.
Use Genuine High Strength Locking Sealant or equivalent.
Refer to GI-22, "Recommended Chemical Products and
Sealants".
c. Press-fit spark plug tube so that its height (H) is as specified in
using suitable tool. Refer to EM-139, "Cylinder Head".
CAUTION:
• When press-fitting, take care not to deform spark plug
tube.
• After press-fitting, wipe off liquid gasket protruding onto AWBIA2404ZZ
cylinder-head upper face.
11. Install spark plug. Refer to EM-18, "Removal and Installation".
Inspection After Disassembly INFOID:0000000011557866
CYLINDER HEAD DISTORTION

Clean the surface of the cylinder head. Use a reliable straightedge and feeler gauge to check the flatness of
cylinder head surface.

CYLINDER HEAD
Check along six positions as shown. Refer to EM-94, "Disassembly
and Assembly" A
If it exceeds the limit, replace the cylinder head.
The limit for cylinder head resurfacing is determined by the cyl-
inder block resurfacing. Refer to EM-139, "Cylinder Head"
EM
After resurfacing cylinder head, check that camshaft rotates freely by
hand. If resistance is felt, cylinder head must be replaced.
SEM861E
D
VALVE GUIDE CLEARANCE
1. Measure valve deflection (D) using a suitable tool (C) as shown (Valve and valve guide mostly wear in this
direction). Measuring direction (E) should be 90° (B) of camshaft direction (A). Refer to EM-139,
E
"Cylinder Head".
Maximum deflection : 0.25 mm (0.010 in)

F
AWBIA2405ZZ
2. If it exceeds the limit, check valve to valve guide clearance with I

a suitable tool (A).
a. Measure valve stem diameter and valve guide inner diameter.
Refer to EM-139, "Cylinder Head". J
b. Check that clearance is within specification.
(Valve guide clearance) = (Valve guide inner diameter) - (Valve
stem diameter). Refer to EM-139, "Cylinder Head". K
c. If it exceeds the limit, replace valve or valve guide.
L
AWBIA2406ZZ
VALVE GUIDE REPLACEMENT

When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide. M
1. To remove valve guide, heat cylinder head to 110 - 130°C (230 -
266°F) by soaking in heated oil (A).
WARNING: N
Cylinder head contains heat. When working, wear protective
equipment to avoid getting burned.
O
P
AWBIA2407ZZ

CYLINDER HEAD
2. Drive out the valve guide with a press [under a 20 kN (2.2 US
ton) pressure] or hammer and suitable tool.
SEM931C
3. Ream cylinder head valve guide hole using suitable tool (A).
Refer to EM-139, "Cylinder Head".
AWBIA2408ZZ
4. Heat cylinder head to 110 - 130°C (230 - 266°F) by soaking in

heated oil and press new valve guide from camshaft side into
the cylinder head to the dimensions as shown. Refer to EM-139,
"Cylinder Head".
WARNING:
Cylinder head contains heat. When working, wear protective
SEM950E
5. Using a suitable tool (A), apply a reamer finish to the valve

guide.
Intake and exhaust : 6.000 - 6.018 mm

finished size (0.2362 - 0.2369 in)
AWBIA2408ZZ
VALVE SEAT CONTACT

CYLINDER HEAD
• After confirming that the dimensions of valve guides and valves are
within specifications, perform this procedure. A
• Apply Prussian blue onto contacting surface of valve seat to check
the condition of the valve contact on the surface.
• Check if the contact area band is continuous all around the circum-
EM
ference.
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has NG conditions even after the recheck, replace
valve seat. C
SBIA0322E
D
VALVE SEAT REPLACEMENT
1. Bore out old seat (A) until it collapses. Boring should not con-
tinue beyond the bottom face of the seat recess in cylinder
E
head. Set the machine depth stop to ensure this.
2. Ream cylinder head recess for service valve seat. Refer to EM-
139, "Cylinder Head"
F
AWBIA2409ZZ
H
Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.
3. Heat cylinder head to 110 - 130°C (230 - 266°F) by soaking in heated oil. I
WARNING:
Cylinder head contains heat. when working, wear protective
equipment to avoid getting burned. J
AWBIA2407ZZ
M
4. Press fit valve seat until it seats on the bottom.
5. Cut or grind valve seat using suitable tool to the specified dimensions. Refer to EM-139, "Cylinder Head".
N
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. Refer to EM-139,
"Cylinder Head". O
SEM892B

CYLINDER HEAD
8. Use a depth gauge to measure the distance between the mount-
ing surface of the cylinder head spring seat and the valve stem
end on the exhaust (A) and intake (B) sides. If the distance is
shorter than specified, repeat step 5 to adjust it. If it is longer,
replace the valve seat with a new one. Refer to EM-139,
"Cylinder Head".
AWBIA2410ZZ
VALVE SPRING SQUARENESS

Set try square (A) along the side of valve spring and rotate the
spring. Valve spring should contact (B) the try square (A) (Measure
the maximum clearance between the top face of spring and try
square. Refer to EM-139, "Cylinder Head".
AWBIA2411ZZ
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

Check valve spring pressure at specified spring height.
If it is not within specifications, replace the spring. Refer to EM-139,
"Cylinder Head".
SEM113

ENGINE MOUNT
ENGINE MOUNT
A
ENGINE MOUNT (FRONT)
ENGINE MOUNT (FRONT) : Removal and Installation INFOID:0000000011220679
EM
WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels. C
CAUTION:
• Always work safely.
• Do not start work until the engine and exhaust system are cooled completely.
D
• Refer to the applicable sections for warnings, cautions, notes, and instructions if necessary proce-
dures are not included in this section.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill- E
ing.
REMOVAL
F
1. Remove the air cleaner case (upper), air cleaner case (lower), front air duct, and air duct hose and reso-
nator assembly. Refer to EM-26, "Removal and Installation".
2. Remove the battery and battery tray assembly. Refer to PG-88, "Removal and Installation".
G
4. Remove the fender protector side covers (RH/LH). Refer to EXT-36, "FENDER PROTECTOR : Exploded
View".
H
5. Partially remove the fender protectors (RH/LH). Refer to EXT-36, "FENDER PROTECTOR : Exploded
View".
6. Remove the radiator assembly. Refer to CO-13, "Removal and Installation".
I
7. Remove the engine cooling fan shroud and motor assembly. Refer to CO-15, "Removal and Installation".
8. Remove the exhaust manifold heat shield (LH). Refer to EM-33, "Exploded View".
9. Support the engine with a suitable tool. J
10. Disconnect the engine mount insulator (front) vacuum hose.
11. Remove the engine mount insulator (front) nut (A).
K
AWBIA1241GB
N
12. Loosen the engine mount bracket (front) bolts in the reverse
order shown.
O
: Engine front
JPBIA1731ZZ
13. Remove the engine mount bracket (front).

ENGINE MOUNT
14. Remove the engine mount insulator (front) bolts in the reverse
order as shown.
: Front
JPBIA1735ZZ
15. Remove the engine mount insulator (front).
AWBIA1242GB
INSTALLATION
CAUTION:
• Do not damage or spill engine oil on the engine mount insulator (front).
• Check engine mount insulator (front) is seated properly before tightening.
1. Install the engine mount insulator (front).
AWBIA1242GB
2. Install the engine mount insulator (front) bolts and tighten to

specification in the order shown.
: Front
Engine mount insulator (front) : 55 N·m (5.6 kg-m,

bolts 41 ft-lb)
JPBIA1735ZZ
3. Install the engine mount bracket (front) to the engine block.

ENGINE MOUNT
4. Tighten the engine mount bracket (front) bolts to specification in
the order shown. A
: Engine front
EM
Engine mount bracket (front) : 40 N·m (4.1 kg-m,
bolts 30 ft-lb)
C
JPBIA1731ZZ
D
5. Install the engine mount insulator (front) nut (A) and tighten to
specification.
Engine mount insulator (front) : 103 N·m (11 kg-m, E

nut 76 ft-lb)
G
AWBIA1241GB

H

ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >
UNIT REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
FWD
FWD : Exploded View INFOID:0000000011220680
AWBIA2442ZZ
1. Gusset 2. Rear torque rod 3. Rear torque rod bracket

4. Upper torque rod 5. Engine mounting insulator (RH) 6. Engine mounting bracket (RH)
7. Engine mounting insulator (front) 8. Engine mounting bracket (front) 9. Vacuum hose
10. Vacuum tube (front) 11. Vacuum hose 12. Engine mounting insulator (LH)
13. Engine mounting insulator (rear) 14. Engine mounting bracket (rear) 15. Engine mounting stay (rear)
A. To electronic controlled engine mount B. To transmission Front
control solenoid valve
FWD : Removal and Installation INFOID:0000000011220681
WARNING:
• Place chocks at front and back of rear wheels.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• Always work safely.
dures are not included in the engine section.

ENGINE ASSEMBLY
• For supporting, lifting and jacking points, refer to GI-29, "Garage Jack and Safety Stand and 2-Pole
Lift". A
• Always use the support point specified for lifting.
• Support the vehicle at the rear axle jacking point with transmission jack or similar tool before remov-
ing the engine in preparation for the backward shift of the center of gravity.
EM
NOTE:
ing.
C
REMOVAL
Outline
Remove the engine and transmission with the front suspension member as a unit. Separate the engine from D
the transmission and remove from the front suspension member.
Preparation
1. Release fuel pressure. Refer to EC-166, "Work Procedure". E
2. Drain engine coolant. Refer to CO-9, "Changing Engine Coolant".
CAUTION:
• Perform this step when the engine is cold. F
• Do not allow the engine coolant to contact the drive belts.
3. Remove the front under cover. Refer to EXT-40, "FRONT UNDER COVER : Removal and Installation".
4. Remove the front road wheels and tires. Refer to WT-68, "Removal and Installation". G
5. Remove the fender protector (LH/RH): Refer to EXT-36, "FENDER PROTECTOR : Removal and Installa-
tion".
Engine Room H
1. Remove cowl top and cowl top extension. Refer to EXT-34, "Exploded View".
2. Remove the air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor and air duct
I
assembly. Refer to EM-26, "Exploded View".
4. Drain the power steering fluid. Refer to ST-30, "Draining and Refilling". J
5. Disconnect engine room harness at the CVT and ECM connectors.
CAUTION:
Protect the harness connector with plastic bags or suitable covering to help prevent damage and
intrusion of foreign materials into the connectors. K
6. Remove the battery tray. Refer to PG-86, "Removal and Installation".
7. Disconnect heater hoses (engine side). Refer to HA-43, "Removal and Installation".
L
8. Remove upper and lower radiator hoses. Refer to CO-13, "Exploded View".
9. Remove high pressure pipe, low pressure pipe, high pressure flexible hose, and low pressure flexible
hose. Refer to HA-33, "Exploded View".
M
10. Remove EVAP hose.
11. Disconnect fuel feed hose quick connector at fuel tube side. Refer to EM-49, "Exploded View".
12. Disconnect CVT control cable. Refer to TM-196, "Exploded View". N
13. Disconnect brake booster vacuum hose at brake booster. Refer to BR-32, "Exploded View".
14. Remove harness ground cable.
15. Disconnect low pressure hose from steering pump. Refer to ST-40, "Removal and Installation". O
16. Disconnect high pressure piping from steering pump. Refer to ST-40, "Removal and Installation".
17. Disconnect the wiring harness from the distribution/fuse block.
P
18. Disconnect the CVT fluid cooler hoses from the CVT.
19. Remove the upper RH upper torque rod.
20. Remove engine mounting insulator (RH) three upper nuts.
Vehicle Underbody
1. Remove exhaust front tube. Refer to EX-5, "Exploded View".

ENGINE ASSEMBLY
2. Disconnect steering lower joint at power steering gear assembly and release steering lower shaft. Refer to
ST-42, "Exploded View".
3. Disconnect front stabilizer connecting rod. Refer to FSU-15, "Exploded View".
4. Remove front brake caliper assembles with piping connected and position them aside. Refer to BR-38,
"BRAKE CALIPER ASSEMBLY : Removal and Installation".
5. Remove rear plate cover from oil pan (upper). Then remove nuts attaching the drive plate to the torque
converter. Refer to EM-134, "Dowel Pin Alignment".
6. Remove crankshaft position sensor (POS). Refer to EM-38, "Exploded View".
CAUTION:
• Do not allow metal powder to adhere to magnetic part at sensor tip.
• Do not place sensors in a location where they are exposed to magnetism.
Removal
1. Use suitable tool to securely support bottom of front suspension
member.
CAUTION:
Put a piece of wood or something similar as the supporting
surface to secure a completely stable condition.
PBIC1190E
2. Remove front suspension member mounting nuts and bolts. Refer to FSU-20, "Exploded View".
3. Carefully lower table to remove the engine, the transmission and the front suspension member. When per-
forming work, observe the following caution:
CAUTION:
• Confirm there is no interference with the vehicle.
• Repeatedly check to ensure all harnesses are disconnected before and during engine removal.
• Check all connection points have been disconnected.
• Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support the vehi-
cle at rear jacking point(s) to prevent it from falling off the lift.
Separation

ENGINE ASSEMBLY
1. Install engine slingers into front of cylinder head (bank 1) (3) and
rear of cylinder head (bank 2) (2). A
(1). : Engine rear slinger

(2). : Engine front slinger (upper) EM
(3). : Engine front slinger (lower)
: Engine front
C
A. : 28.0 N·m (2.9 kg-m, 21 ft-lb)
G
AWBIA2412ZZ
2. Disconnect vacuum hose from front engine mounting insulator.

3. Remove CVT fluid level indicator and CVT charging pipe. Refer to TM-219, "Exploded View". H
4. Remove starter. Refer to STR-20, "Removal and Installation".
5. Remove front drive shaft (LH/RH). Refer to FAX-19, "Removal and Installation (LH)" and FAX-21,
"Removal and Installation (RH)". I
6. Remove coolant reservoir.
7. Remove engine mounting insulator (rear).
J
8. Disconnect CVT unit harness connector from CVT.
9. Remove transmission to engine bolts. Refer to TM-219, "Exploded View".
10. Separate engine and transmission assembly. Refer to TM-220, "Removal and Installation". K
11. Lift the engine from the front suspension member.
CAUTION:
• Repeatedly check to ensure all harnesses are disconnected before and during engine lifting.
L
• Avoid spilling engine oil or grease onto the engine mounting insulators to prevent damage to
engine mounting insulators.
INSTALLATION M
CAUTION:
• Do not damage the engine mounting insulator. Do not spill engine oil on the engine mounting insula-
tor. N
• Check all mounting insulators are seated properly, then tighten nuts and bolts.
O
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If there is less than
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak- P
NOTE:

ENGINE ASSEMBLY


AWD
AWD : Exploded View INFOID:0000000011220682
AWBIA2443ZZ
1. Rear torque rod 2. Rear torque rod bracket 3. Engine mounting bracket (RH)
4. Upper torque rod 5. Engine mounting insulator (RH) 6. Engine mounting insulator (front)
7. Engine mounting bracket (front) 8. Vacuum tube (front) 9. Vacuum hose
10. Vacuum hose 11. Engine mounting insulator (LH) 12. Engine mounting insulator (rear)
13. Rear engine mount bracket (LH) A. To electronic controlled engine mount Front
control solenoid valve

ENGINE ASSEMBLY
AWD : Removal and Installation INFOID:0000000011220683
A
WARNING:
• Place chocks at front and back of rear wheels. EM
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• Always work safely. C
dures are not included in the engine section. D
• For supporting, lifting and jacking points, refer to GI-29, "Garage Jack and Safety Stand and 2-Pole
Lift".
• Always use the support point specified for lifting.
E
• Support the vehicle at the rear axle jacking point with transmission jack or similar tool before remov-
ing the engine in preparation for the backward shift of the center of gravity.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill- F
ing.
REMOVAL
G
Outline
Remove the engine and transmission with the front suspension member as a unit. Separate the engine from
the transmission and remove from the front suspension member.
H
Preparation
1. Release fuel pressure. Refer to EC-166, "Work Procedure".
2. Drain engine coolant. Refer to CO-9, "Changing Engine Coolant". I
CAUTION:
• Perform this step when the engine is cold.
• Do not allow the engine coolant to contact the drive belts. J
3. Remove the front under cover. Refer to EXT-40, "FRONT UNDER COVER : Removal and Installation".
4. Remove the front road wheels and tires. Refer to WT-68, "Removal and Installation".
5. Remove the fender protector (LH/RH): Refer to EXT-36, "FENDER PROTECTOR : Removal and Installa- K
tion".
Engine Room
1. Remove cowl top and cowl top extension. Refer to EXT-34, "Exploded View". L
2. Remove the air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor and air duct
assembly. Refer to EM-26, "Exploded View".
3. Remove the engine room cover. Refer to EM-25, "Removal and Installation". M
4. Remove coolant reservoir.
5. Drain the power steering fluid. Refer to ST-30, "Draining and Refilling".
N
6. Disconnect engine room harness at the CVT and ECM connectors.
CAUTION:
Protect the harness connector with plastic bags or suitable covering to help prevent damage and
intrusion of foreign materials into the connectors. O
7. Remove the battery tray. Refer to PG-86, "Removal and Installation".
8. Disconnect heater hoses (engine side). Refer to HA-43, "Removal and Installation".
P
9. Remove upper and lower radiator hoses. Refer to CO-13, "Exploded View".
10. Remove high pressure pipe, low pressure pipe, high pressure flexible hose, and low pressure flexible
hose. Refer to HA-33, "Exploded View".
11. Remove EVAP hose.
12. Disconnect fuel feed hose quick connector at fuel tube side. Refer to EM-49, "Exploded View".
13. Disconnect CVT control cable. Refer to TM-196, "Exploded View".

ENGINE ASSEMBLY
14. Disconnect brake booster vacuum hose at brake booster. Refer to BR-32, "Exploded View".
15. Remove harness ground cable.
16. Disconnect low pressure hose from steering pump. Refer to ST-40, "Removal and Installation".
17. Disconnect high pressure piping from steering pump. Refer to ST-40, "Removal and Installation".
18. Disconnect the wiring harness from the distribution/fuse block.
19. Disconnect the CVT fluid cooler hoses from the CVT.
20. Remove the upper RH upper torque rod.
21. Remove engine mounting insulator (RH) three upper nuts.
Vehicle Underbody
1. Remove exhaust front tube. Refer to EX-5, "Exploded View".
2. Remove rear propeller shaft. Refer to DLN-89, "Removal and Installation".
3. Disconnect steering lower joint at power steering gear assembly and release steering lower shaft. Refer to
ST-42, "Exploded View".
4. Disconnect front stabilizer connecting rod. Refer to FSU-15, "Exploded View".
5. Remove front brake caliper assembles with piping connected and position them aside. Refer to BR-38,
"BRAKE CALIPER ASSEMBLY : Removal and Installation".
6. Remove rear plate cover from oil pan (upper). Then remove nuts attaching the drive plate to the torque
converter. Refer to EM-134, "Dowel Pin Alignment".
7. Remove crankshaft position sensor (POS). Refer to EM-38, "Exploded View".
CAUTION:
• Do not allow metal powder to adhere to magnetic part at sensor tip.
• Do not place sensors in a location where they are exposed to magnetism.
Removal
1. Use suitable tool to securely support bottom of front suspension
member.
CAUTION:
Put a piece of wood or something similar as the supporting
surface to secure a completely stable condition.
PBIC1190E
2. Remove front suspension member mounting nuts and bolts. Refer to FSU-20, "Exploded View".
3. Carefully lower table to remove the engine, the transmission and the front suspension member. When per-
forming work, observe the following caution:
CAUTION:
• Confirm there is no interference with the vehicle.
• Repeatedly check to ensure all harnesses are disconnected before and during engine removal.
• Check all connection points have been disconnected.
• Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support the vehi-
cle at rear jacking point(s) to prevent it from falling off the lift.
Separation

ENGINE ASSEMBLY
1. Install engine slingers into front of cylinder head (bank 1) (3) and
rear of cylinder head (bank 2) (2). A
(1). : Engine rear slinger

(2). : Engine front slinger (upper) EM
(3). : Engine front slinger (lower)
: Engine front
C
A. : 28.0 N·m (2.9 kg-m, 21 ft-lb)
G
AWBIA2412ZZ
2. Disconnect vacuum hose from front engine mounting insulator.

3. Remove CVT fluid level indicator and CVT charging pipe. Refer to TM-219, "Exploded View". H
4. Remove starter. Refer to STR-20, "Removal and Installation".
5. Remove exhaust manifold and three way catalyst. Refer to EM-33, "Exploded View".
I
6. Remove front drive shaft (LH/RH). Refer to FAX-19, "Removal and Installation (LH)" and FAX-21,
"Removal and Installation (RH)".
7. Remove nut from engine mounting insulator (rear). Refer to EM-108, "AWD : Exploded View".
J
8. Remove nut from engine mounting insulator (front). Refer to EM-108, "AWD : Exploded View".
9. Disconnect CVT unit harness connector from CVT.
10. Remove transfer assembly. Refer to DLN-60, "Removal and Installation". K
11. Remove transmission to engine bolts. Refer to TM-219, "Exploded View".
12. Separate engine and transmission assembly. Refer to TM-220, "Removal and Installation".
13. Lift the engine from the front suspension member. L
CAUTION:
• Repeatedly check to ensure all harnesses are disconnected before and during engine lifting.
• Avoid spilling engine oil or grease onto the engine mounting insulators to prevent damage to M
engine mounting insulators.
INSTALLATION
Installation is in the reverse order of removal. N
CAUTION:
• Do not damage the engine mounting insulator. Do not spill engine oil on the engine mounting insula-
tor.
• Check all mounting insulators are seated properly, then tighten nuts and bolts. O

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If there is less than
P
NOTE:

ENGINE ASSEMBLY



CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
UNIT DISASSEMBLY AND ASSEMBLY A
CYLINDER BLOCK
EM
AWBIA1354ZZ

CYLINDER BLOCK
1. Reinforcement plate 2. Drive plate 3. Rear oil seal retainer

4. Rear oil seal 5. Sub harness 6. Knock sensor
7. Cylinder block 8. Thrust bearing (upper) 9. Main bearing (upper)
10. Crankshaft 11. Crankshaft key 12. Thrust bearing (lower)
13. Main bearing (lower) 14. Main bearing cap 15. Main bearing cap bolt
16. Main bearing beam 17. Baffle plate 18. Connecting rod bolt
19. Connecting rod bearing cap 20. Connecting rod bearing 21. Connecting rod
22. Snap ring 23. Piston pin 24. Piston
25. Oil ring 26. Second ring 27. Top ring
28. Pilot converter 29. Oil jet 30. Gasket (for Canada)
31. Cylinder block heater (for Canada) A. Crankshaft side B. Chamfered
C. Refer to INSTALLATION D. Front mark
Disassembly and Assembly INFOID:0000000011557868
CAUTION:
• Apply new engine oil to parts as marked in illustrations before installation.
• Place removed parts such as bearings and bearing caps in their proper order and direction.
• When installing the connecting rod nuts and main bearing cap bolts, apply new engine oil to the
threads and mating surfaces
• Do not allow any magnetic materials to contact the signal plate teeth on the drive plate.
DISASSEMBLY
1. Remove the engine assembly. Refer to EM-104, "FWD : Removal and Installation" (FWD) or EM-109,
"AWD : Removal and Installation" (AWD).
2. Remove the drive plate. Refer to EM-113, "Exploded View".
3. Remove pilot converter using suitable tool (A).
AWBIA2057ZZ
4. Cut away liquid gasket and remove rear oil seal retainer using
suitable tool (A). Refer to EM-5, "Precaution for Liquid Gasket".
Tool number : KV10111100 (J-37228)

CAUTION:
• Be careful not to damage mounting surface.
• If rear oil seal retainer is removed, replace it with a new
one.
NOTE:
Rear oil seal and retainer form a single part and are replaced as
an assembly. AWBIA2398ZZ

CYLINDER BLOCK
5. Install the engine on engine stand (A). Any commercially avail-
able engine stand (A) can be used. A
CAUTION:
• Use an engine stand (A) that has a load capacity [approxi-
mately 240kg (529 lb) or more] large enough for support-
EM
ing the engine weight.
• Before removing the hanging chains, make sure the
engine stand (A) is stable and there is no risk of overturn-
ing. C
AWBIA2413ZZ
D
6. Remove the knock sensor.
CAUTION:
Carefully handle sensor to avoid shocking it.
E
7. Drain engine coolant. Refer to CO-9, "Changing Engine Coolant".
8. Drain engine oil. Refer to LU-9, "Changing Engine Oil".
9. Remove the upper oil pan. Refer to EM-39, "Removal and Installation (Upper Oil Pan)". F
10. Remove the crankshaft pulley.
• Use a suitable tool to prevent the crankshaft from turning.
11. Remove the timing chain. Refer to EM-65, "Removal and Installation". G
12. Remove the cylinder head. Refer to EM-91, "Removal and Installation".
13. Remove the piston and connecting rod assemblies. H

a. Position the crankshaft pin corresponding to the connecting rod
to be removed onto the bottom dead center.
b. Remove the connecting rod cap. I
c. Using a suitable tool (A), push the piston and connecting rod
assembly out to the cylinder head side.
• Before removing the piston and connecting rod assembly, J
check the connecting rod side clearance. Refer to EM-146,
"Connecting Rod Bearing".
AWBIA2470ZZ K
14. Remove the connecting rod bearings.

CAUTION: L
• When removing the connecting rod side bearings, note the installation position. Keep them in
the correct order.
15. Remove the piston rings from the piston.
M
• Use a piston ring expander (A).
CAUTION:
• When removing the piston rings, be careful not to damage
the piston. Do not expand the rings excessively. N
• Be careful to mark the rings if they are to be reused so
they are installed in their original position.
• Before removing the piston rings, check the piston ring side clear- O
ance. Refer to EM-124, "Inspection".
AWBIA2415ZZ
P

CYLINDER BLOCK
16. Remove the piston from the connecting rod as follows.
a. Using a suitable tool (A), remove the snap ring.
CAUTION:
Do not reuse snap rings, always replace with new ones.
AWBIA2416ZZ
b. Heat the pistons to 60° - 70°C (140° - 158°F) utilizing suitable

tool (A).
WARNING:
Pistons contain heat. When working, wear protective equip-
ment to avoid getting burned.
AWBIA2417ZZ
c. Push out the piston pin with a suitable tool with an outer diame-
ter of approximately 20 mm (0.8 in).
PBIC0262E
17. Remove the baffle plate from the main bearing beam.
18. Loosen the bolts in the reverse order shown and remove the
main bearing beam, bearing caps and crankshaft.
• Before loosening the main bearing cap bolts, measure the
crankshaft side clearance.
Refer to EM-124, "Inspection".
: Engine front
JPBIA0439ZZ

CYLINDER BLOCK
19. Remove the oil jets (A) and dowel pins.
A
EM
AWBIA2418ZZ
D
20. Remove the main bearings and thrust bearings from the cylinder block and main bearing caps.
• When removing them, note the direction and position. Keep them in the correct order for installation.
E
21. Remove the water drain plug (A), connector bolt (D), water drain
plug (C) and water drain plug O-ring (B) on the cylinder block.
CAUTION: F
Do not reuse water drain plug O-ring (B)
NOTE:
For Canada, connector bolt (D) is a block heater, not a water drain G
plug.
AWBIA2481ZZ
L
ASSEMBLY
1. Blow out the coolant and oil passages and cylinder bore to remove any foreign materials.
CAUTION: M
Use goggles to protect your eyes.

CYLINDER BLOCK
2. Install the cylinder block drain plugs.
• Apply sealant to the threads of the water drain plug (A), and
connector bolt (D), (if removed).
CAUTION:
Do not reuse water drain plug O-ring (B).
: Engine front
NOTE:
• For Canada, connector bolt (D) is a block heater, not a water
drain plug.
• Use Genuine High Performance Thread Sealant or equiva-
lent. Refer to GI-22, "Recommended Chemical Products and
Sealants".
• Tighten each plug and connector bolt to specifications.
Water drain plug (B) (ex- : 62.0 N·m (6.3 kg-m, 46 ft-lb)
cept Canada)
Block heater (B) (Canada) : 39.0 N·m (4.0 kg-m, 29 ft-lb)
Connector Bolt (C) : 27.0 N·m (2.8 kg-m, 20 ft-lb)
Water drain plug (D) : 78.0 N·m (8.0 kg-m, 58 ft-lb)
AWBIA2481ZZ
3. Install the oil jets (A).

• Insert the oil jet dowel pin into the cylinder block dowel pin
hole, and tighten the bolts.
: Engine front
AWBIA2418ZZ
4. Install the main bearings and the thrust bearings (C).

a. Remove dust, dirt, and oil on the bearing mating surfaces of the
cylinder block and the main bearing cap.
b. Install the thrust bearings (C) to both sides (D) of the No. 3 jour-
nal housing on the cylinder block (A) and the main bearing cap.
• Install the thrust bearings (C) with the oil groove (B) facing the
crankshaft arm (outside).
• Install bearing with a projection on one end on cylinder block
and bearing with a projection at center on cap. Align each pro-
jection with mating notch.
AWBIA2419ZZ
: Engine front

CYLINDER BLOCK
5. Set the upper main bearings (A) and the lower main bearings
(B) in their proper positions on the cylinder block. A
• Confirm the correct main bearings are used. Refer to EM-124,
"Inspection".
NOTE:
EM
The upper main bearings (A) have an oil groove. The lower main
bearings do not have an oil groove.
: Engine front C
AWBIA2420ZZ
D
6. Instructions for the reuse of the main bearing cap bolts.
• A plastic zone tightening method is used for tightening the
main bearing cap bolts. Measure (d1) and (d2) as shown. E
• For (d2), select the minimum diameter in the measuring area.
• If the difference between (d1) and (d2) exceeds the limit,
replace the bolts for assembly.
F
Limit (d1 - d2) : 0.11 mm (0.0043 in)
G
AWBIA2421ZZ
7. After installing the crankshaft, lower main bearings, main bearing caps, main bearing beam, and bearing H
cap bolts. Tighten the bearing cap bolts in the numerical order as shown.
CAUTION:
Position main bearing caps in accordance with the numeri-
cal stamp (A). I
: Engine front
J
AWBIA2475ZZ
L
a. Make sure that the front marks (B) on the main bearing beam
faces the front of the engine.
b. Prior to tightening all the bearing cap bolts, place the bearing M
beam in its proper position by shifting the crankshaft in the axial
position.
c. After tightening the bearing cap bolts, make sure the crankshaft N
turns smoothly.
d. Lubricate the threads and seat surfaces of the bolts with new
engine oil. O
e. Tighten the bolts in two stages: SEM456G
CAUTION:
P

CYLINDER BLOCK
Measure the tightening angle in two stages using Tool (A). Do
not measure with eyes only, be sure to use Tool (A).
Stage 1 : 32.3 - 38.3 N·m (3.3 - 3.9 kg-m, 24 - 28 ft-lb)

Stage 2 : 90° - 95° degrees clockwise
Tool number : KV10112100 (BT-8653-A)
AWBIA2423ZZ
8. Measure crankshaft end play.

• If beyond the limit, replace the thrust bearing with a new one.
Refer to EM-142, "Cylinder Block".
SEM852E
9. Install the piston to the connecting rod.

a. Using suitable snap ring pliers, install the snap ring fully into the
pin-groove of the piston rear side.
CAUTION:
Do not reuse snap rings.
(A) : Piston front mark

(B) : Oil hole
(C) : Connecting rod front mark
(D) : Cylinder No.
AWBIA0026ZZ
b. Install the piston to the connecting rod.

• Heat the piston using suitable tool (A) until the piston pin can
be pushed in by hand without excess force [approximately 60 -
70°C (140 - 158°F)]. From the front to the rear, insert the pis-
ton pin into the piston and through the connecting rod.
WARNING:
Pistons contain heat. When working, wear protective
AWBIA2417ZZ

CYLINDER BLOCK
• Assemble so that the piston front mark (B) on the crown and
the oil hole (C), connecting rod front mark (D) and Cylinder No. A
(E) on the connecting rod are positioned as shown.
: Engine front
EM
(A) : Piston grade number
(F) : Pin grade number
(G) : Crown I.D. code C
AWBIA1399ZZ
D
c. Install the snap ring (A) into the front of the piston pin-groove.
• After installing, check that the connecting rod pivots smoothly
on the pin.
CAUTION: E
Do not reuse snap rings, always replace with new ones.
G
AWBIA2416ZZ
10. Using a piston ring expander, install the piston rings. H

(A) : Top ring
(B) : Second ring
I
CAUTION:
• Be careful not to damage the piston.
• When the piston rings are not replaced, remount the rings
J
in their original positions.
• When replacing the piston rings, those without stamped
surface (A) can be mounted either side up.
• Install the second ring with the stamped surface (B) facing JPBIA0263ZZ K
upward. If the ring is not stamped it can face in either
direction.
L
• Position each ring with the gap as shown, referring to the pis-
ton front mark.
M
A. : Top ring gap
B. : Front mark
C. : Oil ring upper or lower rail gap
N
D. : Second ring and oil ring spacer gap
E. : Oil ring upper or lower rail gap
O
AWBIA2424ZZ

CYLINDER BLOCK
11. Install the connecting rod bearings (A) to the connecting rod and
the connecting rod cap (B).
• When installing the connecting rod bearings (A), apply engine
oil to the bearing surface (crankshaft side). Do not apply oil to
the back surface (connecting rod and cap side), but thoroughly
clean it.
• When installing, align the connecting rod bearing (A) protru-
sion with the notch of the connecting rod to install.
• Check that the oil holes on the connecting rod (B) and on the
corresponding bearing (A) are aligned.
AWBIA2425ZZ
12. Install the piston and connecting rod assembly into the corre-
sponding cylinder.
• Position the crankshaft pin corresponding to the connecting
rod to be installed onto the bottom dead center.
• Apply engine oil sufficiently to the cylinder bore, piston, and
crankshaft pin.
• Match the cylinder position with the cylinder No. (B) on the
connecting rod to install.
• Install the piston with the piston front mark (A) on the crown
facing the front of the engine ( ) using a suitable tool.
AWBIA0029ZZ
(C) : Oil hole
CAUTION:
Be careful not to damage the crankshaft pin and cylinder wall, resulting from interference of the
connecting rod big end.
13. Install the connecting rod cap.
• Observing the sample codes (A), match the stamped cylinder
number marks (F) on the connecting rod with those on the cyl-
inder cap for installation.
• Install the piston connecting rod assembly and cap so that the
front mark on the cap and piston are facing the front of the
engine.
• Lubricate the threads and seat surfaces with new engine
oil.
(B). : Small end diameter grade AWBIA2426ZZ
(C). : Weight grade

(D). : Management code
(E). : Front mark
14. Check the connecting rod cap bolts before reusing, then install
in their original position in the connecting rod. The bolts should
screw in smoothly by hand.
• Measure the outer diameter of the connecting rod cap bolt as
shown.
Outer diameter (d) of the connecting rod bolt

Standard : 7.90 - 8.00 mm (0.3110 - 0.3150 in)
Limit : 7.75 mm (0.3051 in)
A. : 19 mm (0.75 in) AWBIA2427ZZ
15. Tighten the connecting rod nuts in two stages using Tool:

CYLINDER BLOCK
Stage 1 : 19 - 21 N·m (1.9 - 2.1 kg-m, 14 - 15 ft-lb) A

Stage 2 : 90° - 95° degrees clockwise
CAUTION:
Always use either an angle wrench or protractor. Avoid EM
tightening based on visual check alone.
Tool number : KV10112100 (BT-8653-A) C

• Apply engine oil to the threads and seats of the connecting rod
bolts and nuts. SEM953E
• After tightening the nuts, make sure that the crankshaft rotates D
smoothly.
• Check the connecting rod side clearance. If beyond the limit, replace the connecting rod and/or crank-
shaft. Refer to EM-142, "Cylinder Block". E
16. Install the baffle plate to the main bearing beam.
17. Install the knock sensor (A).
• Make sure that there is no foreign material on the cylinder F
block mating surface and the back surface of the knock sensor
(A).
• Install the knock sensor (A) with the connector facing the rear
of the engine. G
• Do not tighten the bolts while holding the connector.
• Make sure that the knock sensor (A) does not interfere with
other parts. H
: Engine front AWBIA2428ZZ
CAUTION: I
If any impact by dropping occurs to the knock sensor (A), replace it with new one.
J
18. Install the cylinder head. Refer to EM-91, "Removal and Installation".
19. Install the timing chain. Refer to EM-65, "Removal and Installation".
20. Install the oil pan. Refer to EM-38, "Removal and Installation (Lower Oil Pan)" and EM-39, "Removal and K
Installation (Upper Oil Pan)".
21. Remove the engine from the stand.
L
22. Install the pilot converter with its chamfer facing crankshaft as
shown.
M
: Crankshaft side
O
JPBIA0210ZZ

CYLINDER BLOCK
23. Install the rear oil seal using Tool (A).

a. Loosen the wing nut (B) on the end of the Tool (A).
b. Insert the arbor (D) into the crankshaft pilot hole until the outer
lip (C) of the Tool (A) covers the edge of the crankshaft sealing
surface.
c. Tighten the wing nut (B) to secure the Tool (A) to the crankshaft.
ALBIA0652ZZ
d. Apply sealant to rear oil seal retainer as shown.

Use Genuine Silicone RTV Sealant, or equivalent. Refer to
CAUTION:
ing liquid gasket.
AWBIA0028ZZ
e. Lubricate the sealing surface of the new rear main seal with new engine oil.
f. Slide the new rear main seal (1) over the Tool (A) and onto the
crankshaft.
g. Loosen the wing nut and push the threaded rod into the handle
to remove the Tool (A).
h. Tighten the rear oil seal retainer bolts to specification. Refer to
EM-89, "Removal and Installation of Rear Oil Seal".
ALBIA0653ZZ
24. Install the drive plate. Refer to EM-113, "Exploded View".

25. Install the engine assembly into the vehicle. Refer to EM-104, "FWD : Removal and Installation" (FWD) or
EM-109, "AWD : Removal and Installation" (AWD).
Inspection INFOID:0000000011557869
PISTON AND PISTON PIN CLEARANCE

Inner Diameter of Piston Pin Hole
• Measure the inner diameter of piston pin hole (dp). Refer to EM-
142, "Cylinder Block".
AEM023
Outer Diameter of Piston Pin

CYLINDER BLOCK
• Measure outer diameter of piston pin (Dp) using suitable tool (A).
Refer to EM-124, "Inspection". A
EM
AWBIA2429ZZ
: Engine front
(A) : Piston Grade No. E
(B) : Piston front mark
(C) : Oil hole
(D) : Connecting rod front mark F
(E) : Cylinder No.
(F) : Pin Grade No.
G
AWBIA0027ZZ
Piston and Piston Pin Interference Fit H

Standard Interference Fit = (Dp) – (dp)
Standard : 0.002 – 0.010 mm (0.0001 – 0.0004 in)

I
• If clearance exceeds specification, replace either or both of piston/piston pin assembly and connecting rod
assembly with reference to specification of each part.
PISTON RING SIDE CLEARANCE J
• Measure side clearance of piston ring and piston ring groove with
suitable tool (B).
• If out of specification, replace piston ring assembly (D). If clear- K
ance exceeds maximum limit with new rings, replace piston. Refer
to EM-142, "Cylinder Block".
A. : NG L
C. : OK
M
AWBIA2430ZZ
PISTON RING END GAP

N
• Insert piston ring (C) until it is in the middle of the cylinder bore and
measure the end gap using suitable tool (A).
• If out of specification, replace piston ring (C). Refer to EM-142,
"Cylinder Block" O
B. : Piston Press Fit

P
AWBIA2431ZZ
CONNECTING ROD BEND AND TORSION

CYLINDER BLOCK
• Use suitable tool (A) to measure bend (B) and torsion (B).
• If bend (B) or torsion (B) exceeds the limit, replace connecting rod
assembly. Refer to EM-146, "Connecting Rod Bearing".
AWBIA2433ZZ
AWBIA2432ZZ
CONNECTING ROD BEARING HOUSING DIAMETER (BIG END)

• Install the connecting rod cap without the connecting rod bearing
installed. After tightening the connecting rod nut to the specified
torque, measure the connecting rod bearing housing big end inner
diameter using a suitable tool (A). Refer to EM-146,
"Connecting Rod Bearing".
AWBIA2434ZZ
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)

Inner Diameter of Connecting Rod (Small End)
• Measure inner diameter of piston pin bushing using a suitable tool
(A). Refer to EM-146, "Connecting Rod Bearing".
AWBIA2435ZZ
Outer Diameter of Piston Pin

• Measure outer diameter of piston pin using suitable tool (A). Refer
AWBIA2436ZZ
Connecting Rod Bushing Oil Clearance (Small End)

CYLINDER BLOCK
(Connecting rod small end oil clearance) = (Inner diameter of con-
necting rod small end) – (Outer diameter of piston pin). Refer to EM- A
• If the measured value exceeds the standard, replace the connect-
ing rod assembly and/or piston and piston pin assembly.
EM
• If replacing the piston and piston pin assembly, use the Table for
Selective Fitting for Piston to select the piston corresponding to the
applicable bore grade of the cylinder block to be used. Follow the
"PISTON-TO-CYLINDER BORE CLEARANCE" procedure. C
A. : Sample codes
AWBIA2426ZZ
B. : Small end diameter grade D
C. : Weight grade
D. : Management code
E. : Front mark E
F. : Cylinder number
Factory installed parts grading: F
: : Engine front
(A) : Piston Grade No. G
(B) : Piston front mark
(C) : Oil hole
(D) : Connecting rod front mark H
(E) : Cylinder No.
(F) : Pin Grade No.
(G) : Crown I.D. code I
AWBIA1399ZZ
Service parts apply only to grade 0. J

Unit: mm (in)
Grade 0 1
22.000 - 22.006 22.006 - 22.012 K
Connecting rod small end inner diameter
(0.8661 - 0.8664) (0.8664 - 0.8666)
21.989 - 21.995 21.995 - 22. 001
Piston pin outer diameter
(0.8657 - 0.8659) (0.8659 - 0.8662) L
21.993 - 21.999 21.999 - 22.005
Piston pin hole diameter
(0.8659 - 0.8661) (0.8661 - 0.8663)
CYLINDER BLOCK DISTORTION M

• Using a scraper, remove any old gasket material on the cylinder
block surface and remove any oil, scale, carbon, or other contami-
nation. N
CAUTION:
Be careful not to allow gasket flakes to enter the oil or coolant
passages.
O
• Using suitable tools (A/B), measure the distortion on the block
upper face at different points in six directions. Refer to EM-142,
"Cylinder Block".
• If out of specification, resurface the cylinder block. The allowable P
amount of resurfacing is dependent on the amount of any cylinder
AWBIA2437ZZ
head resurfacing. The resurfacing limit is [amount of cylinder head
resurfacing] + [amount of cylinder head resurfacing] = 0.2 mm (0.008 in).
Cylinder block height : 214.95 - 215.05 mm

(8.4626 - 8.4665 in)

CYLINDER BLOCK
INNER DIAMETER OF MAIN BEARING HOUSING
• Install the main bearing caps with the main bearings removed, and tighten the bolts to the specified torque.
• Using a bore gauge, measure the inner diameter of the main bear-
ing housing (A). Refer to EM-142, "Cylinder Block".
• If out of the standard, replace the cylinder block and main bearing
caps as an assembly.
NOTE:
These components cannot be replaced as a single unit, because
they were processed together.
SEM845E
PISTON-TO-CYLINDER BORE CLEARANCE

1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at (A), (B) and (C). The X axis
is in the longitudinal direction of the engine.
Cylinder bore inner diameter
Grade No. Standard inner diameter Wear limit

No. 1 95.500 - 95.510 mm (3.7598 - 3.7602 in)
No. 2 95.510 - 95.520 mm (3.7602 - 3.7606 in) 0.20 mm (0.0079 in)
No. 3 95.520 - 95.530 mm (3.7606 - 3.7610 in)
SEM843E
If it exceeds the limit, rebore all cylinders. Replace cylinder block

if necessary. Refer to EM-142, "Cylinder Block".
JPBIA2238GB
2. Check for scratches and seizure. If seizure is found, hone it.

• If both cylinder block and piston are replaced with new
ones, select piston of the same grade number punched on
cylinder block rear position. These numbers are punched
in either Arabic or Roman numerals.
A. : Cylinder bore grade

B. : Small end diameter grade
C. : Management code
: Engine front
AWBIA2438ZZ

CYLINDER BLOCK
3. Measure piston skirt diameter. Refer to EM-142,
"Cylinder Block". A
EM
SEM258C
D
4. Check that piston-to-bore clearance is within specification. Refer
• The piston-to-bore clearance is measured at the (B) level in E
the cylinder as shown.
G
JPBIA2238GB
5. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter (A). H
Rebored size calculation :D=A+B−C

I
where,
(D) : Bored diameter
(A) : Piston diameter as measured J
(B) : Piston-to-bore clearance
(C) : Honing allowance 0.02 mm (0.0008 in)
K
6. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted
after boring.
7. Cut cylinder bores.
L
• 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.
8. Hone cylinders to obtain specified piston-to-bore clearance. M
9. Measure finished cylinder bore for out-of-round and taper.
• Measurement should be done after cylinder bore cools down.
N
CRANKSHAFT
1. Check the crankshaft main and pin journals for scoring, wear, or
cracks. O
2. Measure the journals for taper and out-of-round. Refer to EM-
P
Taper :A-B
Out-of-round :X-Y
AWBIA2439ZZ

CYLINDER BLOCK
3. Measure crankshaft runout.
a. Place a V-block on a precise flat table to support the journals on
the both ends of the crankshaft.
b. Place a dial gauge straight up on the No. 3 journal.
c. While rotating the crankshaft, read the movement of the pointer
on the dial gauge. Refer to EM-142, "Cylinder Block".
SEM346D
BEARING CLEARANCE
• Use either of the following two methods, however method (A) gives more reliable results and so is the pre-
ferred method.
Method A (Using Bore Gauge and Micrometer)
Main Bearing
1. Set the upper main bearings (A) and the lower main bearings
(B) in their proper positions on the cylinder block.
• Confirm the correct main bearings are used. Refer to EM-124,
"Inspection".
NOTE:
The upper main bearings (A) have an oil groove. The lower main
bearings do not have an oil groove.
: Engine front
AWBIA2420ZZ
2. Install the main bearing caps and bearing beam to the cylinder block. Tighten all bolts in the numerical
order as specified. Refer to EM-114, "Disassembly and Assembly".
3. Measure the inner diameters (A) of each main bearing as

shown.
SEM845E
4. Measure the outer diameters (Dm) of each crankshaft main jour-

nal as shown.
5. Calculate the main bearing clearance. Refer to EM-145,
"Main Bearing".
• If it exceeds the limit, replace the bearing.
• If clearance cannot be adjusted using any standard bearing
grade, grind crankshaft journal and use an undersized bear-
ing.
AEM033

CYLINDER BLOCK
• When grinding the crankshaft journal, confirm that the (L)
dimension in the fillet role is more than the specified limit. A
Refer to EM-142, "Cylinder Block".
EM
SEM964
D
6. If the crankshaft or the cylinder block is replaced with a new one, select thickness of the main bearings as
follows:
a. The grade number of each cylinder block main journal is E
punched on the respective cylinder block. These numbers are
punched in either Arabic or Roman numerals. If measured diam-
eter is out of the grade punched, decide suitable grade from F
available main bearings.
A. : Cylinder bore grade

B. : Small end diameter grade
G
C. : Management code
: Engine front
AWBIA2438ZZ
H
b. The grade number of each crankshaft main journal is punched

on the crankshaft end. These numbers are punched in either
I
Arabic or Roman numerals. If measured diameter is out of grade
punched, decide the suitable grade from available main bear-
ings.
J
A. : Journal diameter grade
B. : Identification code
C. : Pin diameter grade K
AWBIA2440ZZ

CYLINDER BLOCK
c. Select the main bearing suitable thickness according to the following table:
PBIC0814E
Connecting Rod Bearing (Big End)

1. Install the connecting rod bearing to the connecting rod and cap.
2. Install the connecting rod cap to the connecting rod. Tighten to specification. Refer to EM-114, "Disassem-
bly and Assembly".
3. Measure the inner diameter (C) of each connecting rod (big end)
using suitable tool (A) as shown.
AWBIA2441ZZ

CYLINDER BLOCK
4. Measure the outer diameter (Dp) of each crankshaft pin journal.
5. Calculate the connecting rod bearing clearance. Refer to EM- A
146, "Connecting Rod Bearing".
Connecting rod bearing clearance = (C) - (Dp)
6. If the calculated clearance exceeds the specified limit, replace EM
the bearings.
7. If the clearance cannot be adjusted within the standard of any
bearing, grind the crankshaft journal and use undersized bear- C
ings.
AEM034
D
8. If the crankshaft is replaced with a new one, select the connect-
ing rod bearings according to the following table:
Connecting Rod Bearing Grade Number (Identification E
Color)
Crankshaft pin journal grade Connecting rod bearing grade

F
number number
0 0 (black)
1 1 (brown) G
2 2 (green)
AWBIA2440ZZ
These numbers are punched in either Arabic or Roman numer-

als. H
A. : Journal diameter grade

B. : Identification code I
C. : Pin diameter grade
Method B (Using Plastigage)

• Remove oil and dust on the crankshaft pin and the surfaces of J
each bearing completely.
• Cut a Plastigage slightly shorter than the bearing width, and place
it in crankshaft axial direction, avoiding oil holes. K
• Install the connecting rod bearings to the connecting rod cap, and
tighten the connecting rod nuts to the specified torque.
CAUTION:
L
Do not rotate the crankshaft.
• Remove the connecting rod cap and bearings, and using the scale
on the Plastigage bag, measure the Plastigage width.
NOTE: M
SEM142
The procedure when the measured value exceeds the repair limit
is same as that described in "Method A (Using Bore Gauge and Micrometer)".
DRIVE PLATE RUNOUT N
Use dial gauge to measure the runout (Total Indicator Reading) as
shown. Refer to EM-147, "Drive Plate".
CAUTION: O
• The signal plate is built into the drive assembly. Be careful not
to damage the signal plate, particularly the teeth.
P
SEM849EB
• Check the drive plate and signal plate for deformation or cracks.

CYLINDER BLOCK
• Keep all magnetized objects away from the signal plate, particularly the teeth.
OIL JET
• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs.
• If it is not operating properly, replace oil jet.
OIL JET RELIEF VALVE
• Using a clean plastic stick, press check valve in oil jet relief valve.
Make sure that valve moves smoothly with proper reaction force.
• If it is not operating properly, replace oil jet relief valve.
EMU0468D
Dowel Pin Alignment INFOID:0000000011557870
REMOVAL
1. Use suitable tool to lock the drive plate and match mark (A) the
drive plate before removing the bolts.
CAUTION:
Do not damage the ring gear teeth or the signal plate teeth
behind the ring gear.
ALBIA0522ZZ
2. Remove drive plate.

• Loosen the drive plate in a diagonal order.
CAUTION:
• Do not place drive plate with signal plate facing down.
• When handling the signal plate, take care not to damage or scratch it.
• Handle the signal plate in a manner that prevents it from becoming magnetized.
INSTALLATION
• When installing the drive plate to the crankshaft, use the match
mark (A) as shown to correctly align the crankshaft side dowel pin
to the drive plate side dowel pin hole.
ALBIA0522ZZ

CYLINDER BLOCK
• Install the drive plate and the reinforcement plate in the direction
as shown. A
A. : Signal plate
B. : Crankshaft EM
C. : Pilot converter
D. : Reinforcement plate
E. : Rounded C
F. : Ring gear
Engine front AWBIA2453ZZ
D
• Tighten the drive plate bolts to specification in a diagonal pattern. Refer to EM-113, "Exploded View".
- Use a suitable tool to lock the drive plate.
E

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000011568115
GENERAL SPECIFICATIONS
Cylinder arrangement V-6

3 3,498 (213.45)
Displacement cm (cu in)
Bore and stroke mm (in) 95.5 x 81.4 (3.760 x 3.205)
Valve arrangement DOHC
Firing order 1-2-3-4-5-6
Compression 2
Number of piston rings
Oil 1
Number of main bearings 4
Compression ratio 10.3:1
Standard 1,275 (12.75, 13.0, 185)
Compression pressure
Minimum 981 (9.81, 10.0, 142)
kPa (kg/cm2, psi)/300 rpm
Differential limit between cylinders 98 (0.98, 1.0, 14)
Cylinder number
SEM713A
Valve timing
(Valve timing control - “OFF”)
PBIC0187E
Unit: degree
a b c d e f
240 240 −10 70 10 50
Drive Belt INFOID:0000000011568116
DRIVE BELT
Tension of drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Spark Plug INFOID:0000000011568117
A
SPARK PLUG
Unit: mm (in)
EM
Make DENSO
Standard type* FXE22HR11
Gap Standard 1.1 (0.043) C
Intake Manifold INFOID:0000000011568118

D
INTAKE MANIFOLD
Unit: mm (in)
E
Items Limit
Surface distortion Intake manifold 0.1 (0.004)
F
Exhaust Manifold INFOID:0000000011568119
EXHAUST MANIFOLD
G
Unit: mm (in)
Items Limit
Surface distortion Exhaust manifold 0.3 (0.012) H
Camshaft INFOID:0000000011568120
I
CAMSHAFT
Unit: mm (in)
M
SEM671
Items Standard Limit

No. 1 0.045 - 0.086 (0.0018 - 0.0034) N
Camshaft journal oil clearance 0.15 (0.0059)
No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030)
No. 1 26.000 - 26.021 (1.0236 - 1.0244) —
Camshaft bracket inner diameter O
No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) —
No. 1 25.935 - 25.955 (1.0211 - 1.0218) —
Camshaft journal diameter
No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) —
P
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)
Intake 45.475 - 45.665 (1.7904 - 1.7978) 0.2 (0.008)*1
Camshaft lobe height “A”
Exhaust 45.485 - 45.675 (1.7907 - 1.7982) 0.2 (0.008)*1
Camshaft runout [TIR*2] Less than 0.02 (0.0008) 0.05 (0.0020)
Camshaft sprocket runout [TIR*2] Less than 0.15 (0.0059) —

*1: Cam wear limit
*2: Total indicator reading
VALVE LIFTER
Unit: mm (in)
Items Standard
Valve lifter outer diameter 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter bore diameter 34.000 - 34.016 (1.3386 - 1.3392)
Valve lifter clearance 0.023 - 0.029 (0.0009 - 0.0011)
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)
KBIA0119E
Thickness
3.00 (0.1181)
3.02 (0.1189)
3.04 (0.1197)
3.06 (0.1205)
3.08 (0.1213)
3.10 (0.1220)
3.12 (0.1228)
3.14 (0.1236)
3.16 (0.1244)
3.18 (0.1252)
3.20 (0.1260)
3.22 (0.1268)
3.24 (0.1276)
3.26 (0.1283)
3.28 (0.1291)
3.30 (0.1299)
3.32 (0.1307)
3.34 (0.1315)
3.36 (0.1323)

EM
KBIA0119E
D
Thickness
3.38 (0.1331)
E
3.40 (0.1339)
3.42 (0.1346)
3.44 (0.1354) F
3.46 (0.1362)
3.48 (0.1370)
G
3.50 (0.1378)
Cylinder Head INFOID:0000000011568121

H
CYLINDER HEAD
Unit: mm (in) I
PBIC0924E
M
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Normal cylinder head height (H) 126.4 (4.98) — N
Spark plug tube installation height 38.2 +0.5/- 0.5 (1.5 +0.020 / -0.020) —
VALVE DIMENSIONS
O

Unit: mm (in)
SEM188
Intake 36.6 - 36.9 (1.441 - 1.453)

Valve head diameter (D)
Exhaust 30.2 - 30.5 (1.189 - 1.201)
Intake 102.02 (4.0165)
Valve length (L)
Exhaust 99.56 (3.9197)
Intake 5.965 - 5.980 (0.2348 - 0.2354)
Valve stem diameter (d)
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Intake
Valve seat angle α) 45°15′ - 45°45′
Exhaust
Intake 1.15 - 1.45 (0.0453 - 0.0571)
Valve margin (T)
Exhaust 1.45 - 1.75 (0.0571 - 0.0689)
Valve margin (T) limit More than 0.5 (0.020)
Valve stem end surface grinding limit Less than 0.2 (0.008)
VALVE OIL SEAL

Unit: mm (in)
Description Standard
Valve oil seal installation height 14.3 - 14.9 (0.563 - 0.587)
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) 5.3 - 5.5 (0.2087 - 0.2165)
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 (0.0031)
Valve guide clearance A
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.01 (0.004)
Valve deflection Intake — 0.24 (0.0094)

Exhaust — 0.28 (0.0110) EM
Projection length (L) 12.6 - 12.8 (0.496 - 0.504)
VALVE SEAT
C
Unit: mm (in)
PBIC2745E
Items Standard Oversize (Service) [0.5 (0.02)] G

Cylinder head seat recess diameter "D" Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164)
Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)
H
Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202)
Valve seat outer diameter "d"
Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676)
Intake 0.081 - 0.113 (0.0032 - 0.0044) I
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038)
Intake 34.6 (1.362)
Diameter "d1"*1 J
Exhaust 27.7 (1.091)
Intake 35.9 - 36.4 (1.413 - 1.433)
Diameter "d2"*2
Exhaust 31.680 - 31.696 (1.2472 - 1.2479) K
Intake 30°
Angle "α1"
Exhaust 30°
Intake 45° L
Angle "α2"
Exhaust 45°
Intake 60°
Angle "α3" M
Exhaust 60°
Intake 1.18 - 1.22 (0.0465 - 0.0480)
Contacting width "W"*3
Exhaust 1.38 - 1.42 (0.0543 - 0.0559) N
Intake 5.9 - 6.0 (0.232 - 0.236) 5.0 - 5.1 (0.197 - 0.201)
Height "h"
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.9 - 5.0 (0.193 - 0.197)
O
Intake 41.16 - 41.76 (1.6205 - 1.6441)
Depth "H"
Exhaust 41.09 - 41.69 (1.6177 - 1.6413)
*1: Diameter made by intersection point of conic angles "α1" and "α2" P
*2: Diameter made by intersection point of conic angles "α2" and "α3"
*: Machining data
VALVE SPRING

Items Standard
Free height 48.51 mm (1.9098 in)
Installation height 38.66 mm (1.5220 in)
Installation load 166 - 188 N (16.9 - 19.2 kg, 37.3 - 42.3 lb)
Height during valve open 28.66 mm (1.1283 in)
Load with valve open 384 - 432 N (39.2 - 44.1 kg, 86.3 - 97.1 lb)
Unit: mm (in)
Items Limit
Squareness 2.0 (0.079)
Cylinder Block INFOID:0000000011568122
CYLINDER BLOCK
Unit: mm (in)
JPBIA2238GB
Standard Less than 0.03 (0.0012)

Surface distortion
Limit 0.10 (0.0039)
Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602)
Main bearing housing 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 0.20 (0.0079)
Out-of-round 0.015 (0.0006)
Limit
Taper (Difference between A and C) 0.015 (0.0006)

Grade No. A 63.993 - 63.994 (2.5194 - 2.5194)
Grade No. B 63.994 - 63.995 (2.5194 - 2.5195) A
Grade No. C 63.995 - 63.996 (2.5195 - 2.5195)
Grade No. D 63.996 - 63.997 (2.5195 - 2.5196)
Grade No. E 63.997 - 63.998 (2.5196 - 2.5196)
Grade No. F 63.998 - 63.999 (2.5196 - 2.5196) EM
Grade No. G 63.999 - 64.000 (2.5196 - 2.5197)
Grade No. H 64.000 - 64.001 (2.5197 - 2.5197)
Grade No. J 64.001 - 64.002 (2.5197 - 2.5198)
Grade No. K 64.002 - 64.003 (2.5198 - 2.5198)
C
Grade No. L 64.003 - 64.004 (2.5198 - 2.5198)
Grade No. M 64.004 - 64.005 (2.5198 - 2.5199)
Main bearing housing inner diameter grade (Without bearing)
Grade No. N 64.005 - 64.006 (2.5199 - 2.5199) D
Grade No. P 64.006 - 64.007 (2.5199 - 2.5200)
Grade No. R 64.007 - 64.008 (2.5200 - 2.5200)
Grade No. S 64.008 - 64.009 (2.5200 - 2.5200)
Grade No. T 64.009 - 64.010 (2.5200 - 2.5201) E
Grade No. U 64.010 - 64.011 (2.5201 - 2.5201)
Grade No. V 64.011 - 64.012 (2.5201 - 2.5202)
Grade No. W 64.012 - 64.013 (2.5202 - 2.5202)
Grade No. X 64.013 - 64.014 (2.5202 - 2.5202) F
Grade No. Y 64.014 - 64.015 (2.5202 - 2.5203)
Grade No. 4 64.015 - 64.016 (2.5203 - 2.5203)
Grade No. 7 64.016 - 64.017 (2.5203 - 2.5203)
G
Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)
AVAILABLE PISTON
Unit: mm (in) H
SEM882E
L
Items Grade* Standard
Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594)
Piston skirt diameter (A) Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) M
Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602)
(a) dimension 38.0 (1.496)
Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) N
Piston pin hole diameter
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663)
Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012)
O
PISTON RING
Unit: mm (in) P
Top 0.045 - 0.080 (0.0018 - 0.0031) —
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) —
Oil ring 0.045 - 0.125 (0.0018 - 0.0049) —

Top 0.23 - 028 (0.0091 - 0.0110) 0.50 (0.0197)
End gap 2nd 0.33 - 0.43 (0.0130 - 0.0169) 0.62 (0.0244)
Oil (rail ring) 0.20 - 0.45 (0.0079 - 0.0177) 0.80 (0.0315)
PISTON PIN
Unit: mm (in)
Items Grade* Standard Limit

Grade No. 0 21.989 - 21.995 (0.8657 - 0.8659) —
Piston pin outer diameter
Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
Connecting rod bushing oil clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.030 (0.0012)
CONNECTING ROD
Unit: mm (in)
Center distance 144.15 - 144.25 (5.68 - 5.68)

Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
Connecting rod small end inner diameter 23.980 - 24.000 (0.9441 - (0.9449)
Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664)
Connecting rod bushing inner diameter2
Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666)
Connecting rod big end diameter (Without bearing) 55.000 - 55.013 (2.1654 - 2.1659)
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Side clearance
Limit 0.40 (0.0157)
1: Always check with the Parts Department for the latest parts information.
2: After installing in connecting rod.
CRANKSHAFT
Unit: mm (in)
SEM645 SBIA0535E

Grade1 Dimension
A
Grade No. A 59.975 - 59.974 (2.3612 - 2.3612)
Grade No. B 59.974 - 59.973 (2.3612 - 2.3611)
Grade No. C 59.973 - 59.972 (2.3611 - 2.3611)
Grade No. D 59.972 - 59.971 (2.3611 - 2.3611) EM
Grade No. E 59.971 - 59.970 (2.3611 - 2.3610)
Grade No. F 59.970 - 59.969 (2.3610 - 2.3610)
Grade No. G 59.969 - 59.968 (2.3610 - 2.3609)
Grade No. H 59.968 - 59.967 (2.3609 - 2.3609) C
Grade No. J 59.967 - 59.966 (2.3609 - 2.3609)
Grade No. K 59.966 - 59.965 (2.3609 - 2.3608)
Grade No. L 59.965 - 59.964 (2.3608 - 2.3608)
Main journal diameter.(Dm) grade Standard Grade No. M 59.964 - 59.963 (2.3608 - 2.3607) D
Grade No. N 59.963 - 59.962 (2.3607 - 2.3607)
Grade No. P 59.962 - 59.961 (2.3607 - 2.3607)
Grade No. R 59.961 - 59.960 (2.3607 - 2.3606) E
Grade No. S 59.960 - 59.959 (2.3606 - 2.3606)
Grade No. T 59.959 - 59.958 (2.3606 - 2.3605)
Grade No. U 59.958 - 59.957 (2.3605 - 2.3605)
Grade No. V 59.957 - 59.956 (2.3605 - 2.3605) F
Grade No. W 59.956 - 59.955 (2.3605 - 2.3604)
Grade No. X 59.955 - 59.954 (2.3604 - 2.3604)
Grade No. Y 59.954 - 59.953 (2.3604 - 2.3603)
Grade No. 4 59.953 - 59.952 (2.3603 - 2.3603) G
Grade No. 7 59.952 - 59.951 (2.3603 - 2.3603)
Grade No. 0 51.968 - 51.974 (2.0460 - 2.0462)
Pin journal diameter. (Dp) grade Standard Grade No. 1 51.962 - 51.968 (2.0457 - 2.0460) H
Grade No. 2 51.956 - 51.962 (2.0445 - 2.0457)
Center distance (r) 40.66 - 40.74 (1.6008 - 1.6039)
I
Taper [Difference between (A) and (B)] Less than 0.002 (0.0001)
Limit
Out-of-round [Difference between (X) and (Y)] Less than 0.002 (0.0001)
Standard Less than 0.05 (0.0020) J
Crankshaft runout [TIR*]
Limit 0.10 (0.0039)
Standard 0.10 - 0.25 (0.0039 - 0.0098)
Crankshaft end play K
Limit 0.30 (0.0118)
Fillet role of crankshaft journal Standard More than 0.10 (0.0039)
*: Total indicator reading L
Main Bearing INFOID:0000000011568123
M
MAIN BEARING
Unit: mm (in)
PBIC2619E
Grade number* Thickness Identification color Remarks

0 2.000 - 2.003 (0.0787 - 0.0789) Black
1 2.003 - 2.006 (0.0789 - 0.0790) Brown
2 2.006 - 2.009 (0.0790 - 0.0791) Green
3 2.009 - 2.012 (0.0791 - 0.0792) Yellow Grade is the same
for upper and lower
4 2.012 - 2.015 (0.0792 - 0.0793) Blue bearings.
5 2.015 - 2.018 (0.0793 - 0.0794) Pink
6 2.018 - 2.021 (0.0794 - 0.0796) Purple
7 2.021 - 2.024 (0.0796 - 0.0797) White
UPR 2.003 - 2.006 (0.0789 - 0.0790) Brown
01
LWR 2.000 - 2.003 (0.0787 - 0.0789) Black
UPR 2.006 - 2.009 (0.0790 - 0.0791) Green
12
LWR 2.003 - 2.006 (0.0789 - 0.0790) Brown
UPR 2.009 - 2.012 (0.0791 - 0.0792) Yellow
23
LWR 2.006 - 2.009 (0.0790 - 0.0791) Green
UPR 2.012 - 2.015 (0.0792 - 0.0793) Blue Grade and color are
34 different for upper
LWR 2.009 - 2.012 (0.0791 - 0.0792) Yellow and lower bearings.
UPR 2.015 - 2.018 (0.0793 - 0.0794) Pink
45
LWR 2.012 - 2.015 (0.0792 - 0.0793) Blue
UPR 2.018 - 2.021 (0.0794 - 0.0796) Purple
56
LWR 2.015 - 2.018 (0.0793 - 0.0794) Pink
UPR 2.021 - 2.024 (0.0796 - 0.0797) White
67
LWR 2.018 - 2.021 (0.0794 - 0.0796) Purple
UNDERSIZE
Unit: mm (in)
Items Thickness Main journal diameter

0.25 (0.0098) 2.132 - 2.140 (0.0839 - 0.0843) Grind so that bearing clearance is the specified value.
MAIN BEARING OIL CLEARANCE

Unit: mm (in)

Main bearing oil clearance 0.012 - 0.022 (0.0005 - 0.0009)* 0.065 (0.0026)
*: Actual clearance
Connecting Rod Bearing INFOID:0000000011568124
CONNECTING ROD BEARING

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

0 1.500 - 1.503 (0.0591 - 0.0592) Black
1 1.503 - 1.506 (0.0592 - 0.0593) Brown
2 1.506 - 1.509 (0.0593 - 0.0594) Green
UNDERSIZE
Unit: mm (in)
Items Thickness Crank pin journal diameter (Dp)

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 0.020 - 0.045 (0.0008 - 0.0018)* 0.070 (0.0028)
EM
*: Actual clearance
Drive Plate INFOID:0000000011568125
C
Unit: mm (in)
Drive plate runout [TIR]* - on torque converter mount surface Less than 0.35 (0.0138)
Drive plate runout [TIR]* - on ring gear 0.5 (0.0197) D
*: Total indicator reading

Nissan-Murano 2015 EN Motor E137da4f0c

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ENGINE

Revision: October 2014 EM-1 2015 Murano

ROCKER COVER .............................................. 45 ENGINE MOUNT (FRONT) ..................................... 101

Revision: October 2014 EM-2 2015 Murano

Parts Requiring Angular Tightening INFOID:0000000011220619 O

Revision: October 2014 EM-3 2015 Murano

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

Handling and disposal of sodium-filled exhaust valves requires spe-

(A) : Identification mark of sodium-filled exhaust valve

DEALER DISPOSAL INSTRUCTIONS

Precaution for Liquid Gasket INFOID:0000000011607899

REMOVAL OF LIQUID GASKET SEALING

Revision: October 2014 EM-5 2015 Murano

Tool Number : KV10111100 (J-37228)

LIQUID GASKET APPLICATION PROCEDURE

3. Attach liquid gasket tube to the suitable tool.

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

Revision: October 2014 EM-6 2015 Murano

16441 6N210 Removing fuel tube quick connectors in en-

KV10111100 Removing oil pan and timing chain case

KV991J0050 Loosening or tightening air fuel ratio A/F sen- P

Revision: October 2014 EM-7 2015 Murano

— Installing front main seal

— Installing rear main seal

KV10112100 Tightening bolts for bearing cap, cylinder

Commercial Service Tool INFOID:0000000011538119

Manual lift table caddy Removing and installing engine

Revision: October 2014 EM-8 2015 Murano

Tube presser Pressing the tube of liquid gasket D

Pulley holder Crankshaft pulley removing and installing

Valve seat cutter set Finishing valve seat dimensions

Piston ring expander Removing and installing piston ring P

Revision: October 2014 EM-9 2015 Murano

Valve guide drift Removing and installing valve guide

Valve guide reamer 1: Reaming valve guide inner hole

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

KV10115600 Installing valve oil seal

Power tool Loosening nuts, screws, and bolts

KV10107902 Removing valve oil seal

Revision: October 2014 EM-10 2015 Murano

KV10115300 Disassembling and assembling

(J-45816) Removing and installing CVT drive plate bolts I

Revision: October 2014 EM-11 2015 Murano

1. Camshaft bearing noise 2. Piston pin noise 3. Piston slap noise

Revision: October 2014 EM-12 2015 Murano

1. Locate the area where noise occurs. C

Operating condition of engine

Piston and piston pin

Revision: October 2014 EM-13 2015 Murano

1. Drive belt auto-tensioner 2. Generator 3. A/C compressor

Checking Drive Belt INFOID:0000000011220626

• Drive belt tension is automatically adjusted by the drive belt auto-tensioner.

Revision: October 2014 EM-14 2015 Murano

4. Insert a rod approximately 6 mm (0.24 in) in diameter through D

Revision: October 2014 EM-15 2015 Murano

1. Drive belt auto-tensioner

Revision: October 2014 EM-16 2015 Murano

Revision: October 2014 EM-17 2015 Murano

1. Ignition coil 2. Spark plug 3. Rocker cover (RH)